[Title 49 CFR ]
[Code of Federal Regulations (annual edition) - October 1, 2011 Edition]
[From the U.S. Government Printing Office]
[[Page i]]
Title 49
Transportation
________________________
Parts 178 to 199
Revised as of October 1, 2011
Containing a codification of documents of general
applicability and future effect
As of October 1, 2011
Published by the Office of the Federal Register
National Archives and Records Administration as a
Special Edition of the Federal Register
[[Page ii]]
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[[Page iii]]
As of October 1, 2011
Title 49, Parts 100 to 185
and
Title 49, Parts 186 to 199
Revised as of October 1, 2010
Is Replaced by
Title 49, Parts 100 to 177
and
Title 49, Parts 178 to 199
[[Page v]]
Table of Contents
Page
Explanation................................................. vii
Title 49:
SUBTITLE B--Other Regulations Relating to Transportation
(Continued)
Chapter I--Pipeline and Hazardous Materials Safety
Administration, Department of Transportation
(Continued) 5
Finding Aids:
Table of CFR Titles and Chapters........................ 631
Alphabetical List of Agencies Appearing in the CFR...... 651
List of CFR Sections Affected........................... 661
[[Page vi]]
----------------------------
Cite this Code: CFR
To cite the regulations in
this volume use title,
part and section number.
Thus, 49 CFR 178.1 refers
to title 49, part 178,
section 1.
----------------------------
[[Page vii]]
EXPLANATION
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Each volume of the Code is revised at least once each calendar year
and issued on a quarterly basis approximately as follows:
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[[Page viii]]
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[[Page ix]]
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October 1, 2011.
[[Page xi]]
THIS TITLE
Title 49--Transportation is composed of nine volumes. The parts in
these volumes are arranged in the following order: Parts 1-99, parts
100-177, parts 178-199, parts 200-299, parts 300-399, parts 400-571,
parts 572-999, parts 1000-1199, and part 1200 to end. The first volume
(parts 1-99) contains current regulations issued under subtitle A--
Office of the Secretary of Transportation; the second volume (parts 100-
177) and the third volume (parts 178-199) contain the current
regulations issued under chapter I--Pipeline and Hazardous Materials
Safety Administration (DOT); the fourth volume (parts 200-299) contains
the current regulations issued under chapter II--Federal Railroad
Administration (DOT); the fifth volume (parts 300-399) contains the
current regulations issued under chapter III--Federal Motor Carrier
Safety Administration (DOT); the sixth volume (parts 400-571) contains
the current regulations issued under chapter IV--Coast Guard (DHS), and
some of chapter V--National Highway Traffic Safety Administration (DOT);
the seventh volume (parts 572-999) contains the rest of the regulations
issued under chapter IV, and the current regulations issued under
chapter VI--Federal Transit Administration (DOT), chapter VII--National
Railroad Passenger Corporation (AMTRAK), and chapter VIII--National
Transportation Safety Board; the eighth volume (parts 1000-1199)
contains the current regulations issued under chapter X--Surface
Transportation Board and the ninth volume (part 1200 to end) contains
the current regulations issued under chapter X--Surface Transportation
Board, chapter XI--Research and Innovative Technology Administration,
and chapter XII--Transportation Security Administration, Department of
Transportation. The contents of these volumes represent all current
regulations codified under this title of the CFR as of October 1, 2011.
In the volume containing parts 100-177, see Sec. 172.101 for the
Hazardous Materials Table. The Federal Motor Vehicle Safety Standards
appear in part 571.
Redesignation tables for chapter III--Federal Motor Carrier Safety
Administration, Department of Transportation and chapter XII--
Transportation Security Administration, Department of Transportation
appear in the Finding Aids section of the fifth and ninth volumes.
For this volume, Susannah C. Hurley was Chief Editor. The Code of
Federal Regulations publication program is under the direction of
Michael L. White, assisted by Ann Worley.
[[Page 1]]
TITLE 49--TRANSPORTATION
(This book contains parts 178 to 199)
--------------------------------------------------------------------
Editorial Note: Other regulations issued by the Department of
Transportation appear in 14 CFR chapters I and II, 23 CFR, 33 CFR
chapters I and IV, 44 CFR chapter IV, 46 CFR chapters I through III, 48
CFR chapter 12, and 49 CFR chapters I through VI.
SUBTITLE B--Other Regulations Relating to Transportation (Continued)
Part
chapter I--Pipeline and Hazardous Materials Safety
Administration, DOT (Continued)........................... 178
[[Page 3]]
Subtitle B--Other Regulations Relating to Transportation (Continued)
[[Page 5]]
CHAPTER I--PIPELINE AND HAZARDOUS MATERIALS SAFETY ADMINISTRATION,
DEPARTMENT OF TRANSPORTATION (CONTINUED)
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SUBCHAPTER D--PIPELINE SAFETY
Part Page
178 Specifications for packagings............... 7
179 Specifications for tank cars................ 257
180 Continuing qualification and maintenance of
packagings.............................. 315
181-189 [Reserved]
190 Pipeline safety programs and rulemaking
procedures.............................. 371
191 Transportation of natural and other gas by
pipeline; annual reports, incident
reports, and safety-related condition
reports................................. 392
192 Transportation of natural and other gas by
pipeline: Minimum Federal safety
standards............................... 398
193 Liquefied natural gas facilities: Federal
safety standards........................ 512
194 Response plans for onshore oil pipelines.... 531
195 Transportation of hazardous liquids by
pipeline................................ 542
196-197 [Reserved]
198 Regulations for grants to aid State pipeline
safety programs......................... 611
199 Drug and alcohol testing.................... 614
[[Page 7]]
PART 178_SPECIFICATIONS FOR PACKAGINGS--Table of Contents
Sec.
178.1 Purpose and scope.
178.2 Applicability and responsibility.
178.3 Marking of packagings.
Subpart A [Reserved]
Subpart B_Specifications for Inside Containers, and Linings
178.33 Specification 2P; inner nonrefillable metal receptacles.
178.33-1 Compliance.
178.33-2 Type and size.
178.33-3 Inspection.
178.33-4 Duties of inspector.
178.33-5 Material.
178.33-6 Manufacture.
178.33-7 Wall thickness.
178.33-8 Tests.
178.33-9 Marking.
178.33a Specification 2Q; inner nonrefillable metal receptacles.
178.33a-1 Compliance.
178.33a-2 Type and size.
178.33a-3 Inspection.
178.33a-4 Duties of inspector.
178.33a-5 Material.
178.33a-6 Manufacture.
178.33a-7 Wall thickness.
178.33a-8 Tests.
178.33a-9 Marking.
178.33b Specification 2S; inner nonrefillable plastic receptacles
178.33b-1 Compliance.
178.33b-2 Type and size.
178.33b-3 Inspection.
178.33b-4 Duties of inspector.
178.33b-5 Material.
178.33b-6 Manufacture.
178.33b-7 Design qualification test.
178.33b-8 Production tests.
178.33b-9 Marking.
Subpart C_Specifications for Cylinders
178.35 General requirements for specification cylinders.
178.36 Specification 3A and 3AX seamless steel cylinders.
178.37 Specification 3AA and 3AAX seamless steel cylinders.
178.38 Specification 3B seamless steel cylinders.
178.39 Specification 3BN seamless nickel cylinders.
178.42 Specification 3E seamless steel cylinders.
178.44 Specification 3HT seamless steel cylinders for aircraft use.
178.45 Specification 3T seamless steel cylinders.
178.46 Specification 3AL seamless aluminum cylinders.
178.47 Specification 4DS welded stainless steel cylinders for aircraft
use.
178.50 Specification 4B welded or brazed steel cylinders.
178.51 Specification 4BA welded or brazed steel cylinders.
178.53 Specification 4D welded steel cylinders for aircraft use.
178.55 Specification 4B240ET welded or brazed cylinders.
178.56 Specification 4AA480 welded steel cylinders.
178.57 Specification 4L welded insulated cylinders.
178.58 Specification 4DA welded steel cylinders for aircraft use.
178.59 Specification 8 steel cylinders with porous fillings for
acetylene.
178.60 Specification 8AL steel cylinders with porous fillings for
acetylene.
178.61 Specification 4BW welded steel cylinders with electric-arc welded
longitudinal seam.
178.65 Specification 39 non-reusable (non-refillable) cylinders.
178.68 Specification 4E welded aluminum cylinders.
178.69 Responsibilities and requirements for manufacturers of UN
pressure receptacles.
178.70 Approval of UN pressure receptacles.
178.71 Specifications for UN pressure receptacles.
178.74 Approval of MEGCs.
178.75 Specifications for MEGCs.
Appendix A to Subpart C--Illustrations: Cylinder Tensile Sample
Subparts D-G [Reserved]
Subpart H_Specifications for Portable Tanks
178.251--178.253-5 [Reserved]
178.255 Specification 60; steel portable tanks.
178.255-1 General requirements.
178.255-2 Material.
178.255-3 Expansion domes.
178.255-4 Closures for manholes and domes.
178.255-5 Bottom discharge outlets.
178.255-6 Loading and unloading accessories.
178.255-7 Protection of valves and accessories.
178.255-8 Safety devices.
178.255-9 Compartments.
178.255-10 Lining.
178.255-11 Tank mountings.
178.255-12 Pressure test.
178.255-13 Repair of tanks.
178.255-14 Marking.
178.255-15 Report.
178.273 Approval of Specification UN portable tanks.
178.274 Specification for UN portable tanks.
[[Page 8]]
178.275 Specification for UN Portable Tanks intended for the
transportation of liquid and solid hazardous materials.
178.276 Requirements for the design, construction, inspection and
testing of portable tanks intended for the transportation of
non-refrigerated liquefied compressed gases.
178.277 Requirements for the design, construction, inspection and
testing of portable tanks intended for the transportation of
refrigerated liquefied gases.
Subpart I [Reserved]
Subpart J_Specifications for Containers for Motor Vehicle Transportation
178.318 Specification MC 201; container for detonators and percussion
caps.
178.318-1 Scope.
178.318-2 Container.
178.318-3 Marking.
178.320 General requirements applicable to all DOT specification cargo
tank motor vehicles.
178.337 Specification MC 331; cargo tank motor vehicle primarily for
transportation of compressed gases as defined in subpart G of
part 173 of this subchapter.
178.337-1 General requirements.
178.337-2 Material.
178.337-3 Structural integrity.
178.337-4 Joints.
178.337-5 Bulkheads, baffles and ring stiffeners.
178.337-6 Closure for manhole.
178.337-7 Overturn protection.
178.337-8 Openings, inlets and outlets.
178.337-9 Pressure relief devices, piping, valves, hoses, and fittings.
178.337-10 Accident damage protection.
178.337-11 Emergency discharge control.
178.337-12 [Reserved]
178.337-13 Supporting and anchoring.
178.337-14 Gauging devices.
178.337-15 Pumps and compressors.
178.337-16 Testing.
178.337-17 Marking.
178.337-18 Certification.
178.338 Specification MC-338; insulated cargo tank motor vehicle.
178.338-1 General requirements.
178.338-2 Material.
178.338-3 Structural integrity.
178.338-4 Joints.
178.338-5 Stiffening rings.
178.338-6 Manholes.
178.338-7 Openings.
178.338-8 Pressure relief devices, piping, valves, and fittings.
178.338-9 Holding time.
178.338-10 Accident damage protection.
178.338-11 Discharge control devices.
178.338-12 Shear section.
178.338-13 Supporting and anchoring.
178.338-14 Gauging devices.
178.338-15 Cleanliness.
178.338-16 Inspection and testing.
178.338-17 Pumps and compressors.
178.338-18 Marking.
178.338-19 Certification.
178.340-178.343 [Reserved]
178.345 General design and construction requirements applicable to
Specification DOT 406 (Sec. 178.346), DOT 407 (Sec.
178.347), and DOT 412 (Sec. 178.348) cargo tank motor
vehicles.
178.345-1 General requirements.
178.345-2 Material and material thickness.
178.345-3 Structural integrity.
178.345-4 Joints.
178.345-5 Manhole assemblies.
178.345-6 Supports and anchoring.
178.345-7 Circumferential reinforcements.
178.345-8 Accident damage protection.
178.345-9 Pumps, piping, hoses and connections.
178.345-10 Pressure relief.
178.345-11 Tank outlets.
178.345-12 Gauging devices.
178.345-13 Pressure and leakage tests.
178.345-14 Marking.
178.345-15 Certification.
178.346 Specification DOT 406; cargo tank motor vehicle.
178.346-1 General requirements.
178.346-2 Material and thickness of material.
178.346-3 Pressure relief.
178.346-4 Outlets.
178.346-5 Pressure and leakage tests.
178.347 Specification DOT 407; cargo tank motor vehicle.
178.347-1 General requirements.
178.347-2 Material and thickness of material.
178.347-3 Manhole assemblies.
178.347-4 Pressure relief.
178.347-5 Pressure and leakage test.
178.348 Specification DOT 412; cargo tank motor vehicle.
178.348-1 General requirements.
178.348-2 Material and thickness of material.
178.348-3 Pumps, piping, hoses and connections.
178.348-4 Pressure relief.
178.348-5 Pressure and leakage test.
Subpart K_Specifications for Packagings for Class 7 (Radioactive)
Materials
178.350 Specification 7A; general packaging, Type A.
178.356 Specification 20PF phenolic-foam insulated, metal overpack.
178.356-1 General requirements.
178.356-2 Materials of construction and other requirements.
178.356-3 Tests.
178.356-4 Required markings.
178.356-5 Typical assembly detail.
[[Page 9]]
178.358 Specification 21PF fire and shock resistant, phenolic-foam
insulated, metal overpack.
178.358-1 General requirements.
178.358-2 Materials of construction and other requirements.
178.358-3 Modification of Specification 21PF-1 overpacks.
178.358-4 Construction of Specification 21PF-1B overpacks.
178.358-5 Required markings.
178.358-6 Typical assembly detail.
178.360 Specification 2R; inside containment vessel.
178.360-1 General requirements.
178.360-2 Manufacture.
178.360-3 Dimensions.
178.360-4 Closure devices.
Subpart L_Non-bulk Performance-Oriented Packaging Standards
178.500 Purpose, scope and definitions.
178.502 Identification codes for packagings.
178.503 Marking of packagings.
178.504 Standards for steel drums.
178.505 Standards for aluminum drums.
178.506 Standards for metal drums other than steel or aluminum.
178.507 Standards for plywood drums.
178.508 Standards for fiber drums.
178.509 Standards for plastic drums and jerricans.
178.510 Standards for wooden barrels.
178.511 Standards for aluminum and steel jerricans.
178.512 Standards for steel or aluminum boxes.
178.513 Standards for boxes of natural wood.
178.514 Standards for plywood boxes.
178.515 Standards for reconstituted wood boxes.
178.516 Standards for fiberboard boxes.
178.517 Standards for plastic boxes.
178.518 Standards for woven plastic bags.
178.519 Standards for plastic film bags.
178.520 Standards for textile bags.
178.521 Standards for paper bags.
178.522 Standards for composite packagings with inner plastic
receptacles.
178.523 Standards for composite packagings with inner glass, porcelain,
or stoneware receptacles.
Subpart M_Testing of Non-bulk Packagings and Packages
178.600 Purpose and scope.
178.601 General requirements.
178.602 Preparation of packagings and packages for testing.
178.603 Drop test.
178.604 Leakproofness test.
178.605 Hydrostatic pressure test.
178.606 Stacking test.
178.607 Cooperage test for bung-type wooden barrels.
178.608 Vibration standard.
178.609 Test requirements for packagings for infectious substances.
Subpart N_IBC Performance-Oriented Standards
178.700 Purpose, scope and definitions.
178.702 IBC codes.
178.703 Marking of IBCs.
178.704 General IBC standards.
178.705 Standards for metal IBCs.
178.706 Standards for rigid plastic IBCs.
178.707 Standards for composite IBCs.
178.708 Standards for fiberboard IBCs.
178.709 Standards for wooden IBCs.
178.710 Standards for flexible intermediate bulk containers.
Subpart O_Testing of IBCs
178.800 Purpose and scope.
178.801 General requirements.
178.802 Preparation of fiberboard IBCs for testing.
178.803 Testing and certification of IBCs.
178.810 Drop test.
178.811 Bottom lift test.
178.812 Top lift test.
178.813 Leakproofness test.
178.814 Hydrostatic pressure test.
178.815 Stacking test.
178.816 Topple test.
178.817 Righting test.
178.818 Tear test.
178.819 Vibration test.
Subpart P_Large Packagings Standards
178.900 Purpose and scope.
178.905 Large Packaging identification codes.
178.910 Marking of Large Packagings.
178.915 General Large Packaging standards.
178.920 Standards for metal Large Packagings.
178.925 Standards for rigid plastic Large Packagings.
178.930 Standards for fiberboard Large Packagings.
178.935 Standards for wooden Large Packagings.
178.940 Standards for flexible Large Packagings.
Subpart Q_Testing of Large Packagings
178.950 Purpose and scope.
178.955 General requirements.
178.960 Preparation of Large Packagings for testing.
178.965 Drop test.
178.970 Bottom lift test.
178.975 Top lift test.
178.980 Stacking test.
178.985 Vibration test.
Appendix A to Part 178--Specifications for Steel
[[Page 10]]
Appendix B to Part 178--Alternative Leakproofness Test Methods
Appendix C to Part 178--Nominal and Minimum Thicknesses of Steel Drums
and Jerricans
Appendix D to Part 178--Thermal Resistance Test
Appendix E to Part 178--Flame Penetration Resistance Test
Authority: 49 U.S.C. 5101-5128; 49 CFR 1.53.
Sec. 178.1 Purpose and scope.
This part prescribes the manufacturing and testing specifications
for packaging and containers used for the transportation of hazardous
materials in commerce.
[Amdt. 178-40, 42 FR 2689, Jan. 13, 1977. Redesignated by Amdt. 178-97,
55 FR 52715, Dec. 21, 1990]
Sec. 178.2 Applicability and responsibility.
(a) Applicability. (1) The requirements of this part apply to
packagings manufactured--
(i) To a DOT specification, regardless of country of manufacture; or
(ii) To a UN standard, for packagings manufactured within the United
States. For UN standard packagings manufactured outside the United
States, see Sec. 173.24(d)(2) of this subchapter. For UN standard
packagings for which standards are not prescribed in this part, see
Sec. 178.3(b).
(2) A manufacturer of a packaging subject to the requirements of
this part is primarily responsible for compliance with the requirements
of this part. However, any person who performs a function prescribed in
this part shall perform that function in accordance with this part.
(b) Specification markings. When this part requires that a packaging
be marked with a DOT specification or UN standard marking, marking of
the packaging with the appropriate DOT or UN markings is the
certification that--
(1) Except as otherwise provided in this section, all requirements
of the DOT specification or UN standard, including performance tests,
are met; and
(2) All functions performed by, or on behalf of, the person whose
name or symbol appears as part of the marking conform to requirements
specified in this part.
(c) Notification. (1) Except as specifically provided in Sec. Sec.
178.337-18 and 178.345-10 of this part, the manufacturer or other person
certifying compliance with the requirements of this part, and each
subsequent distributor of that packaging must:
(i) Notify each person to whom that packaging is transferred--
(A) Of all requirements in this part not met at the time of
transfer, and
(B) With information specifying the type(s) and dimensions of the
closures, including gaskets and any other components needed to ensure
that the packaging is capable of successfully passing the applicable
performance tests. This information must include any procedures to be
followed, including closure instructions for inner packagings and
receptacles, to effectively assemble and close the packaging for the
purpose of preventing leakage in transportation. Closure instructions
must provide for a consistent and repeatable means of closure that is
sufficient to ensure the packaging is closed in the same manner as it
was tested. For packagings sold or represented as being in conformance
with the requirements of this subchapter applicable to transportation by
aircraft, this information must include relevant guidance to ensure that
the packaging, as prepared for transportation, will withstand the
pressure differential requirements in Sec. 173.27 of this subchapter.
(ii) Retain copies of each written notification for the amount of
time that aligns with the packaging's periodic retest date, i.e., every
12 months for single or composite packagings and every 24 months for
combination packagings; and
(iii) Make copies of all written notifications available for
inspection by a representative of the Department.
(2) The notification required in accordance with this paragraph (c)
may be in writing or by electronic means, including e-mailed
transmission or transmission on a CD or similar device. If a
manufacturer or subsequent distributor of the packaging utilizes
electronic means to make the required notifications, the notification
must be specific to the packaging in question and must be in a form that
can be
[[Page 11]]
printed in hard copy by the person receiving the notification.
(d) Except as provided in paragraph (c) of this section, a packaging
not conforming to the applicable specifications or standards in this
part may not be marked to indicate such conformance.
(e) Definitions. For the purpose of this part--
Manufacturer means the person whose name and address or symbol
appears as part of the specification markings required by this part or,
for a packaging marked with the symbol of an approval agency, the person
on whose behalf the approval agency certifies the packaging.
Specification markings mean the packaging identification markings
required by this part including, where applicable, the name and address
or symbol of the packaging manufacturer or approval agency.
(f) No packaging may be manufactured or marked to a packaging
specification that was in effect on September 30, 1991, and that was
removed from this part 178 by a rule published in the Federal Register
on December 21, 1990 and effective October 1, 1991.
[Amdt. 178-97, 55 FR 52715, Dec. 21, 1990; 56 FR 66284, Dec. 20, 1991,
as amended by Amdt. No. 178-106, 59 FR 67519, Dec. 29, 1994; Amdt. 178-
117, 62 FR 14338, Mar. 26, 1997; 68 FR 45041, July 31, 2003; 69 FR
34612, June 22, 2004; 75 FR 5395, Feb. 2, 2010; 75 FR 60339, Sept. 30,
2010]
Sec. 178.3 Marking of packagings.
(a) Each packaging represented as manufactured to a DOT
specification or a UN standard must be marked on a non-removable
component of the packaging with specification markings conforming to the
applicable specification, and with the following:
(1) In an unobstructed area, with letters, and numerals identifying
the standards or specification (e.g. UN 1A1, DOT 4B240ET, etc.).
(2) Unless otherwise specified in this part, with the name and
address or symbol of the packaging manufacturer or, where specifically
authorized, the symbol of the approval agency certifying compliance with
a UN standard. Symbols, if used, must be registered with the Associate
Administrator. Duplicative symbols are not authorized.
(3) The markings must be stamped, embossed, burned, printed or
otherwise marked on the packaging to provide adequate accessibility,
permanency, contrast, and legibility so as to be readily apparent and
understood.
(4) Unless otherwise specified, letters and numerals must be at
least 12.0 mm (0.47 inches) in height except that for packagings of less
than or equal to 30 L (7.9 gallons) capacity for liquids or 30 kg (66
pounds) capacity for solids the height must be at least 6.0 mm (0.2
inches). For packagings having a capacity of 5 L (1 gallon) or 5 kg (11
pounds) or less, letters and numerals must be of an appropriate size.
(5) For packages with a gross mass of more than 30 kg (66 pounds),
the markings or a duplicate thereof must appear on the top or on a side
of the packaging.
(b) A UN standard packaging for which the UN standard is set forth
in this part may be marked with the United Nations symbol and other
specification markings only if it fully conforms to the requirements of
this part. A UN standard packaging for which the UN standard is not set
forth in this part may be marked with the United Nations symbol and
other specification markings for that standard as provided in the ICAO
Technical Instructions or the IMDG Code subject to the following
conditions:
(1) The U.S. manufacturer must establish that the packaging conforms
to the applicable provisions of the ICAO Technical Instructions (IBR,
see Sec. 171.7 of this subchapter) or the IMDG Code (IBR, see Sec.
171.7 of this subchapter), respectively.
(2) If an indication of the name of the manufacturer or other
identification of the packaging as specified by the competent authority
is required, the name and address or symbol of the manufacturer or the
approval agency certifying compliance with the UN standard must be
entered. Symbols, if used, must be registered with the Associate
Administrator.
(3) The letters ``USA'' must be used to indicate the State
authorizing the allocation of the specification marks if the packaging
is manufactured in the United States.
[[Page 12]]
(c) Where a packaging conforms to more than one UN standard or DOT
specification, the packaging may bear more than one marking, provided
the packaging meets all the requirements of each standard or
specification. Where more than one marking appears on a packaging, each
marking must appear in its entirety.
(d) No person may mark or otherwise certify a packaging or container
as meeting the requirements of a manufacturing special permit unless
that person is the holder of or a party to that special permit, an agent
of the holder or party for the purpose of marking or certification, or a
third party tester.
[Amdt. 178-97, 55 FR 52716, Dec. 21, 1990; 56 FR 66284, Dec. 20, 1991,
as amended by Amdt. No. 178-106, 59 FR 67519, Dec. 29, 1994; Amdt. 178-
113, 61 FR 21102, May 9, 1996; 65 FR 50462, Aug. 18, 2000; 66 FR 45386,
Aug. 28, 2001; 67 FR 61015, Sept. 27, 2002; 68 FR 75748, Dec. 31, 2003;
70 FR 73166, Dec. 9, 2005]
Subpart A [Reserved]
Subpart B_Specifications for Inside Containers, and Linings
Source: 29 FR 18823, Dec. 29, 1964, unless otherwise noted.
Redesignated at 32 FR 5606, Apr. 5, 1967.
Sec. 178.33 Specification 2P; inner nonrefillable metal receptacles.
Sec. 178.33-1 Compliance.
(a) Required in all details.
(b) [Reserved]
Sec. 178.33-2 Type and size.
(a) Single-trip inside containers. Must be seamless, or with seams,
welded, soldered, brazed, double seamed, or swedged.
(b) The maximum capacity of containers in this class shall not
exceed one liter (61.0 cubic inches). The maximum inside diameter shall
not exceed 3 inches.
[29 FR 18813, Dec. 29, 1964, as amended by Order 71, 31 FR 9074, July 1,
1966. Redesignated at 32 FR 5606, Apr. 5, 1967, and amended by Amdt.
178-101, 58 FR 50237, Sept. 24, 1993; 66 FR 45386, Aug. 28, 2001]
Sec. 178.33-3 Inspection.
(a) By competent inspector.
(b) [Reserved]
Sec. 178.33-4 Duties of inspector.
(a) To inspect material and completed containers and witness tests,
and to reject defective materials or containers.
(b) [Reserved]
Sec. 178.33-5 Material.
(a) Uniform quality steel plate such as black plate, electro-tin
plate, hot dipped tin plate, tern plate or other commercially accepted
can making plate; or nonferrous metal of uniform drawing quality.
(b) Material with seams, cracks, laminations or other injurious
defects not authorized.
Sec. 178.33-6 Manufacture.
(a) By appliances and methods that will assure uniformity of
completed containers; dirt and scale to be removed as necessary; no
defect acceptable that is likely to weaken the finished container
appreciably; reasonably smooth and uniform surface finish required.
(b) Seams when used must be as follows:
(1) Circumferential seams: By welding, swedging, brazing, soldering,
or double seaming.
(2) Side seams: By welding, brazing, or soldering.
(c) Ends: The ends shall be of pressure design.
[29 FR 18823, Dec. 29, 1964, as amended by Order 71, 31 FR 9074, July 1,
1966. Redesignated at 32 FR 5606, Apr. 5, 1967]
Sec. 178.33-7 Wall thickness.
(a) The minimum wall thickness for any container shall be 0.007
inch.
(b) [Reserved]
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967]
Sec. 178.33-8 Tests.
(a) One out of each lot of 25,000 containers or less, successively
produced per day shall be pressure tested to destruction and must not
burst below 240 psig gauge pressure. The container
[[Page 13]]
tested shall be complete with end assembled.
(b) Each such 25,000 containers or less, successively produced per
day, shall constitute a lot and if the test container shall fail, the
lot shall be rejected or ten additional containers may be selected at
random and subjected to the test under which failure occurred. These
containers shall be complete with ends assembled. Should any of the ten
containers thus tested fail, the entire lot must be rejected. All
containers constituting a lot shall be of like material, size, design
construction, finish, and quality.
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967, as amended by 66 FR 45387, Aug. 28, 2001]
Sec. 178.33-9 Marking.
(a) By means of printing, lithographing, embossing, or stamping,
each container must be marked to show:
(1) DOT-2P.
(2) Name or symbol of person making the mark specified in paragraph
(a)(1) of this section. Symbol, if used, must be registered with the
Associate Administrator.
(b) [Reserved]
[Amdt. 178-40, 41 FR 38181, Sept. 9, 1976, as amended by Amdt. 178-97,
56 FR 66287, Dec. 20, 1991; 66 FR 45386, Aug. 28, 2001]
Sec. 178.33a Specification 2Q; inner nonrefillable metal receptacles.
Sec. 178.33a-1 Compliance.
(a) Required in all details.
(b) [Reserved]
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967]
Sec. 178.33a-2 Type and size.
(a) Single-trip inside containers. Must be seamless, or with seams
welded, soldered, brazed, double seamed, or swedged.
(b) The maximum capacity of containers in this class shall not
exceed 1 L (61.0 cubic inches). The maximum inside diameter shall not
exceed 3 inches.
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967, and amended by Amdt. 178-43, 42 FR 42208, Aug. 22, 1977; Amdt.
178-101, 58 FR 50237, Sept. 24, 1993; 66 FR 45387, Aug. 28, 2001]
Sec. 178.33a-3 Inspection.
(a) By competent inspector.
(b) [Reserved]
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967]
Sec. 178.33a-4 Duties of inspector.
(a) To inspect material and completed containers and witness tests,
and to reject defective materials or containers.
(b) [Reserved]
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967]
Sec. 178.33a-5 Material.
(a) Uniform quality steel plate such as black plate, electrotin
plate, hot dipped tinplate, ternplate or other commercially accepted can
making plate; or nonferrous metal of uniform drawing quality.
(b) Material with seams, cracks, laminations or other injurious
defects not authorized.
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967]
Sec. 178.33a-6 Manufacture.
(a) By appliances and methods that will assure uniformity of
completed containers; dirt and scale to be removed as necessary; no
defect acceptable that is likely to weaken the finished container
appreciably; reasonably smooth and uniform surface finish required.
(b) Seams when used must be as follows:
(1) Circumferential seams. By welding, swedging, brazing, soldering,
or double seaming.
(2) Side seams. By welding, brazing or soldering.
(c) Ends. The ends shall be of pressure design.
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967]
Sec. 178.33a-7 Wall thickness.
(a) The minimum wall thickness for any container shall be 0.008
inch.
(b) [Reserved]
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967]
[[Page 14]]
Sec. 178.33a-8 Tests.
(a) One out of each lot of 25,000 containers or less, successively
produced per day, shall be pressure tested to destruction and must not
burst below 270 psig gauge pressure. The container tested shall be
complete with end assembled.
(b) Each such 25,000 containers or less, successively produced per
day, shall constitute a lot and if the test container shall fail, the
lot shall be rejected or ten additional containers may be selected at
random and subjected to the test under which failure occurred. These
containers shall be complete with ends assembled. Should any of the ten
containers thus tested fail, the entire lot must be rejected. All
containers constituting a lot shall be of like material, size, design,
construction, finish and quality.
[Order 71, 31 FR 9074, July 1, 1966. Redesignated at 32 FR 5606, Apr. 5,
1967, as amended by 66 FR 45387, Aug. 28, 2001]
Sec. 178.33a-9 Marking.
(a) By means of printing, lithographing, embossing, or stamping,
each container must be marked to show:
(1) DOT-2Q.
(2) Name or symbol of person making the mark specified in paragraph
(a)(1) of this section. Symbol, if used, must be registered with the
Associate Administrator.
(b) [Reserved]
[Amdt. 178-40, 41 FR 38181, Sept. 9, 1976, as amended by Amdt. 178-97,
56 FR 66287, Dec. 20, 1991; 66 FR 45386, Aug. 28, 2001]
Sec. 178.33b Specification 2S; inner nonrefillable plastic receptacles.
Sec. 178.33b-1 Compliance.
(a) Required in all details.
(b) [Reserved]
[74 FR 2268, Jan. 14, 2009]
Sec. 178.33b-2 Type and size.
(a) Single-trip inside containers.
(b) The maximum capacity of containers in this class shall not
exceed one liter (61.0 cubic inches). The maximum inside diameter shall
not exceed 3 inches.
[74 FR 2268, Jan. 14, 2009]
Sec. 178.33b-3 Inspection.
(a) By competent inspector.
(b) [Reserved]
[74 FR 2268, Jan. 14, 2009]
Sec. 178.33b-4 Duties of inspector.
(a) To inspect material and completed containers and witness tests,
and to reject defective materials or containers.
(b) [Reserved]
[74 FR 2268, Jan. 14, 2009]
Sec. 178.33b-5 Material.
(a) The receptacles must be constructed of polyethylene
terephthalate (PET), polyethylene napthalate (PEN), polyamide (Nylon) or
a blend of PET, PEN, ethyl vinyl alcohol (EVOH) and/or Nylon.
(b) Material with seams, cracks, laminations or other injurious
defects are forbidden.
[74 FR 2268, Jan. 14, 2009]
Sec. 178.33b-6 Manufacture.
(a) Each container must be manufactured by thermoplastic processes
that will assure uniformity of the completed container. No used material
other than production residues or regrind from the same manufacturing
process may be used. The packaging must be adequately resistant to aging
and to degradation caused either by the substance contained or by
ultraviolet radiation.
(b) [Reserved]
[74 FR 2268, Jan. 14, 2009]
Sec. 178.33b-7 Design qualification test.
(a) Drop testing. (1) To ensure that creep does not affect the
ability of the container to retain the contents, each new design must be
drop tested as follows: Three groups of twenty-five filled containers
must be dropped from 1.8 m (5.9 ft) on to a rigid, non-resilient, flat
and horizontal surface. One group must be conditioned at 38 [deg]C (100
[deg]F) for 26 weeks, the second group for 100 hours at 50 [deg]C (122
[deg]F) and the third group for 18 hours at 55 [deg]C (131 [deg]F),
prior to performing the drop test. The closure, or sealing component of
the container, must not be protected during the test. The orientation of
the test container
[[Page 15]]
at drop must be statistically random, but direct impact on the valve or
valve closure must be avoided.
(2) Criteria for passing the drop test: The containers must not
break or leak.
(b) Design qualification testing must be completed if the design is
manufactured with a new mold or if there is any change in the properties
of the material of construction.
[75 FR 73, Jan. 4, 2010]
Sec. 178.33b-8 Production tests.
(a) Burst Testing. (1) One out of each lot of 5,000 containers or
less, successively produced per day must be pressure tested to
destruction and must not burst below 240 psig. The container tested must
be complete as intended for transportation.
(2) Each such 5,000 containers or less, successively produced per
day, shall constitute a lot and if the test container shall fail, the
lot shall be rejected or ten additional containers may be selected at
random and subjected to the test under which failure occurred. These
containers shall be complete as intended for transportation. Should any
of the ten containers thus tested fail, the entire lot must be rejected.
All containers constituting a lot shall be of like material, size,
design construction, finish, and quality.
(b) [Reserved]
[74 FR 2268, Jan. 14, 2009, as amended at 75 FR 74, Jan. 4, 2010]
Sec. 178.33b-9 Marking.
(a) Each container must be clearly and permanently marked to show:
(1) DOT-2S.
(2) Name or symbol of person making the mark specified in paragraph
(a)(1) of this section. Symbol, if used, must be registered with the
Associate Administrator.
(b) [Reserved]
[74 FR 2268, Jan. 14, 2009]
Subpart C_Specifications for Cylinders
Sec. 178.35 General requirements for specification cylinders.
(a) Compliance. Compliance with the requirements of this subpart is
required in all details.
(b) Inspections and analyses. Chemical analyses and tests required
by this subchapter must be made within the United States, unless
otherwise approved in writing by the Associate Administrator, in
accordance with subpart I of part 107 of this chapter. Inspections and
verification must be performed by--
(1) An independent inspection agency approved in writing by the
Associate Administrator, in accordance with subpart I of part 107 of
this chapter; or
(2) For DOT Specifications 3B, 3BN, 3E, 4B, 4BA, 4D (water capacity
less than 1,100 cubic inches), 4B240ET, 4AA480, 4L, 8, 8AL, 4BW, 39
(marked service pressure 900 p.s.i.g. or lower) and 4E manufactured in
the United States, a competent inspector of the manufacturer.
(c) Duties of inspector. The inspector shall determine that each
cylinder made is in conformance with the applicable specification.
Except as otherwise specified in the applicable specification, the
inspector shall perform the following:
(1) Inspect all material and reject any not meeting applicable
requirements. For cylinders made by the billet-piercing process, billets
must be inspected and shown to be free from pipe, cracks, excessive
segregation and other injurious defects after parting or, when
applicable, after nick and cold break.
(2) Verify the material of construction meets the requirements of
the applicable specification by--
(i) Making a chemical analysis of each heat of material;
(ii) Obtaining a certified chemical analysis from the material
manufacturer for each heat of material (a ladle analysis is acceptable);
or
(iii) If an analysis is not provided for each heat of material by
the material manufacturer, by making a check analysis of a sample from
each coil, sheet, or tube.
(3) Verify compliance of cylinders with the applicable specification
by--
(i) Verifying identification of material is proper;
(ii) Inspecting the inside of the cylinder before closing in ends;
(iii) Verifying that the heat treatment is proper;
[[Page 16]]
(iv) Obtaining samples for all tests and check chemical analyses
(Note: Recommended locations for test specimens taken from welded
cylinders are depicted in Figures 1 through 5 in Appendix C to this
subpart for the specific construction design.);
(v) Witnessing all tests;
(vi) Verify threads by gauge;
(vii) Reporting volumetric capacity and tare weight (see report
form) and minimum thickness of wall noted; and
(viii) Verifying that each cylinder is marked in accordance with the
applicable specification.
(4) Inspector's report. Prepare a report containing, at a minimum,
the applicable information listed in CGA C-11 (IBR, see Sec. 171.7 of
this subchapter). Any additional information or markings that are
required by the applicable specification must be shown on the test
report. The signature of the inspector on the reports certifies that the
processes of manufacture and heat treatment of cylinders were observed
and found satisfactory. The inspector must furnish the completed test
reports required by this subpart to the maker of the cylinder and, upon
request, to the purchaser. The test report must be retained by the
inspector for fifteen years from the original test date of the cylinder.
(d) Defects and attachments. Cylinders must conform to the
following:
(1) A cylinder may not be constructed of material with seams, cracks
or laminations, or other injurious defects.
(2) Metal attachments to cylinders must have rounded or chamfered
corners or must be protected in such a manner as to prevent the
likelihood of causing puncture or damage to other hazardous materials
packages. This requirement applies to anything temporarily or
permanently attached to the cylinder, such as metal skids.
(e) Safety devices. Pressure relief devices and protection for
valves, safety devices, and other connections, if applied, must be as
required or authorized by the appropriate specification, and as required
in Sec. 173.301 of this subchapter.
(f) Markings. Markings on a DOT Specification cylinder must conform
to applicable requirements.
(1) Each cylinder must be marked with the following information:
(i) The DOT specification marking must appear first, followed
immediately by the service pressure. For example, DOT-3A1800.
(ii) The serial number must be placed just below or immediately
following the DOT specification marking.
(iii) A symbol (letters) must be placed just below, immediately
before or following the serial number. Other variations in sequence of
markings are authorized only when necessitated by a lack of space. The
symbol and numbers must be those of the manufacturer. The symbol must be
registered with the Associate Administrator; duplications are not
authorized.
(iv) The inspector's official mark and date of test (such as 5-95
for May 1995) must be placed near the serial number. This information
must be placed so that dates of subsequent tests can be easily added. An
example of the markings prescribed in this paragraph (f)(1) is as
follows:
DOT-3A1800
1234
XY
AB 5-95
Or;
DOT-3A1800-1234-XY
AB 5-95
Where:
DOT-3A = specification number
1800 = service pressure
1234 = serial number
XY = symbol of manufacturer
AB = inspector's mark
5-95 = date of test
(2) Additional required marking must be applied to the cylinder as
follows:
(i) The word ``spun'' or ``plug'' must be placed near the DOT
specification marking when an end closure in the finished cylinder has
been welded by the spinning process, or effected by plugging.
(ii) As prescribed in specification 3HT (Sec. 178.44) or 3T (Sec.
178.45), if applicable.
(3) Marking exceptions. A DOT 3E cylinder is not required to be
marked with an inspector's mark or a serial number.
(4) Unless otherwise specified in the applicable specification, the
markings on each cylinder must be stamped plainly and permanently on the
shoulder, top head, or neck.
[[Page 17]]
(5) The size of each marking must be at least 0.25 inch or as space
permits.
(6) Other markings are authorized provided they are made in low
stress areas other than the side wall and are not of a size and depth
that will create harmful stress concentrations. Such marks may not
conflict with any DOT required markings.
(g) Manufacturer's reports. At or before the time of delivery to the
purchaser, the cylinder manufacturer must have all completed
certification documents listed in CGA C-11. The manufacturer of the
cylinders must retain the reports required by this subpart for 15 years
from the original test date of the cylinder.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45185,
Aug. 28, 2001; 67 FR 51652, Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003; 76
FR 43531, July 20, 2011]
Sec. 178.36 Specification 3A and 3AX seamless steel cylinders.
(a) Type size and service pressure. In addition to the requirements
of Sec. 178.35, cylinders must conform to the following:
(1) A DOT-3A cylinder is a seamless steel cylinder with a water
capacity (nominal) not over 1,000 pounds and a service pressure of at
least 150 psig.
(2) A DOT-3AX is a seamless steel cylinder with a water capacity not
less than 1,000 pounds and a service pressure of at least 500 psig,
conforming to the following requirements:
(i) Assuming the cylinder is to be supported horizontally at its two
ends only and to be uniformly loaded over its entire length consisting
of the weight per unit of length of the straight cylindrical portion
filled with water and compressed to the specified test pressure; the sum
of two times the maximum tensile stress in the bottom fibers due to
bending, plus that in the same fibers (longitudinal stress), due to
hydrostatic test may not exceed 80 percent of the minimum yield strength
of the steel at such maximum stress. Wall thickness must be increased
when necessary to meet the requirement.
(ii) To calculate the maximum longitudinal tensile stress due to
bending, the following formula must be used:
S=Mc/I
(iii) To calculate the maximum longitudinal tensile stress due to
hydrostatic test pressure, the following formula must be used:
S = A1 P/A2
where:
S = tensile stress--p.s.i.;
M = bending moment-inch pounds--(wl\2\)/8;
w = weight per inch of cylinder filled with water;
l = length of cylinder-inches;
c = radius (D)/(2) of cylinder-inches;
I = moment of inertia--0.04909 (D\4\-d\4\) inches fourth;
D = outside diameter-inches;
d = inside diameter-inches;
A1 = internal area in cross section of cylinder-square
inches;
A2 = area of metal in cross section of cylinder-square
inches;
P=hydrostatic test pressure-psig.
(b) Steel. Open-hearth or electric steel of uniform quality must be
used. Content percent may not exceed the following: Carbon, 0.55;
phosphorous, 0.045; sulphur, 0.050.
(c) Identification of material. Material must be identified by any
suitable method, except that plates and billets for hot-drawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No fissure or other defect is permitted
that is likely to weaken the finished cylinder appreciably. A reasonably
smooth and uniform surface finish is required. If not originally free
from such defects, the surface may be machined or otherwise treated to
eliminate these defects. The thickness of the bottoms of cylinders
welded or formed by spinning is, under no condition, to be less than two
times the minimum wall thickness of the cylindrical shell; such bottom
thicknesses must be measured within an area bounded by a line
representing the points of contact between the cylinder and floor when
the cylinder is in a vertical position.
(e) Welding or brazing. Welding or brazing for any purpose
whatsoever is prohibited except as follows:
(1) Welding or brazing is authorized for the attachment of neckrings
and footrings which are non-pressure parts
[[Page 18]]
and only to the tops and bottoms of cylinders having a service pressure
of 500 psig or less. Cylinders, neckrings, and footrings must be made of
weldable steel, the carbon content of which may not exceed 0.25 percent
except in the case of 4130X steel which may be used with proper welding
procedures.
(2) As permitted in paragraph (d) of this section.
(3) Cylinders used solely in anhydrous ammonia service may have a
\1/2\ inch diameter bar welded within their concave bottoms.
(f) Wall thickness. For cylinders with service pressure less than
900 psig, the wall stress may not exceed 24,000 psig. A minimum wall
thickness of 0.100 inch is required for any cylinder over 5 inches
outside diameter. Wall stress calculation must be made by using the
following formula:
S = [P(1.3D\2\+0.4d\2\)]/(D\2\-d\2\)
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test or 450 psig
whichever is the greater;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. The completed cylinder must be uniformly and
properly heat-treated prior to tests.
(h) Openings in cylinders and connections (valves, fuse plugs, etc.)
for those openings. Threads are required on openings.
(1) Threads must be clean cut, even, without checks, and to gauge.
(2) Taper threads, when used, must be of length not less than as
specified for American Standard taper pipe threads.
(3) Straight threads having at least 6 engaged threads are
authorized. Straight threads must have a tight fit and calculated shear
strength of at least 10 times the test pressure of the cylinder.
Gaskets, adequate to prevent leakage, are required.
(i) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test, as follows:
(1) The test must be by water-jacket, or other suitable methods,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus the test pressure cannot be maintained the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent, volumetric expansion may not exceed 10 percent of the
total volumetric expansion at test pressure.
(4) Each cylinder must be tested to at least \5/3\ times service
pressure.
(j) Flattening test. A flattening test must be performed on one
cylinder taken at random out of each lot of 200 or less, by placing the
cylinder between wedge shaped knife edges having a 60[deg] included
angle, rounded to \1/2\-inch radius. The longitudinal axis of the
cylinder must be at a 90-degree angle to knife edges during the test.
For lots of 30 or less, flattening tests are authorized to be made on a
ring at least 8 inches long cut from each cylinder and subjected to same
heat treatment as the finished cylinder.
(k) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material as follows:
(1) The test is required on 2 specimens cut from 1 cylinder taken at
random out of each lot of 200 or less. For lots of 30 or less, physical
tests are authorized to be made on a ring at least 8 inches long cut
from each cylinder and subjected to same heat treatment as the finished
cylinder.
(2) Specimens must conform to the following:
(i) Gauge length of 8 inches with a width of not over 1\1/2\ inches,
a gauge length of 2 inches with a width of not over 1\1/2\ inches, or a
gauge length of at least 24 times thickness with width not over 6 times
thickness is authorized when cylinder wall is not over \3/16\ inch
thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends
[[Page 19]]
may be flattened to within 1 inch of each end of the reduced section.
(iii) When size of cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold, by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2-percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy the entire stress-strain diagram
must be plotted and the yield strength determined from the 0.2 percent
offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psig and the
strain indicator reading must be set at the calculated corresponding
strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(l) Acceptable results for physical and flattening tests. Either of
the following is an acceptable result:
(1) An elongation at least 40 percent for a 2-inch gauge length or
at least 20 percent in other cases and yield strength not over 73
percent of tensile strength. In this instance, the flattening test is
not required.
(2) An elongation at least 20 percent for a 2-inch gauge length or
10 percent in other cases and a yield strength not over 73 percent of
tensile strength. In this instance, the flattening test is required,
without cracking, to 6 times the wall thickness.
(m) Leakage test. All spun cylinders and plugged cylinders must be
tested for leakage by gas or air pressure after the bottom has been
cleaned and is free from all moisture subject to the following
conditions and limitations:
(1) Pressure, approximately the same as but no less than service
pressure, must be applied to one side of the finished bottom over an
area of at least \1/16\ of the total area of the bottom but not less
than \3/4\ inch in diameter, including the closure, for at least 1
minute, during which time the other side of the bottom exposed to
pressure must be covered with water and closely examined for indications
of leakage. Except as provided in paragraph (n) of this section, a
cylinder that is leaking must be rejected.
(2) A spun cylinder is one in which an end closure in the finished
cylinder has been welded by the spinning process.
(3) A plugged cylinder is one in which a permanent closure in the
bottom of a finished cylinder has been effected by a plug.
(4) As a safety precaution, if the manufacturer elects to make this
test before the hydrostatic test, the manufacturer should design the
test apparatus so that the pressure is applied to the smallest area
practicable, around the point of closure, and so as to use the smallest
possible volume of air or gas.
(n) Rejected cylinders. Reheat treatment is authorized for rejected
cylinders. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding or spinning is not authorized. Spun
cylinders rejected under the provisions of paragraph (m) of this section
may be removed from the spun cylinder category
[[Page 20]]
by drilling to remove defective material, tapping and plugging.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 62 FR 51561,
Oct. 1, 1997; 66 FR 45185, 45386-45387, Aug. 28, 2001; 67 FR 51652, Aug.
8, 2002; 68 FR 75748, Dec. 31, 2003; 73 FR 57006, Oct. 1, 2008]
Sec. 178.37 Specification 3AA and 3AAX seamless steel cylinders.
(a) Type, size and service pressure. In addition to the requirements
of Sec. 178.35, cylinders must conform to the following:
(1) A DOT-3AA cylinder is a seamless steel cylinder with a water
capacity (nominal) of not over 1,000 pounds and a service pressure of at
least 150 psig.
(2) A DOT-3AAX cylinder is a seamless steel cylinder with a water
capacity of not less than 1,000 pounds and a service pressure of at
least 500 psig, conforming to the following requirements:
(i) Assuming the cylinder is to be supported horizontally at its two
ends only and to be uniformly loaded over its entire length consisting
of the weight per unit of length of the straight cylindrical portion
filled with water and compressed to the specified test pressure; the sum
of two times the maximum tensile stress in the bottom fibers due to
bending, plus that in the same fibers (longitudinal stress), due to
hydrostatic test pressure may not exceed 80 percent of the minimum yield
strength of the steel at such maximum stress. Wall thickness must be
increased when necessary to meet the requirement.
(ii) To calculate the maximum tensile stress due to bending, the
following formula must be used:
S = Mc/I
(iii) To calculate the maximum longitudinal tensile stress due to
hydrostatic test pressure, the following formula must be used:
S = A\1\P/A\2\
Where:
S = tensile stress-p.s.i.;
M = bending moment-inch pounds (wl\2\)/8;
w = weight per inch of cylinder filled with water;
l = length of cylinder-inches;
c = radius (D)/(2) of cylinder-inches;
I = moment of inertia-0.04909 (D\4\-d\4\) inches fourth;
D = outside diameter-inches;
d = inside diameter-inches;
A\1\ = internal area in cross section of cylinder-square inches;
A\2\ = area of metal in cross section of cylinder-square inches;
P = hydrostatic test pressure-psig.
(b) Authorized steel. Open-hearth, basic oxygen, or electric steel
of uniform quality must be used. A heat of steel made under the
specifications in table 1 of this paragraph (b), check chemical analysis
of which is slightly out of the specified range, is acceptable, if
satisfactory in all other respects, provided the tolerances shown in
table 2 of this paragraph (b) are not exceeded. When a carbon-boron
steel is used, a hardenability test must be performed on the first and
last ingot of each heat of steel. The results of this test must be
recorded on the Record of Chemical Analysis of Material for Cylinders
required by Sec. 178.35. This hardness test must be made \5/16\-inch
from the quenched end of the Jominy quench bar and the hardness must be
at least Rc 33 and no more than Rc 53. The following chemical analyses
are authorized:
Table 1--Authorized Materials
--------------------------------------------------------------------------------------------------------------------------------------------------------
Inter- mediate
Designation 4130X (percent) NE-8630 (percent) 9115 (percent) 9125 (percent) Carbon-boron manganese
(see Note 1) (see Note 1) (see Note 1) (see Note 1) (percent) (percent)
--------------------------------------------------------------------------------------------------------------------------------------------------------
Carbon.......................... 0.25/0.35......... 0.28/0.33......... 0.10/0.20......... 0.20/0.30......... 0.27-0.37......... 0.40 max.
Manganese....................... 0.40/0.90......... 0.70/0.90......... 0.50/0.75......... 0.50/0.75......... 0.80-1.40......... 1.35/1.65.
Phosphorus...................... 0.04 max.......... 0.04 max.......... 0.04 max.......... 0.04 max.......... 0.035 max......... 0.04 max.
Sulfur.......................... 0.05 max.......... 0.04 max.......... 0.04 max.......... 0.04 max.......... 0.045 max......... 0.05 max.
Silicon......................... 0.15/0.35......... 0.20/0.35......... 0.60/0.90......... 0.60/0.90......... 0.3 max........... 0.10/0.30.
Chromium........................ 0.80/1.10......... 0.40/0.60......... 0.50/0.65......... 0.50/0.65.
Molybdenum...................... 0.15/0.25......... 0.15/0.25
Zirconium....................... .................. .................. 0.05/0.15......... 0.05/0.15
Nickel.......................... .................. 0.40/0.70.........
Boron........................... .................. .................. .................. .................. 0.0005/0.003.
--------------------------------------------------------------------------------------------------------------------------------------------------------
Note 1: This designation may not be restrictive and the commercial steel is limited in analysis as shown in this table.
[[Page 21]]
Table 2--Check Analysis Tolerances
----------------------------------------------------------------------------------------------------------------
Tolerance (percent) over
the maximum limit or
under the minimum limit
Element Limit or maximum specified (percent) -------------------------
Under Over
minimum maximum
limit limit
----------------------------------------------------------------------------------------------------------------
Carbon........................................ To 0.15 incl.......................... 0.02 0.03
Over 0.15 to 0.40 incl................ .03 .04
Manganese..................................... To 0.60 incl.......................... .03 .03
Over 0.60 to 1.15 incl................ 0.04 0.04
Over 1.15 to 2.50 incl................ 0.05 0.05
Phosphorus\1\................................. All ranges............................ ........... .01
Sulphur....................................... All ranges............................ ........... .01
Silicon....................................... To 0.30 incl.......................... .02 .03
Over 0.30 to 1.00 incl................ .05 .05
Nickel........................................ To 1.00 incl.......................... .03 .03
Chromium...................................... To 0.90 incl.......................... .03 .03
0.90 to 2.90 incl..................... .05 .05
Molybdenum.................................... To 0.20 incl.......................... .01 .01
Over 0.20 to 0.40..................... .02 .02
Zirconium..................................... All ranges............................ .01 .05
----------------------------------------------------------------------------------------------------------------
\1\ Rephosphorized steels not subject to check analysis for phosphorus.
(c) Identification of material. Material must be identified by any
suitable method except that plates and billets for hot-drawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No fissure or other defects is permitted
that is likely to weaken the finished cylinder appreciably. A reasonably
smooth and uniform surface finish is required. If not originally free
from such defects, the surface may be machined or otherwise treated to
eliminate these defects. The thickness of the bottoms of cylinders
welded or formed by spinning is, under no condition, to be less than two
times the minimum wall thickness of the cylindrical shell; such bottom
thicknesses must be measured within an area bounded by a line
representing the points of contact between the cylinder and floor when
the cylinder is in a vertical position.
(e) Welding or brazing. Welding or brazing for any purpose
whatsoever is prohibited except as follows:
(1) Welding or brazing is authorized for the attachment of neckrings
and footrings which are non-pressure parts, and only to the tops and
bottoms of cylinders having a service pressure of 500 psig or less.
Cylinders, neckrings, and footrings must be made of weldable steel, the
carbon content of which may not exceed 0.25 percent except in the case
of 4130X steel which may be used with proper welding procedure.
(2) As permitted in paragraph (d) of this section.
(f) Wall thickness. The thickness of each cylinder must conform to
the following:
(1) For cylinders with a service pressure of less than 900 psig, the
wall stress may not exceed 24,000 psi. A minimum wall thickness of 0.100
inch is required for any cylinder with an outside diameter of over 5
inches.
(2) For cylinders with service pressure of 900 psig or more the
minimum wall must be such that the wall stress at the minimum specified
test pressure may not exceed 67 percent of the minimum tensile strength
of the steel as determined from the physical tests required in
paragraphs (k) and (l) of this section and must be not over 70,000 psi.
(3) Calculation must be made by the formula:
S = [P(1.3D\2\+0.4d\2\)]/(D\2\-d\2\)
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test or 450 psig
whichever is the greater;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. The completed cylinders must be uniformly and
properly
[[Page 22]]
heat treated prior to tests. Heat treatment of cylinders of the
authorized analyses must be as follows:
(1) All cylinders must be quenched by oil, or other suitable medium
except as provided in paragraph (g)(5) of this section.
(2) The steel temperature on quenching must be that recommended for
the steel analysis, but may not exceed 1750 [deg]F.
(3) All steels must be tempered at a temperature most suitable for
that steel.
(4) The minimum tempering temperature may not be less than 1000
[deg]F except as noted in paragraph (g)(6) of this section.
(5) Steel 4130X may be normalized at a temperature of 1650 [deg]F
instead of being quenched and cylinders so normalized need not be
tempered.
(6) Intermediate manganese steels may be tempered at temperatures
not less than 1150 [deg]F., and after heat treating each cylinder must
be submitted to a magnetic test to detect the presence of quenching
cracks. Cracked cylinders must be rejected and destroyed.
(7) Except as otherwise provided in paragraph (g)(6) of this
section, all cylinders, if water quenched or quenched with a liquid
producing a cooling rate in excess of 80 percent of the cooling rate of
water, must be inspected by the magnetic particle, dye penetrant or
ultrasonic method to detect the presence of quenching cracks. Any
cylinder designed to the requirements for specification 3AA and found to
have a quenching crack must be rejected and may not be requalified.
Cylinders designed to the requirements for specification 3AAX and found
to have cracks must have cracks removed to sound metal by mechanical
means. Such specification 3AAX cylinders will be acceptable if the
repaired area is subsequently examined to assure no defect, and it is
determined that design thickness requirements are met.
(h) Openings in cylinders and connections (valves, fuse plugs, etc.)
for those openings. Threads are required on openings.
(1) Threads must be clean cut, even, without checks, and to gauge.
(2) Taper threads, when used, must be of a length not less than as
specified for American Standard taper pipe threads.
(3) Straight threads having at least 6 engaged threads are
authorized. Straight threads must have a tight fit and a calculated
shear strength of at least 10 times the test pressure of the cylinder.
Gaskets, adequate to prevent leakage, are required.
(i) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Each cylinder must be tested to at least \5/3\ times the service
pressure.
(j) Flattening test. A flattening test must be performed on one
cylinder taken at random out of each lot of 200 or less, by placing the
cylinder between wedge shaped knife edges having a 60[deg] included
angle, rounded to \1/2\-inch radius. The longitudinal axis of the
cylinder must be at a 90-degree angle to knife edges during the test.
For lots of 30 or less, flattening tests are authorized to be made on a
ring at least 8 inches long cut from each cylinder and subjected to the
same heat treatment as the finished cylinder. Cylinders may be subjected
to a bend test in lieu of the flattening test. Two bend test specimens
must be taken in accordance with ISO 9809-1 or ASTM E 290 (IBR, see
Sec. 171.7 of this subchapter), and must be subjected to the bend test
specified therein.
[[Page 23]]
(k) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material as follows:
(1) The test is required on 2 specimens cut from 1 cylinder taken at
random out of each lot of 200 or less. For lots of 30 or less, physical
tests are authorized to be made on a ring at least 8 inches long cut
from each cylinder and subjected to the same heat treatment as the
finished cylinder.
(2) Specimens must conform to the following:
(i) Gauge length of 8 inches with a width of not over 1\1/2\ inches,
a gauge length of 2 inches with a width of not over 1\1/2\ inches, or a
gauge length of at least 24 times the thickness with width not over 6
times thickness when the thickness of the cylinder wall is not over \3/
16\ inch.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within 1 inch of each end of the reduced
section.
(iii) When size of cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold, by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi, the strain
indicator reading being set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(l) Acceptable results for physical, flattening and bend tests. An
acceptable result for physical and flattening tests is elongation of at
least 20 percent for 2 inches of gauge length or at least 10 percent in
other cases. Flattening is required, without cracking, to 6 times the
wall thickness of the cylinder. An acceptable result for the alternative
bend test is no crack when the cylinder is bent inward around the
mandrel until the interior edges are not further apart than the diameter
of the mandrel.
(m) Leakage test. All spun cylinders and plugged cylinders must be
tested for leakage by gas or air pressure after the bottom has been
cleaned and is free from all moisture. Pressure, approximately the same
as but no less than the service pressure, must be applied to one side of
the finished bottom over an area of at least \1/16\ of the total area of
the bottom but not less than \3/4\ inch in diameter, including the
closure, for at least one minute, during which time the other side of
the bottom exposed to pressure must be covered with water and closely
examined for indications of leakage. Except as provided in paragraph (n)
of this section, a cylinder must be rejected if there is any leaking.
(1) A spun cylinder is one in which an end closure in the finished
cylinder has been welded by the spinning process.
(2) A plugged cylinder is one in which a permanent closure in the
bottom of a finished cylinder has been effected by a plug.
(3) As a safety precaution, if the manufacturer elects to make this
test
[[Page 24]]
before the hydrostatic test, the manufacturer should design the test
apparatus so that the pressure is applied to the smallest area
practicable, around the point of closure, and so as to use the smallest
possible volume of air or gas.
(n) Rejected cylinders. Reheat treatment is authorized for rejected
cylinders. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding or spinning is not authorized. Spun
cylinders rejected under the provision of paragraph (m) of this section
may be removed from the spun cylinder category by drilling to remove
defective material, tapping and plugging.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 65 FR 58631,
Sept. 29, 2000; 66 FR 45386-45387, Aug. 28, 2001; 67 FR 51652, Aug. 8,
2002; 68 FR 75748, Dec. 31, 2003; 76 FR 43531, July 20, 2011]
Sec. 178.38 Specification 3B seamless steel cylinders.
(a) Type, size, and service pressure. A DOT 3B cylinder is seamless
steel cylinder with a water capacity (nominal) of not over 1,000 pounds
and a service pressure of at least 150 to not over 500 psig.
(b) Steel. Open-hearth or electric steel of uniform quality must be
used. Content percent may not exceed the following: carbon, 0.55;
phosphorus, 0.045; sulphur, 0.050.
(c) Identification of material. Material must be identified by any
suitable method except that plates and billets for hot-drawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No fissure or other defect is permitted
that is likely to weaken the finished cylinder appreciably. A reasonably
smooth and uniform surface finish is required. If not originally free
from such defects, the surface may be machined or otherwise treated to
eliminate these defects. The thickness of the bottoms of cylinders
welded or formed by spinning is, under no condition, to be less than two
times the minimum wall thickness of the cylindrical shell; such bottom
thicknesses to be measured within an area bounded by a line representing
the points of contact between the cylinder and floor when the cylinder
is in a vertical position.
(e) Welding or brazing. Welding or brazing for any purpose
whatsoever is prohibited except as follows:
(1) Welding or brazing is authorized for the attachment of neckrings
and footrings which are non-pressure parts, and only to the tops and
bottoms of cylinders having a service pressure of 500 psig or less.
Cylinders, neckrings, and footrings must be made of weldable steel,
carbon content of which may not exceed 0.25 percent except in the case
of 4130X steel which may be used with proper welding procedure.
(2) As permitted in paragraph (d) of this section.
(f) Wall thickness. The wall stress may not exceed 24,000 psi. The
minimum wall thickness is 0.090 inch for any cylinder with an outside
diameter of 6 inches. Calculation must be made by the following formula:
S = [P(1.3D\2\+0.4d\2\)]/(D\2\-d\2\)
Where:
S = wall stress in psi;
P = at least two times service pressure or 450 psig, whichever is the
greater;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. The completed cylinders must be uniformly and
properly heat-treated prior to tests.
(h) Openings in cylinders and connections (valves, fuse plugs, etc.)
for those openings. Threads, conforming to the following, are required
on all openings:
(1) Threads must be clean cut, even, without checks, and to gauge.
(2) Taper threads when used, must be of a length not less than as
specified for American Standard taper pipe threads.
(3) Straight threads having at least 4 engaged threads are
authorized. Straight threads must have a tight fit, and calculated shear
strength at least 10 times the test pressure of the cylinder. Gaskets,
adequate to prevent leakage, are required.
(i) Hydrostatic test. Cylinders must successfully withstand a
hydrostatic test, as follows:
[[Page 25]]
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy either of 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to insure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Cylinders must be tested as follows:
(i) Each cylinder; to at least 2 times service pressure; or
(ii) 1 cylinder out of each lot of 200 or less; to at least 3 times
service pressure. Others must be examined under pressure of 2 times
service pressure and show no defect.
(j) Flattening test. A flattening test must be performed on one
cylinder taken at random out of each lot of 200 or less, by placing the
cylinder between wedge shaped knife edges having a 60[deg] included
angle, rounded to \1/2\-inch radius. The longitudinal axis of the
cylinder must be at a 90-degree angle to knife edges during the test.
For lots of 30 or less, flattening tests are authorized to be made on a
ring at least 8 inches long cut from each cylinder and subjected to same
heat treatment as the finished cylinder.
(k) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material, as follows:
(1) The test is required on 2 specimens cut from 1 cylinder taken at
random out of each lot of 200 or less. For lots of 30 or less, physical
tests are authorized to be made on a ring at least 8 inches long cut
from each cylinder and subjected to same heat treatment as the finished
cylinder.
(2) Specimens must conform to the following:
(i) Gauge length of 8 inches with a width of not over 1\1/2\ inches;
or a gauge length of 2 inches with a width of not over 1\1/2\ inches; or
a gauge length at least 24 times the thickness with a width not over 6
times thickness is authorized when a cylinder wall is not over \3/16\
inch thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within one inch of each end of the reduced
section.
(iii) When size of cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold, by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi, and the
strain indicator reading being set at the calculated corresponding
strain.
[[Page 26]]
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(l) Acceptable results for physical and flattening tests. Either of
the following is an acceptable result:
(1) An elongation of at least 40 percent for a 2-inch gauge length
or at least 20 percent in other cases and yield strength not over 73
percent of tensile strength. In this instance, the flattening test is
not required.
(2) An elongation of at least 20 percent for a 2-inch gauge length
or 10 percent in other cases and yield strength not over 73 percent of
tensile strength. Flattening is required, without cracking, to 6 times
the wall thickness.
(m) Leakage test. All spun cylinders and plugged cylinders must be
tested for leakage by gas or air pressure after the bottom has been
cleaned and is free from all moisture, subject to the following
conditions and limitations:
(1) Pressure, approximately the same as but no less than service
pressure, must be applied to one side of the finished bottom over an
area of at least \1/16\ of the total area of the bottom but not less
than \3/4\ inch in diameter, including the closure, for at least one
minute, during which time the other side of the bottom exposed to
pressure must be covered with water and closely examined for indications
of leakage. Except as provided in paragraph (n) of this section, a
cylinder must be rejected if there is any leaking.
(2) A spun cylinder is one in which an end closure in the finished
cylinder has been welded by the spinning process.
(3) A plugged cylinder is one in which a permanent closure in the
bottom of a finished cylinder has been effected by a plug.
(4) As a safety precaution, if the manufacturer elects to make this
test before the hydrostatic test, he should design his apparatus so that
the pressure is applied to the smallest area practicable, around the
point of closure, and so as to use the smallest possible volume of air
or gas.
(n) Rejected cylinders. Reheat treatment of rejected cylinders is
authorized. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding or spinning is not authorized. Spun
cylinders rejected under the provisions of paragraph (m) of this section
may be removed from the spun cylinder category by drilling to remove
defective material, tapping and plugging.
(o) Marking. Markings may be stamped into the sidewalls of cylinders
having a service pressure of 150 psig if all of the following conditions
are met:
(1) Wall stress at test pressure may not exceed 24,000 psi.
(2) Minimum wall thickness must be not less than 0.090 inch.
(3) Depth of stamping must be no greater than 15 percent of the
minimum wall thickness, but may not exceed 0.015 inch.
(4) Maximum outside diameter of cylinder may not exceed 5 inches.
(5) Carbon content of cylinder may not exceed 0.25 percent. If the
carbon content exceeds 0.25 percent, the complete cylinder must be
normalized after stamping.
(6) Stamping must be adjacent to the top head.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended by 66 FR 45185,
45386-45388, Aug. 28, 2001; 67 FR 51652, Aug. 8, 2002; 68 FR 75748, Dec.
31, 2003]
Sec. 178.39 Specification 3BN seamless nickel cylinders.
(a) Type, size and service pressure. A DOT 3BN cylinder is a
seamless nickel cylinder with a water capacity (nominal) not over 125
pounds water capacity (nominal) and a service pressure at least 150 to
not over 500 psig.
(b) Nickel. The percentage of nickel plus cobalt must be at least
99.0 percent.
(c) Identification of material. The material must be identified by
any suitable method except that plates and billets for hot-drawn
cylinders must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. Cylinders closed in by spinning
process are not authorized.
[[Page 27]]
(e) Welding or brazing. Welding or brazing for any purpose
whatsoever is prohibited except that welding is authorized for the
attachment of neckrings and footrings which are nonpressure parts, and
only to the tops and bottoms of cylinders. Neckrings and footrings must
be of weldable material, the carbon content of which may not exceed 0.25
percent. Nickel welding rod must be used.
(f) Wall thickness. The wall stress may not exceed 15,000 psi. A
minimum wall thickness of 0.100 inch is required for any cylinder over 5
inches in outside diameter. Wall stress calculation must be made by
using the following formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test or 450 psig
whichever is the greater;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. The completed cylinders must be uniformly and
properly heat-treated prior to tests.
(h) Openings in cylinders and connections (valves, fuse plugs, etc.)
for those openings. Threads conforming to the following are required on
openings:
(1) Threads must be clean cut, even, without checks, and to gauge.
(2) Taper threads, when used, to be of length not less than as
specified for American Standard taper pipe threads.
(3) Straight threads having at least 6 engaged threads are
authorized. Straight threads must have a tight fit and a calculated
shear strength of at least 10 times the test pressure of the cylinder.
Gaskets, adequate to prevent leakage, are required.
(i) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test, as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy either of 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Each cylinder must be tested to at least 2 times service
pressure.
(j) Flattening test. A flattening test must be performed on one
cylinder taken at random out of each lot of 200 or less, by placing the
cylinder between wedge shaped knife edges having a 60[deg] included
angle, rounded to \1/2\-inch radius. The longitudinal axis of the
cylinder must be at a 90-degree angle to knife edges during the test.
For lots of 30 or less, flattening tests are authorized to be made on a
ring at least 8 inches long cut from each cylinder and subjected to same
heat treatment as the finished cylinder.
(k) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material, as follows:
(1) The test is required on 2 specimens cut from 1 cylinder taken at
random out of each lot of 200 or less. For lots of 30 or less, physical
tests are authorized to be made on a ring at least 8 inches long cut
from each cylinder and subjected to same heat treatment as the finished
cylinder.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width of not over 1\1/2\
inches, a gauge length of 2 inches with a width of not over 1\1/2\
inches, or a gauge length of at least 24 times the thickness with a
width not over 6 times thickness is authorized when a cylinder wall is
not over \3/16\ inch thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within one inch of each end of the reduced
section.
(iii) When size of cylinder does not permit securing straight
specimens,
[[Page 28]]
the specimens may be taken in any location or direction and may be
straightened or flattened cold, by pressure only, not by blows. When
specimens are so taken and prepared, the inspector's report must show in
connection with record of physical tests detailed information in regard
to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi, and the
strain indicator reading must be set at the calculated corresponding
strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(l) Acceptable results for physical and flattening tests. Either of
the following is an acceptable result:
(1) An elongation of at least 40 percent for a 2 inch gauge length
or at least 20 percent in other cases and yield point not over 50
percent of tensile strength. In this instance, the flattening test is
not required.
(2) An elongation of at least 20 percent for a 2 inch gauge length
or 10 percent in other cases and a yield point not over 50 percent of
tensile strength. Flattening is required, without cracking, to 6 times
the wall thickness.
(m) Rejected cylinders. Reheat treatment is authorized for rejected
cylinders. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding is not authorized.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended by 66 FR 45185,
45386, 45388, Aug. 28, 2001; 67 FR 51652, Aug. 8, 2002; 68 FR 75748,
Dec. 31, 2003]
Sec. 178.42 Specification 3E seamless steel cylinders.
(a) Type, size, and service pressure. A DOT 3E cylinder is a
seamless steel cylinder with an outside diameter not greater than 2
inches nominal, a length less than 2 feet and a service pressure of
1,800 psig.
(b) Steel. Open-hearth or electric steel of uniform quality must be
used. Content percent may not exceed the following: Carbon, 0.55;
phosphorus, 0.045; sulphur, 0.050.
(c) Identification of steel. Materials must be identified by any
suitable method.
(d) Manufacture. Cylinders must be manufactured by best appliances
and methods. No defect is permitted that is likely to weaken the
finished cylinder appreciably. A reasonably smooth and uniform surface
finish is required. The thickness of the spun bottom is, under no
condition, to be less than two times the minimum wall thickness of the
cylindrical shell; such bottom thickness must be measured within an area
bounded by a line representing the points of contact between the
cylinder and floor when the cylinder is in a vertical position.
(e) Openings in cylinders and connections (valves, fuse plugs, etc.)
for those openings. Threads conforming to the following are required on
openings.
(1) Threads must be clean cut, even, without checks, and to gauge.
(2) Taper threads, when used, must be of length not less than as
specified for American Standard taper pipe threads.
(3) Straight threads having at least 4 engaged threads are
authorized. Straight threads must have a tight fit and a calculated
shear strength of at least 10 times the test pressure of the
[[Page 29]]
cylinder. Gaskets, adequate to prevent leakage, are required.
(f) Hydrostatic test. Cylinders must be tested as follows:
(1) One cylinder out of each lot of 500 or less must be subjected to
a hydrostatic pressure of 6,000 psig or higher.
(2) The cylinder referred to in paragraph (f)(1) of this section
must burst at a pressure higher than 6,000 psig without fragmenting or
otherwise showing lack of ductility, or must hold a pressure of 12,000
psig for 30 seconds without bursting. In which case, it must be
subjected to a flattening test without cracking to six times wall
thickness between knife edges, wedge shaped 60 degree angle, rounded out
to a \1/2\ inch radius. The inspector's report must be suitably changed
to show results of latter alternate and flattening test.
(3) Other cylinders must be examined under pressure of at least
3,000 psig and not to exceed 4,500 psig and show no defect. Cylinders
tested at a pressure in excess of 3,600 psig must burst at a pressure
higher than 7,500 psig when tested as specified in paragraph (f)(2) of
this section. The pressure must be maintained for at least 30 seconds
and sufficiently longer to ensure complete examination.
(g) Leakage test. All spun cylinders and plugged cylinders must be
tested for leakage by gas or air pressure after the bottom has been
cleaned and is free from all moisture subject to the following
conditions and limitations:
(1) A pressure, approximately the same as but not less than the
service pressure, must be applied to one side of the finished bottom
over an area of at least \1/16\ of the total area of the bottom but not
less than \3/4\ inch in diameter, including the closure, for at least
one minute, during which time the other side of the bottom exposed to
pressure must be covered with water and closely examined for indications
of leakage. Accept as provided in paragraph (h) of this section, a
cylinder must be rejected if there is any leakage.
(2) A spun cylinder is one in which an end closure in the finished
cylinder has been welded by the spinning process.
(3) A plugged cylinder is one in which a permanent closure in the
bottom of a finished cylinder has been effected by a plug.
(4) As a safety precaution, if the manufacturer elects to make this
test before the hydrostatic test, the manufacturer shall design the test
apparatus so that the pressure is applied to the smallest area
practicable, around the point of closure, and so as to use the smallest
possible volume of air or gas.
(h) Rejected cylinders. Reheat treatment is authorized for rejected
cylinders. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding or spinning is not authorized. Spun
cylinders rejected under the provisions of paragraph (g) of this section
may be removed from the spun cylinder category by drilling to remove
defective material, tapping and plugging.
(i) Marking. Markings required by Sec. 178.35 must be stamped
plainly and permanently on the shoulder, top head, neck or sidewall of
each cylinder.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended by 66 FR 45386,
Aug. 28, 2001]
Sec. 178.44 Specification 3HT seamless steel cylinders for aircraft use.
(a) Type, size and service pressure. A DOT 3HT cylinder is a
seamless steel cylinder with a water capacity (nominal) of not over 150
pounds and a service pressure of at least 900 psig.
(b) Authorized steel. Open hearth or electric furnace steel of
uniform quality must be used. A heat of steel made under the
specifications listed in Table 1 in this paragraph (b), a check chemical
analysis that is slightly out of the specified range is acceptable, if
satisfactory in all other respects, provided the tolerances shown in
Table 2 in this paragraph (b) are not exceeded. The maximum grain size
shall be 6 or finer. The grain size must be determined in accordance
with ASTM E 112-88 (IBR, see Sec. 171.7 of this subchapter). Steel of
the following chemical analysis is authorized:
Table 1--Authorized Materials
------------------------------------------------------------------------
Designation AISI 4130 (percent)
------------------------------------------------------------------------
Carbon................................. 0.28/0.33
Manganese.............................. 0.40/0.60
Phosphorus............................. 0.040 maximum
Sulfur................................. 0.040 maximum
[[Page 30]]
Silicon................................ 0.15/0.35
Chromium............................... 0.80/1.10
Molybdenum............................. 0.15/0.25
------------------------------------------------------------------------
Table 2--Check Analysis Tolerances
------------------------------------------------------------------------
Tolerance
(percent) over the
maximum limit or
under the minimum
Element Limit or maximum limit
specified (percent) -------------------
Under Over
minimum maximum
limit limit
------------------------------------------------------------------------
Carbon....................... Over 0.15 to 0.40 .03 .04
incl.
Manganese.................... To 0.60 incl......... .03 .03
Phosphorus\1\................ All ranges........... ........ .01
Sulphur...................... All ranges........... ........ .01
Silicon...................... To 0.30 incl......... .02 .03
Over 0.30 to 1.00 .05 .05
incl.
Chromium..................... To 0.90 incl......... .03 .03
Over 0.90 to 2.10 .05 .05
incl.
Molybdenum................... To 0.20 incl......... .01 .01
Over 0.20 to 0.40 .02 .02
incl.
------------------------------------------------------------------------
\1\ Rephosphorized steels not subject to check analysis for phosphorus.
(c) Identification of material. Material must be identified by any
suitable method. Steel stamping of heat identifications may not be made
in any area which will eventually become the side wall of the cylinder.
Depth of stamping may not encroach upon the minimum prescribed wall
thickness of the cylinder.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No fissure or other defect is permitted
that is likely to weaken the finished container appreciably. The general
surface finish may not exceed a roughness of 250 RMS. Individual
irregularities such as draw marks, scratches, pits, etc., should be held
to a minimum consistent with good high stress pressure vessel
manufacturing practices. If the cylinder is not originally free of such
defects or does not meet the finish requirements, the surface may be
machined or otherwise treated to eliminate these defects. The point of
closure of cylinders closed by spinning may not be less than two times
the prescribed wall thickness of the cylindrical shell. The cylinder end
contour must be hemispherical or ellipsoidal with a ratio of major-to-
minor axis not exceeding two to one and with the concave side to
pressure.
(e) Welding or brazing. Welding or brazing for any purpose
whatsoever is prohibited, except that welding by spinning is permitted
to close the bottom of spun cylinders. Machining or grinding to produce
proper surface finish at point of closure is required.
(f) Wall thickness. (1) Minimum wall thickness for any cylinder must
be 0.050 inch. The minimum wall thickness must be such that the wall
stress at the minimum specified test pressure may not exceed 75 percent
of the minimum tensile strength of the steel as determined from the
physical tests required in paragraph (m) of this section and may not be
over 105,000 psi.
(2) Calculations must be made by the formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = Wall stress in psi;
P = Minimum test pressure prescribed for water jacket test;
D = Outside diameter in inches;
d = Inside diameter in inches.
(3) Wall thickness of hemispherical bottoms only permitted to 90
percent of minimum wall thickness of cylinder sidewall but may not be
less than 0.050 inch. In all other cases, thickness to be no less than
prescribed minimum wall.
(g) Heat treatment. The completed cylinders must be uniformly and
properly heated prior to tests. Heat treatment of the cylinders of the
authorized analysis must be as follows:
(1) All cylinders must be quenched by oil, or other suitable medium.
(2) The steel temperature on quenching must be that recommended for
the steel analysis, but may not exceed 1750 [deg]F.
(3) The steel must be tempered at a temperature most suitable for
the particular steel analysis but not less than 850 [deg]F.
(4) All cylinders must be inspected by the magnetic particle or dye
penetrant method to detect the presence of quenching cracks. Any
cylinder found to have a quenching crack must be rejected and may not be
requalified.
[[Page 31]]
(h) Openings in cylinders and connections (valves, fuse plugs, etc.)
for those openings. Threads conforming to the following are required on
openings:
(1) Threads must be clean cut, even, without cracks, and to gauge.
(2) Taper threads, when used, must be of length not less than as
specified for National Gas Tapered Thread (NGT) as required by American
Standard Compressed Gas Cylinder Valve Outlet and Inlet Connections.
(3) Straight threads having at least 6 engaged threads are
authorized. Straight threads must have a tight fit and a calculated
shear stress of at least 10 times the test pressure of the cylinder.
Gaskets, adequate to prevent leakage, are required.
(i) Hydrostatic test. Each cylinder must withstand a hydrostatic
test, as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. Pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy either of 1 percent of 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, which ever
is the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Each cylinder must be tested to at least \5/3\ times service
pressure.
(j) Cycling tests. Prior to the initial shipment of any specific
cylinder design, cyclic pressurization tests must have been performed on
at least three representative samples without failure as follows:
(1) Pressurization must be performed hydrostatically between
approximately zero psig and the service pressure at a rate not in excess
of 10 cycles per minute. Adequate recording instrumentation must be
provided if equipment is to be left unattended for periods of time.
(2) Tests prescribed in paragraph (j)(1) of this section must be
repeated on one random sample out of each lot of cylinders. The cylinder
may then be subjected to a burst test.
(3) A lot is defined as a group of cylinders fabricated from the
same heat of steel, manufactured by the same process and heat treated in
the same equipment under the same conditions of time, temperature, and
atmosphere, and may not exceed a quantity of 200 cylinders.
(4) All cylinders used in cycling tests must be destroyed.
(k) Burst test. One cylinder taken at random out of each lot of
cylinders must be hydrostatically tested to destruction.
(l) Flattening test. A flattening test must be performed on one
cylinder taken at random out of each lot of 200 or less, by placing the
cylinder between wedge shaped knife edges having a 60[deg] included
angle, rounded to \1/2\-inch radius. The longitudinal axis of the
cylinder must be at a 90-degree angle to knife edges during the test.
For lots of 30 or less, flattening tests are authorized to be made on a
ring at least 8 inches long cut from each cylinder and subjected to same
heat treatment as the finished cylinder.
(m) Physical tests. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material, as follows:
(1) Test is required on 2 specimens cut from 1 cylinder taken at
random out of each lot of cylinders.
(2) Specimens must conform to the following:
(i) A gauge length of at least 24 times the thickness with a width
not over six times the thickness. The specimen, exclusive of grip ends,
may not be flattened. Grip ends may be flattened to within one inch of
each end of the reduced section. When size of cylinder does not permit
securing straight specimens, the specimens may be taken in any location
or direction and may be straightened or flattened cold by pressure only,
not by blows. When specimens are so taken and prepared, the inspector's
report must show in
[[Page 32]]
connection with the record of physical tests detailed information in
regard to such specimens.
(ii) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length.
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi, the strain
indicator reading being set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(n) Magnetic particle inspection. Inspection must be performed on
the inside of each container before closing and externally on each
finished container after heat treatment. Evidence of discontinuities,
which in the opinion of a qualified inspector may appreciably weaken or
decrease the durability of the cylinder, must be cause for rejection.
(o) Leakage test. All spun cylinders and plugged cylinders must be
tested for leakage by dry gas or dry air pressure after the bottom has
been cleaned and is free from all moisture, subject to the following
conditions and limitations:
(1) Pressure, approximately the same as but not less than service
pressure, must be applied to one side of the finished bottom over an
area of at least \1/16\ of the total area of the bottom but not less
than \3/4\ inch in diameter, including the closure, for at least one
minute, during which time the other side of the bottom exposed to
pressure must be covered with water and closely examined for indications
of leakage. Except as provided in paragraph (q) of this section, a
cylinder must be rejected if there is leakage.
(2) A spun cylinder is one in which an end closure in the finished
cylinder has been welded by the spinning process.
(3) A plugged cylinder is one in which a permanent closure in the
bottom of a finished cylinder has been effected by a plug.
(4) As a safety precaution, if the manufacturer elects to make this
test before the hydrostatic test, the manufacturer should design the
test apparatus so that the pressure is applied to the smallest area
practicable, around the point of closure, and so as to use the smallest
possible volume of air or gas.
(p) Acceptable results of tests. Results of the flattening test,
physical tests, burst test, and cycling test must conform to the
following:
(1) Flattening required without cracking to ten times the wall
thickness of the cylinder.
(2) Physical tests:
(i) An elongation of at least 6 percent for a gauge length of 24
times the wall thickness.
(ii) The tensile strength may not exceed 165,000 p.s.i.
(3) The burst pressure must be at least \4/3\ times the test
pressure.
(4) Cycling-at least 10,000 pressurizations.
(q) Rejected cylinders. Reheat treatment is authorized for rejected
cylinders. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding or spinning is not authorized. For
each cylinder subjected to reheat treatment during original manufacture,
sidewall measurements must be made to verify that the minimum sidewall
thickness meets specification requirements after the final heat
treatment.
[[Page 33]]
(r) Marking. (1) Cylinders must be marked by low stress type steel
stamping in an area and to a depth which will insure that the wall
thickness measured from the root of the stamping to the interior surface
is equal to or greater than the minimum prescribed wall thickness.
Stamping must be permanent and legible. Stamping on side wall not
authorized.
(2) The rejection elastic expansion (REE), in cubic cm (cc), must be
marked on the cylinder near the date of test. The REE for a cylinder is
1.05 times its original elastic expansion.
(3) Name plates are authorized, provided that they can be
permanently and securely attached to the cylinder. Attachment by either
brazing or welding is not permitted. Attachment by soldering is
permitted provided steel temperature does not exceed 500 [deg]F.
(s) Inspector's report. In addition to the requirements of Sec.
178.35, the inspector's report must indicate the rejection elastic
expansion (REE), in cubic cm (cc).
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 62 FR 51561,
Oct. 1, 1997; 65 FR 58631, Sept. 29, 2000; 66 FR 45385, Aug. 28, 2001;
67 FR 51652, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31, 2003]
Sec. 178.45 Specification 3T seamless steel cylinder.
(a) Type, size, and service pressure. A DOT 3T cylinder is a
seamless steel cylinder with a minimum water capacity of 1,000 pounds
and a minimum service pressure of 1,800 psig. Each cylinder must have
integrally formed heads concave to pressure at both ends. The inside
head shape must be hemispherical, ellipsoidal in which the major axis is
two times the minor axis, or a dished shape falling within these two
limits. Permanent closures formed by spinning are prohibited.
(b) Material, steel. Only open hearth, basic oxygen, or electric
furnace process steel of uniform quality is authorized. The steel
analysis must conform to the following:
Analysis Tolerances
------------------------------------------------------------------------
Check Analysis
Element Ladle analysis -----------------
Under Over
------------------------------------------------------------------------
Carbon........................... 0.35 to 0.50....... 0.03 0.04
Manganese........................ 0.75 to 1.05....... 0.04 0.04
Phosphorus (max)................. 0.035.............. ....... 0.01
Sulphur (max).................... 0.04............... ....... 0.01
Silicon.......................... 0.15 to 0.35....... 0.02 0.03
Chromium......................... 0.80 to 1.15....... 0.05 0.05
Molybdenum....................... 0.15 to 0.25....... 0.02 0.02
------------------------------------------------------------------------
(1) A heat of steel made under the specifications in the table in
this paragraph (b), the ladle analysis of which is slightly out of the
specified range, is acceptable if satisfactory in all other aspects.
However, the check analysis tolerances shown in the table in this
paragraph (b) may not be exceeded except as approved by the Department.
(2) Material with seams, cracks, laminations, or other injurious
defects is not permitted.
(3) Material used must be identified by any suitable method.
(c) Manufacture. General manufacturing requirements are as follows:
(1) Surface finish must be uniform and reasonably smooth.
(2) Inside surfaces must be clean, dry, and free of loose particles.
(3) No defect of any kind is permitted if it is likely to weaken a
finished cylinder.
(4) If the cylinder surface is not originally free from the defects,
the surface may be machined or otherwise treated to eliminate these
defects provided the minimum wall thickness is maintained.
(5) Welding or brazing on a cylinder is not permitted.
(d) Wall thickness. The minimum wall thickness must be such that the
wall stress at the minimum specified test pressure does not exceed 67
percent of the minimum tensile strength of the steel as determined by
the physical tests required in paragraphs (j) and (k) of this section. A
wall stress of more than 90,500 p.s.i. is not permitted. The minimum
wall thickness for any cylinder may not be less than 0.225 inch.
(1) Calculation of the stress for cylinders must be made by the
following formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = Wall stress in psi;
[[Page 34]]
P = Minimum test pressure, at least \5/3\ service pressure;
D = Outside diameter in inches;
d = Inside diameter in inches.
(2) Each cylinder must meet the following additional requirement
which assumes a cylinder horizontally supported at its two ends and
uniformly loaded over its entire length. This load consists of the
weight per inch of length of the straight cylindrical portion filled
with water compressed to the specified test pressure. The wall thickness
must be increased when necessary to meet this additional requirement:
(i) The sum of two times the maximum tensile stress in the bottom
fibers due to bending (see paragraph (d)(2)(ii) of this section), plus
the maximum tensile stress in the same fibers due to hydrostatic testing
(see paragraph (d)(2)(iii) of this section) may not exceed 80 percent of
the minimum yield strength of the steel at this maximum stress.
(ii) The following formula must be used to calculate the maximum
tensile stress due to bending:
S = Mc / I
Where:
S = Tensile stress in psi;
M = Bending moment in inch-pounds (wl\2\/8);
I = Moment of inertia--0.04909 (D\4\-d\4\) in inches fourth;
c = Radius (D/2) of cylinder in inches;
w = Weight per inch of cylinder filled with water;
l = Length of cylinder in inches;
D = Outside diameter in inches;
d = Inside diameter in inches.
(iii) The following formula must be used to calculate the maximum
longitudinal tensile stress due to hydrostatic test pressure:
S = A1 P / A2
Where:
S = Tensile stress in psi;
A1 = Internal area in cross section of cylinder in square
inches;
P = Hydrostatic test pressure-psig;
A2 = Area of metal in cross section of cylinder in square
inches.
(e) Heat treatment. Each completed cylinder must be uniformly and
properly heat treated prior to testing, as follows:
(1) Each cylinder must be heated and held at the proper temperature
for at least one hour per inch of thickness based on the maximum
thickness of the cylinder and then quenched in a suitable liquid medium
having a cooling rate not in excess of 80 percent of water. The steel
temperature on quenching must be that recommended for the steel
analysis, but it must never exceed 1750 [deg]F.
(2) After quenching, each cylinder must be reheated to a temperature
below the transformation range but not less than 1050 [deg]F., and must
be held at this temperature for at least one hour per inch of thickness
based on the maximum thickness of the cylinder. Each cylinder must then
be cooled under conditions recommended for the steel.
(f) Openings. Openings in cylinders must comply with the following:
(1) Openings are permitted on heads only.
(2) The size of any centered opening in a head may not exceed one
half the outside diameter of the cylinder.
(3) Openings in a head must have ligaments between openings of at
least three times the average of their hole diameter. No off-center
opening may exceed 2.625 inches in diameter.
(4) All openings must be circular.
(5) All openings must be threaded. Threads must be in compliance
with the following:
(i) Each thread must be clean cut, even, without any checks, and to
gauge.
(ii) Taper threads, when used, must be the American Standard Pipe
thread (NPT) type and must be in compliance with the requirements of NBS
Handbook H-28 (IBR, see Sec. 171.7 of this subchapter).
(iii) Taper threads conforming to National Gas Taper thread (NGT)
standards must be in compliance with the requirements of NBS Handbook H-
28.
(iv) Straight threads conforming with National Gas Straight thread
(NGS) standards are authorized. These threads must be in compliance with
the requirements of NBS Handbook H-28.
(g) Hydrostatic test. Each cylinder must be tested at an internal
pressure by the water jacket method or other
[[Page 35]]
suitable method, conforming to the following requirements:
(1) The testing apparatus must be operated in a manner that will
obtain accurate data. Any pressure gauge used must permit reading to an
accuracy of one percent. Any expansion gauge used must permit reading of
the total expansion to an accuracy of one percent.
(2) Any internal pressure applied to the cylinder after heat
treatment and before the official test may not exceed 90 percent of the
test pressure.
(3) The pressure must be maintained sufficiently long to assure
complete expansion of the cylinder. In no case may the pressure be held
less than 30 seconds.
(4) If, due to failure of the test apparatus, the required test
pressure cannot be maintained, the test must be repeated at a pressure
increased by 10 percent or 100 psig, whichever is lower or, the cylinder
must be reheat treated.
(5) Permanent volumetric expansion of the cylinder may not exceed 10
percent of its total volumetric expansion at the required test pressure.
(6) Each cylinder must be tested to at least \5/3\ times its service
pressure.
(h) Ultrasonic examination. After the hydrostatic test, the
cylindrical section of each vessel must be examined in accordance with
ASTM E 213 for shear wave and E 114 for straight beam (IBR, Standard see
Sec. 171.7 of this subchapter). The equipment used must be calibrated
to detect a notch equal to five percent of the design minimum wall
thickness. Any discontinuity indication greater than that produced by
the five percent notch must be cause for rejection of the cylinder,
unless the discontinuity is repaired within the requirements of this
specification.
(i) Basic requirements for tension and Charpy impact tests.
Cylinders must be subjected to a tension and Charpy impact as follows:
(1) When the cylinders are heat treated in a batch furnace, two
tension specimens and three Charpy impact specimens must be tested from
one of the cylinders or a test ring from each batch. The lot size
represented by these tests may not exceed 200 cylinders.
(2) When the cylinders are heat treated in a continuous furnace, two
tension specimens and three Charpy impact specimens must be tested from
one of the cylinders or a test ring from each four hours or less of
production. However, in no case may a test lot based on this production
period exceed 200 cylinders.
(3) Each specimen for the tension and Charpy impact tests must be
taken from the side wall of a cylinder or from a ring which has been
heat treated with the finished cylinders of which the specimens must be
representative. The axis of the specimens must be parallel to the axis
of the cylinder. Each cylinder or ring specimen for test must be of the
same diameter, thickness, and metal as the finished cylinders they
represent. A test ring must be at least 24 inches long with ends covered
during the heat treatment process so as to simulate the heat treatment
process of the finished cylinders it represents.
(4) A test cylinder or test ring need represent only one of the
heats in a furnace batch provided the other heats in the batch have
previously been tested and have passed the tests and that such tests do
not represent more than 200 cylinders from any one heat.
(5) The test results must conform to the requirements specified in
paragraphs (j) and (k) of this section.
(6) When the test results do not conform to the requirements
specified, the cylinders represented by the tests may be reheat treated
and the tests repeated. Paragraph (i)(5) of this section applies to any
retesting.
(j) Basic conditions for acceptable physical testing. The following
criteria must be followed to obtain acceptable physical test results:
(1) Each tension specimen must have a gauge length of two inches
with a width not exceeding one and one-half inches. Except for the grip
ends, the specimen may not be flattened. The grip ends may be flattened
to within one inch of each end of the reduced section.
(2) A specimen may not be heated after heat treatment specified in
paragraph (d) of this section.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gage length.
(i) This yield strength must be determined by the ``offset'' method
or the
[[Page 36]]
``extension under load'' method described in ASTM E 8 (IBR, see Sec.
171.7 of this subchapter).
(ii) For the ``extension under load'' method, the total strain (or
extension under load) corresponding to the stress at which the 0.2
percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gage length under
appropriate load and adding thereto 0.2 percent of the gage length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. However, when the degree of accuracy of this method is
questionable the entire stress-strain diagram must be plotted and the
yield strength determined from the 0.2 percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set with the specimen under a stress of 12,000 p.s.i. and the strain
indicator reading set at the calculated corresponding strain.
(iv) The cross-head speed of the testing machine may not exceed \1/
8\ inch per minute during the determination of yield strength.
(4) Each impact specimen must be Charpy V-notch type size 10 mm x 10
mm taken in accordance with paragraph 11 of ASTM A 333 (IBR, see Sec.
171.7 of this subchapter). When a reduced size specimen is used, it must
be the largest size obtainable.
(k) Acceptable physical test results. Results of physical tests must
conform to the following:
(1) The tensile strength may not exceed 155,000 p.s.i.
(2) The elongation must be at least 16 percent for a two-inch gage
length.
(3) The Charpy V-notch impact properties for the three impact
specimens which must be tested at 0 [deg]F may not be less than the
values shown as follows:
------------------------------------------------------------------------
Average value for Minimum value (1
Size of specimen (mm) acceptance (3 specimen only of
specimens) the 3)
------------------------------------------------------------------------
10.0x10.0...................... 25.0 ft. lbs...... 20.0 ft. lbs.
10.0x7.5....................... 21.0 ft. lbs...... 17.0 ft. lbs.
10.0x5.0....................... 17.0 ft. lbs...... 14.0 ft. lbs.
------------------------------------------------------------------------
(4) After the final heat treatment, each vessel must be hardness
tested on the cylindrical section. The tensile strength equivalent of
the hardness number obtained may not be more than 165,000 p.s.i. (Rc
36). When the result of a hardness test exceeds the maximum permitted,
two or more retests may be made; however, the hardness number obtained
in each retest may not exceed the maximum permitted.
(l) Rejected cylinders. Reheat treatment is authorized for rejected
cylinders. However, each reheat treated cylinder must subsequently pass
all the prescribed tests. Repair by welding is not authorized.
(m) Markings. Marking must be done by stamping into the metal of the
cylinder. All markings must be legible and located on a shoulder.
(n) Inspector's report. In addition to the requirements of Sec.
178.35, the inspector's report for the physical test report, must
indicate the average value for three specimens and the minimum value for
one specimen for each lot number.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45385,
43588, Aug. 28, 2001; 67 FR 51652, Aug. 8, 2002; 68 FR 48571, Aug. 14,
2003; 68 FR 75748, 75749, Dec. 31, 2003]
Sec. 178.46 Specification 3AL seamless aluminum cylinders.
(a) Size and service pressure. A DOT 3AL cylinder is a seamless
aluminum cylinder with a maximum water capacity of 1000 pounds and
minimum service pressure of 150 psig.
(b) Authorized material and identification of material. The material
of construction must meet the following conditions:
(1) Starting stock must be cast stock or traceable to cast stock.
(2) Material with seams, cracks, laminations, or other defects
likely to weaken the finished cylinder may not be used.
(3) Material must be identified by a suitable method that will
identify the alloy, the aluminum producer's cast number, the solution
heat treat batch number and the lot number.
(4) The material must be of uniform quality. Only the following heat
treatable aluminum alloys in table 1 and 2 are permitted as follows:
[[Page 37]]
Table 1--Heat or Cast Analysis for Aluminum; Similar to ``Aluminum Association''\1\ Alloy 6061
[CHEMICAL ANALYSIS IN WEIGHT PERCENT\2\]
----------------------------------------------------------------------------------------------------------------
Other
Si Fe Cu min/ Mn Mg Cr min/ Zn Ti Pb Bi ----------------
min/ max max max min/ max max max max max each total A1
max max max max
----------------------------------------------------------------------------------------------------------------
0.4/ 0.7 0.15/ 0.15 0.8/ 0.04/ 0.25 0.15 0.005 0.005 0.05 0.15 Bal.
0.8 0.4 1.2 0.35
----------------------------------------------------------------------------------------------------------------
\1\ The ``Aluminum Association'' refers to ``Aluminum Standards and Data 1993'', published by the Aluminum
Association Inc.
\2\ Except for ``Pb'' and ``Bi'', the chemical composition corresponds with that of Table 1 of ASTM B 221 (IBR,
see Sec. 171.7 of this subchapter) for Aluminum Association alloy 6061.
Table 2--Mechanical Property Limits
----------------------------------------------------------------------------------------------------------------
Tensile strength--PSI Elongation--percent
---------------------------------------- minimum for 2 or 4D \1\
Ultimate--minimum Yield--minimum size specimen
----------------------------------------------------------------------------------------------------------------
6061-T6............................................ 38,000 35,000 \2\14
----------------------------------------------------------------------------------------------------------------
\1\ ``D'' represents specimen diameters. When the cylinder wall is greater than \3/16\ inch thick, a retest
without reheat treatment using the 4D size specimen is authorized if the test using the 2 inch size specimen
fails to meet elongation requirements.
\2\ When cylinder wall is not over \3/16\-inch thick, 10 percent elongation is authorized when using a 24tx6t
size test specimen.
(5) All starting stock must be 100 percent ultrasonically inspected,
along the length at right angles to the central axis from two positions
at 90[deg] to one another. The equipment and continuous scanning
procedure must be capable of detecting and rejecting internal defects
such as cracks which have an ultrasonic response greater than that of a
calibration block with a \5/64\-inch diameter flat bottomed hole.
(6) Cast stock must have uniform equiaxed grain structure not to
exceed 500 microns maximum.
(7) Any starting stock not complying with the provisions of
paragraphs (b)(1) through (b)(6) of this section must be rejected.
(c) Manufacture. Cylinders must be manufactured in accordance with
the following requirements:
(1) Cylinder shells must be manufactured by the backward extrusion
method and have a cleanliness level adequate to ensure proper
inspection. No fissure or other defect is acceptable that is likely to
weaken the finished cylinder below the design strength requirements. A
reasonably smooth and uniform surface finish is required. If not
originally free from such defects, the surface may be machined or
otherwise conditioned to eliminate these defects.
(2) Thickness of the cylinder base may not be less than the
prescribed minimum wall thickness of the cylindrical shell. The cylinder
base must have a basic torispherical, hemispherical, or ellipsoidal
interior base configuration where the dish radius is no greater than 1.2
times the inside diameter of the shell. The knuckle radius may not be
less than 12 percent of the inside diameter of the shell. The interior
base contour may deviate from the true torispherical, hemispherical or
ellipsoidal configuration provided that--
(i) Any areas of deviation are accompanied by an increase in base
thickness;
(ii) All radii of merging surfaces are equal to or greater than the
knuckle radius;
(iii) Each design has been qualified by successfully passing the
cycling tests in this paragraph (c); and
(iv) Detailed specifications of the base design are available to the
inspector.
(3) For free standing cylinders, the base thickness must be at least
two times the minimum wall thickness along the line of contact between
the cylinder base and the floor when the cylinders are in the vertical
position.
(4) Welding or brazing is prohibited.
(5) Each new design and any significant change to any acceptable
design must be qualified for production by testing prototype samples as
follows:
(i) Three samples must be subjected to 100,000 pressure reversal
cycles between zero and service pressure or 10,000 pressure reversal
cycles between zero and test pressure, at a rate not in
[[Page 38]]
excess of 10 cycles per minute without failure.
(ii) Three samples must be pressurized to destruction and failure
may not occur at less than 2.5 times the marked cylinder service
pressure. Each cylinder must remain in one piece. Failure must initiate
in the cylinder sidewall in a longitudinal direction. Rate of
pressurization may not exceed 200 psig per second.
(6) In this specification ``significant change'' means a 10 percent
or greater change in cylinder wall thickness, service pressure, or
diameter; a 30 percent or greater change in water capacity or base
thickness; any change in material; over 100 percent increase in size of
openings; or any change in the number of openings.
(d) Wall thickness. The minimum wall thickness must be such that the
wall stress at the minimum specified test pressure will not exceed 80
percent of the minimum yield strength nor exceed 67 percent of the
minimum ultimate tensile strength as verified by physical tests in
paragraph (i) of this section. The minimum wall thickness for any
cylinder with an outside diameter greater than 5 inches must be 0.125
inch. Calculations must be made by the following formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = Wall stress in psi;
P = Prescribed minimum test pressure in psig (see paragraph (g) of this
section);
D = Outside diameter in inches; and
d = Inside diameter in inches.
(e) Openings. Openings must comply with the following requirements:
(1) Openings are permitted in heads only.
(2) The size of any centered opening in a head may not exceed one-
half the outside diameter of the cylinder.
(3) Other openings are permitted in the head of a cylinder if:
(i) Each opening does not exceed 2.625 inches in diameter, or one-
half the outside diameter of the cylinder; whichever is less;
(ii) Each opening is separated from each other by a ligament; and
(iii) Each ligament which separates two openings must be at least
three times the average of the diameters of the two openings.
(4) All openings must be circular.
(5) All openings must be threaded. Threads must comply with the
following:
(i) Each thread must be clean cut, even, without checks, and to
gauge.
(ii) Taper threads, when used, must conform to one of the following:
(A) American Standard Pipe Thread (NPT) type, conforming to the
requirements of NBS Handbook H-28 (IBR, see Sec. 171.7 of this
subchapter);
(B) National Gas Taper Thread (NGT) type, conforming to the
requirements of NBS Handbook H-28; or
(C) Other taper threads conforming to other standards may be used
provided the length is not less than that specified for NPT threads.
(iii) Straight threads, when used, must conform to one of the
following:
(A) National Gas Straight Thread (NGS) type, conforming to the
requirements of NBS Handbook H-28;
(B) Unified Thread (UN) type, conforming to the requirements of NBS
Handbook H-28;
(C) Controlled Radius Root Thread (UN) type, conforming to the
requirements of NBS Handbook H-28; or
(D) Other straight threads conforming to other recognized standards
may be used provided that the requirements in paragraph (e)(5)(iv) of
this section are met.
(iv) All straight threads must have at least 6 engaged threads, a
tight fit, and a factor of safety in shear of at least 10 at the test
pressure of the cylinder. Shear stress must be calculated by using the
appropriate thread shear area in accordance with NBS Handbook H-28.
(f) Heat treatment. Prior to any test, all cylinders must be
subjected to a solution heat treatment and aging treatment appropriate
for the aluminum alloy used.
(g) Hydrostatic test. Each cylinder must be subjected to an internal
test pressure using the water jacket equipment and method or other
suitable equipment and method and comply with the following
requirements:
(1) The testing apparatus must be operated in a manner so as to
obtain accurate data. The pressure gauge used
[[Page 39]]
must permit reading to an accuracy of one percent. The expansion gauge
must permit reading the total expansion to an accuracy of either one
percent or 0.1 cubic centimeter.
(2) The test pressure must be maintained for a sufficient period of
time to assure complete expansion of the cylinder. In no case may the
pressure be held less than 30 seconds. If, due to failure of the test
apparatus, the required test pressure cannot be maintained, the test may
be repeated at a pressure increased by 10 percent or 100 psig, whichever
is lower. If the test apparatus again fails to maintain the test
pressure, the cylinder being tested must be rejected. Any internal
pressure applied to the cylinder before any official test may not exceed
90 percent of the test pressure.
(3) The minimum test pressure is the greatest of the following:
(i) 450 psig regardless of service pressure;
(ii) Two times the service pressure for cylinders having service
pressure less than 500 psig; or
(iii) Five-thirds times the service pressure for cylinders having a
service pressure of at least 500 psig.
(4) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(h) Flattening test. One cylinder taken at random out of each lot
must be subjected to a flattening test as follows:
(1) The test must be between knife edges, wedge shaped, having a
60[deg] included angle, and rounded in accordance with the following
table. The longitudinal axis of the cylinder must be at an angle 90[deg]
to the knife edges during the test. The flattening test table is as
follows:
Table 3--Flattening Test Table
------------------------------------------------------------------------
Radius
Cylinder wall thickness in inches in
inches
------------------------------------------------------------------------
Under .150.................................................... .500
.150 to .249.................................................. .875
.250 to .349.................................................. 1.500
.350 to .449.................................................. 2.125
.450 to .549.................................................. 2.750
.550 to .649.................................................. 3.500
.650 to .749.................................................. 4.125
------------------------------------------------------------------------
(2) An alternate bend test in accordance with ASTM E 290 using a
mandrel diameter not more than 6 times the wall thickness is authorized
to qualify lots that fail the flattening test of this section without
reheat treatment. If used, this test must be performed on two samples
from one cylinder taken at random out of each lot of 200 cylinders or
less.
(3) Each test cylinder must withstand flattening to nine times the
wall thickness without cracking. When the alternate bend test is used,
the test specimens must remain uncracked when bent inward around a
mandrel in the direction of curvature of the cylinder wall until the
interior edges are at a distance apart not greater than the diameter of
the mandrel.
(i) Mechanical properties test. Two test specimens cut from one
cylinder representing each lot of 200 cylinders or less must be
subjected to the mechanical properties test, as follows:
(1) The results of the test must conform to at least the minimum
acceptable mechanical property limits for aluminum alloys as specified
in paragraph (b) of this section.
(2) Specimens must be 4D bar or gauge length 2 inches with width not
over 1\1/2\ inch taken in the direction of extrusion approximately
180[deg] from each other; provided that gauge length at least 24 times
thickness with width not over 6 times thickness is authorized, when
cylinder wall is not over \3/16\ inch thick. The specimen, exclusive of
grip ends, may not be flattened. Grip ends may be flattened to within
one inch of each end of the reduced section. When the size of the
cylinder does not permit securing straight specimens, the specimens may
be taken in any location or direction and may be straightened or
flattened cold by pressure only, not by blows. When such specimens are
used, the inspector's report must show that the specimens were so taken
and prepared. Heating of specimens for any purpose is forbidden.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length.
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM B
557 (IBR, see Sec. 171.7 of this subchapter).
[[Page 40]]
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
10,000,000 psi. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 6,000 psi, the strain
indicator reading being set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(j) Rejected cylinder. Reheat treatment of rejected cylinders is
authorized one time. Subsequent thereto, cylinders must pass all
prescribed tests to be acceptable.
(k) Duties of inspector. In addition to the requirements of Sec.
178.35, the inspector shall:
(1) Verify compliance with the provisions of paragraph (b) of this
section by:
(i) Performing or witnessing the performance of the chemical
analyses on each melt or cast lot or other unit of starting material; or
(ii) Obtaining a certified chemical analysis from the material or
cylinder manufacturer for each melt, or cast of material; or
(iii) Obtaining a certified check analysis on one cylinder out of
each lot of 200 cylinders or less, if a certificate containing data to
indicate compliance with the material specification is obtained.
(2) The inspector shall verify ultrasonic inspection of all material
by inspection or by obtaining the material producer's certificate of
ultrasonic inspection. Ultrasonic inspection must be performed or
verified as having been performed in accordance with paragraph (c) of
this section.
(3) The inspector must also determine that each cylinder complies
with this specification by:
(i) Selecting the samples for check analyses performed by other than
the material producer;
(ii) Verifying that the prescribed minimum thickness was met by
measuring or witnessing the measurement of the wall thickness; and
(iii) Verifying that the identification of material is proper.
(4) Prior to initial production of any design or design change,
verify that the design qualification tests prescribed in paragraph
(c)(6) of this section have been performed with acceptable results.
(l) Definitions. (1) In this specification, a ``lot'' means a group
of cylinders successively produced having the same:
(i) Size and configuration;
(ii) Specified material of construction;
(iii) Process of manufacture and heat treatment;
(iv) Equipment of manufacture and heat treatment; and
(v) Conditions of time, temperature and atmosphere during heat
treatment.
(2) In no case may the lot size exceed 200 cylinders, but any
cylinder processed for use in the required destructive physical testing
need not be counted as being one of the 200.
(m) Inspector's report. In addition to the information required by
Sec. 178.35, the record of chemical analyses must also include the
alloy designation, and applicable information on iron, titanium, zinc,
magnesium and any other applicable element used in the construction of
the cylinder.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386-
45388, Aug. 28, 2001; 67 FR 51652, Aug. 8, 2002; 68 FR 75749, Dec. 31,
2003]
Sec. 178.47 Specification 4DS welded stainless steel cylinders for aircraft
use.
(a) Type, size, and service pressure. A DOT 4DS cylinder is either a
welded stainless steel sphere (two seamless hemispheres) or
circumferentially welded cylinder both with a water capacity of not over
100 pounds and a
[[Page 41]]
service pressure of at least 500 but not over 900 psig.
(b) Steel. Types 304, 321 and 347 stainless steel are authorized
with proper welding procedure. A heat of steel made under the
specifications in table 1 in this paragraph (b), check chemical analysis
of which is slightly out of the specified range, is acceptable, if
satisfactory in all other respects, provided the tolerances shown in
table 2 in this paragraph (b) are not exceeded, except as approved by
Associate Administrator. The following chemical analyses are authorized:
Table 1--Authorized Materials
----------------------------------------------------------------------------------------------------------------
Stainless steels
----------------------------------------------------------------------------
304 (percent) 321 (percent) 347 (percent)
----------------------------------------------------------------------------------------------------------------
Carbon (max)....................... 0.08 0.08 0.08
Manganese (max).................... 2.00 2.00 2.00
Phosphorus (max)................... .030 .030 .030
Sulphur (max)...................... .030 .030 .030
Silicon (max)...................... .75 .75 .75
Nickel............................. 8.0/11.0 9.0/13.0 9.0/13.0
Chromium........................... 18.0/20.0 17.0/20.0 17.0/20.0
Molybdenum
Titanium........................... .......................... (\1\)
Columbium.......................... .......................... .......................... (\2\)
----------------------------------------------------------------------------------------------------------------
\1\ Titanium may not be more than 5C and not more than 0.60%.
\2\ Columbium may not be less than 10C and not more than 1.0%.
Table 2--Check Analysis Tolerances
----------------------------------------------------------------------------------------------------------------
Tolerance (percent) over
the maximum limit or
under the minimum limit
Element Limit or maximum specified (percent) -------------------------
Under Over
minimum maximum
limit limit
----------------------------------------------------------------------------------------------------------------
Carbon......................... To 0.15 incl......................................... 0.01 0.01
Manganese...................... Over 1.15 to 2.50 incl............................... 0.05 0.05
Phosphorus\1\.................. All ranges........................................... ........... .01
Sulphur........................ All ranges........................................... ........... .01
Silicon........................ Over 0.30 to 1.00 incl............................... .05 .05
Nickel......................... Over 5.30 to 10.00 incl.............................. .10 .10
Over 10.00 to 14.00 incl............................. .15 .15
Chromium....................... Over 15.00 to 20.00 incl............................. .20 .20
Titanium....................... All ranges........................................... .05 .05
Columbium...................... All ranges........................................... .05 .05
----------------------------------------------------------------------------------------------------------------
\1\Rephosphorized steels not subject to check analysis for phosphorus.
(c) Identification of material. Materials must be identified by any
suitable method.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably, a reasonably smooth and
uniform surface finish is required. No abrupt change in wall thickness
is permitted. Welding procedures and operators must be qualified in
accordance with CGA Pamphlet C-3 (IBR, see Sec. 171.7 of this
subchapter). All seams of the sphere or cylinder must be fusion welded.
Seams must be of the butt type and means must be provided for
accomplishing complete penetration of the joint.
(e) Attachments. Attachments to the container are authorized by
fusion welding provided that such attachments are made of weldable
stainless steel in accordance with paragraph (b) of this section.
(f) Wall thickness. The minimum wall thickness must be such that the
wall stress at the minimum specified test pressure may not be over
60,000 psig. A minimum wall thickness of 0.040 inch is required for any
diameter container. Calculations must be made by the following formulas:
[[Page 42]]
(1) Calculation for sphere must be made by the formula:
S = PD / 4tE
Where:
S = Wall stress in psi;
P = Test pressure prescribed for water jacket test, i.e., at least two
times service pressure, in psig;
D = Outside diameter in inches;
t = Minimum wall thickness in inches;
E = 0.85 (provides 85 percent weld efficiency factor which must be
applied in the girth weld area and heat zones which zone must extend a
distance of 6 times wall thickness from center of weld);
E = 1.0 (for all other areas).
(2) Calculation for a cylinder must be made by the formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = Wall stress in psi;
P = Test pressure prescribed for water jacket test, i.e., at least two
times service pressure, in psig;
D = Outside diameter in inches;
d = Inside diameter in inches.
(g) Heat treatment. The seamless hemispheres and cylinders may be
stress relieved or annealed for forming. Welded container must be stress
relieved at a temperature of 775 [deg]F 25[deg]
after process treatment and before hydrostatic test.
(h) Openings in container. Openings must comply with the following:
(1) Each opening in the container must be provided with a fitting,
boss or pad of weldable stainless steel securely attached to the
container by fusion welding.
(2) Attachments to a fitting, boss, or pad must be adequate to
prevent leakage. Threads must comply with the following:
(i) Threads must be clean cut, even, without checks, and tapped to
gauge.
(ii) Taper threads to be of length not less than as specified for
American Standard taper pipe threads.
(iii) Straight threads having at least 4 engaged threads, to have
tight fit and calculated shear strength at least 10 times the test
pressure of the container; gaskets required, adequate to prevent
leakage.
(i) Process treatment. Each container must be hydraulically
pressurized in a water jacket to at least 100 percent, but not more than
110 percent, of the test pressure and maintained at this pressure for a
minimum of 3 minutes. Total and permanent expansion must be recorded and
included in the inspector's report.
(j) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test as follows:
(1) The test must be by water-jacket, operated so as to obtain
accurate data. The pressure gauge must permit reading to an accuracy of
1 percent. The expansion gauge must permit reading of total expansion to
an accuracy either of 1 percent or 0.1 cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. If, due to failure of
the test apparatus, the test pressure cannot be maintained, the test may
be repeated at a pressure increased by 10 percent or 100 psig, whichever
is the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Each container must be tested to at least 2 times service
pressure.
(5) Container must then be inspected. Any wall thickness lower than
that required by paragraph (f) of this section must be cause for
rejection. Bulges and cracks must be cause for rejection. Welded joint
defects exceeding requirements of paragraph (k) of this section must be
cause for rejection.
(k) Radiographic inspection. Radiographic inspection is required on
all welded joints which are subjected to internal pressure, except that
at the discretion of the disinterested inspector, openings less than 25
percent of the container diameter need not be subjected to radiographic
inspection. Evidence of any defects likely to seriously weaken the
container is cause for rejection. Radiographic inspection must be
performed subsequent to the hydrostatic test.
(l) Burst test. One container taken at random out of 200 or less
must be hydrostatically tested to destruction. Rupture pressure must be
included as part of the inspector's report.
(m) Flattening test. A flattening test must be performed as follows:
(1) For spheres the test must be at the weld between parallel steel
plates
[[Page 43]]
on a press with welded seam at right angles to the plates. Test one
sphere taken at random out of each lot of 200 or less after the
hydrostatic test. Any projecting appurtenances may be cut off (by
mechanical means only) prior to crushing.
(2) For cylinders the test must be between knife edges, wedge
shaped, 60[deg] angle, rounded to \1/2\-inch radius. Test one cylinder
taken at random out of each lot of 200 or less, after the hydrostatic
test.
(n) Acceptable results for flattening and burst tests. Acceptable
results for flattening and burst tests are as follows:
(1) Flattening required to 50 percent of the original outside
diameter without cracking.
(2) Burst pressure must be at least 3 times the service pressure.
(o) Rejected containers. Repair of welded seams by welding prior to
process treatment is authorized. Subsequent thereto, containers must be
heat treated and pass all prescribed tests.
(p) Duties of inspector. In addition to the requirements of Sec.
178.35, the inspector must verify that all tests are conducted at
temperatures between 60 [deg]F and 90 [deg]F.
(q) Marking. Markings must be stamped plainly and permanently on a
permanent attachment or on a metal nameplate permanently secured to the
container by means other than soft solder.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386,
45388, Aug. 28, 2001; 67 FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31,
2003]
Sec. 178.50 Specification 4B welded or brazed steel cylinders.
(a) Type, size, and service pressure. A DOT 4B is a welded or brazed
steel cylinder with longitudinal seams that are forged lap-welded or
brazed and with water capacity (nominal) not over 1,000 pounds and a
service pressure of at least 150 but not over 500 psig. Cylinders closed
in by spinning process are not authorized.
(b) Steel. Open-hearth, electric or basic oxygen process steel of
uniform quality must be used. Content percent may not exceed the
following: Carbon, 0.25; phosphorus, 0.045; sulphur, 0.050.
(c) Identification of material. Material must be identified by any
suitable method except that plates and billets for hotdrawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. Exposed bottom welds on cylinders
over 18 inches long must be protected by footrings. Welding procedures
and operators must be qualified in accordance with CGA Pamphlet C-3
(IBR, see Sec. 171.7 of this subchapter). Seams must be made as
follows:
(1) Welded or brazed circumferential seams. Heads attached by
brazing must have a driving fit with the shell, unless the shell is
crimped, swedged, or curled over the skirt or flange of the head, and be
thoroughly brazed until complete penetration by the brazing material of
the brazed joint is secured. Depth of brazing from end of shell must be
at least four times the thickness of shell metal.
(2) Longitudinal seams in shells. Longitudinal seams must be forged
lap welded, by copper brazing, by copper alloy brazing, or by silver
alloy brazing. Copper alloy composition must be: Copper, 95 percent
minimum; Silicon, 1.5 percent to 3.85 percent; Manganese, 0.25 percent
to 1.10 percent. The melting point of the silver alloy brazing material
must be in excess of 1000 [deg]F. When brazed, the plate edge must be
lapped at least eight times the thickness of plate, laps being held in
position, substantially metal to metal, by riveting or electric spot-
welding; brazing must be done by using a suitable flux and by placing
brazing material on one side of seam and applying heat until this
material shows uniformly along the seam of the other side.
(e) Welding or brazing. Only the attachment of neckrings, footrings,
handles, bosses, pads, and valve protection rings to the tops and
bottoms of cylinders by welding or brazing is authorized. Such
attachments and the portion
[[Page 44]]
of the container to which they are attached must be made of weldable
steel, the carbon content of which may not exceed 0.25 percent except in
the case of 4130X steel which may be used with proper welding procedure.
(f) Wall thickness. The wall thickness of the cylinder must comply
with the following requirements:
(1) For cylinders with outside diameters over 6 inches the minimum
wall thickness must be 0.090 inch. In any case, the minimum wall
thickness must be such that calculated wall stress at minimum test
pressure (paragraph (i)(4) of this section) may not exceed the following
values:
(i) 24,000 psi for cylinders without longitudinal seam.
(ii) 22,800 psig for cylinders having copper brazed or silver alloy
brazed longitudinal seam.
(iii) 18,000 psi for cylinders having forged lapped welded
longitudinal seam.
(2) Calculation must be made by the formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test or 450 psig
whichever is the greater;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. Cylinder body and heads, formed by drawing or
pressing, must be uniformly and properly heat treated prior to tests.
(h) Opening in cylinders. Openings in cylinders must conform to the
following:
(1) Each opening in cylinders, except those for safety devices, must
be provided with a fitting, boss, or pad, securely attached to cylinder
by brazing or by welding or by threads. Fitting, boss, or pad must be of
steel suitable for the method of attachment employed, and which need not
be identified or verified as to analysis except that if attachment is by
welding, carbon content may not exceed 0.25 percent. If threads are
used, they must comply with the following:
(i) Threads must be clean cut, even without checks, and tapped to
gauge.
(ii) Taper threads to be of length not less than as specified for
American Standard taper pipe threads.
(iii) Straight threads, having at least 4 engaged threads, to have
tight fit and calculated shear strength at least 10 times the test
pressure of the cylinder; gaskets required, adequate to prevent leakage.
(iv) A brass fitting may be brazed to the steel boss or flange on
cylinders used as component parts of hand fire extinguishers.
(2) The closure of a fitting, boss, or pad must be adequate to
prevent leakage.
(i) Hydrostatic test. Cylinders must withstand a hydrostatic test as
follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy either of 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Cylinders must be tested as follows:
(i) At least one cylinder selected at random out of each lot of 200
or less must be tested as outlined in paragraphs (i)(1), (i)(2), and
(i)(3) of this section to at least two times service pressure.
(ii) All cylinders not tested as outlined in paragraph (i)(4)(i) of
this section must be examined under pressure of at least two times
service pressure and show no defect.
(j) Flattening test. After the hydrostatic test, a flattening test
must be performed on one cylinder taken at random out or each lot of 200
or less, by placing the cylinder between wedge
[[Page 45]]
shaped knife edges having a 60[deg] included angle, rounded to \1/2\-
inch radius. The longitudinal axis of the cylinder must be at a 90-
degree angle to knife edges during the test. For lots of 30 or less,
flattening tests are authorized to be made on a ring at least 8 inches
long cut from each cylinder and subjected to same heat treatment as the
finished cylinder.
(k) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material as follows:
(1) The test is required on 2 specimens cut from 1 cylinder, or part
thereof heat-treated as required, taken at random out of each lot of 200
or less. For lots of 30 or less, physical tests are authorized to be
made on a ring at least 8 inches long cut from each cylinder and
subjected to same heat treatment as the finished cylinder.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width of not over 1\1/2\
inches, a gauge length of 2 inches with a width of not over 1\1/2\
inches, or a gauge length at least 24 times the thickness with a width
not over 6 times the thickness is authorized when a cylinder wall is not
over \3/16\ inch thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within one inch of each end of the reduced
section.
(iii) When size of cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold, by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi, and strain
indicator reading must be set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(l) Acceptable results for physical and flattening tests. Either of
the following is an acceptable result:
(1) An elongation of at least 40 percent for a 2-inch gauge length
or at least 20 percent in other cases and yield strength not over 73
percent of tensile strength. In this instance, a flattening test is not
required.
(2) When cylinders are constructed of lap welded pipe, flattening
test is required, without cracking, to 6 times the wall thickness. In
such case, the rings (crop ends) cut from each end of pipe, must be
tested with the weld 45[deg] or less from the point of greatest stress.
If a ring fails, another from the same end of pipe may be tested.
(m) Rejected cylinders. Reheat treatment is authorized for rejected
cylinder. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair of brazed seams by brazing and welded seams by
welding is authorized.
(n) Markings. Markings must be stamped plainly and permanently in
any of the following locations on the cylinder:
(1) On shoulders and top heads when they are not less than 0.087-
inch thick.
[[Page 46]]
(2) On side wall adjacent to top head for side walls which are not
less than 0.090 inch thick.
(3) On a cylindrical portion of the shell which extends beyond the
recessed bottom of the cylinder, constituting an integral and non-
pressure part of the cylinder.
(4) On a metal plate attached to the top of the cylinder or
permanent part thereof; sufficient space must be left on the plate to
provide for stamping at least six retest dates; the plate must be at
least \1/16\-inch thick and must be attached by welding, or by brazing.
The brazing rod must melt at a temperature of 1100 [deg]F. Welding or
brazing must be along all the edges of the plate.
(5) On the neck, neckring, valve boss, valve protection sleeve, or
similar part permanently attached to the top of the cylinder.
(6) On the footring permanently attached to the cylinder, provided
the water capacity of the cylinder does not exceed 25 pounds.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 62 FR 51561,
Oct. 1, 1997; 66 FR 45385, 45388, Aug. 28, 2001; 67 FR 51653, Aug. 8,
2002; 68 FR 75748, Dec. 31, 2003]
Sec. 178.51 Specification 4BA welded or brazed steel cylinders.
(a) Type, size, and service pressure. A DOT 4BA cylinder is a
cylinder, either spherical or cylindrical in shape, with a water
capacity of 1,000 pounds or less and a service pressure of at least 225
and not over 500 psig. Closures made by the spinning process are not
authorized.
(1) Spherical type cylinders must be made from two seamless
hemispheres joined by the welding of one circumferential seam.
(2) Cylindrical type cylinders must be of circumferentially welded
or brazed construction.
(b) Steel. The steel used in the construction of the cylinder must
be as specified in table 1 of appendix A to this part.
(c) Identification of material. Material must be identified by any
suitable method except that plates and billets for hotdrawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. Exposed bottom welds on cylinders
over 18 inches long must be protected by footrings.
(1) Seams must be made as follows:
(i) Minimum thickness of heads and bottoms must be not less than 90
percent of the required thickness of the side wall.
(ii) Circumferential seams must be made by welding or by brazing.
Heads must be attached by brazing and must have a driving fit with the
shell, unless the shell is crimped, swedged or curled over the skirt or
flange of the head and must be thoroughly brazed until complete
penetration by the brazing material of the brazed joint is secured.
Depth of brazing from end of the shell must be at least four times the
thickness of shell metal.
(iii) Longitudinal seams in shells must be made by copper brazing,
copper alloy brazing, or by silver alloy brazing. Copper alloy
composition must be: Copper 95 percent minimum, Silicon 1.5 percent to
3.85 percent, Manganese 0.25 percent to 1.10 percent. The melting point
of the silver alloy brazing material must be in excess of 1,000 [deg]F.
The plate edge must be lapped at least eight times the thickness of
plate, laps being held in position, substantially metal to metal, by
riveting or by electric spot-welding. Brazing must be done by using a
suitable flux and by placing brazing material on one side of seam and
applying heat until this material shows uniformly along the seam of the
other side. Strength of longitudinal seam: Copper brazed longitudinal
seam must have strength at least \3/2\ times the strength of the steel
wall.
(2) Welding procedures and operators must be qualified in accordance
with CGA Pamphlet C-3 (IBR, see Sec. 171.7 of this subchapter).
(e) Welding and brazing. Only the welding or brazing of neckrings,
footrings, handles, bosses, pads, and valve protection rings to the tops
and
[[Page 47]]
bottoms of cylinders is authorized. Provided that such attachments and
the portion of the container to which they are attached are made of
weldable steel, the carbon content of which may not exceed 0.25 percent
except in the case of 4130x steel which may be used with proper welding
procedure.
(f) Wall thickness. The minimum wall thickness of the cylinder must
meet the following conditions:
(1) For any cylinder with an outside diameter of greater than 6
inches, the minimum wall thickness is 0.078 inch. In any case the
minimum wall thickness must be such that the calculated wall stress at
the minimum test pressure may not exceed the lesser value of any of the
following:
(i) The value shown in table 1 of appendix A to this part, for the
particular material under consideration;
(ii) One-half of the minimum tensile strength of the material
determined as required in paragraph (j) of this section;
(iii) 35,000 psi; or
(iv) Further provided that wall stress for cylinders having copper
brazed longitudinal seams may not exceed 95 percent of any of the above
values. Measured wall thickness may not include galvanizing or other
protective coating.
(2) Cylinders that are cylindrical in shape must have the wall
stress calculated by the formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test;
D = outside diameter in inches;
d = inside diameter in inches.
(3) Cylinders that are spherical in shape must have the wall stress
calculated by the formula:
S = PD / 4tE
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test;
D = outside diameter in inches;
t = minimum wall thickness in inches;
E = 0.85 (provides 85 percent weld efficiency factor which must be
applied in the girth weld area and heat affected zones which zone must
extend a distance of 6 times wall thickness from center line of weld);
E = 1.0 (for all other areas).
(4) For a cylinder with a wall thickness less than 0.100 inch, the
ratio of tangential length to outside diameter may not exceed 4.1.
(g) Heat treatment. Cylinders must be heat treated in accordance
with the following requirements:
(1) Each cylinder must be uniformly and properly heat treated prior
to test by the applicable method shown in table 1 of appendix A to this
part. Heat treatment must be accomplished after all forming and welding
operations, except that when brazed joints are used, heat treatment must
follow any forming and welding operations, but may be done before,
during or after the brazing operations.
(2) Heat treatment is not required after the welding or brazing of
weldable low carbon parts to attachments of similar material which have
been previously welded or brazed to the top or bottom of cylinders and
properly heat treated, provided such subsequent welding or brazing does
not produce a temperature in excess of 400 [deg]F in any part of the top
or bottom material.
(h) Openings in cylinders. Openings in cylinders must comply with
the following requirements:
(1) Any opening must be placed on other than a cylindrical surface.
(2) Each opening in a spherical type cylinder must be provided with
a fitting, boss, or pad of weldable steel securely attached to the
container by fusion welding.
(3) Each opening in a cylindrical type cylinder must be provided
with a fitting, boss, or pad, securely attached to container by brazing
or by welding.
(4) If threads are used, they must comply with the following:
(i) Threads must be clean-cut, even, without checks and tapped to
gauge.
(ii) Taper threads must be of a length not less than that specified
for American Standard taper pipe threads.
(iii) Straight threads, having at least 4 engaged threads, must have
a tight fit and a calculated shear strength of at least 10 times the
test pressure of the cylinder. Gaskets, adequate to prevent leakage, are
required.
[[Page 48]]
(i) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test, as follows:
(1) The test must be by water jacket, or other suitable method,
operated so as to obtain accurate data. A pressure gauge must permit
reading to an accuracy of 1 percent. An expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat treatment and previous to the official test may not
exceed 90 percent of the test pressure.
(3) Permanent volumetric expansion may not exceed 10 percent of the
total volumetric expansion at test pressure.
(4) Cylinders must be tested as follows:
(i) At least one cylinder selected at random out of each lot of 200
or less must be tested as outlined in paragraphs (i)(1), (i)(2), and
(i)(3) of this section to at least two times service pressure.
(ii) All cylinders not tested as outlined in paragraph (i)(4)(i) of
this section must be examined under pressure of at least two times
service pressure and show no defect.
(j) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material, as follows:
(1) The test is required on 2 specimens cut from one cylinder or
part thereof having passed the hydrostatic test and heat-treated as
required, taken at random out of each lot of 200 or less. Physical tests
for spheres are required on 2 specimens cut from flat representative
sample plates of the same heat taken at random from the steel used to
produce the spheres. This flat steel from which 2 specimens are to be
cut must receive the same heat treatment as the spheres themselves.
Sample plates must be taken from each lot of 200 or less spheres.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
or a gauge length of 2 inches with a width not over 1\1/2\ inches, or a
gauge length at least 24 times the thickness with a width not over 6
times the thickness is authorized when a cylinder wall is not over \3/
16\ inch thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within one inch of each end of the reduced
section.
(iii) When size of the cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold, by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load''), corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain
reference must be set while the specimen is under a stress of 12,000
psi, and the strain indicator reading must be set at the calculated
corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
[[Page 49]]
(k) Elongation. Physical test specimens must show at least a 40
percent elongation for a 2-inch gauge length or at least 20 percent in
other cases. Except that these elongation percentages may be reduced
numerically by 2 for 2-inch specimens, and by 1 in other cases, for each
7,500 psi increment of tensile strength above 50,000 psi to a maximum of
four such increments.
(l) Tests of welds. Except for brazed seams, welds must be tested as
follows:
(1) Tensile test. A specimen must be cut from one cylinder of each
lot of 200 or less, or welded test plate. The welded test plate must be
of one of the heats in the lot of 200 or less which it represents, in
the same condition and approximately the same thickness as the cylinder
wall except that in no case must it be of a lesser thickness than that
required for a quarter size Charpy impact specimen. The weld must be
made by the same procedures and subjected to the same heat treatment as
the major weld on the cylinder. The specimen must be taken from across
the major seam and must be prepared and tested in accordance with and
must meet the requirements of CGA Pamphlet C-3 (IBR, see Sec. 171.7 of
this subchapter). Should this specimen fail to meet the requirements,
specimens may be taken from two additional cylinders or welded test
plates from the same lot and tested. If either of the latter specimens
fail to meet the requirements, the entire lot represented must be
rejected.
(2) Guided bend test. A root bend test specimen must be cut from the
cylinder or welded test plate, used for the tensile test specified in
paragraph (l)(1) of this section. Specimens must be taken from across
the major seam and must be prepared and tested in accordance with and
must meet the requirements of CGA Pamphlet C-3.
(3) Alternate guided-bend test. This test may be used and must be as
required by CGA Pamphlet C-3. The specimen must be bent until the
elongation at the outer surface, adjacent to the root of the weld,
between the lightly scribed gage lines a to b, must be at least 20
percent, except that this percentage may be reduced for steels having a
tensile strength in excess of 50,000 psig, as provided in paragraph (k)
of this section.
(m) Rejected cylinders. Reheat treatment is authorized for rejected
cylinders. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair of brazed seams by brazing and welded seams by
welding is authorized.
(n) Markings. Markings must be stamped plainly and permanently in
one of the following locations on the cylinder:
(1) On shoulders and top heads not less than 0.087 inch thick.
(2) On side wall adjacent to top head for side walls not less than
0.090 inch thick.
(3) On a cylindrical portion of the shell which extends beyond the
recessed bottom of the cylinder constituting an integral and non-
pressure part of the cylinder.
(4) On a plate attached to the top of the cylinder or permanent part
thereof; sufficient space must be left on the plate to provide for
stamping at least six retest dates; the plate must be at least \1/16\
inch thick and must be attached by welding, or by brazing at a
temperature of at least 1100 [deg]F., throughout all edges of the plate.
(5) On the neck, neckring, valve boss, valve protection sleeve, or
similar part permanently attached to the top of the cylinder.
(6) On the footring permanently attached to the cylinder, provided
the water capacity of the cylinder does not exceed 25 pounds.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 4535,
Aug. 28, 2001; 67 FR 16015, Sept. 27, 2002; 67 FR 51653, Aug. 8, 2002;
68 FR 75748, Dec. 31, 2003]
Sec. 178.53 Specification 4D welded steel cylinders for aircraft use.
(a) Type, size, and service pressure. A DOT 4D cylinder is a welded
steel sphere (two seamless hemispheres) or circumferentially welded
cylinder (two seamless drawn shells) with a water capacity not over 100
pounds and a service pressure of at least 300 but not over 500 psig.
Cylinders closed in by spinning process are not authorized.
(b) Steel. Open-hearth or electric steel of uniform and weldable
quality must be used. Content may not exceed the
[[Page 50]]
following: Carbon, 0.25; phosphorus, 0.045; sulphur, 0.050, except that
the following steels commercially known as 4130X and Type 304, 316, 321,
and 347 stainless steels may be used with proper welding procedure. A
heat of steel made under table 1 in this paragraph (b), check chemical
analysis of which is slightly out of the specified range, is acceptable,
if satisfactory in all other respects, provided the tolerances shown in
table 2 in this paragraph (b) are not exceeded, except as approved by
the Associate Administrator. The following chemical analyses are
authorized:
Table 1--4130X Steel
------------------------------------------------------------------------
4130X Percent
------------------------------------------------------------------------
Carbon..................................... 0.25/0.35.
Manganese.................................. 0.40/0.60.
Phosphorus................................. 0.04 max.
Sulphur.................................... 0.05 max
Silicon.................................... 0.15/0.35.
Chromium................................... 0.80/1.10.
Molybdenum................................. 0.15/0.25.
Zirconium.................................. None.
Nickel..................................... None.
------------------------------------------------------------------------
Table 2--Authorized Stainless Steels
----------------------------------------------------------------------------------------------------------------
Stainless steels
---------------------------------------------------------------
304 (percent) 316 (percent) 321 (percent) 347 (percent)
----------------------------------------------------------------------------------------------------------------
Carbon (max).................................... 0.08 0.08 0.08 0.08
Manganese (max)................................. 2.00 2.00 2.00 2.00
Phosphorus (max)................................ .030 .045 .030 .030
Sulphur (max)................................... .030 .030 .030 .030
Silicon (max)................................... .75 1.00 .75 .75
Nickel.......................................... 8.0/11.0 10.0/14.0 9.0/13.0 9.0/13.0
Chromium........................................ 18.0/20.0 16.0/18.0 17.0/20.0 17.0/20.0
Molybdenum...................................... .............. 2.0/3.0 .............. ..............
Titanium........................................ .............. .............. (\1\) ..............
Columbium....................................... .............. .............. .............. (\2\)
----------------------------------------------------------------------------------------------------------------
\1\ Titanium may not be less than 5C and not more than 0.60%.
\2\ Columbium may not be less than 10C and not more than 1.0%.
Table 3--Check Analysis Tolerances
----------------------------------------------------------------------------------------------------------------
Tolerance (percent) over
the maximum limit or
under the minimum limit
Element Limit or maximum specified (percent) -------------------------
Under Over
minimum maximum
limit limit
----------------------------------------------------------------------------------------------------------------
Carbon......................... To 0.15 incl......................................... 0.01 0.01
Over 0.15 to 0.40 incl............................... .03 .04
Manganese...................... To 0.60 incl......................................... .03 .03
Over 1.15 to 2.50 incl............................... .05 .05
Phosphorus \1\................. All ranges........................................... ........... .01
Sulphur........................ All ranges........................................... ........... .01
Silicon........................ To 0.30 incl......................................... .02 .03
Over 0.30 to 1.00 incl............................... .05 .05
Nickel......................... Over 5.30 to 10.00 incl.............................. .10 .10
Over 10.00 to 14.00 incl............................. .15 .15
Chromium....................... To 0.90 incl......................................... .03 .03
Over 0.90 to 2.10 incl............................... .05 .05
Over 15.00 to 20.00 incl............................. .20 .20
Molybdenum..................... To 0.20 incl......................................... .01 .01
Over 0.20 to 0.40 incl............................... .02 .02
Over 1.75 to 3.0 incl................................ .10 .10
Titanium....................... All ranges........................................... .05 .05
Columbium...................... All ranges........................................... .05 .05
----------------------------------------------------------------------------------------------------------------
\1\ Rephosphorized steels not subject to check analysis for phosphorus.
(c) Identification of material. Material must be identified by any
suitable method except that plates and billets for hotdrawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is
[[Page 51]]
permitted that is likely to weaken the finished container appreciably. A
reasonably smooth and uniform surface finish is required. Welding
procedures and operators must be qualified in accordance with CGA
Pamphlet C-3 (IBR, see Sec. 171.7 of this subchapter).
(e) Wall thickness. The wall stress at the minimum test pressure may
not exceed 24,000 psi, except where steels commercially known as 4130X,
types 304, 316, 321, and 347 stainless steels are used, stress at the
test pressures may not exceed 37,000 psi. The minimum wall thickness for
any container having a capacity of 1,100 cubic inches or less is 0.04
inch. The minimum wall thickness for any container having a capacity in
excess of 1,100 cubic inches is 0.095 inch. Calculations must be done by
the following:
(1) Calculation for a ``sphere'' must be made by the formula:
S = PD / 4tE
Where:
S = wall stress in psi;
P = test pressure prescribed for water jacket test, i.e., at least two
times service pressure, in psig;
D = outside diameter in inches;
t = minimum wall thickness in inches;
E = 0.85 (provides 85 percent weld efficiency factor which must be
applied in the girth weld area and heat affected zones which zone must
extend a distance of 6 times wall thickness from center line of weld);
E = 1.0 (for all other areas).
(2) Calculation for a cylinder must be made by the formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\T12\)
Where:
S = wall stress in psi;
P = test pressure prescribed for water jacket test, i.e., at least two
times service pressure, in psig;
D = outside diameter in inches;
d = inside diameter in inches.
(f) Heat treatment. The completed cylinders must be uniformly and
properly heat-treated prior to tests.
(g) Openings in container. Openings in cylinders must comply with
the following:
(1) Each opening in the container, except those for safety devices,
must be provided with a fitting, boss, or pad, securely attached to the
container by brazing or by welding or by threads. If threads are used,
they must comply with the following:
(i) Threads must be clean cut, even, without checks, and tapped to
gauge.
(ii) Taper threads must be of a length not less than that specified
for American Standard taper pipe threads.
(iii) Straight threads, having at least 4 engaged threads, must have
a tight fit and calculated shear strength of at least 10 times the test
pressure of the container. Gaskets, adequate to prevent leakage, are
required.
(2) Closure of a fitting, boss, or pad must be adequate to prevent
leakage.
(h) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test, as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. A pressure gauge must permit a
reading to an accuracy of 1 percent. An expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of the
total volumetric expansion at test pressure.
(4) Containers must be tested as follows:
(i) Each container to at least 2 times service pressure; or
(ii) One container out of each lot of 200 or less to at least 3
times service pressure. Others must be examined under pressure of 2
times service pressure and show no defects.
(i) Flattening test for spheres and cylinders. Spheres and cylinders
must be subjected to a flattening test as follows:
(1) One sphere taken at random out of each lot of 200 or less must
be subjected to a flattening test as follows:
(i) The test must be performed after the hydrostatic test.
[[Page 52]]
(ii) The test must be between parallel steel plates on a press with
a welded seam at right angles to the plates. Any projecting
appurtenances may be cut off (by mechanical means only) prior to
crushing.
(2) One cylinder taken at random out of each lot of 200 or less must
be subjected to a flattening test, as follows:
(i) The test must be performed after the hydrostatic test.
(ii) The test must be between knife edges, wedge shaped, 60[deg]
angle, rounded to \1/2\ inch radius. For lots of 30 or less, physical
tests are authorized to be made on a ring at least 8 inches long cut
from each cylinder and subjected to the same heat treatment as the
finished cylinder.
(j) Physical test and specimens for spheres and cylinders. Spheres
and cylinders must be subjected to a physical test as follows:
(1) Physical test for spheres are required on 2 specimens cut from a
flat representative sample plate of the same heat taken at random from
the steel used to produce the sphere. This flat steel from which the 2
specimens are to be cut must receive the same heat-treatment as the
spheres themselves. Sample plates must be taken for each lot of 200 or
less spheres.
(2) Specimens for spheres must have a gauge length 2 inches with a
width not over 1\1/2\ inches, or a gauge length at least 24 times the
thickness with a width not over 6 times the thickness is authorized when
a wall is not over \3/16\ inch thick.
(3) Physical test for cylinders is required on 2 specimens cut from
1 cylinder taken at random out of each lot of 200 or less. For lots of
30 or less, physical tests are authorized to be made on a ring at least
8 inches long cut from each cylinder and subjected to the same heat
treatment as the finished cylinder.
(4) Specimens for cylinders must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
or a gauge length of 2 inches with a width not over 1\1/2\ inches, or a
gauge length at least 24 times the thickness with a width not over 6
times the thickness is authorized when a cylinder wall is not over \3/
16\ inch thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within 1 inch of each end of the reduced
section. Heating of the specimen for any purpose is not authorized.
(5) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi and the strain
indicator reading being set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(k) Acceptable results for physical and flattening tests. Either of
the following is an acceptable result:
(1) An elongation of at least 40 percent for a 2 inch gauge length
or at least 20 percent in other cases and yield strength not over 73
percent of tensile strength. In this instance, the flattening test is
not required.
(2) An elongation of at least 20 percent for a 2 inch gauge length
or 10 percent in other cases. Flattening is required to 50 percent of
the original outside diameter without cracking.
(l) Rejected cylinders. Reheat-treatment is authorized for rejected
cylinders. Subsequent thereto, containers
[[Page 53]]
must pass all prescribed tests to be acceptable. Repair of welded seams
by welding prior to reheat-treatment is authorized.
(m) Marking. Marking on each container by stamping plainly and
permanently are only authorized where the metal is at least 0.09 inch
thick, or on a metal nameplate permanently secured to the container by
means other than soft solder, or by means that would not reduce the wall
thickness.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386,
45388, Aug. 28, 2001; 67 FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31,
2003]
Sec. 178.55 Specification 4B240ET welded or brazed cylinders.
(a) Type, spinning process, size and service pressure. A DOT 4B240ET
cylinder is a brazed type cylinder made from electric resistance welded
tubing. The maximum water capacity of this cylinder is 12 pounds or 333
cubic inches and the service must be 240 psig. The maximum outside
diameter of the shell must be five inches and maximum length of the
shell is 21 inches. Cylinders closed in by a spinning process are
authorized.
(b) Steel. Open-hearth, basic oxygen, or electric steel of uniform
quality must be used. Plain carbon steel content may not exceed the
following: Carbon, 0.25; phosphorus, 0.045; sulfur, 0.050. The addition
of other elements for alloying effect is prohibited.
(c) Identification of material. Material must be identified by any
suitable method.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. Heads may be attached to shells by
lap brazing or may be formed integrally. The thickness of the bottom of
cylinders welded or formed by spinning is, under no condition, to be
less than two times the minimum wall thickness of the cylindrical shell.
Such bottom thicknesses must be measured within an area bounded by a
line representing the points of contact between the cylinder and the
floor when the cylinder is in a vertical position. Seams must conform to
the following:
(1) Circumferential seams must be by brazing only. Heads must be
attached to shells by the lap brazing method and must overlap not less
than four times the wall thickness. Brazing material must have a melting
point of not less than 1000 [deg]F. Heads must have a driving fit with
the shell unless the shell is crimped, swedged, or curled over the skirt
or flange of the head and be thoroughly brazed until complete
penetration of the joint by the brazing material is secured. Brazed
joints may be repaired by brazing.
(2) Longitudinal seams in shell must be by electric resistance
welded joints only. No repairs to longitudinal joints is permitted.
(3) Welding procedures and operators must be qualified in accordance
with CGA C-3 (IBR, see Sec. 171.7 of this subchapter).
(e) Welding or brazing. Only the attachment, by welding or brazing,
to the tops and bottoms of cylinders of neckrings, footrings, handles,
bosses, pads, and valve protection rings is authorized. Provided that
such attachments and the portion of the container to which they are
attached are made of weldable steel, the carbon content of which may not
exceed 0.25 percent.
(f) Wall thickness. The wall stress must be at least two times the
service pressure and may not exceed 18,000 psi. The minimum wall
thickness is 0.044 inch. Calculation must be made by the following
formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = wall stress in psig;
P = 2 times service pressure;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. Heads formed by drawing or pressing must be
uniformly and properly heat treated prior to tests. Cylinders with
integral formed heads or bases must be subjected to a normalizing
operation. Normalizing and brazing operations may be combined, provided
the operation is carried out at a temperature in excess of the upper
critical temperature of the steel.
[[Page 54]]
(h) Openings in cylinders. Openings in cylinders must comply with
the following:
(1) Each opening in cylinders, except those for safety devices, must
be provided with a fitting, boss, or pad, securely attached to the
cylinder by brazing or by welding or by threads. A fitting, boss, or pad
must be of steel suitable for the method of attachment employed, and
which need not be identified or verified as to analysis, except that if
attachment is by welding, carbon content may not exceed 0.25 percent. If
threads are used, they must comply with the following:
(i) Threads must be clean cut, even without checks, and tapped to
gauge.
(ii) Taper threads to be of length not less than as specified for
American Standard taper pipe threads.
(iii) Straight threads, having at least 4 engaged threads, to have
tight fit and calculated shear strength at least 10 times the test
pressure of the cylinder; gaskets required, adequate to prevent leakage.
(2) Closure of a fitting, boss, or pad must be adequate to prevent
leakage.
(i) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Cylinders must be tested as follows:
(i) At least one cylinder selected at random out of each lot of 200
or less must be tested as outlined in paragraphs (i)(1), (i)(2), and
(i)(3) of this section to at least two times service pressure.
(ii) All cylinders not tested as outlined in paragraph (i)(4)(i) of
this section must be examined under pressure of at least two times
service pressure and show no defect.
(5) Each 1000 cylinders or less successively produced each day must
constitute a lot. One cylinder must be selected from each lot and
hydrostatically tested to destruction. If this cylinder bursts below
five times the service pressure, then two additional cylinders must be
selected and subjected to this test. If either of these cylinders fails
by bursting below five times the service pressure then the entire lot
must be rejected. All cylinders constituting a lot must be of identical
size, construction heat-treatment, finish, and quality.
(j) Flattening test. Following the hydrostatic test, one cylinder
taken at random out of each lot of 200 or less, must be subjected to a
flattening test that is between knife edges, wedge shaped, 60[deg]
angle, rounded to \1/2\ inch radius.
(k) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material, as follows:
(1) The test is required on 2 specimens cut from 1 cylinder, or part
thereof heat-treated as required, taken at random out of each lot of 200
or less in the case of cylinders of capacity greater than 86 cubic
inches and out of each lot of 500 or less for cylinders having a
capacity of 86 cubic inches or less.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
a gauge length of 2 inches with a width not over 1\1/2\ inches, or a
gauge length at least 24 times the thickness with a width not over 6
times the thickness is authorized when a cylinder wall is not over \3/
16\ inch thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within one inch of each end of the reduced
section.
[[Page 55]]
(iii) When size of cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi and the strain
indicator reading being set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(l) Acceptable results for physical and flattening tests. Acceptable
results for the physical and flattening tests are an elongation of at
least 40 percent for a 2 inch gauge length or at least 20 percent in
other cases and a yield strength not over 73 percent of tensile
strength. In this instance the flattening test is required, without
cracking, to six times the wall thickness with a weld 90[deg] from the
direction of the applied load. Two rings cut from the ends of length of
pipe used in production of a lot may be used for the flattening test
provided the rings accompany the lot which they represent in all thermal
processing operations. At least one of the rings must pass the
flattening test.
(m) Leakage test. All spun cylinders and plugged cylinders must be
tested for leakage by gas or air pressure after the bottom has been
cleaned and is free from all moisture, subject to the following
conditions:
(1) Pressure, approximately the same as but no less than service
pressure, must be applied to one side of the finished bottom over an
area of at least \1/16\ of the total area of the bottom but not less
than \3/4\ inch in diameter, including the closure, for at least 1
minute, during which time the other side of the bottom exposed to
pressure must be covered with water and closely examined for indications
of leakage. Except as provided in paragraph (n) of this section,
cylinders which are leaking must be rejected.
(2) A spun cylinder is one in which an end closure in the finished
cylinder has been welded by the spinning process.
(3) A plugged cylinder is one in which a permanent closure in the
bottom of a finished cylinder has been effected by a plug.
(4) As a safety precaution, if the manufacturer elects to make this
test before the hydrostatic test, he should design his apparatus so that
the pressure is applied to the smallest area practicable, around the
point of closure, and so as to use the smallest possible volume of air
or gas.
(n) Rejected cylinders. Repairs of rejected cylinders is authorized.
Cylinders that are leaking must be rejected, except that:
(1) Spun cylinders rejected under the provisions of paragraph (m) of
this section may be removed from the spun cylinder category by drilling
to remove defective material, tapping, and plugging.
(2) Brazed joints may be rebrazed.
(3) Subsequent to the operations noted in paragraphs (n)(1) and
(n)(2) of this section, acceptable cylinders must pass all prescribed
tests.
[[Page 56]]
(o) Marking. Markings on each cylinder must be by stamping plainly
and permanently on shoulder, top head, neck or valve protection collar
which is permanently attached to the cylinders and forming an integral
part thereof, provided that cylinders not less than 0.090 inch thick may
be stamped on the side wall adjacent to top head.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386,
Aug. 28, 2001; 67 FR 51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31,
2003]
Sec. 178.56 Specification 4AA480 welded steel cylinders.
(a) Type, size, and service pressure. A DOT 4AA480 cylinder is a
welded steel cylinder having a water capacity (nominal) not over 1,000
pounds water capacity and a service pressure of 480 psig. Closures
welded by spinning process not permitted.
(b) Steel. The limiting chemical composition of steel authorized by
this specification must be as shown in table I of appendix A to this
part.
(c) Identification of material. Material must be identified by any
suitable method except that plates and billets for hotdrawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. Exposed bottom welds on cylinders
over 18 inches long must be protected by footrings. Minimum thickness of
heads and bottoms may not be less than 90 percent of the required
thickness of the side wall. Seams must be made as follows:
(1) Circumferential seams must be welded. Brazing is not authorized.
(2) Longitudinal seams are not permitted.
(3) Welding procedures and operators must be qualified in accordance
with CGA C-3 (IBR, see Sec. 171.7 of this subchapter).
(e) Welding. Only the welding of neckrings, footrings, bosses, pads,
and valve protection rings to the tops and bottoms of cylinders is
authorized. Provided that such attachments are made of weldable steel,
the carbon content of which does not exceed 0.25 percent.
(f) Wall thickness. The wall thickness of the cylinder must conform
to the following:
(1) For cylinders with an outside diameter over 5 inches, the
minimum wall thickness is 0.078 inch. In any case, the minimum wall
thickness must be such that the calculated wall stress at the minimum
test pressure (in paragraph (i) of this section) may not exceed the
lesser value of either of the following:
(i) One-half of the minimum tensile strength of the material
determined as required in paragraph (j) of this section; or
(ii) 35,000 psi.
(2) Calculation must be made by the formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test;
D = outside diameter in inches;
d = inside diameter in inches.
(3) The ratio of tangential length to outside diameter may not
exceed 4.0 for cylinders with a wall thickness less than 0.100 inch.
(g) Heat treatment. Each cylinder must be uniformly and properly
heat treated prior to tests. Any suitable heat treatment in excess of
1100 [deg]F is authorized except that liquid quenching is not permitted.
Heat treatment must be accomplished after all forming and welding
operations. Heat treatment is not required after welding weldable low
carbon parts to attachments of similar material which have been
previously welded to the top or bottom of cylinders and properly heat
treated, provided such subsequent welding does not produce a temperature
in excess of 400 [deg]F., in any part of the top or bottom material.
(h) Openings in cylinders. Openings in cylinders must conform to the
following:
(1) All openings must be in the heads or bases.
[[Page 57]]
(2) Each opening in the cylinder, except those for safety devices,
must be provided with a fitting boss, or pad, securely attached to the
cylinder by welding or by threads. If threads are used they must comply
with the following:
(i) Threads must be clean-cut, even without checks and cut to gauge.
(ii) Taper threads to be of length not less than as specified for
American Standard taper pipe threads.
(iii) Straight threads having at least 6 engaged threads, must have
a tight fit and a calculated shear strength at least 10 times the test
pressure of the cylinder. Gaskets, adequate to prevent leakage, are
required.
(3) Closure of a fitting, boss or pad must be adequate to prevent
leakage.
(i) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test as follows:
(1) The test must be by water jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds or
sufficiently longer to assure complete expansion. Any internal pressure
applied after heat-treatment and before the official test may not exceed
90 percent of the test pressure. If, due to failure of test apparatus,
the test pressure cannot be maintained, the test may be repeated at a
pressure increased by 10 percent or 100 psig, whichever is lower.
(3) Permanent volumetric expansion may not exceed 10 percent of the
total volumetric expansion at test pressure.
(4) Cylinders must be tested as follows:
(i) At least one cylinder selected at random out of each lot of 200
or less must be tested as described in paragraphs (i)(1), (i)(2), and
(i)(3) of this section, to at least two times service pressure. If a
selected cylinder fails, then two additional specimens must be selected
at random from the same lot and subjected to the prescribed test. If
either of these fails the test, then each cylinder in that lot must be
so tested; and
(ii) Each cylinder not tested as prescribed in paragraph (i)(4)(i)
of this section must be examined under pressure of at least two times
service pressure and must show no defect. A cylinder showing a defect
must be rejected unless it may be requalified under paragraph (m) of
this section.
(j) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material, as follows:
(1) The test is required on 2 specimens cut from one cylinder having
passed the hydrostatic test, or part thereof heat-treated as required,
taken at random out of each lot of 200 or less.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
a gauge length of 2 inches with a width not over 1\1/2\ inches, or a
gauge length at least 24 times the thickness with a width not over 6
times thickness is authorized when the cylinder wall is not over \3/16\
inch thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within one inch of each end of the reduced
section.
(iii) When size of cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold, by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load''), corresponding to
[[Page 58]]
the stress at which the 0.2 percent permanent strain occurs may be
determined with sufficient accuracy by calculating the elastic extension
of the gauge length under appropriate load and adding thereto 0.2
percent of the gauge length. Elastic extension calculations must be
based on an elastic modulus of 30,000,000. In the event of controversy,
the entire stress-strain diagram must be plotted and the yield strength
determined from the 0.2 percent offset.
(iii) For the purpose of strain measurement, the initial strain
reference must be set while the specimen is under a stress of 12,000 psi
and the strain indicator reading being set at the calculated
corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(k) Elongation. Physical test specimens must show at least a 40
percent elongation for 2-inch gauge lengths or at least a 20 percent
elongation in other cases. Except that these elongation percentages may
be reduced numerically by 2 for 2-inch specimens and by 1 in other cases
for each 7,500 psi increment of tensile strength above 50,000 psi to a
maximum of four such increments.
(l) Tests of welds. Welds must be tested as follows:
(1) Tensile test. A specimen must be cut from one cylinder of each
lot of 200 or less, or a welded test plate. The welded test plate must
be of one of the heats in the lot of 200 or less which it represents, in
the same condition and approximately the same thickness as the cylinder
wall except that it may not be of a lesser thickness than that required
for a quarter size Charpy impact specimen. The weld must be made by the
same procedures and subjected to the same heat treatment as the major
weld on the cylinder. The specimens must be taken across the major seam
and must be prepared and tested in accordance with and must meet the
requirements of CGA Pamphlet C-3. Should this specimen fail to meet the
requirements, specimens may be taken from two additional cylinders or
welded test plates from the same lot and tested. If either of the latter
specimens fail to meet the requirements, the entire lot represented must
be rejected.
(2) Guided bend test. A root bend test specimen must be cut from the
cylinder or a welded test plate, used for the tensile test specified in
paragraph (l)(1) of this section. Specimens must be taken from across
the major seam and must be prepared and tested in accordance with and
must meet the requirements of CGA Pamphlet C-3.
(3) Alternate guided-bend test. This test may be used and must be as
required by CGA Pamphlet C-3. The specimen must be bent until the
elongation at the outer surface, adjacent to the root of the weld,
between the lightly scribed gage lines-a to b, is at least 20 percent,
except that this percentage may be reduced for steels having a tensile
strength in excess of 50,000 psi, as provided in paragraph (k) of this
section.
(m) Rejected cylinders. Reheat treatment of rejected cylinders is
authorized. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair of welded seams by welding is authorized.
(n) Markings. Markings must be stamped plainly and permanently in
one of the following locations on the cylinder:
(1) On shoulders and top heads not less than 0.087 inch thick.
(2) On neck, valve boss, valve protection sleeve, or similar part
permanently attached to top end of cylinder.
(3) On a plate attached to the top of the cylinder or permanent part
thereof: sufficient space must be left on the plate to provide for
stamping at least six retest dates: the plate must be at least \1/16\
inch thick and must be attached by welding or by brazing at a
temperature of at least 1100 [deg]F, throughout all edges of the plate.
(4) Variations in location of markings authorized only when
necessitated by lack of space.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386,
Aug. 28, 2001; 67 FR 51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31,
2003]
[[Page 59]]
Sec. 178.57 Specification 4L welded insulated cylinders.
(a) Type, size, service pressure, and design service temperature. A
DOT 4L cylinder is a fusion welded insulated cylinder with a water
capacity (nominal) not over 1,000 pounds water capacity and a service
pressure of at least 40 but not greater than 500 psig conforming to the
following requirements:
(1) For liquefied hydrogen service, the cylinders must be designed
to stand on end, with the axis of the cylindrical portion vertical.
(2) The design service temperature is the coldest temperature for
which a cylinder is suitable. The required design service temperatures
for each cryogenic liquid is as follows:
------------------------------------------------------------------------
Cryogenic liquid Design service temperature
------------------------------------------------------------------------
Argon..................................... Minus 320 [deg]F or colder.
Helium.................................... Minus 452 [deg]F or colder.
Hydrogen.................................. Minus 42 3 [deg]F or colder.
Neon...................................... Minus 411 [deg]F or colder.
Nitrogen.................................. Minus 320 [deg]F or colder.
Oxygen.................................... Minus 320 [deg]F or colder.
------------------------------------------------------------------------
(b) Material. Material use in the construction of this specification
must conform to the following:
(1) Inner containment vessel (cylinder). Designations and limiting
chemical compositions of steel authorized by this specification must be
as shown in table 1 in paragraph (o) of this section.
(2) Outer jacket. Steel or aluminum may be used subject to the
requirements of paragraph (o)(2) of this section.
(c) Identification of material. Material must be identified by any
suitable method.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart and to the following requirements:
(1) No defect is permitted that is likely to weaken the finished
cylinder appreciably. A reasonably smooth and uniform surface finish is
required. The shell portion must be a reasonably true cylinder.
(2) The heads must be seamless, concave side to the pressure,
hemispherical or ellipsoidal in shape with the major diameter not more
than twice the minor diameter. Minimum thickness of heads may not be
less than 90 percent of the required thickness of the sidewall. The
heads must be reasonably true to shape, have no abrupt shape changes,
and the skirts must be reasonably true to round.
(3) The surface of the cylinder must be insulated. The insulating
material must be fire resistant. The insulation on non-evacuated jackets
must be covered with a steel jacket not less than 0.060-inch thick or an
aluminum jacket not less than 0.070 inch thick, so constructed that
moisture cannot come in contact with the insulating material. If a
vacuum is maintained in the insulation space, the evacuated jacket must
be designed for a minimum collapsing pressure of 30 psig differential
whether made of steel or aluminum. The construction must be such that
the total heat transfer, from the atmosphere at ambient temperature to
the contents of the cylinder, will not exceed 0.0005 Btu per hour, per
Fahrenheit degree differential in temperature, per pound of water
capacity of the cylinder. For hydrogen, cryogenic liquid service, the
total heat transfer, with a temperature differential of 520 Fahrenheit
degrees, may not exceed that required to vent 30 SCF of hydrogen gas per
hour.
(4) For a cylinder having a design service temperature colder than
minus 320 [deg]F, a calculation of the maximum weight of contents must
be made and that weight must be marked on the cylinder as prescribed in
Sec. 178.35.
(5) Welding procedures and operations must be qualified in
accordance with CGA Pamphlet C-3 (IBR, see Sec. 171.7 of this
subchapter). In addition, an impact test of the weld must be performed
in accordance with paragraph (l) of this section as part of the
qualification of each welding procedure and operator.
(e) Welding. Welding of the cylinder must be as follows:
(1) All seams of the cylinder must be fusion welded. A means must be
provided for accomplishing complete penetration of the joint. Only butt
or joggle butt joints for the cylinder seams are authorized. All joints
in the cylinder must have reasonably true alignment.
(2) All attachments to the sidewalls and heads of the cylinder must
be by fusion welding and must be of a
[[Page 60]]
weldable material complying with the impact requirements of paragraph
(l) of this section.
(3) For welding the cylinder, each procedure and operator must be
qualified in accordance with the sections of CGA Pamphlet C-3 that
apply. In addition, impact tests of the weld must be performed in
accordance with paragraph (l) of this section as part of the
qualification of each welding procedure and operator.
(4) Brazing, soldering and threading are permitted only for joints
not made directly to the cylinder body. Threads must comply with the
requirements of paragraph (h) of this section.
(f) Wall thickness. The minimum wall thickness of the cylinder must
be such that the calculated wall stress at the minimum required test
pressure may not exceed the least value of the following:
(1) 45,000 psi.
(2) One-half of the minimum tensile strength across the welded seam
determined in paragraph (l) of this section.
(3) One-half of the minimum tensile strength of the base metal
determined as required in paragraph (j) of this section.
(4) The yield strength of the base metal determined as required in
paragraph (l) of this section.
(5) Further provided that wall stress for cylinders having
longitudinal seams may not exceed 85 percent of the above value,
whichever applies.
(6) Calculation must be made by the following formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
where:
S = wall stress in pounds psi;
P = minimum test pressure prescribed for pressure test in psig;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. Heat treatment is not permitted.
(h) Openings in cylinder. Openings in cylinders must conform to the
following:
(1) Openings are permitted in heads only. They must be circular and
may not exceed 3 inches in diameter or one third of the cylinder
diameter, whichever is less. Each opening in the cylinder must be
provided with a fitting, boss or pad, either integral with, or securely
attached to, the cylinder body by fusion welding. Attachments to a
fitting, boss or pad may be made by welding, brazing, mechanical
attachment, or threading.
(2) Threads must comply with the following:
(i) Threads must be clean-cut, even, without checks and cut to
gauge.
(ii) Taper threads to be of a length not less than that specified
for NPT.
(iii) Straight threads must have at least 4 engaged threads, tight
fit and calculated shear strength at least 10 times the test pressure of
the cylinder. Gaskets, which prevent leakage and are inert to the
hazardous material, are required.
(i) Pressure test. Each cylinder, before insulating and jacketing,
must be examined under a pressure of at least 2 times the service
pressure maintained for at least 30 seconds without evidence of leakage,
visible distortion or other defect. The pressure gauge must permit
reading to an accuracy of 1 percent.
(j) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, and elongation as follows:
(1) The test is required on 2 specimens selected from material of
each heat and in the same condition as that in the completed cylinder.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
a gauge length of 2 inches with width not over 1\1/2\ inches, or a gauge
length at least 24 times thickness with a width not over 6 times
thickness (authorized when cylinder wall is not over \1/16\ inch thick).
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within one inch of each end of the reduced
section.
(iii) When size of the cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold by pressure only, not by blows.
When specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
[[Page 61]]
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load''), corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic expansion of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on the elastic modulus of
the material used. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain
reference must be set while the specimen is under a stress of 12,000 psi
and the strain indicator reading being set at the calculated
corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(k) Acceptable results for physical tests. Physical properties must
meet the limits specified in paragraph (o)(1), table 1, of this section,
for the particular steel in the annealed condition. The specimens must
show at least a 20 percent elongation for a 2-inch gage length. Except
that the percentage may be reduced numerically by 2 for each 7,500 psi
increment of tensile strength above 100,000 psi to a maximum of 5 such
increments. Yield strength and tensile strength must meet the
requirements of paragraph (o)(1), table 1, of this section.
(l) Tests of welds. Welds must be tested as follows:
(1) Tensile test. A specimen must be cut from one cylinder of each
lot of 200 or less, or welded test plate. The welded test plate must be
of one of the heats in the lot of 200 or less which it represents, in
the same condition and approximately the same thickness as the cylinder
wall except that it may not be of a lesser thickness than that required
for a quarter size Charpy impact specimen. The weld must be made by the
same procedures and subjected to the same heat treatment as the major
weld on the cylinder. The specimen must be taken across the major seam
and must be prepared in accordance with and must meet the requirements
of CGA Pamphlet C-3. Should this specimen fail to meet the requirements,
specimens may be taken from two additional cylinders or welded test
plates from the same lot and tested. If either of the latter specimens
fails to meet the requirements, the entire lot represented must be
rejected.
(2) Guided bend test. A ``root'' bend test specimen must be cut from
the cylinder or welded test plate, used for the tensile test specified
in paragraph (l)(1) of this section and from any other seam or
equivalent welded test plate if the seam is welded by a procedure
different from that used for the major seam. Specimens must be taken
across the particular seam being tested and must be prepared and tested
in accordance with and must meet the requirements of CGA Pamphlet C-3.
(3) Alternate guided-bend test. This test may be used and must be as
specified in CGA Pamphlet C-3. The specimen must be bent until the
elongation at the outer surface, adjacent to the root of the weld,
between the lightly scribed gage lines a to b, is at least 20 percent,
except that this percentage may be reduced for steels having a tensile
strength in excess of 100,000 psig, as provided in paragraph (c) of this
section.
(4) Impact tests. One set of three impact test specimens (for each
test) must be prepared and tested for determining the impact properties
of the deposited weld metal--
(i) As part of the qualification of the welding procedure.
(ii) As part of the qualification of the operators.
(iii) For each ``heat'' of welding rodor wire used.
[[Page 62]]
(iv) For each 1,000 feet of weld made with the same heat of welding
rod or wire.
(v) All impact test specimens must be of the charpy type, keyhole or
milled U-notch, and must conform in all respects to ASTM E 23 (IBR, see
Sec. 171.7 of this subchapter). Each set of impact specimens must be
taken across the weld and have the notch located in the weld metal. When
the cylinder material thickness is 2.5 mm or thicker, impact specimens
must be cut from a cylinder or welded test plate used for the tensile or
bend test specimens. The dimension along the axis of the notch must be
reduced to the largest possible of 10 mm, 7.5 mm, 5 mm or 2.5 mm,
depending upon cylinder thickness. When the material in the cylinder or
welded test plate is not of sufficient thickness to prepare 2.5 mm
impact test specimens, 2.5 mm specimens must be prepared from a welded
test plate made from \1/8\ inch thick material meeting the requirements
specified in paragraph (o)(1), table 1, of this section and having a
carbon analysis of .05 minimum, but not necessarily from one of the
heats used in the lot of cylinders. The test piece must be welded by the
same welding procedure as used on the particular cylinder seam being
qualified and must be subjected to the same heat treatment.
(vi) Impact test specimens must be cooled to the design service
temperature. The apparatus for testing the specimens must conform to
requirements of ASTM Standard E 23. The test piece, as well as the
handling tongs, must be cooled for a length of time sufficient to reach
the service temperature. The temperature of the cooling device must be
maintained within a range of plus or minus 3 [deg]F. The specimen must
be quickly transferred from the cooling device to the anvil of the
testing machine and broken within a time lapse of not more than six
seconds.
(vii) The impact properties of each set of impact specimens may not
be less than the values in the following table:
------------------------------------------------------------------------
Minimum Minimum
impact value impact value
required for permitted on
Size of specimen avg. of each one only of
set of three a set of
specimens three (ft.-
(ft.-lb.) lb.)
------------------------------------------------------------------------
10 mmx10 mm................................. 15 10
10 mmx7.5 mm................................ 12.5 8.5
10 mmx5 mm.................................. 10 7.0
10 mmx2.5 mm................................ 5 3.5
------------------------------------------------------------------------
(viii) When the average value of the three specimens equals or
exceeds the minimum value permitted for a single specimen and the value
for more than one specimen is below the required average value, or when
the value for one specimen is below the minimum value permitted for a
single specimen, a retest of three additional specimens must be made.
The value of each of these retest specimens must equal or exceed the
required average value. When an erratic result is caused by a defective
specimen, or there is uncertainty in test procedure, a retest is
authorized.
(m) Radiographic examination. Cylinders must be subject to a
radiographic examination as follows:
(1) The techniques and acceptability of radiographic inspection must
conform to the standards set forth in CGA Pamphlet C-3.
(2) One finished longitudinal seam must be selected at random from
each lot of 100 or less successively produced and be radiographed
throughout its entire length. Should the radiographic examination fail
to meet the requirements of paragraph (m)(1) of this section, two
additional seams of the same lot must be examined, and if either of
these fail to meet the requirements of (m)(1) of this section, only
those passing are acceptable.
(n) Rejected cylinders. Reheat treatment of rejected cylinders is
authorized. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Welds may be repaired by suitable methods of fusion
welding.
(o) Authorized materials of construction. Authorized materials of
construction are as follows:
(1) Inner containment vessel (cylinder). Electric furnace steel of
uniform quality must be used. Chemical analysis must conform to ASTM A
240/A 240M (IBR, see Sec. 171.7 of this subchapter),
[[Page 63]]
Type 304 stainless steel. Chemical analysis must conform to ASTM A240,
Type 304 Stainless Steel. A heat of steel made under table 1 and table 2
in this paragraph (o)(1) is acceptable, even though its check chemical
analysis is slightly out of the specified range, if it is satisfactory
in all other respects, provided the tolerances shown in table 3 in this
paragraph (o)(1) are not exceeded. The following chemical analyses and
physical properties are authorized:
Table 1--Authorized Materials
------------------------------------------------------------------------
Chemical analysis, limits in
Designation percent
------------------------------------------------------------------------
Carbon \1\............................. 0.08 max.
Manganese.............................. 2.00 max.
Phosphorus............................. 0.045 max.
Sulphur................................ 0.030 max.
Silicon................................ 1.00 max.
Nickel................................. 8.00-10.50.
Chromium............................... 18.00-20.00.
Molybdenum............................. None.
Titanium............................... None.
Columbium.............................. None.
------------------------------------------------------------------------
\1\ The carbon analysis must be reported to the nearest hundredth of one
percent.
Table 2--Physical Properties
------------------------------------------------------------------------
Physical
properties
(annealed)
------------------------------------------------------------------------
Tensile strength, p.s.i. (minimum).......................... 75,000
Yield strength, p.s.i. (minimum)............................ 30,000
Elongation in 2 inches (minimum) percent.................... 30.0
Elongation other permissible gauge lengths (minimum) percent 15.0
------------------------------------------------------------------------
Table 3--Check Analysis Tolerances
------------------------------------------------------------------------
Tolerance
over the
maximum
Elements Limit or specified range limit or
(percent) under the
minimum
limit
------------------------------------------------------------------------
Carbon......................... To 0.030, incl........... 0.005
Over 0.30 to 0.20, incl.. 0.01
Manganese...................... To 1.00 incl............. .03
Over 1.00 to 3.00, incl.. 0.04
Phosphorus \1\................. To 0.040, incl........... 0.005
Over 0.040 to 0.020 incl. 0.010
Sulphur........................ To .40 incl.............. 0.005
Silicon........................ To 1.00, incl............ 0.05
Nickel......................... Over 5.00 to 10.00, incl. 0.10
Over 10.00 to 20.00, incl 0.15
Chromium....................... Over 15.00 to 20.00, incl 0.20
------------------------------------------------------------------------
\1\ Rephosphorized steels not subject to check analysis for phosphorus.
(2) Outer jacket. (i) Nonflammable cryogenic liquids. Cylinders
intended for use in the transportation of nonflammable cryogenic liquid
must have an outer jacket made of steel or aluminum.
(ii) Flammable cryogenic liquids. Cylinders intended for use in the
transportation of flammable cryogenic liquid must have an outer jacket
made of steel.
(p) Markings. (1) Markings must be stamped plainly and permanently
on shoulder or top head of jacket or on a permanently attached plate or
head protective ring.
(2) The letters ``ST'', followed by the design service temperature
(for example, ST-423F), must be marked on cylinders having a design
service temperature of colder than minus 320 [deg]F only. Location to be
just below the DOT mark.
(3) The maximum weight of contents, in pounds (for example, ``Max.
Content 51 ''), must be marked on cylinders having a design
service temperature colder than minus 320 [deg]F only. Location to be
near symbol.
(4) Special orientation instructions must be marked on the cylinder
(for example, THIS END UP), if the cylinder is used in an orientation
other than vertical with openings at the top of the cylinder.
(5) If the jacket of the cylinder is constructed of aluminum, the
letters ``AL'' must be marked after the service pressure marking.
Example: DOT-4L150 AL.
(6) Except for serial number and jacket material designation, each
marking prescribed in this paragraph (p) must be duplicated on each
cylinder by any suitable means.
(q) Inspector's report. In addition to the information required by
Sec. 178.35, the inspector's reports must contain information on:
(1) The jacket material and insulation type;
(2) The design service temperature
( [deg]F); and
(3) The impact test results, on a lot basis.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386-
45388, Aug. 28, 2001; 67 FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31,
2003]
[[Page 64]]
Sec. 178.58 Specification 4DA welded steel cylinders for aircraft use.
(a) Type, size, and service pressure. A DOT 4DA is a welded steel
sphere (two seamless hemispheres) or a circumferentially welded cylinder
(two seamless drawn shells) with a water capacity not over 100 pounds
and a service pressure of at least 500 but not over 900 psig.
(b) Steel. Open-hearth or electric steel of uniform quality must be
used. A heat of steel made under table 1 in this paragraph (b), check
chemical analysis of which is slightly out of the specified range, is
acceptable, if satisfactory in all other respects, provided the
tolerances shown in table 2 in this paragraph (b) are not exceeded
except as approved by the Associate Administrator. The following
chemical analyses are authorized:
Table 1--Authorized Materials
------------------------------------------------------------------------
4130 Percent
------------------------------------------------------------------------
Carbon.................................... 0.28/0.33.
Manganese................................. 0.40/0.60.
Phosphorus................................ 0.040 max.
Sulfur.................................... 0.040 max.
Silicon................................... 0.15/0.35.
Chromium.................................. 0.80/1.10.
Molybdenum................................ 0.15/0.25.
------------------------------------------------------------------------
Table 2--Check Analysis Tolerances
----------------------------------------------------------------------------------------------------------------
Tolerance (percent) over the maximum limit or
Limit or maximum under the minimum limit
Element specified (percent) -------------------------------------------------
Under minimum limit Over maximum limit
----------------------------------------------------------------------------------------------------------------
Carbon............................... Over 0.15 to 0.40 incl. .03.................... .04
Manganese............................ To 0.60 incl........... .03.................... .03
Phosphorus\1\........................ All ranges............. ....................... .01
Sulphur.............................. All ranges............. ....................... .01
Silicon.............................. To 0.30 incl........... .02.................... .03
Over 0.30 to 1.00 incl. .05.................... .05
Chromium............................. To 0.90 incl........... .03.................... .03
Over 0.90 to 2.10 incl. .05.................... .05
Molybdenum........................... To 0.20 incl........... .01.................... .01
Over 0.20 to 0.40, incl .02.................... .02
----------------------------------------------------------------------------------------------------------------
\1\ Rephosphorized steels not subject to check analysis for phosphorus.
(c) Identification of material. Materials must be identified by any
suitable method except that plates and billets for hot-drawn containers
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured in accordance with
the following requirements:
(1) By best appliances and methods. No defect is acceptable that is
likely to weaken the finished container appreciably. A reasonably smooth
and uniform surface finish is required. No abrupt change in wall
thickness is permitted. Welding procedures and operators must be
qualified in accordance with CGA Pamphlet C-3 (IBR, see Sec. 171.7 of
this subchapter).
(2) All seams of the sphere or cylinders must be fusion welded.
Seams must be of the butt or joggle butt type and means must be provided
for accomplishing complete penetration of the joint.
(e) Welding. Attachments to the container are authorized by fusion
welding provided that such attachments are made of weldable steel, the
carbon content of which may not exceed 0.25 percent except in the case
of 4130 steel.
(f) Wall thickness. The minimum wall thickness must be such that the
wall stress at the minimum specified test pressure may not exceed 67
percent of the minimum tensile strength of the steel as determined from
the physical and burst tests required and may not be over 70,000 p.s.i.
For any diameter container, the minimum wall thickness is 0.040 inch.
Calculations must be made by the formulas in (f)(1) or (f)(2) of this
section:
(1) Calculation for a sphere must be made by the following formula:
S = PD / 4tE
Where:
S = wall stress in pounds psi;
P = test pressure prescribed for water jacket test, i.e., at least 2
times service pressure, in psig;
D = outside diameter in inches;
t = minimum wall thickness in inches;
E = 0.85 (provides 85 percent weld efficiency factor which must be
applied in the girth weld area and heat affected zones which zone must
extend a distance of 6 times wall thickness from center line of weld);
E = 1.0 (for all other areas).
(2) Calculation for a cylinder must be made by the following
formula:
S = [P(1.3D \2\ + 0.4d \2\)] / (D \2\ - d \2\)
Where:
S = wall stress in pounds psi;
[[Page 65]]
P = test pressure prescribed for water jacket test, i.e., at least 2
times service pressure, in psig;
D = outside diameter in inches;
d = inside diameter in inches.
(g) Heat treatment. The completed containers must be uniformly and
properly heat-treated prior to tests. Heat-treatment of containers of
the authorized analysis must be as follows:
(1) All containers must be quenched by oil, or other suitable medium
except as provided in paragraph (g)(4) of this section.
(2) The steel temperature on quenching must be that recommended for
the steel analysis, but may not exceed 1,750 [deg]F.
(3) The steel must be tempered at the temperature most suitable for
the analysis except that in no case shall the tempering temperature be
less than 1,000 [deg]F.
(4) The steel may be normalized at a temperature of 1,650 [deg]F
instead of being quenched, and containers so normalized need not be
tempered.
(5) All cylinders, if water quenched or quenched with a liquid
producing a cooling rate in excess of 80 percent of the cooling rate of
water, must be inspected by the magnetic particle or dye penetrant
method to detect the presence of quenching cracks. Any cylinder found to
have a quench crack must be rejected and may not be requalified.
(h) Openings in container. Openings in the container must comply
with the following requirements:
(1) Each opening in the container must be provided with a fitting,
boss, or pad of weldable steel securely attached to the container by
fusion welding.
(2) Attachments to a fitting, boss, or pad must be adequate to
prevent leakage. Threads must comply with the following:
(i) Threads must be clean cut, even, without checks, and tapped to
gauge.
(ii) Taper threads to be of length not less than as specified for
American Standard taper pipe threads.
(iii) Straight threads, having at least 4 engaged threads, to have
tight fit and calculated shear strength at least 10 times the test
pressure of the container; gaskets required, adequate to prevent
leakage.
(i) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to accuracy either of 1 percent or 0.1 cubic
centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure. If, due to failure of the test
apparatus, the test pressure cannot be maintained, the test may be
repeated at a pressure increased by 10 percent or 100 psig, whichever is
the lower.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) Each container must be tested to at least 2 times service
pressure.
(j) Burst test. One container taken at random out of 200 or less
must be hydrostatically tested to destruction. The rupture pressure must
be included as part of the inspector's report.
(k) Flattening test. Spheres and cylinders must be subjected to a
flattening test as follows:
(1) Flattening test for spheres. One sphere taken at random out of
each lot of 200 or less must be subjected to a flattening test as
follows:
(i) The test must be performed after the hydrostatic test.
(ii) The test must be at the weld between the parallel steel plates
on a press with a welded seam, at right angles to the plates. Any
projecting appurtenances may be cut off (by mechanical means only) prior
to crushing.
(2) Flattening test for cylinders. One cylinder taken at random out
of each lot of 200 or less, must be subjected to a flattening test as
follows:
(i) The test must be performed after the hydrostatic test.
(ii) The test cylinder must be placed between wedge-shaped knife
edges having a 60[deg] angle, rounded to a \1/2\-inch radius.
[[Page 66]]
(l) Radiographic inspection. Radiographic examinations is required
on all welded joints which are subjected to internal pressure, except
that at the discretion of the disinterested inspector, openings less
than 25 percent of the sphere diameter need not be subjected to
radiographic inspection. Evidence of any defects likely to seriously
weaken the container must be cause for rejection.
(m) Physical test and specimens for spheres and cylinders. Spheres
and cylinders must be subjected to a physical test as follows:
(1) A physical test for a sphere is required on 2 specimens cut from
a flat representative sample plate of the same heat taken at random from
the steel used to produce the sphere. This flat steel from which the 2
specimens are to be cut must receive the same heat-treatment as the
spheres themselves. Sample plates to be taken for each lot of 200 or
less spheres.
(2) Specimens for spheres have a gauge length of 2 inches with a
width not over 1\1/2\ inches, or a gauge length at least 24 times
thickness with a width not over 6 times thickness is authorized when
wall of sphere is not over \3/16\ inch thick.
(3) A physical test for cylinders is required on 2 specimens cut
from 1 cylinder taken at random out of each lot of 200 or less.
(4) Specimens for cylinder must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
a gauge length of 2 inches with a width not over 1\1/2\ inches, a gauge
length at least 24 times thickness with a width not over 6 times
thickness is authorized when a cylinder wall is not over \3/16\ inch
thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within 1 inch of each end of the reduced
section.
(iii) Heating of a specimen for any purpose is not authorized.
(5) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
percent offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi and the strain
indicator reading being set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(n) Acceptable results for physical, flattening, and burst tests.
The following are acceptable results of the physical, flattening and
burst test:
(1) Elongation must be at least 20 percent for a 2-inch gauge length
or 10 percent in other cases.
(2) Flattening is required to 50 percent of the original outside
diameter without cracking.
(3) Burst pressure must be at least 3 times service pressure.
(o) Rejected containers. Reheat-treatment of rejected cylinders is
authorized. Subsequent thereto, containers must pass all prescribed
tests to be acceptable. Repair of welded seams by welding prior to
reheat-treatment is authorized.
(p) Marking. Markings on each container must be stamped plainly and
permanently on a permanent attachment or on a metal nameplate
permanently secured to the container by means other than soft solder.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386,
45388, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002; 67 FR 61015, Sept. 27,
2002; 68 FR 75748, Dec. 31, 2003]
[[Page 67]]
Sec. 178.59 Specification 8 steel cylinders with porous fillings for
acetylene.
(a) Type and service pressure. A DOT 8 cylinder is a seamless
cylinder with a service pressure of 250 psig. The following steel is
authorized:
(1) A longitudinal seam if forge lap welded;
(2) Attachment of heads by welding or by brazing by dipping process;
or
(3) A welded circumferential body seam if the cylinder has no
longitudinal seam.
(b) Steel. Open-hearth, electric or basic oxygen process steel of
uniform quality must be used. Content percent may not exceed the
following: Carbon, 0.25; phosphorus, 0.045; sulphur, 0.050.
(c) Identification of steel. Materials must be identified by any
suitable method except that plates and billets for hot-drawn cylinders
must be marked with the heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is acceptable that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. Welding procedures and operators
must be qualified in accordance with CGA Pamphlet C-3 (IBR, see Sec.
171.7 of this subchapter).
(e) Exposed bottom welds. Exposed bottom welds on cylinders over 18
inches long must be protected by footrings.
(f) Heat treatment. Body and heads formed by drawing or pressing
must be uniformly and properly heat treated prior to tests.
(g) Openings. Openings in the cylinders must comply with the
following:
(1) Standard taper pipe threads are required;
(2) Length may not be less than as specified for American Standard
pipe threads; tapped to gauge; clean cut, even, and without checks.
(h) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) One cylinder out of each lot of 200 or less must be
hydrostatically tested to at least 750 psig. Cylinders not so tested
must be examined under pressure of between 500 and 600 psig and show no
defect. If hydrostatically tested cylinder fails, each cylinder in the
lot may be hydrostatically tested and those passing are acceptable.
(i) Leakage test. Cylinders with bottoms closed in by spinning must
be subjected to a leakage test by setting the interior air or gas
pressure to not less than the service pressure. Cylinders which leak
must be rejected.
(j) Physical test. A physical test must be conducted as follows:
(1) The test is required on 2 specimens cut longitudinally from 1
cylinder or part thereof taken at random out of each lot of 200 or less,
after heat treatment.
(2) Specimens must conform to a gauge length of 8 inches with a
width not over 1\1/2\ inches, a gauge length of 2 inches with width not
over 1\1/2\, or a gauge length at least 24 times thickness with a width
not over 6 times thickness is authorized when a cylinder wall is not
over \3/16\ inch thick.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the
[[Page 68]]
gauge length under appropriate load and adding thereto 0.2 percent of
the gauge length. Elastic extension calculations must be based on an
elastic modulus of 30,000,000. In the event of controversy, the entire
stress-strain diagram must be plotted and the yield strength determined
from the 0.2 offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi and the strain
indicator reading being set at the calculated corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(4) Yield strength may not exceed 73 percent of tensile strength.
Elongation must be at least 40 percent in 2 inch or 20 percent in other
cases.
(k) Rejected cylinders. Reheat treatment of rejected cylinder is
authorized. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding is authorized.
(l) Porous filling. (1) Cylinders must be filled with a porous
material in accordance with the following:
(i) The porous material may not disintegrate or sag when wet with
solvent or when subjected to normal service;
(ii) The porous filling material must be uniform in quality and free
of voids, except that a well drilled into the filling material beneath
the valve is authorized if the well is filled with a material of such
type that the functions of the filling material are not impaired;
(iii) Overall shrinkage of the filling material is authorized if the
total clearance between the cylinder shell and filling material, after
solvent has been added, does not exceed \1/2\ of 1 percent of the
respective diameter or length, but not to exceed \1/8\ inch, measured
diametrically and longitudinally;
(iv) The clearance may not impair the functions of the filling
material;
(v) The installed filling material must meet the requirements of CGA
C-12 (IBR, see Sec. 171.7 of this subchapter); and
(vi) Porosity of filling material may not exceed 80 percent except
that filling material with a porosity of up to 92 percent may be used
when tested with satisfactory results in accordance with CGA Pamphlet C-
12.
(2) When the porosity of each cylinder is not known, a cylinder
taken at random from a lot of 200 or less must be tested for porosity.
If the test cylinder fails, each cylinder in the lot may be tested
individually and those cylinders that pass the test are acceptable.
(3) For filling that is molded and dried before insertion in
cylinders, porosity test may be made on a sample block taken at random
from material to be used.
(4) The porosity of the filling material must be determined. The
amount of solvent at 70 [deg]F for a cylinder:
(i) Having shell volumetric capacity above 20 pounds water capacity
(nominal) may not exceed the following:
------------------------------------------------------------------------
Maximum
acetone
solvent
Percent porosity of filler percent
shell
capacity by
volume
------------------------------------------------------------------------
90 to 92................................................... 43.4
87 to 90................................................... 42.0
83 to 87................................................... 40.0
80 to 83................................................... 38.6
75 to 80................................................... 36.2
70 to 75................................................... 33.8
65 to 70................................................... 31.4
------------------------------------------------------------------------
(ii) Having volumetric capacity of 20 pounds or less water capacity
(nominal), may not exceed the following:
------------------------------------------------------------------------
Maximum
acetone
solvent
Percent porosity of filler percent
shell
capacity by
volume
------------------------------------------------------------------------
90 to 92................................................... 41.8
83 to 90................................................... 38.5
80 to 83................................................... 37.1
75 to 80................................................... 34.8
70 to 75................................................... 32.5
65 to 70................................................... 30.2
------------------------------------------------------------------------
(m) Tare weight. The tare weight is the combined weight of the
cylinder proper, porous filling, valve, and solvent, without removable
cap.
(n) Duties of inspector. In addition to the requirements of Sec.
178.35, the inspector is required to--
(1) Certify chemical analyses of steel used, signed by manufacturer
thereof; also verify by, check analyses of samples taken from each heat
or from 1 out
[[Page 69]]
of each lot of 200 or less, plates, shells, or tubes used.
(2) Verify compliance of cylinder shells with all shell
requirements; inspect inside before closing in both ends; verify heat
treatment as proper; obtain all samples for all tests and for check
analyses; witness all tests; verify threads by gauge; report volumetric
capacity and minimum thickness of wall noted.
(3) Prepare report on manufacture of steel shells in form prescribed
in Sec. 178.35. Furnish one copy to manufacturer and three copies to
the company that is to complete the cylinders.
(4) Determine porosity of filling and tare weights; verify
compliance of marking with prescribed requirements; obtain necessary
copies of steel shell reports; and furnish complete reports required by
this specification to the person who has completed the manufacture of
the cylinders and, upon request, to the purchaser. The test reports must
be retained by the inspector for fifteen years from the original test
date of the cylinder.
(o) Marking. (1) Marking on each cylinder must be stamped plainly
and permanently on or near the shoulder, top head, neck or valve
protection collar which is permanently attached to the cylinder and
forming integral part thereof.
(2) Tare weight of cylinder, in pounds and ounces, must be marked on
the cylinder.
(3) Cylinders, not completed, when delivered must each be marked for
identification of each lot of 200 or less.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386,
Aug. 28, 2001; 67 FR 61016, Sept. 27, 2002; 67 FR 51654, Aug. 8, 2002;
68 FR 75748, 75749, Dec. 31, 2003]
Sec. 178.60 Specification 8AL steel cylinders with porous fillings for
acetylene.
(a) Type and service pressure. A DOT 8AL cylinder is a seamless
steel cylinder with a service pressure of 250 psig. However, the
attachment of heads by welding or by brazing by dipping process and a
welded circumferential body seam is authorized. Longitudinal seams are
not authorized.
(b) Authorized steel. The authorized steel is as specified in table
I of appendix A to this part.
(c) Identification of steel. Material must be identified by any
suitable method except that plates and billets for hot-drawn cylinders
must be marked with heat number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. Welding procedures and operators
must be qualified in accordance with CGA Pamphlet C-3 (IBR, see Sec.
171.7 of this subchapter).
(e) Footrings. Exposed bottom welds on cylinders over 18 inches long
must be protected by footrings.
(f) Welding or brazing. Welding or brazing for any purpose
whatsoever is prohibited except as follows:
(1) The attachment to the tops or bottoms of cylinders of neckrings,
footrings, handlers, bosses, pads, and valve protecting rings is
authorized provided that such attachments and the portion of the
container to which they are attached are made of weldable steel, the
carbon content of which may not exceed 0.25 percent.
(2) Heat treatment is not required after welding or brazing weldable
low carbon parts to attachments, specified in paragraph (f)(1) of this
section, of similar material which have been previously welded or brazed
to the top or bottom of cylinders and properly heat treated, provided
such subsequent welding or brazing does not produce a temperature in
excess of 400 [deg]F in any part of the top or bottom material.
(g) Wall thickness; wall stress. The wall thickness/wall stress of
the cylinder must conform to the following:
(1) The calculated wall stress at 750 psi may not exceed 35,000 psi,
or one-half of the minimum ultimate strength of the steel as determined
in paragraph (l) of this section, whichever value is the smaller. The
measured wall thickness may not include galvanizing or other protective
coating.
(i) Calculation of wall stress must be made by the formula:
[[Page 70]]
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = wall stress in pounds psi;
P = 750 psig (minimum test pressure);
D = outside diameter in inches;
d = inside diameter in inches.
(ii) Either D or d must be calculated from the relation D = d + 2t,
where t = minimum wall thickness.
(2) Cylinders with a wall thickness less than 0.100 inch, the ratio
of straight side wall length to outside diameter may not exceed 3.5.
(3) For cylinders having outside diameter over 5 inches, the minimum
wall thickness must be 0.087 inch.
(h) Heat treatment. Each cylinder must be uniformly and properly
heat treated, prior to tests, by any suitable method in excess of 1100
[deg]F. Heat treatment must be accomplished after all forming and
welding operations, except that when brazed joints are used, heat
treatment must follow any forming and welding operations but may be done
before, during, or after the brazing operations. Liquid quenching is not
authorized.
(i) Openings. Standard taper pipe threads required in all openings.
The length of the opening may not be less than as specified for American
Standard pipe threads; tapped to gauge; clean cut, even, and without
checks.
(j) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit
reading of total expansion to an accuracy of either 1 percent or 0.1
cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat-treatment and previous to the official test may not
exceed 90 percent of the test pressure.
(3) Permanent volumetric expansion may not exceed 10 percent of
total volumetric expansion at test pressure.
(4) One cylinder out of each lot of 200 or less must be
hydrostatically tested to at least 750 psig. Cylinders not so tested
must be examined under pressure of between 500 and 600 psig and show no
defect. If a hydrostatically tested cylinder fails, each cylinder in the
lot may be hydrostatically tested and those passing are acceptable.
(k) Leakage test. Cylinders with bottoms closed in by spinning must
be leakage tested by setting the interior air or gas pressure at not
less than the service pressure. Any cylinder that leaks must be
rejected.
(l) Physical test. A physical test must be conducted as follows;
(1) The test is required on 2 specimens cut longitudinally from 1
cylinder or part thereof taken at random out of each lot of 200 or less,
after heat treatment.
(2) Specimens must conform to a gauge length of 8 inches with a
width not over 1\1/2\ inches, a gauge length 2 inches with a width not
over 1\1/2\ inches, or a gauge length at least 24 times thickness with a
width not over 6 times thickness is authorized when a cylinder wall is
not over \3/16\ inch thick.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``offset''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load'') corresponding to the stress at which the
0.2 percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2
offset.
(iii) For the purpose of strain measurement, the initial strain must
be set while the specimen is under a stress of 12,000 psi, the strain
indicator reading being set at the calculated corresponding strain.
[[Page 71]]
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(m) Elongation. Physical test specimens must show at least a 40
percent elongation for a 2 inch gauge length or at least a 20 percent
elongation in other cases. Except that these elongation percentages may
be reduced numerically by 2 for 2 inch specimens and 1 in other cases
for each 7,500 psi increment of tensile strength above 50,000 psi to a
maximum of four such increments.
(n) Weld tests. Specimens taken across the circumferentially welded
seam must be cut from one cylinder taken at random from each lot of 200
or less cylinders after heat treatment and must pass satisfactorily the
following tests:
(1) Tensile test. A specimen must be cut from one cylinder of each
lot of 200 or less, or welded test plate. The specimen must be taken
from across the major seam and must be prepared and tested in accordance
with and must meet the requirements of CGA Pamphlet C-3. Should this
specimen fail to meet the requirements, specimens may be taken from two
additional cylinders or welded test plates from the same lot and tested.
If either of the latter specimens fail to meet the requirements, the
entire lot represented must be rejected.
(2) Guided bend test. A root bend test specimen must be cut from the
cylinder or welded test plate, used for the tensile test specified in
paragraph (n)(1) of this section. Specimens must be prepared and tested
in accordance with and must meet the requirements of CGA Pamphlet C-3.
(3) Alternate guided-bend test. This test may be used and must be as
required by CGA Pamphlet C-3. The specimen must be bent until the
elongation at the outer surface, adjacent to the root of the weld,
between the lightly scribed gage lines-a to b, must be at least 20
percent, except that this percentage may be reduced for steels having a
tensile strength in excess of 50,000 psi, as provided in paragraph (m)
of this section.
(o) Rejected cylinders. Reheat treatment of rejected cylinders is
authorized. Subsequent thereto, cylinders must pass all prescribed tests
to be acceptable. Repair by welding is authorized.
(p) Porous filling. (1) Cylinders must be filled with a porous
material in accordance with the following:
(i) The porous material may not disintegrate or sag when wet with
solvent or when subjected to normal service;
(ii) The filling material must be uniform in quality and free of
voids, except that a well drilled into the filling material beneath the
valve is authorized if the well is filled with a material of such type
that the functions of the filling material are not impaired;
(iii) Overall shrinkage of the filling material is authorized if the
total clearance between the cylinder shell and filling material, after
solvent has been added, does not exceed \1/2\ of 1 percent of the
respective diameter or length but not to exceed \1/8\ inch, measured
diametrically and longitudinally;
(iv) The clearance may not impair the functions of the filling
material;
(v) The installed filling material must meet the requirements of CGA
C-12 (IBR, see Sec. 171.7 of this subchapter); and
(vi) Porosity of filling material may not exceed 80 percent except
that filling material with a porosity of up to 92 percent may be used
when tested with satisfactory results in accordance with CGA Pamphlet C-
12.
(2) When the porosity of each cylinder is not known, a cylinder
taken at random from a lot of 200 or less must be tested for porosity.
If the test cylinder fails, each cylinder in the lot may be tested
individually and those cylinders that pass the test are acceptable.
(3) For filling that is molded and dried before insertion in
cylinders, porosity test may be made on sample block taken at random
from material to be used.
(4) The porosity of the filling material must be determined; the
amount of solvent at 70 [deg]F for a cylinder:
(i) Having shell volumetric capacity above 20 pounds water capacity
(nominal) may not exceed the following:
[[Page 72]]
------------------------------------------------------------------------
Maximum acetone
Percent porosity of filler solvent percent shell
capacity by volume
------------------------------------------------------------------------
90 to 92....................................... 43.4
87 to 90....................................... 42.0
83 to 87....................................... 40.0
80 to 83....................................... 38.6
75 to 80....................................... 36.2
70 to 75....................................... 33.8
65 to 70....................................... 31.4
------------------------------------------------------------------------
(ii) Having volumetric capacity of 20 pounds or less water capacity
(nominal), may not exceed the following:
------------------------------------------------------------------------
Maximum acetone
Percent porosity of filler solvent percent shell
capacity by volume
------------------------------------------------------------------------
90 to 92....................................... 41.8
83 to 90....................................... 38.5
80 to 83....................................... 37.1
75 to 80....................................... 34.8
70 to 75....................................... 32.5
65 to 70....................................... 30.2
------------------------------------------------------------------------
(q) Tare weight. The tare weight is the combined weight of the
cylinder proper, porous filling, valve, and solvent, but without
removable cap.
(r) Duties of inspector. In addition to the requirements of Sec.
178.35, the inspector shall--
(1) Certify chemical analyses of steel used, signed by manufacturer
thereof; also verify by check analyses, of samples taken from each heat
or from 1 out of each lot of 200 or less plates, shells, or tubes used.
(2) Verify compliance of cylinder shells with all shell
requirements, inspect inside before closing in both ends, verify heat
treatment as proper; obtain all samples for all tests and for check
analyses, witness all tests; verify threads by gauge, report volumetric
capacity and minimum thickness of wall noted.
(3) Report percentage of each specified alloying element in the
steel. Prepare report on manufacture of steel shells in form prescribed
in Sec. 178.35. Furnish one copy to manufacturer and three copies to
the company that is to complete the cylinders.
(4) Determine porosity of filling and tare weights; verify
compliance of marking with prescribed requirements; obtain necessary
copies of steel shell reports prescribed in paragraph (b) of this
section; and furnish complete test reports required by this
specification to the person who has completed the manufacturer of the
cylinders and, upon request, to the purchaser. The test reports must be
retained by the inspector for fifteen years from the original test date
of the cylinder.
(s) Marking. (1) Tare weight of cylinder, in pounds and ounces, must
be marked on the cylinder.
(2) Cylinders, not completed, when delivered must each be marked for
identification of each lot of 200 or less.
(3) Markings must be stamped plainly and permanently in locations in
accordance with the following:
(i) On shoulders and top heads not less than 0.087 inch thick; or
(ii) On neck, valve boss, valve protection sleeve, or similar part
permanently attached to the top end of cylinder; or
(iii) On a plate of ferrous material attached to the top of the
cylinder or permanent part thereof; the plate must be at least \1/16\
inch thick, and must be attached by welding, or by brazing at a
temperature of at least 1,100 [deg]F throughout all edges of the plate.
Sufficient space must be left on the plate to provide for stamping at
least four (4) retest dates.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 66 FR 45386,
45388, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002; 68 FR 75748, 75749,
Dec. 31, 2003]
Sec. 178.61 Specification 4BW welded steel cylinders with electric-arc welded
longitudinal seam.
(a) Type, size and service pressure. A DOT 4BW cylinder is a welded
type steel cylinder with a longitudinal electric-arc welded seam, a
water capacity (nominal) not over 1,000 pounds and a service pressure at
least 225 and not over 500 psig gauge. Cylinders closed in by spinning
process are not authorized.
(b) Authorized steel. Steel used in the construction of the cylinder
must conform to the following:
(1) The body of the cylinder must be constructed of steel conforming
to the limits specified in table 1 of appendix A to this part.
(2) Material for heads must meet the requirements of paragraph (a)
of this section or be open hearth, electric or basic oxygen carbon steel
of uniform quality. Content percent may not exceed the following: Carbon
0.25, Manganese 0.60, Phosphorus 0.045, Sulfur
[[Page 73]]
0.050. Heads must be hemispherical or ellipsoidal in shape with a
maximum ratio of 2.1. If low carbon steel is used, the thickness of such
heads must be determined by using a maximum wall stress of 24,000 p.s.i.
in the formula described in paragraph (f)(4) of this section.
(c) Identification of material. Material must be identified by any
suitable method.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart and the following:
(1) No defect is permitted that is likely to weaken the finished
cylinder appreciably. A reasonably smooth and uniform surface is
required. Exposed bottom welds on cylinders over 18 inches long must be
protected by footrings. Minimum thickness of heads may not be less than
90 percent of the required thickness of the sidewall. Heads must be
concave to pressure.
(2) Circumferential seams must be by electric-arc welding. Joints
must be butt with one member offset (joggle butt) or lap with minimum
overlap of at least four times nominal sheet thickness.
(3) Longitudinal seams in shells must conform to the following:
(i) Longitudinal electric-arc welded seams must be of the butt
welded type. Welds must be made by a machine process including automatic
feed and welding guidance mechanisms. Longitudinal seams must have
complete joint penetration, and must be free from undercuts, overlaps or
abrupt ridges or valleys. Misalignment of mating butt edges may not
exceed \1/6\ of nominal sheet thickness or \1/32\ inch whichever is
less. All joints with nominal sheet thickness up to and including \1/8\
inch must be tightly butted. When nominal sheet thickness is greater
than \1/8\ inch, the joint must be gapped with maximum distance equal to
one-half the nominal sheet thickness or \1/32\ inch whichever is less.
Joint design, preparation and fit-up must be such that requirements of
this paragraph (d) are satisfied.
(ii) Maximum joint efficiency must be 1.0 when each seam is
radiographed completely. Maximum joint efficiency must be 0.90 when one
cylinder from each lot of 50 consecutively welded cylinders is spot
radiographed. In addition, one out of the first five cylinders welded
following a shut down of welding operations exceeding four hours must be
spot radiographed. Spot radiographs, when required, must be made of a
finished welded cylinder and must include the girth weld for 2 inches in
both directions from the intersection of the longitudinal and girth
welds and include at least 6 inches of the longitudinal weld. Maximum
joint efficacy of 0.75 must be permissible without radiography.
(4) Welding procedures and operators must be qualified in accordance
with CGA Pamphlet C-3 (IBR, see Sec. 171.7 of this subchapter).
(e) Welding of attachments. The attachment to the tops and bottoms
only of cylinders by welding of neckrings, footrings, handles, bosses,
pads and valve protection rings is authorized provided that such
attachments and the portion of the container to which they are attached
are made of weldable steel, the carbon content of which may not exceed
0.25 percent.
(f) Wall thickness. For outside diameters over 6 inches the minimum
wall thickness must be 0.078 inch. For a cylinder with a wall thickness
less than 0.100 inch, the ratio of tangential length to outside diameter
may not exceed 4 to1 (4:1). In any case the minimum wall thickness must
be such that the wall stress calculated by the formula listed in
paragraph (f)(4) of this section may not exceed the lesser value of any
of the following:
(1) The value referenced in paragraph (b) of this section for the
particular material under consideration.
(2) One-half of the minimum tensile strength of the material
determined as required in paragraph (j) of this section.
(3) 35,000 psi.
(4) Stress must be calculated by the following formula:
S = [2P(1.3D\2\ + 0.4d\2\)] / [E(D\2\ - d\2\)]
where:
S = wall stress, psi;
P = service pressure, psig;
D = outside diameter, inches;
d = inside diameter, inches;
[[Page 74]]
E = joint efficiency of the longitudinal seam (from paragraph (d) of
this section).
(g) Heat treatment. Each cylinder must be uniformly and properly
heat treated prior to test by the applicable method referenced in Table
1 of appendix A to this part. Heat treatment must be accomplished after
all forming and welding operations. Heat treatment is not required after
welding or brazing of weldable low carbon parts to attachments of
similar material which have been previously welded to the top or bottom
of cylinders and properly heat treated, provided such subsequent welding
or brazing does not produce a temperature in excess of 400 [deg]F in any
part of the top or bottom material.
(h) Openings in cylinders. Openings in the cylinder must conform to
the following:
(1) All openings must be in the heads or bases.
(2) Openings in cylinders must be provided with adequate fittings,
bosses, or pads, integral with or securely attached to the cylinder by
welding.
(3) Threads must comply with the following:
(i) Threads must be clean cut and to gauge.
(ii) Taper threads must be of length not less than as specified for
American Standard Taper Pipe threads.
(iii) Straight threads, having at least 4 engaged threads, to have
tight fit and calculated shear strength at least 10 times the test
pressure of the cylinder; gaskets required, adequate to prevent leakage.
(4) Closure of fittings, boss or pads must be adequate to prevent
leakage.
(i) Hydrostatic test. Cylinders must withstand a hydrostatic test,
as follows:
(1) The test must be by water-jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
readings to an accuracy of 1 percent. The expansion gauge must permit
readings of total volumetric expansion to an accuracy either of 1
percent or 0.1 cubic centimeter.
(2) Pressure must be maintained for at least 30 seconds and
sufficiently longer to ensure complete expansion. Any internal pressure
applied after heat treatment and previous to the official test may not
exceed 90 percent of the test pressure.
(3) Permanent volumetric expansion may not exceed 10 percent of the
total volumetric expansion at test pressure.
(4) Cylinders must be tested as follows:
(i) At least 1 cylinder selected at random out of each lot of 200 or
less must be tested as outlined in paragraphs (i)(1), (i)(2), and (i)(3)
of this section to at least two times service pressure.
(ii) All cylinders not tested as outlined in paragraph (i)(4)(i) of
this section must be examined under pressure of at least two times
service pressure and show no defect.
(5) One finished cylinder selected at random out of each lot of 500
or less successively produced must be hydrostatically tested to 4 times
service pressure without bursting.
(j) Physical tests. Cylinders must be subjected to a physical test
as follows:
(1) Specimens must be taken from one cylinder after heat treatment
and chosen at random from each lot of 200 or less, as follows:
(i) Body specimen. One specimen must be taken longitudinally from
the body section at least 90 degrees away from the weld.
(ii) Head specimen. One specimen must be taken from either head on a
cylinder when both heads are made of the same material. However, if the
two heads are made of differing materials, a specimen must be taken from
each head.
(iii) If due to welded attachments on the top head there is
insufficient surface from which to take a specimen, it may be taken from
a representative head of the same heat treatment as the test cylinder.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
a gauge length of 2 inches with a width not over 1\1/2\ inches, or a
gauge length at least 24 times thickness with a width not over 6 times
thickness is authorized when a cylinder wall is not over \3/16\ inch
thick.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within 1 inch of each end of the reduced
section.
[[Page 75]]
(iii) When size of the cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be straightened or flattened cold, by pressure only, not by blows
when specimens are so taken and prepared, the inspector's report must
show in connection with record of physical tests detailed information in
regard to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by either the ``off-set''
method or the ``extension under load'' method as prescribed in ASTM E 8
(IBR, see Sec. 171.7 of this subchapter).
(ii) In using the ``extension under load'' method, the total strain
(or ``extension under load''), corresponding to the stress at which the
0.2-percent permanent strain occurs may be determined with sufficient
accuracy by calculating the elastic extension of the gauge length under
appropriate load and adding thereto 0.2 percent of the gauge length.
Elastic extension calculations must be based on an elastic modulus of
30,000,000. In the event of controversy, the entire stress-strain
diagram must be plotted and the yield strength determined from the 0.2-
percent offset.
(iii) For the purpose of strain measurement, the initial strain
reference must be set while the specimen is under a stress of 12,000 psi
and the strain indicator reading being set at the calculated
corresponding strain.
(iv) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(k) Elongation. Physical test specimens must show at least a 40
percent elongation for a 2-inch gauge length or at least a 20 percent
elongation in other cases. Except that these elongation percentages may
be reduced numerically by 2 for 2-inch specimens and by 1 in other cases
for each 7,500 psi increment of tensile strength above 50,000 psi to a
maximum of four increments.
(l) Tests of welds. Welds must be subjected to the following tests:
(1) Tensile test. A specimen must be cut from one cylinder of each
lot of 200 or less. The specimen must be taken from across the
longitudinal seam and must be prepared and tested in accordance with and
must meet the requirements of CGA Pamphlet C-3.
(2) Guided bend test. A root test specimen must be cut from the
cylinder used for the tensile test specified in paragraph (l)(1) of this
section. Specimens must be taken from across the longitudinal seam and
must be prepared and tested in accordance with and must meet the
requirements of CGA Pamphlet C-3.
(3) Alternate guided bend test. This test may be used and must be as
required by CGA Pamphlet C-3. The specimen must be bent until the
elongation at the outer surface, adjacent to the root of the weld,
between the lightly scribed gauge lines a to b, must be at least 20
percent, except that this percentage may be reduced for steels having a
tensile strength in excess of 50,000 psi, as provided in paragraph (k)
of this section.
(m) Radiographic examination. Welds of the cylinders must be
subjected to a radiographic examination as follows:
(1) Radiographic inspection must conform to the techniques and
acceptability criteria set forth in CGA Pamphlet C-3. When fluoroscopic
inspection is used, permanent film records need not be retained.
(2) Should spot radiographic examination fail to meet the
requirements of paragraph (m)(1) of this section, two additional welds
from the same lot of 50 cylinders or less must be examined, and if
either of these fail to meet the requirements, each cylinder must be
examined as previously outlined; only those passing are acceptable.
(n) Rejected cylinders. (1) Unless otherwise stated, if a sample
cylinder or specimen taken from a lot of cylinders fails the prescribed
test, then two additional specimens must be selected from the same lot
and subjected to the prescribed test. If either of these fails the test,
then the entire lot must be rejected.
[[Page 76]]
(2) Reheat treatment of rejected cylinders is authorized. Subsequent
thereto, cylinders must pass all prescribed tests to be acceptable.
Repair of welded seams by welding is authorized provided that all
defective metal is cut away and the joint is rewelded as prescribed for
original welded joints.
(o) Markings. Markings must be stamped plainly and permanently in
any of the following locations on the cylinder:
(1) On shoulders and top heads when they are not less than 0.087-
inch thick.
(2) On a metal plate attached to the top of the cylinder or
permanent part thereof; sufficient space must be left on the plate to
provide for stamping at least six retest dates; the plate must be at
least \1/16\-inch thick and must be attached by welding, or by brazing.
The brazing rod is to melt at a temperature of 1100 [deg]F Welding or
brazing must be along all the edges of the plate.
(3) On the neck, valve boss, valve protection sleeve, or similar
part permanently attached to the top of the cylinder.
(4) On the footring permanently attached to the cylinder, provided
the water capacity of the cylinder does not exceed 25 pounds.
(p) Inspector's report. In addition to the information required by
Sec. 178.35, the inspector's report must indicate the type and amount
of radiography.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 64 FR 51919,
Sept. 27, 1999; 66 FR 45386, 45388, Aug. 28, 2001; 67 FR 51654, Aug. 6,
2002; 67 FR 61016, Sept. 27, 2002; 68 FR 57633, Oct. 6, 2003; 68 FR
75748, Dec. 31, 2003]
Sec. 178.65 Specification 39 non-reusable (non-refillable) cylinders.
(a) Type, size, service pressure, and test pressure. A DOT 39
cylinder is a seamless, welded, or brazed cylinder with a service
pressure not to exceed 80 percent of the test pressure. Spherical
pressure vessels are authorized and covered by references to cylinders
in this specification.
(1) Size limitation. Maximum water capacity may not exceed: (i) 55
pounds (1,526 cubic inches) for a service pressure of 500 p.s.i.g. or
less, and (ii) 10 pounds (277 cubic inches) for a service pressure in
excess of 500 p.s.i.g.
(2) Test pressure. The minimum test pressure is the maximum pressure
of contents at 130 [deg]F or 180 p.s.i.g. whichever is greater.
(3) Pressure of contents. The term ``pressure of contents'' as used
in this specification means the total pressure of all the materials to
be shipped in the cylinder.
(b) Material; steel or aluminum. The cylinder must be constructed of
either steel or aluminum conforming to the following requirements:
(1) Steel. (i) The steel analysis must conform to the following:
------------------------------------------------------------------------
Ladle Check
analysis analysis
------------------------------------------------------------------------
Carbon, maximum percent............................. 0.12 0.15
Phosphorus, maximum percent......................... .04 .05
Sulfur, maximum percent............................. .05 .06
------------------------------------------------------------------------
(ii) For a cylinder made of seamless steel tubing with integrally
formed ends, hot drawn, and finished, content percent for the following
may not exceed: Carbon, 0.55; phosphorous, 0.045; sulfur, 0.050.
(iii) For non-heat treated welded steel cylinders, adequately killed
deep drawing quality steel is required.
(iv) Longitudinal or helical welded cylinders are not authorized for
service pressures in excess of 500 p.s.i.g.
(2) Aluminum. Aluminum is not authorized for service pressures in
excess of 500 psig. The analysis of the aluminum must conform to the
Aluminum Association standard for alloys 1060, 1100, 1170, 3003, 5052,
5086, 5154, 6061, and 6063, as specified in its publication entitled
``Aluminum Standards and Data'' (IBR, see Sec. 171.7 of this
subchapter).
(3) Material with seams, cracks, laminations, or other injurious
defects not permitted.
(4) Material used must be identified by any suitable method.
(c) Manufacture. (1) General manufacturing requirements are as
follows:
(i) The surface finish must be uniform and reasonably smooth.
(ii) Inside surfaces must be clean, dry, and free of loose
particles.
(iii) No defect of any kind is permitted if it is likely to weaken a
finished cylinder.
(2) Requirements for seams:
[[Page 77]]
(i) Brazing is not authorized on aluminum cylinders.
(ii) Brazing material must have a melting point of not lower than
1,000 [deg]F.
(iii) Brazed seams must be assembled with proper fit to ensure
complete penetration of the brazing material throughout the brazed
joint.
(iv) Minimum width of brazed joints must be at least four times the
thickness of the shell wall.
(v) Brazed seams must have design strength equal to or greater than
1.5 times the minimum strength of the shell wall.
(vi) Welded seams must be properly aligned and welded by a method
that provides clean, uniform joints with adequate penetration.
(vii) Welded joints must have a strength equal to or greater than
the minimum strength of the shell material in the finished cylinder.
(3) Attachments to the cylinder are permitted by any means which
will not be detrimental to the integrity of the cylinder. Welding or
brazing of attachments to the cylinder must be completed prior to all
pressure tests.
(4) Welding procedures and operators must be qualified in accordance
with CGA Pamphlet C-3 (IBR, see Sec. 171.7 of this subchapter).
(d) Wall thickness. The minimum wall thickness must be such that the
wall stress at test pressure does not exceed the yield strength of the
material of the finished cylinder wall. Calculations must be made by the
following formulas:
(1) Calculation of the stress for cylinders must be made by the
following formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = Wall stress, in psi;
P = Test pressure in psig;
D = Outside diameter, in inches;
d = Inside diameter, in inches.
(2) Calculation of the stress for spheres must be made by the
following formula:
S = PD / 4t
Where:
S = Wall stress, in psi;
P = Test pressure i psig;
D = Outside diameter, in inches;
t = Minimum wall thickness, in inches.
(e) Openings and attachments. Openings and attachments must conform
to the following:
(1) Openings and attachments are permitted on heads only.
(2) All openings and their reinforcements must be within an
imaginary circle, concentric to the axis of the cylinder. The diameter
of the circle may not exceed 80 percent of the outside diameter of the
cylinder. The plane of the circle must be parallel to the plane of a
circumferential weld and normal to the long axis of the cylinder.
(3) Unless a head has adequate thickness, each opening must be
reinforced by a securely attached fitting, boss, pad, collar, or other
suitable means.
(4) Material used for welded openings and attachments must be of
weldable quality and compatible with the material of the cylinder.
(f) Pressure tests. (1) Each cylinder must be tested at an internal
pressure of at least the test pressure and must be held at that pressure
for at least 30 seconds.
(i) The leakage test must be conducted by submersion under water or
by some other method that will be equally sensitive.
(ii) If the cylinder leaks, evidences visible distortion, or any
other defect, while under test, it must be rejected (see paragraph (h)
of this section).
(2) One cylinder taken from the beginning of each lot, and one from
each 1,000 or less successively produced within the lot thereafter, must
be hydrostatically tested to destruction. The entire lot must be
rejected (see paragraph (h) of this section) if:
(i) A failure occurs at a gage pressure less than 2.0 times the test
pressure;
(ii) A failure initiates in a braze or a weld or the heat affected
zone thereof;
(iii) A failure is other than in the sidewall of a cylinder
longitudinal with its long axis; or
(iv) In a sphere, a failure occurs in any opening, reinforcement, or
at a point of attachment.
(3) A ``lot'' is defined as the quantity of cylinders successively
produced per production shift (not exceeding 10 hours) having identical
size, design,
[[Page 78]]
construction, material, heat treatment, finish, and quality.
(g) Flattening test. One cylinder must be taken from the beginning
of production of each lot (as defined in paragraph (f)(3) of this
section) and subjected to a flattening test as follows:
(1) The flattening test must be made on a cylinder that has been
tested at test pressure.
(2) A ring taken from a cylinder may be flattened as an alternative
to a test on a complete cylinder. The test ring may not include the heat
affected zone or any weld. However, for a sphere, the test ring may
include the circumferential weld if it is located at a 45 degree angle
to the ring, 5 degrees.
(3) The flattening must be between 60 degrees included-angle, wedge
shaped knife edges, rounded to a 0.5 inch radius.
(4) Cylinders and test rings may not crack when flattened so that
their outer surfaces are not more than six times wall thickness apart
when made of steel or not more than ten times wall thickness apart when
made of aluminum.
(5) If any cylinder or ring cracks when subjected to the specified
flattening test, the lot of cylinders represented by the test must be
rejected (see paragraph (h) of this section).
(h) Rejected cylinders. Rejected cylinders must conform to the
following requirements:
(1) If the cause for rejection of a lot is determinable, and if by
test or inspection defective cylinders are eliminated from the lot, the
remaining cylinders must be qualified as a new lot under paragraphs (f)
and (g) of this section.
(2) Repairs to welds are permitted. Following repair, a cylinder
must pass the pressure test specified in paragraph (f) of this section.
(3) If a cylinder made from seamless steel tubing fails the
flattening test described in paragraph (g) of this section, suitable
uniform heat treatment must be used on each cylinder in the lot. All
prescribed tests must be performed subsequent to this heat treatment.
(i) Markings. (1) The markings required by this section must be
durable and waterproof. The requirements of Sec. 178.35(h) do not apply
to this section.
(2) Required markings are as follows:
(i) DOT-39.
(ii) NRC.
(iii) The service pressure.
(iv) The test pressure.
(v) The registration number (M****) of the manufacturer.
(vi) The lot number.
(vii) The date of manufacture if the lot number does not establish
the date of manufacture.
(viii) With one of the following statements:
(A) For cylinders manufactured prior to October 1, 1996: ``Federal
law forbids transportation if refilled-penalty up to $25,000 fine and 5
years imprisonment (49 U.S.C. 1809)'' or ``Federal law forbids
transportation if refilled-penalty up to $500,000 fine and 5 years
imprisonment (49 U.S.C. 5124).''
(B) For cylinders manufactured on or after October 1, 1996:
``Federal law forbids transportation if refilled-penalty up to $500,000
fine and 5 years imprisonment (49 U.S.C. 5124).''
(3) The markings required by paragraphs (i)(2)(i) through (i)(2)(v)
of this section must be in numbers and letters at least \1/8\ inch high
and displayed sequentially. For example:
DOT-39 NRC 250/500 M1001.
(4) No person may mark any cylinder with the specification
identification ``DOT-39'' unless it was manufactured in compliance with
the requirements of this section and its manufacturer has a registration
number (M****) from the Associate Administrator.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 65 FR 58631,
Sept. 29, 2000; 66 FR 45389, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002;
68 FR 75748, 75749, Dec. 31, 2003]
Sec. 178.68 Specification 4E welded aluminum cylinders.
(a) Type, size and service pressure. A DOT 4E cylinder is a welded
aluminum cylinder with a water capacity (nominal) of not over 1,000
pounds and a service pressure of at least 225 to not over 500 psig. The
cylinder must be constructed of not more than two seamless drawn shells
with no more than one circumferential weld. The circumferential weld may
not be closer to the point of tangency of the cylindrical portion with
the shoulder than 20 times the
[[Page 79]]
cylinder wall thickness. Cylinders or shells closed in by spinning
process and cylinders with longitudinal seams are not authorized.
(b) Authorized material. The cylinder must be constructed of
aluminum of uniform quality. The following chemical analyses are
authorized:
Table 1--Authorized Materials
------------------------------------------------------------------------
Chemical analysis--limits in
Designation percent 5154 \1\
------------------------------------------------------------------------
Iron plus silicon........................ 0.45 maximum.
Copper................................... 0.10 maximum.
Manganese................................ 0.10 maximum.
Magnesium................................ 3.10/3.90.
Chromium................................. 0.15/0.35.
Zinc..................................... 0.20 maximum.
Titanium................................. 0.20 maximum.
Others, each............................. 0.05 maximum.
Others, total............................ 0.15 maximum.
Aluminum................................. remainder.
------------------------------------------------------------------------
\1\ Analysis must regularly be made only for the elements specifically
mentioned in this table. If, however, the presence of other elements
is indicated in the course of routine analysis, further analysis
should be made to determine conformance with the limits specified for
other elements.
(c) Identification. Material must be identified by any suitable
method that will identify the alloy and manufacturer's lot number.
(d) Manufacture. Cylinders must be manufactured using equipment and
processes adequate to ensure that each cylinder produced conforms to the
requirements of this subpart. No defect is permitted that is likely to
weaken the finished cylinder appreciably. A reasonably smooth and
uniform surface finish is required. All welding must be by the gas
shielded arc process.
(e) Welding. The attachment to the tops and bottoms only of
cylinders by welding of neckrings or flanges, footrings, handles, bosses
and pads and valve protection rings is authorized. However, such
attachments and the portion of the cylinder to which it is attached must
be made of weldable aluminum alloys.
(f) Wall thickness. The wall thickness of the cylinder must conform
to the following:
(1) The minimum wall thickness of the cylinder must be 0.140 inch.
In any case, the minimum wall thickness must be such that calculated
wall stress at twice service pressure may not exceed the lesser value of
either of the following:
(i) 20,000 psi.
(ii) One-half of the minimum tensile strength of the material as
required in paragraph (j) of this section.
(2) Calculation must be made by the following formula:
S = [P(1.3D\2\ + 0.4d\2\)] / (D\2\ - d\2\)
Where:
S = wall stress in psi;
P = minimum test pressure prescribed for water jacket test;
D = outside diameter in inches;
d = inside diameter in inches.
(3) Minimum thickness of heads and bottoms may not be less than the
minimum required thickness of the side wall.
(g) Opening in cylinder. Openings in cylinders must conform to the
following:
(1) All openings must be in the heads or bases.
(2) Each opening in cylinders, except those for safety devices, must
be provided with a fitting, boss, or pad, securely attached to cylinder
by welding by inert gas shielded arc process or by threads. If threads
are used, they must comply with the following:
(i) Threads must be clean-cut, even, without checks and cut to
gauge.
(ii) Taper threads to be of length not less than as specified for
American Standard taper pipe threads.
(iii) Straight threads, having at least 4 engaged threads, to have
tight fit and calculated shear strength at least 10 times the test
pressure of the cylinder; gaskets required, adequate to prevent leakage.
(3) Closure of a fitting, boss, or pad must be adequate to prevent
leakage.
(h) Hydrostatic test. Each cylinder must successfully withstand a
hydrostatic test, as follows:
(1) The test must be by water jacket, or other suitable method,
operated so as to obtain accurate data. The pressure gauge must permit
reading to an accuracy of 1 percent. The expansion gauge must permit a
reading of the total expansion to an accuracy either of 1 percent or 0.1
cubic centimeter.
(2) Pressure of 2 times service pressure must be maintained for at
least 30 seconds and sufficiently longer to insure complete expansion.
Any internal pressure applied previous to the official test may not
exceed 90 percent of the
[[Page 80]]
test pressure. If, due to failure of the test apparatus, the test
pressure cannot be maintained, the test may be repeated at a pressure
increased by 10 percent over the pressure otherwise specified.
(3) Permanent volumetric expansion may not exceed 12 percent of
total volumetric expansion at test pressure.
(4) Cylinders having a calculated wall stress of 18,000 psi or less
at test pressure may be tested as follows:
(i) At least one cylinder selected at random out of each lot of 200
or less must be tested in accordance with paragraphs (h)(1), (h)(2), and
(h)(3) of this section.
(ii) All cylinders not tested as provided in paragraph (h)(4)(i) of
this section must be examined under pressure of at least 2 times service
pressure and show no defect.
(5) One finished cylinder selected at random out of each lot of
1,000 or less must be hydrostatically tested to 4 times the service
pressure without bursting. Inability to meet this requirement must
result in rejection of the lot.
(i) Flattening test. After hydrostatic testing, a flattening test is
required on one section of a cylinder, taken at random out of each lot
of 200 or less as follows:
(1) If the weld is not at midlength of the cylinder, the test
section must be no less in width than 30 times the cylinder wall
thickness. The weld must be in the center of the section. Weld
reinforcement must be removed by machining or grinding so that the weld
is flush with the exterior of the parent metal. There must be no
evidence of cracking in the sample when it is flattened between flat
plates to no more than 6 times the wall thickness.
(2) Guided bend test. A bend test specimen must be cut from the
cylinder used for the physical test specified in paragraph (j) of this
section. Specimen must be taken across the seam, must be a minimum of
1\1/2\ inches wide, edges must be parallel and rounded with a file, and
back-up strip, if used, must be removed by machining. The specimen shall
be tested as follows:
(i) The specimen must be bent to refusal in the guided bend test jig
as illustrated in paragraph 6.10 of CGA C-3 (IBR, see Sec. 171.7 of
this subchapter). The root of the weld (inside surface of the cylinder)
must be located away from the ram of the jig. The specimen must not show
a crack or other open defect exceeding \1/8\ inch in any direction upon
completion of the test. Should this specimen fail to meet the
requirements, specimens may be taken from each of 2 additional cylinders
from the same lot and tested. If either of the latter specimens fails to
meet requirements, the entire lot represented must be rejected.
(ii) Alternatively, the specimen may be tested in a guided bend test
jig as illustrated in Figure 12.1 of The Aluminum Association's 2002
publication, ``Welding Aluminum: Theory and Practice.'' The root of the
weld (inside surface of the cylinder) must be located away from the
mandrel of the jig. No specimen must show a crack or other open defect
exceeding \1/8\ inch in any direction upon completion of the test.
Should this specimen fail to meet the requirements, specimens may be
taken from each of 2 additional cylinders from the same lot and tested.
If either of the latter specimens fails to meet requirements, the entire
lot represented must be rejected.
(j) Physical test. A physical test must be conducted to determine
yield strength, tensile strength, elongation, and reduction of area of
material as follows:
(1) The test is required on 2 specimens cut from one cylinder or
part thereof taken at random out of each lot of 200 or less.
(2) Specimens must conform to the following:
(i) A gauge length of 8 inches with a width not over 1\1/2\ inches,
a gauge length of 2 inches with a width not over 1\1/2\ inches.
(ii) The specimen, exclusive of grip ends, may not be flattened.
Grip ends may be flattened to within 1 inch of each end of the reduced
section.
(iii) When size of cylinder does not permit securing straight
specimens, the specimens may be taken in any location or direction and
may be
[[Page 81]]
straightened or flattened cold, by pressure only, not by blows; when
specimens are so taken and prepared, the inspector's report must show in
connection with record of physical test detailed information in regard
to such specimens.
(iv) Heating of a specimen for any purpose is not authorized.
(3) The yield strength in tension must be the stress corresponding
to a permanent strain of 0.2 percent of the gauge length. The following
conditions apply:
(i) The yield strength must be determined by the ``offset'' method
as prescribed in ASTM E 8 (IBR, see Sec. 171.7 of this subchapter).
(ii) Cross-head speed of the testing machine may not exceed \1/8\
inch per minute during yield strength determination.
(k) Acceptable results for physical tests. An acceptable result of
the physical test requires an elongation to at least 7 percent and yield
strength not over 80 percent of tensile strength.
(l) Weld tests. Welds of the cylinder are required to successfully
pass the following tests:
(1) Reduced section tensile test. A specimen must be cut from the
cylinder used for the physical tests specified in paragraph (j) of this
section. The specimen must be taken from across the seam, edges must be
parallel for a distance of approximately 2 inches on either side of the
weld. The specimen must be fractured in tension. The apparent breaking
stress calculated on the minimum wall thickness must be at least equal
to 2 times the stress calculated under paragraph (f)(2) of this section,
and in addition must have an actual breaking stress of at least 30,000
psi. Should this specimen fail to meet the requirements, specimens may
be taken from 2 additional cylinders from the same lot and tested. If
either of the latter specimens fails to meet requirements, the entire
lot represented must be rejected.
(2) Guided bend test. A bend test specimen must be cut from the
cylinder used for the physical tests specified in paragraph (j) of this
section. Specimen must be taken across the seam, must be 1\1/2\ inches
wide, edges must be parallel and rounded with a file, and back-up strip,
if used, must be removed by machining. The specimen must be bent to
refusal in the guided bend test jig illustrated in paragraph 6.10 of CGA
Pamphlet C-3 (IBR, see Sec. 171.7 of this subchapter). The root of the
weld (inside surface of the cylinder) must be located away from the ram
of the jig. No specimen must show a crack or other open defect exceeding
\1/8\ inch in any direction upon completion of the test. Should this
specimen fail to meet the requirements, specimens may be taken from each
of 2 additional cylinders from the same lot and tested. If either of the
latter specimens fail to meet requirements, the entire lot represented
must be rejected.
(m) Rejected cylinders. Repair of welded seams is authorized.
Acceptable cylinders must pass all prescribed tests.
(n) Inspector's report. In addition to the information required by
Sec. 178.35, the record of chemical analyses must also include
applicable information on iron, titanium, zinc, and magnesium used in
the construction of the cylinder.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 62 FR 51561,
Oct. 1, 1997; 66 FR 45386, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002; 68
FR 75748, Dec. 31, 2003; 69 FR 54046, Sept. 7, 2004; 74 FR 16143, Apr.
9, 2009]
Sec. 178.69 Responsibilities and requirements for manufacturers of UN
pressure receptacles.
(a) Each manufacturer of a UN pressure receptacle marked with
``USA'' as a country of approval must comply with the requirements in
this section. The manufacturer must maintain a quality system, obtain an
approval for each initial pressure receptacle design type, and ensure
that all production of UN pressure receptacles meets the applicable
requirements.
(1) Quality system. The manufacturer of a UN pressure receptacle
must have its quality system approved by the Associate Administrator.
The quality system will initially be assessed through an audit by the
Associate Administrator or his or her representative to determine
whether it meets the requirements of this section. The Associate
Administrator will notify the manufacturer in writing of the results of
the audit. The notification will contain the conclusions of the audit
and
[[Page 82]]
any corrective action required. The Associate Administrator may perform
periodic audits to ensure that the manufacturer operates in accordance
with the quality system. Reports of periodic audits will be provided to
the manufacturer. The manufacturer must bear the cost of audits.
(2) Quality system documentation. The manufacturer must be able to
demonstrate a documented quality system. Management must review the
adequacy of the quality system to assure that it is effective and
conforms to the requirements in Sec. 178.70. The quality system records
must be in English and must include detailed descriptions of the
following:
(i) The organizational structure and responsibilities of personnel
with regard to design and product quality;
(ii) The design control and design verification techniques,
processes, and procedures used when designing the pressure receptacles;
(iii) The relevant procedures for pressure receptacle manufacturing,
quality control, quality assurance, and process operation instructions;
(iv) Inspection and testing methodologies, measuring and testing
equipment, and calibration data;
(v) The process for meeting customer requirements;
(vi) The process for document control and document revision;
(vii) The system for controlling non-conforming material and
records, including procedures for identification, segregation, and
disposition;
(viii) Production, processing and fabrication, including purchased
components, in-process and final materials; and
(ix) Training programs for relevant personnel.
(3) Maintenance of quality system. The manufacturer must maintain
the quality system as approved by the Associate Administrator. The
manufacturer shall notify the Associate Administrator of any intended
changes to the approved quality system prior to making the change. The
Associate Administrator will evaluate the proposed change to determine
whether the amended quality system will satisfy the requirements. The
Associate Administrator will notify the manufacturer of the findings.
(b) Design type approvals. The manufacturer must have each pressure
receptacle design type reviewed by an IIA and approved by the Associate
Administrator in accordance with Sec. 178.70. A cylinder is considered
to be of a new design, compared with an existing approved design, as
stated in the applicable ISO design, construction and testing standard.
(c) Production inspection and certification. The manufacturer must
ensure that each UN pressure receptacle is inspected and certified in
accordance with Sec. 178.71.
[71 FR 33885, June 12, 2006]
Sec. 178.70 Approval of UN pressure receptacles.
(a) Initial design-type approval. The manufacturer of a UN pressure
receptacle must obtain an initial design type approval from the
Associate Administrator. The initial design type approval must be of the
pressure receptacle design as it is intended to be produced. The
manufacturer must arrange for an IIA, approved by the Associate
Administrator in accordance with subpart I of part 107 of this chapter,
to perform a pre-audit of its pressure receptacle manufacturing
operation prior to having an audit conducted by the Associate
Administrator or his designee.
(b) IIA pre-audit. The manufacturer must submit an application for
initial design type approval to the IIA for review. The IIA will examine
the manufacturer's application for initial design type approval for
completeness. An incomplete application will be returned to the
manufacturer with an explanation. If an application is complete, the IIA
will review all technical documentation, including drawings and
calculations, to verify that the design meets all requirements of the
applicable UN pressure receptacle standard and specification
requirements. If the technical documentation shows that the pressure
receptacle prototype design conforms to the applicable standards and
requirements in Sec. 178.70, the
[[Page 83]]
manufacturer will fabricate a prototype lot of pressure receptacles in
conformance with the technical documentation representative of the
design. The IIA will verify that the prototype lot conforms to the
applicable requirements by selecting pressure receptacles and witnessing
their testing. After prototype testing has been satisfactorily
completed, showing the pressure receptacles fully conform to all
applicable specification requirements, the certifying IIA must prepare a
letter of recommendation and a design type approval certificate. The
design type approval certificate must contain the name and address of
the manufacturer and the IIA certifying the design type, the test
results, chemical analyses, lot identification, and all other supporting
data specified in the applicable ISO design, construction and testing
standard. The IIA must provide the certificate and documentation to the
manufacturer.
(c) Application for initial design type approval. If the pre-audit
is found satisfactory by the IIA, the manufacturer will submit the
letter of recommendation from the IIA and an application for design type
approval to the Associate Administrator. An application for initial
design type approval must be submitted for each manufacturing facility.
The application must be in English and, at a minimum, contain the
following information:
(1) The name and address of the manufacturing facility. If the
application is submitted by an authorized representative on behalf of
the manufacturer, the application must include the representative's name
and address.
(2) The name and title of the individual responsible for the
manufacturer's quality system, as required by Sec. 178.69.
(3) The designation of the pressure receptacle and the relevant
pressure receptacle standard.
(4) Details of any refusal of approval of a similar application by a
designated approval agency of another country.
(5) The name and address of the production IIA that will perform the
functions prescribed in paragraph (e) of this section. The IIA must be
approved in writing by the Associate Administrator in accordance with
subpart I of part 107 of this chapter.
(6) Documentation on the manufacturing facility as specified in
Sec. 178.69.
(7) Design specifications and manufacturing drawings, showing
components and subassemblies if relevant, design calculations, and
material specifications necessary to verify compliance with the
applicable pressure receptacle design standard.
(8) Manufacturing procedures and any applicable standards that
describe in detail the manufacturing processes and control.
(9) Design type approval test reports detailing the results of
examinations and tests conducted in accordance with the relevant
pressure receptacle standard, to include any additional data, such as
suitability for underwater applications or compatibility with hydrogen
embrittlement gases.
(d) Modification of approved pressure receptacle design type.
Modification of an approved UN pressure receptacle design type is not
authorized without the approval of the Associate Administrator. A
manufacturer seeking modification of an approved UN pressure receptacle
design type may be required to submit design qualification test data to
the Associate Administrator before production. An audit may be required
as part of the process to modify an approval.
(e) Responsibilities of the production IIA. The production IIA is
responsible for ensuring that each pressure receptacle conforms to the
design type approval. The production IIA must perform the following
functions:
(1) Witness all inspections and tests specified in the UN pressure
receptacle standard to ensure compliance with the standard and that the
procedures adopted by the manufacturer meet the requirements of the
standard;
(2) Verify that the production inspections were performed in
accordance with this section;
(3) Select UN pressure receptacles from a prototype production lot
and witness testing as required for the design type approval;
(4) Ensure that the various design type approval examinations and
tests are performed accurately;
[[Page 84]]
(5) Verify that each pressure receptacle is marked in accordance
with the applicable requirements in Sec. 178.72; and
(6) Furnish complete test reports to the manufacturer and upon
request to the purchaser. The test reports and certificate of compliance
must be retained by the IIA for at least 20 years from the original test
date of the pressure receptacles.
(f) Production inspection audit and certification. (1) If the
application, design drawing and quality control documents are found
satisfactory, PHMSA will schedule an on-site audit of the pressure
receptacle manufacturer's quality system, manufacturing processes,
inspections, and test procedures.
(2) During the audit, the manufacturer will be required to produce
pressure receptacles to the technical standards for which approval is
sought.
(3) The production IIA must witness the required inspections and
verifications on the pressure receptacles during the production run. The
IIA selected by the manufacturer for production inspection and testing
may be different from the IIA who performed the design type approval
verifications.
(4) If the procedures and controls are deemed acceptable, test
sample pressure receptacles will be selected at random from the
production lot and sent to a laboratory designated by the Associate
Administrator for verification testing.
(5) If the pressure receptacle test samples are found to conform to
all the applicable requirements, the Associate Administrator will issue
approvals to the manufacturer and the production IIA to authorize the
manufacture of the pressure receptacles. The approved design type
approval certificate will be returned to the manufacturer.
(6) Upon the receipt of the approved design type approval
certificate from the Associate Administrator, the pressure receptacle
manufacturer must sign the certificate.
(g) Recordkeeping. The production IIA and the manufacturer must
retain a copy of the design type approval certificate and certificate of
compliance records for at least 20 years.
(h) Denial of design type application. If the design type
application is denied, the Associate Administrator will notify the
applicant in writing and provide the reason for the denial. The
manufacturer may request that the Associate Administrator reconsider the
decision. The application request must--
(1) Be written in English and filed within 60 days of receipt of the
decision;
(2) State in detail any alleged errors of fact and law; and
(3) Enclose any additional information needed to support the request
to reconsider.
(i) Appeal. (1) A manufacturer whose reconsideration request is
denied may appeal to the PHMSA Administrator. The appeal must--
(i) Be written in English and filed within 60 days of receipt of the
Associate Administrator's decision on reconsideration;
(ii) State in detail any alleged errors of fact and law;
(iii) Enclose any additional information needed to support the
appeal; and
(iv) State in detail the modification of the final decision sought.
(2) The PHMSA Administrator will grant or deny the relief and inform
the appellant in writing of the decision. PHMSA Administrator's decision
is the final administrative action.
(j) Termination of a design type approval certificate. (1) The
Associate Administrator may terminate an approval certificate issue
under this section if it is determined that, because of a change in
circumstances, the approval no longer is needed or no longer would be
granted if applied for; information upon which the approval was based is
fraudulent or substantially erroneous; or termination of the approval is
necessary to adequately protect against risks to life and property.
(2) Before an approval is terminated, the Associate Administrator
will provide the manufacturer and the approval agency--
(i) Written notice of the facts or conduct believed to warrant the
withdrawal;
(ii) Opportunity to submit oral and written evidence, and
(iii) Opportunity to demonstrate or achieve compliance with the
application requirement.
[[Page 85]]
(3) If the Associate Administrator determines that a certificate of
approval must be withdrawn to preclude a significant and imminent
adverse affect on public safety, the procedures in paragraph (j)(2)(ii)
and (iii) of this section need not be provided prior to withdrawal of
the approval, but shall be provided as soon as practicable thereafter.
[71 FR 33886, June 12, 2006, as amended at 71 FR 54397, Sept. 14, 2006]
Sec. 178.71 Specifications for UN pressure receptacles.
(a) General. Each UN pressure receptacle must meet the requirements
of this section. Requirements for approval, qualification, maintenance,
and testing are contained in Sec. 178.70, and subpart C of part 180 of
this subchapter.
(b) Definitions. The following definitions apply for the purposes of
design and construction of UN pressure receptacles under this subpart:
Alternative arrangement means an approval granted by the Associate
Administrator for a MEGC that has been designed, constructed or tested
to the technical requirements or testing methods other than those
specified for UN pressure receptacles in part 178 or part 180 of this
subchapter.
Bundle of cylinders. See Sec. 171.8 of this subchapter.
Design type means a pressure receptacle design as specified by a
particular pressure receptacle standard.
Design type approval means an overall approval of the manufacturer's
quality system and design type of each pressure receptacle to be
produced within the manufacturer's facility.
UN tube. See Sec. 171.8 of this subchapter.
(c) Following the final heat treatment, all cylinders, except those
selected for batch testing must be subjected to a proof pressure or a
hydraulic volumetric expansion test.
(d) Service equipment. (1) Except for pressure relief devices, UN
pressure receptacle equipment, including valves, piping, fittings, and
other equipment subjected to pressure must be designed and constructed
to withstand at least 1.5 times the test pressure of the pressure
receptacle.
(2) Service equipment must be configured or designed to prevent
damage that could result in the release of the pressure receptacle
contents during normal conditions of handling and transport. Manifold
piping leading to shut-off valves must be sufficiently flexible to
protect the valves and the piping from shearing or releasing the
pressure receptacle contents. The filling and discharge valves and any
protective caps must be secured against unintended opening. The valves
must conform to ISO 10297 (IBR, see Sec. 171.7 of this subchapter) and
be protected as specified in Sec. 173.301b(f) of this subchapter.
(3) UN pressure receptacles that cannot be handled manually or
rolled, must be equipped with devices (e.g., skids, rings, straps)
ensuring that they can be safely handled by mechanical means and so
arranged as not to impair the strength of, nor cause undue stresses, in
the pressure receptacle.
(4) Pressure receptacles filled by volume must be equipped with a
level indicator.
(e) Bundles of cylinders. UN pressure receptacles assembled in
bundles must be structurally supported and held together as a unit and
secured in a manner that prevents movement in relation to the structural
assembly and movement that would result in the concentration of harmful
local stresses. The frame design must ensure stability under normal
operating conditions.
(1) The frame must securely retain all the components of the bundle
and must protect them from damage during conditions normally incident to
transportation. The method of cylinder restraint must prevent any
vertical or horizontal movement or rotation of the cylinder that could
cause undue strain on the manifold. The total assembly must be able to
withstand rough handling, including being dropped or overturned.
(2) The frame must include features designed for the handling and
transportation of the bundle. The lifting rings must be designed to
withstand a design load of 2 times the maximum gross weight. Bundles
with more than one lifting ring must be designed such that a minimum
sling angle of 45 degrees to the horizontal can be achieved during
lifting using the lifting rings. If four
[[Page 86]]
lifting rings are used, their design must be strong enough to allow the
bundle to be lifted by two rings. Where two or four lifting rings are
used, diametrically opposite lifting rings must be aligned with each
other to allow for correct lifting using shackle pins. If the bundle is
filled with forklift pockets, it must contain two forklift pockets on
each side from which it is to be lifted. The forklift pockets must be
positioned symmetrically consistent with the bundle center of gravity.
(3) The frame structural members must be designed for a vertical
load of 2 times the maximum gross weight of the bundle. Design stress
levels may not exceed 0.9 times the yield strength of the material.
(4) The frame must not contain any protrusions from the exterior
frame structure that could cause a hazardous condition.
(5) The frame design must prevent collection of water or other
debris that would increase the tare weight of bundles filled by weight.
(6) The floor of the bundle frame must not buckle during normal
operating conditions and must allow for the drainage of water and debris
from around the base of the cylinders.
(7) If the frame design includes movable doors or covers, they must
be capable of being secured with latches or other means that will not
become dislodged by operational impact loads. Valves that need to be
operated in normal service or in an emergency must be accessible.
(8) For bundles of cylinders, pressure receptacle marking
requirements only apply to the individual cylinders of a bundle and not
to any assembly structure.
(f) Design and construction requirements for UN refillable welded
cylinders. In addition to the general requirements of this section, UN
refillable welded cylinders must conform to the following ISO standards,
as applicable:
(1) ISO 4706: Gas cylinders--Refillable welded steel cylinders--Test
pressure 60 bar and below (IBR, see Sec. 171.7 of this subchapter).
(2) ISO 18172-1: Gas cylinders--Refillable welded stainless steel
cylinders--Part 1: Test pressure 6 MPa and below (IBR, see Sec. 171.7
of this subchapter).
(3) ISO 20703: Gas cylinders--Refillable welded aluminum-alloy
cylinders--Design, construction and testing (IBR, see Sec. 171.7 of
this subchapter).
(g) Design and construction requirements for UN refillable seamless
steel cylinders. In addition to the general requirements of this
section, UN refillable seamless steel cylinders must conform to the
following ISO standards, as applicable:
(1) ISO 9809-1: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 1: Quenched and
tempered steel cylinders with tensile strength less than 1 100 MPa.
(IBR, see Sec. 171.7 of this subchapter).
(2) ISO 9809-2: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 2: Quenched and
tempered steel cylinders with tensile strength greater than or equal to
1 100 MPa. (IBR, see Sec. 171.7 of this subchapter).
(3) ISO 9809-3: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 3: Normalized steel
cylinders. (IBR, see Sec. 171.7 of this subchapter).
(h) Design and construction requirements for UN refillable seamless
aluminum alloy cylinders. In addition to the general requirements of
this section, UN refillable seamless aluminum cylinders must conform to
ISO 7866: Gas cylinders--Refillable seamless aluminum alloy gas
cylinders--Design, construction and testing. (IBR, see Sec. 171.7 of
this subchapter). The use of Aluminum alloy 6351-T6 or equivalent is
prohibited.
(i) Design and construction requirements for UN non-refillable metal
cylinders. In addition to the general requirements of this section, UN
non-refillable metal cylinders must conform to ISO 11118: Gas
cylinders--Non-refillable metallic gas cylinders--Specification and test
methods. (IBR, see Sec. 171.7 of this subchapter.)
(j) Design and construction requirements for UN refillable seamless
steel tubes. In addition to the general requirements of this section, UN
refillable seamless steel tubes must conform to ISO 11120: Gas
cylinders--Refillable seamless steel tubes of water capacity
[[Page 87]]
between 150 L and 3000 L--Design, construction and testing. (IBR, see
Sec. 171.7 of this subchapter).
(k) Design and construction requirements for UN acetylene cylinders.
In addition to the general requirements of this section, UN acetylene
cylinders must conform to the following ISO standards, as applicable:
(1) For the cylinder shell:
(i) ISO 9809-1: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 1: Quenched and
tempered steel cylinders with tensile strength less than 1 100 MPa.
(ii) ISO 9809-3: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 3: Normalized steel
cylinders.
(2) The porous mass in an acetylene cylinder must conform to ISO
3807-2: Cylinders for acetylene--Basic requirements--Part 2: Cylinders
with fusible plugs. (IBR, see Sec. 171.7 of this subchapter).
(l) Design and construction requirements for UN composite cylinders.
(1) In addition to the general requirements of this section, UN
composite cylinders must be designed for unlimited service life and
conform to the following ISO standards, as applicable:
(i) ISO 11119-1: Gas cylinders of composite construction--
Specification and test methods--Part 1: Hoop-wrapped composite gas
cylinders. (IBR, see Sec. 171.7 of this subchapter).
(ii) ISO 11119-2: Gas cylinders of composite construction--
Specification and test methods--Part 2: Fully-wrapped fibre reinforced
composite gas cylinders with load-sharing metal liners. (IBR, see Sec.
171.7 of this subchapter).
(iii) ISO 11119-3: Gas cylinders of composite construction--
Specification and test methods--Part 3: Fully wrapped fibre reinforced
composite gas cylinders with non-load sharing metallic or non-metallic
liners. (IBR, see Sec. 171.7 of this subchapter).
(2) ISO 11119-2 and ISO 11119-3 gas cylinders of composite
construction manufactured in accordance with the requirements for
underwater use must bear the ``UW'' mark.
(m) Design and construction requirements for UN metal hydride
storage systems. In addition to the general requirements of this
section, metal hydride storage systems must conform to the following ISO
standards, as applicable: ISO 16111: Transportable gas storage devices--
Hydrogen absorbed in reversible metal hydride (IBR, see Sec. 171.7 of
this subchapter).
(n) Material compatibility. In addition to the material requirements
specified in the UN pressure receptacle design and construction ISO
standards, and any restrictions specified in part 173 for the gases to
be transported, the requirements of the following standards must be
applied with respect to material compatibility:
(1) ISO 11114-1: Transportable gas cylinders--Compatibility of
cylinder and valve materials with gas contents--Part 1: Metallic
materials. (IBR, see Sec. 171.7 of this subchapter).
(2) ISO 11114-2: Transportable gas cylinders--Compatibility of
cylinder and valve materials with gas contents--Part 2: Non-metallic
materials. (IBR, see Sec. 171.7 of this subchapter).
(o) Protection of closures. Closures and their protection must
conform to the requirements in Sec. 173.301(f) of this subchapter.
(p) Marking of UN refillable pressure receptacles. UN refillable
pressure receptacles must be marked clearly and legibly. The required
markings must be permanently affixed by stamping, engraving, or other
equivalent method, on the shoulder, top end or neck of the pressure
receptacle or on a permanently affixed component of the pressure
receptacle, such as a welded collar. Except for the ``UN'' mark, the
minimum size of the marks must be 5 mm for pressure receptacles with a
diameter greater than or equal to 140 mm, and 2.5 mm for pressure
receptacles with a diameter less than 140 mm. The minimum size of the
``UN'' mark must be 5 mm for pressure receptacles with a diameter less
than 140 mm, and 10 mm for pressure receptacles with a diameter of
greater than or equal to 140 mm. The depth of the markings must not
create harmful stress concentrations. A refillable pressure receptacle
conforming to the UN standard must be marked as follows:
(1) The UN packaging symbol.
[[Page 88]]
[GRAPHIC] [TIFF OMITTED] TR19JA11.035
(2) The ISO standard, for example ISO 9809-1, used for design,
construction and testing. Acetylene cylinders must be marked to indicate
the porous mass and the steel shell, for example: ``ISO 3807-2/ISO 9809-
1.''
(3) The mark of the country where the approval is granted. The
letters ``USA'' must be marked on UN pressure receptacles approved by
the United States. The manufacturer must obtain an approval number from
the Associate Administrator. The manufacturer approval number must
follow the country of approval mark, separated by a slash (for example,
USA/MXXXX). Pressure receptacles approved by more than one national
authority may contain the mark of each country of approval, separated by
a comma.
(4) The identity mark or stamp of the IIA.
(5) The date of the initial inspection, the year (four digits)
followed by the month (two digits) separated by a slash, for example
``2006/04''.
(6) The test pressure in bar, preceded by the letters ``PH'' and
followed by the letters ``BAR''.
(7) The rated charging pressure of the metal hydride storage system
in bar, preceded by the letters ``RCP'' and followed by the letters
``BAR.''
(8) The empty or tare weight. Except for acetylene cylinders, empty
weight is the mass of the pressure receptacle in kilograms, including
all integral parts (e.g., collar, neck ring, foot ring, etc.), followed
by the letters ``KG''. The empty weight does not include the mass of the
valve, valve cap or valve guard or any coating. The empty weight must be
expressed to three significant figures rounded up to the last digit. For
cylinders of less than 1 kg, the empty weight must be expressed to two
significant figures rounded down to the last digit. For acetylene
cylinders, the tare weight must be marked on the cylinders in kilograms.
The tare weight is the sum of the empty weight, mass of the valve, any
coating and all permanently attached parts (e.g., fittings and
accessories) that are not removed during filling. The tare weight must
be expressed to two significant figures rounded down to the last digit.
The tare weight does not include the cylinder cap or any outlet cap or
plug not permanently attached to the cylinder.
(9) The minimum wall thickness of the pressure receptacle in
millimeters followed by the letters ``MM''. This mark is not required
for pressure receptacles with a water capacity less than or equal to 1.0
L or for composite cylinders.
(10) For pressure receptacles intended for the transport of
compressed gases and UN 1001 acetylene, dissolved, the working pressure
in bar, proceeded by the letters ``PW''.
(11) For liquefied gases, the water capacity in liters expressed to
three significant digits rounded down to the last digit, followed by the
letter ``L''. If the value of the minimum or nominal water capacity is
an integer, the digits after the decimal point may be omitted.
(12) Identification of the cylinder thread type (e.g., 25E).
(13) The country of manufacture. The letters ``USA'' must be marked
on cylinders manufactured in the United States.
(14) The serial number assigned by the manufacturer.
(15) For steel pressure receptacles, the letter ``H'' showing
compatibility of the steel, as specified in 1SO 11114-1.
[[Page 89]]
(16) Identification of aluminum alloy, if applicable.
(17) Stamp for nondestructive testing, if applicable.
(18) Stamp for underwater use of composite cylinders, if applicable.
(19) For metal hydride storage systems having a limited life, the
date of expiration indicated by the word ``FINAL,'' followed by the year
(four digits), the month (two digits) and separated by a slash.
(q) Marking sequence. The marking required by paragraph (p) of this
section must be placed in three groups as shown in the example below:
(1) The top grouping contains manufacturing marks and must appear
consecutively in the sequence given in paragraphs (p)(13) through (19)
of this section.
(2) The middle grouping contains operational marks described in
paragraphs (p)(6) through (11) of this section.
(3) The bottom grouping contains certification marks and must appear
consecutively in the sequence given in paragraphs (p)(1) through (5) of
this section.
[[Page 90]]
[GRAPHIC] [TIFF OMITTED] TR19JA11.036
(r) Other markings. Other markings are allowed in areas other than
the side wall, provided they are made in low stress areas and are not of
a size and depth that will create harmful stress concentrations. Such
marks must not conflict with required marks.
[[Page 91]]
(s) Marking of UN non-refillable pressure receptacles. Unless
otherwise specified in this paragraph, each UN non-refillable pressure
receptacle must be clearly and legibly marked as prescribed in paragraph
(p) of this section. In addition, permanent stenciling is authorized.
Except when stenciled, the marks must be on the shoulder, top end or
neck of the pressure receptacle or on a permanently affixed component of
the pressure receptacle (e.g., a welded collar).
(1) The marking requirements and sequence listed in paragraphs
(p)(1) through (19) of this section are required, except the markings in
paragraphs (p)(8), (9), (12) and (18) are not applicable. The required
serial number marking in paragraph (p)(14) may be replaced by the batch
number.
(2) Each receptacle must be marked with the words ``DO NOT REFILL''
in letters of at least 5 mm in height.
(3) A non-refillable pressure receptacle, because of its size, may
substitute the marking required by this paragraph with a label.
Reduction in marking size is authorized only as prescribed in ISO 7225,
Gas cylinders--Precautionary labels. (IBR, see Sec. 171.7 of this
subchapter).
(4) Each non-refillable pressure receptacle must also be legibly
marked by stenciling the following statement: ``Federal law forbids
transportation if refilled-penalty up to $500,000 fine and 5 years in
imprisonment (49 U.S.C. 5124).''
(5) No person may mark a non-refillable pressure receptacle as
meeting the requirements of this section unless it was manufactured in
conformance with this section.
[76 FR 3385, Jan. 19, 2011, as amended at 76 FR 43532, July 20, 2011]
Sec. 178.74 Approval of MEGCs.
(a) Application for design type approval. (1) Each new MEGC design
type must have a design approval certificate. An owner or manufacturer
must apply to an approval agency that is approved by the Associate
Administrator in accordance with subpart E of part 107 of this chapter
+to obtain approval of a new design. When a series of MEGCs is
manufactured without change in the design, the certificate is valid for
the entire series. The design approval certificate must refer to the
prototype test report, the materials of construction of the manifold,
the standards to which the pressure receptacles are made and an approval
number. The compliance requirements or test methods applicable to MEGCs
as specified in this subpart may be varied when the level of safety is
determined to be equivalent to or exceed the requirements of this
subchapter and is approved in writing by the Associate Administrator. A
design approval may serve for the approval of smaller MEGCs made of
materials of the same type and thickness, by the same fabrication
techniques and with identical supports, equivalent closures and other
appurtenances.
(2) Each application for design approval must be in English and
contain the following information:
(i) Two complete copies of all engineering drawings, calculations,
and test data necessary to ensure that the design meets the relevant
specification.
(ii) The manufacturer's serial number that will be assigned to each
MEGC.
(iii) A statement as to whether the design type has been examined by
any approval agency previously and judged unacceptable. Affirmative
statements must be documented with the name of the approval agency,
reason for non-acceptance, and the nature of modifications made to the
design type.
(b) Actions by the approval agency. The approval agency must review
the application for design type approval, including all drawings and
calculations, to ensure that the design of the MEGC meets all
requirements of the relevant specification and to determine whether it
is complete and conforms to the requirements of this section. An
incomplete application will be returned to the applicant with the
reasons why the application was returned. If the application is complete
and all applicable requirements of this section are met, the approval
agency must prepare a MEGC design approval certificate containing the
manufacturer's name and address, results and conclusions of the
examination and necessary data for identification of the design type. If
the Associate Administrator approves the
[[Page 92]]
Design Type Approval Certificate application, the approval agency and
the manufacturer must each maintain a copy of the approved drawings,
calculations, and test data for at least 20 years.
(c) Approval agency's responsibilities. The approval agency is
responsible for ensuring that the MEGC conforms to the design type
approval. The approval agency must:
(1) Witness all tests required for the approval of the MEGC
specified in this section and Sec. 178.75.
(2) Ensure, through appropriate inspection, that each MEGC is
fabricated in all respects in conformance with the approved drawings,
calculations, and test data.
(3) Determine and ensure that the MEGC is suitable for its intended
use and that it conforms to the requirements of this subchapter.
(4) Apply its name, identifying mark or identifying number, and the
date the approval was issued, to the metal identification marking plate
attached to the MEGC upon successful completion of all requirements of
this subpart. Any approvals by the Associate Administrator authorizing
design or construction alternatives (Alternate Arrangements) of the MEGC
(see paragraph (a) of this section) must be indicated on the metal
identification plate as specified in Sec. 178.75(j).
(5) Prepare an approval certificate for each MEGC or, in the case of
a series of identical MEGCs manufactured to a single design type, for
each series of MEGCs. The approval certificate must include all of the
following information:
(i) The information displayed on the metal identification plate
required by Sec. 178.75(j);
(ii) The results of the applicable framework test specified in ISO
1496-3 (IBR, see Sec. 171.7 of this subchapter);
(iii) The results of the initial inspection and test specified in
paragraph (h) of this section;
(iv) The results of the impact test specified in Sec. 178.75(i)(4);
(v) Certification documents verifying that the cylinders and tubes
conform to the applicable standards; and
(vi) A statement that the approval agency certifies the MEGC in
accordance with the procedures in this section and that the MEGC is
suitable for its intended purpose and meets the requirements of this
subchapter. When a series of MEGCs is manufactured without change in the
design type, the certificate may be valid for the entire series of MEGCs
representing a single design type. The approval number must consist of
the distinguishing sign or mark of the country (``USA'' for the United
States of America) where the approval was granted and a registration
number.
(6) Retain on file a copy of each approval certificate for at least
20 years.
(d) Manufacturers' responsibilities. The manufacturer is responsible
for compliance with the applicable specifications for the design and
construction of MEGCs. The manufacturer of a MEGC must:
(1) Comply with all the requirements of the applicable ISO standard
specified in Sec. 178.71;
(2) Obtain and use an approval agency to review the design,
construction and certification of the MEGC;
(3) Provide a statement in the manufacturers' data report certifying
that each MEGC manufactured complies with the relevant specification and
all the applicable requirements of this subchapter; and
(4) Retain records for the MEGCs for at least 20 years. When
required by the specification, the manufacturer must provide copies of
the records to the approval agency, the owner or lessee of the MEGC, and
to a representative of DOT, upon request.
(e) Denial of application for approval. If the Associate
Administrator finds that the MEGC will not be approved for any reason,
the Associate Administrator will notify the applicant in writing and
provide the reason for the denial. The manufacturer may request that the
Associate Administrator reconsider the decision. The application request
must--
(1) Be written in English and filed within 90 days of receipt of the
decision;
(2) State in detail any alleged errors of fact and law; and
(3) Enclose any additional information needed to support the request
to reconsider.
[[Page 93]]
(f) Appeal. (1) A manufacturer whose reconsideration request is
denied may appeal to the PHMSA Administrator. The appeal must--
(i) Be in writing and filed within 90 days of receipt of the
Associate Administrator s decision on reconsideration;
(ii) State in detail any alleged errors of fact and law;
(iii) Enclose any additional information needed to support the
appeal; and
(iv) State in detail the modification of the final decision sought.
(2) The Administrator will grant or deny the relief and inform the
appellant in writing of the decision. The Administrator's decision is
the final administrative action.
(g) Modifications to approved MEGCs. (1) Prior to modification of
any approved MEGC that may affect conformance and safe use, and that may
involve a change to the design type or affect its ability to retain the
hazardous material in transportation, the MEGC's owner must inform the
approval agency that prepared the initial approval certificate for the
MEGC or, if the initial approval agency is unavailable, another approval
agency, of the nature of the modification and request certification of
the modification. The owner must supply the approval agency with all
revised drawings, calculations, and test data relative to the intended
modification. The MEGC's owner must also provide a statement as to
whether the intended modification has been examined and determined to be
unacceptable by any approval agency. The written statement must include
the name of the approval agency, the reason for non-acceptance, and the
nature of changes made to the modification since its original rejection.
(2) The approval agency must review the request for modification. If
the approval agency determines that the proposed modification does not
conform to the relevant specification, the approval agency must reject
the request in accordance with paragraph (d) of this section. If the
approval agency determines that the proposed modification conforms fully
with the relevant specification, the request is accepted. If
modification to an approved MEGC alters any information on the approval
certificate, the approval agency must prepare a new approval certificate
for the modified MEGC and submit the certificate to the Associate
Administrator for approval. After receiving approval from the Associate
Administrator, the approval agency must ensure that any necessary
changes are made to the metal identification plate. A copy of each newly
issued approval certificate must be retained by the approval agency and
the MEGC's owner for at least 20 years. The approval agency must perform
the following activities:
(i) Retain a set of the approved revised drawings, calculations, and
data as specified in Sec. 178.69(b)(4) for at least 20 years;
(ii) Ensure through appropriate inspection that all modifications
conform to the revised drawings, calculations, and test data; and
(iii) Determine the extent to which retesting of the modified MEGC
is necessary based on the nature of the proposed modification, and
ensure that all required retests are satisfactorily performed.
(h) Termination of Approval Certificate. (1) The Associate
Administrator may terminate an approval issued under this section if he
or she determines that--
(i) Because of a change in circumstances, the approval no longer is
needed or no longer would be granted if applied for;
(ii) Information upon which the approval was based is fraudulent or
substantially erroneous;
(iii) Termination of the approval is necessary to adequately protect
against risks to life and property; or
(iv) The MEGC does not meet the specification.
(2) Before an approval is terminated, the Associate Administrator
will provide the person--
(i) Written notice of the facts or conduct believed to warrant the
termination;
(ii) An opportunity to submit oral and written evidence; and
(3) An opportunity to demonstrate or achieve compliance with the
applicable requirements.
(i) Imminent Danger. If the Associate Administrator determines that
a certificate of approval must be terminated to preclude a significant
and imminent
[[Page 94]]
adverse effect on public safety, the Associate Administrator may
terminate the certificate immediately. In such circumstances, the
opportunities of paragraphs (h)(2) and (3) of this section need not be
provided prior to termination of the approval, but must be provided as
soon as practicable thereafter.
[71 FR 33890, June 12, 2006]
Sec. 178.75 Specifications for MEGCs.
(a) General. Each MEGC must meet the requirements of this section.
In a MEGC that meets the definition of a ``container'' within the terms
of the International Convention for Safe Containers (CSC) must meet the
requirements of the CSC as amended and 49 CFR parts 450 through 453, and
must have a CSC approval plate.
(b) Alternate Arrangements. The technical requirements applicable to
MEGCs may be varied when the level of safety is determined to be
equivalent to or exceed the requirements of this subchapter. Such an
alternate arrangement must be approved in writing by the Associate
Administrator. MEGCs approved to an Alternate Arrangement must be marked
as required by paragraph (j) of this section.
(c) Definitions. The following definitions apply:
Leakproofness test means a test using gas subjecting the pressure
receptacles and the service equipment of the MEGC to an effective
internal pressure of not less than 20% of the test pressure.
Manifold means an assembly of piping and valves connecting the
filling and/or discharge openings of the pressure receptacles.
Maximum permissible gross mass or MPGM means the heaviest load
authorized for transport (sum of the tare mass of the MEGC, service
equipment and pressure receptacle).
Service equipment means manifold system (measuring instruments,
piping and safety devices).
Shut-off valve means a valve that stops the flow of gas.
Structural equipment means the reinforcing, fastening, protective
and stabilizing members external to the pressure receptacles.
(d) General design and construction requirements. (1) The MEGC must
be capable of being loaded and discharged without the removal of its
structural equipment. It must possess stabilizing members external to
the pressure receptacles to provide structural integrity for handling
and transport. MEGCs must be designed and constructed with supports to
provide a secure base during transport and with lifting and tie-down
attachments that are adequate for lifting the MEGC including when loaded
to its maximum permissible gross mass. The MEGC must be designed to be
loaded onto a transport vehicle or vessel and equipped with skids,
mountings or accessories to facilitate mechanical handling.
(2) MEGCs must be designed, manufactured and equipped to withstand,
without loss of contents, all normal handling and transportation
conditions. The design must take into account the effects of dynamic
loading and fatigue.
(3) Each pressure receptacle of a MEGC must be of the same design
type, seamless steel, and constructed and tested according to one of the
following ISO standards:
(i) ISO 9809-1: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 1: Quenched and
tempered steel cylinders with tensile strength less than 1 100 MPa.
(IBR, see Sec. 171.7 of this subchapter);
(ii) ISO 9809-2: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 2: Quenched and
tempered steel cylinders with tensile strength greater than or equal to
1 100 MPa. (IBR, see Sec. 171.7 of this subchapter);
(iii) ISO 9809-3: Gas cylinders--Refillable seamless steel gas
cylinders--Design, construction and testing--Part 3: Normalized steel
cylinders. (IBR, see Sec. 171.7 of this subchapter); or
(iv) ISO 11120: Gas cylinders--Refillable seamless steel tubes of
water capacity between 150 L and 3000 L--Design, construction and
testing. (IBR, see Sec. 171.7 of this subchapter).
(4) Pressure receptacles of MEGCs, fittings, and pipework must be
constructed of a material that is compatible with the hazardous
materials intended to be transported, as specified in this subchapter.
[[Page 95]]
(5) Contact between dissimilar metals that could result in damage by
galvanic action must be prevented by appropriate means.
(6) The materials of the MEGC, including any devices, gaskets, and
accessories, must have no adverse effect on the gases intended for
transport in the MEGC.
(7) MEGCs must be designed to withstand, without loss of contents,
at least the internal pressure due to the contents, and the static,
dynamic and thermal loads during normal conditions of handling and
transport. The design must take into account the effects of fatigue,
caused by repeated application of these loads through the expected life
of the MEGC.
(8) MEGCs and their fastenings must, under the maximum permissible
load, be capable of withstanding the following separately applied static
forces (for calculation purposes, acceleration due to gravity (g) = 9.81
m/s\2\):
(i) In the direction of travel: 2g (twice the MPGM multiplied by the
acceleration due to gravity);
(ii) Horizontally at right angles to the direction of travel: 1g
(the MPGM multiplied by the acceleration due to gravity. When the
direction of travel is not clearly determined, the forces must be equal
to twice the MPGM);
(iii) Vertically upwards: 1g (the MPGM multiplied by the
acceleration due to gravity); and
(iv) Vertically downwards: 2g (twice the MPGM (total loading
including the effect of gravity) multiplied by the acceleration due to
gravity.
(9) Under each of the forces specified in paragraph (d)(8) of this
section, the stress at the most severely stressed point of the pressure
receptacles must not exceed the values given in the applicable design
specifications (e.g., ISO 11120).
(10) Under each of the forces specified in paragraph (d)(8) of this
section, the safety factor for the framework and fastenings must be as
follows:
(i) For steels having a clearly defined yield point, a safety factor
of 1.5 in relation to the guaranteed yield strength; or
(ii) For steels with no clearly defined yield point, a safety factor
of 1.5 in relation to the guaranteed 0.2 percent proof strength and, for
austenitic steels, the 1 percent proof strength.
(11) MEGCs must be capable of being electrically grounded to prevent
electrostatic discharge when intended for flammable gases.
(12) The pressure receptacles of a MEGC must be secured in a manner
to prevent movement that could result in damage to the structure and
concentration of harmful localized stresses.
(e) Service equipment. (1) Service equipment must be arranged so
that it is protected from mechanical damage by external forces during
handling and transportation. When the connections between the frame and
the pressure receptacles allow relative movement between the
subassemblies, the equipment must be fastened to allow movement to
prevent damage to any working part. The manifolds, discharge fittings
(pipe sockets, shut-off devices), and shut-off valves must be protected
from damage by external forces. Manifold piping leading to shut-off
valves must be sufficiently flexible to protect the valves and the
piping from shearing, or releasing the pressure receptacle contents. The
filling and discharge devices, including flanges or threaded plugs, and
any protective caps must be capable of being secured against unintended
opening.
(2) Each pressure receptacle intended for the transport of Division
2.3 gases must be equipped with an individual shut-off valve. The
manifold for Division 2.3 liquefied gases must be designed so that each
pressure receptacle can be filled separately and be kept isolated by a
valve capable of being closed during transit. For Division 2.1 gases,
the pressure receptacles must be isolated by an individual shut-off
valve into assemblies of not more than 3,000 L.
(3) For MEGC filling and discharge openings:
(i) Two valves in series must be placed in an accessible position on
each discharge and filling pipe. One of the valves may be a backflow
prevention valve. (ii) The filling and discharge devices may be equipped
to a manifold.
(iii) For sections of piping which can be closed at both ends and
where a liquid product can be trapped, a pressure-
[[Page 96]]
relief valve must be provided to prevent excessive pressure build-up.
(iv) The main isolation valves on a MEGC must be clearly marked to
indicate their directions of closure. All shutoff valves must close by a
clockwise motion of the handwheel.
(v) Each shut-off valve or other means of closure must be designed
and constructed to withstand a pressure equal to or greater than 1.5
times the test pressure of the MEGC.
(vi) All shut-off valves with screwed spindles must close by a
clockwise motion of the handwheel. For other shut-off valves, the open
and closed positions and the direction of closure must be clearly shown.
(vii) All shut-off valves must be designed and positioned to prevent
unintentional opening.
(viii) Ductile metals must be used in the construction of valves or
accessories.
(4) The piping must be designed, constructed and installed to avoid
damage due to expansion and contraction, mechanical shock and vibration.
Joints in tubing must be brazed or have an equally strong metal union.
The melting point of brazing materials must be no lower than 525 [deg]C
(977 [deg]F). The rated pressure of the service equipment and of the
manifold must be not less than two-thirds of the test pressure of the
pressure receptacles.
(f) Pressure relief devices. Each pressure receptacle must be
equipped with one or more pressure relief devices as specified in Sec.
173.301(f) of this subchapter. When pressure relief devices are
installed, each pressure receptacle or group of pressure receptacles of
a MEGC that can be isolated must be equipped with one or more pressure
relief devices. Pressure relief devices must be of a type that will
resist dynamic forces including liquid surge and must be designed to
prevent the entry of foreign matter, the leakage of gas and the
development of any dangerous excess pressure.
(1) The size of the pressure relief devices: CGA S-1.1 (IBR, see
Sec. 171.7 of this subchapter) must be used to determine the relief
capacity of individual pressure receptacles.
(2) Connections to pressure-relief devices: Connections to pressure
relief devices must be of sufficient size to enable the required
discharge to pass unrestricted to the pressure relief device. A shut-off
valve installed between the pressure receptacle and the pressure relief
device is prohibited, except where duplicate devices are provided for
maintenance or other reasons, and the shut-off valves serving the
devices actually in use are locked open, or the shut-off valves are
interlocked so that at least one of the duplicate devices is always
operable and capable of meeting the requirements of paragraph (f)(1) of
this section. No obstruction is permitted in an opening leading to or
leaving from a vent or pressure-relief device that might restrict or
cut-off the flow from the pressure receptacle to that device. The
opening through all piping and fittings must have at least the same flow
area as the inlet of the pressure relief device to which it is
connected. The nominal size of the discharge piping must be at least as
large as that of the pressure relief device.
(3) Location of pressure-relief devices: For liquefied gases, each
pressure relief device must, under maximum filling conditions, be in
communication with the vapor space of the pressure receptacles. The
devices, when installed, must be arranged to ensure the escaping vapor
is discharged upwards and unrestrictedly to prevent impingement of
escaping gas or liquid upon the MEGC, its pressure receptacles or
personnel. For flammable, pyrophoric and oxidizing gases, the escaping
gas must be directed away from the pressure receptacle in such a manner
that it cannot impinge upon the other pressure receptacles. Heat
resistant protective devices that deflect the flow of gas are
permissible provided the required pressure relief device capacity is not
reduced. Arrangements must be made to prevent access to the pressure
relief devices by unauthorized persons and to protect the devices from
damage caused by rollover.
(g) Gauging devices. When a MEGC is intended to be filled by mass,
it must be equipped with one or more gauging devices. Glass level-gauges
and gauges made of other fragile material are prohibited.
(h) MEGC supports, frameworks, lifting and tie-down attachments. (1)
MEGCs
[[Page 97]]
must be designed and constructed with a support structure to provide a
secure base during transport. MEGCs must be protected against damage to
the pressure receptacles and service equipment resulting from lateral
and longitudinal impact and overturning. The forces specified in
paragraph (d)(8) of this section, and the safety factor specified in
paragraph (d)(10) of this section must be considered in this aspect of
the design. Skids, frameworks, cradles or other similar structures are
acceptable. If the pressure receptacles and service equipment are so
constructed as to withstand impact and overturning, additional
protective support structure is not required (see paragraph (h)(4) of
this section).
(2) The combined stresses caused by pressure receptacle mountings
(e.g. cradles, frameworks, etc.) and MEGC lifting and tie-down
attachments must not cause excessive stress in any pressure receptacle.
Permanent lifting and tie-down attachments must be equipped to all
MEGCs. Any welding of mountings or attachments onto the pressure
receptacles is prohibited.
(3) The effects of environmental corrosion must be taken into
account in the design of supports and frameworks.
(4) When MEGCs are not protected during transport as specified in
paragraph (h)(1) of this section, the pressure receptacles and service
equipment must be protected against damage resulting from lateral or
longitudinal impact or overturning. External fittings must be protected
against release of the pressure receptacles' contents upon impact or
overturning of the MEGC on its fittings. Particular attention must be
paid to the protection of the manifold. Examples of protection include:
(i) Protection against lateral impact, which may consist of
longitudinal bars;
(ii) Protection against overturning, which may consist of
reinforcement rings or bars fixed across the frame;
(iii) Protection against rear impact, which may consist of a bumper
or frame;
(iv) Protection of the pressure receptacles and service equipment
against damage from impact or overturning by use of an ISO frame
according to the relevant provisions of ISO 1496-3. (IBR, see Sec.
171.7 of this subchapter).
(i) Initial inspection and test. The pressure receptacles and items
of equipment of each MEGC must be inspected and tested before being put
into service for the first time (initial inspection and test). This
initial inspection and test of an MEGC must include the following:
(1) A check of the design characteristics.
(2) An external examination of the MEGC and its fittings, taking
into account the hazardous materials to be transported.
(3) A pressure test performed at the test pressures specified in
Sec. 173.304b(b)(1) and (2) of this subchapter. The pressure test of
the manifold may be performed as a hydraulic test or by using another
liquid or gas. A leakproofness test and a test of the satisfactory
operation of all service equipment must also be performed before the
MEGC is placed into service. When the pressure receptacles and their
fittings have been pressure-tested separately, they must be subjected to
a leakproof test after assembly.
(4) An MEGC that meets the definition of ``container'' in the CSC
(see 49 CFR 450.3(a)(2)) must be subjected to an impact test using a
prototype representing each design type. The prototype MEGC must be
shown to be capable of absorbing the forces resulting from an impact not
less than 4 times (4 g) the MPGM of the fully loaded MEGC, at a duration
typical of the mechanical shocks experienced in rail transport. A
listing of acceptable methods for performing the impact test is provided
in the UN Recommendations (IBR, see Sec. 171.7 of this subchapter).
(j) Marking. (1) Each MEGC must be equipped with a corrosion
resistant metal plate permanently attached to the MEGC in a conspicuous
place readily accessible for inspection. The pressure receptacles must
be marked according to this section. Affixing the metal plate to a
pressure receptacle is prohibited. At a minimum, the following
information must be marked on the plate by stamping or by any other
equivalent method:
Country of manufacture
[[Page 98]]
UN
[GRAPHIC] [TIFF OMITTED] TR12JN06.002
Approval Country
Approval Number
Alternate Arrangements (see Sec. 178.75(b))
MEGC Manufacturer's name or mark
MEGC's serial number
Approval agency (Authorized body for the design approval)
Year of manufacture
Test pressure: ------ bar gauge
Design temperature range ------ [deg]C to ------ [deg]C
Number of pressure receptacles ------
Total water capacity ------ liters
Initial pressure test date and identification of the Approval Agency
Date and type of most recent periodic tests
Year ------ Month------ Type ------
(e.g. 2004-05, AE/UE, where ``AE'' represents acoustic emission and
``UE'' represents ultrasonic examination)
Stamp of the approval agency who performed or witnessed the most
recent test
(2) The following information must be marked on a metal plate firmly
secured to the MEGC:
Name of the operator
Maximum permissible load mass ------ kg
Working pressure at 15 [deg]C: ------ bar gauge
Maximum permissible gross mass (MPGM) ------ kg
Unladen (tare) mass ------ kg
[71 FR 33892, June 12, 2006, as amended at 73 FR 4719, Jan. 28, 2008]
Sec. Appendix A to Subpart C of Part 178--Illustrations: Cylinder
Tensile Sample
The following figures illustrate the recommended locations for test
specimens taken from welded cylinders:
[[Page 99]]
[GRAPHIC] [TIFF OMITTED] TR08AU02.013
[[Page 100]]
[GRAPHIC] [TIFF OMITTED] TR08AU02.014
[[Page 101]]
[GRAPHIC] [TIFF OMITTED] TR08AU02.015
[[Page 102]]
[GRAPHIC] [TIFF OMITTED] TR08AU02.016
[[Page 103]]
[GRAPHIC] [TIFF OMITTED] TR08AU02.017
[67 FR 51654, Aug. 8, 2002]
[[Page 104]]
Subparts D-G [Reserved]
Subpart H_Specifications for Portable Tanks
Source: 29 FR 18972, Dec. 29, 1964, unless otherwise noted.
Redesignated at 32 FR 5606, Apr. 5, 1967.
Sec. Sec. 178.251--178.253-5 [Reserved]
Sec. 178.255 Specification 60; steel portable tanks.
Sec. 178.255-1 General requirements.
(a) Tanks must be of fusion welded construction, cylindrical in
shape with seamless heads concave to the pressure. Tank shells may be of
seamless construction.
(b) Tanks must be designed, constructed, certified, and stamped in
accordance with Section VIII of the ASME Code (IBR, see Sec. 171.7 of
this subchapter).
(c) Tanks including all permanent attachments must be postweld heat
treated as a unit.
(d) Requirements concerning types of valves, retesting, and
qualification of portable tanks contained in Sec. Sec. 173.32 and
173.315 of this chapter must be observed.
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967,
and amended by Amdt. 178-7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750,
Dec. 31, 2003]
Sec. 178.255-2 Material.
(a) Material used in the tank must be steel of good weldable quality
and conform with the requirements in Sections V, VIII, and IX of the
ASME Code (IBR, see Sec. 171.7 of this subchapter).
(b) The minimum thickness of metal, exclusive of lining material,
for shell and heads of tanks shall be as follows:
------------------------------------------------------------------------
Minimum
Tank capacity thickness
(inch)
------------------------------------------------------------------------
Not more than 1,200 gallons................................. \1/4\
Over 1,200 to 1,800 gallons................................. \5/16\
Over 1,800 gallons.......................................... \3/8\
------------------------------------------------------------------------
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967,
and amended by Amdt. 178-7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750,
Dec. 31, 2003]
Sec. 178.255-3 Expansion domes.
(a) Expansion domes, if applied, must have a minimum capacity of one
percent of the combined capacity of the tank and dome.
(b) [Reserved]
Sec. 178.255-4 Closures for manholes and domes.
(a) The manhole cover shall be designed to provide a secure closure
of the manhole. All covers, not hinged to the tanks, shall be attached
to the outside of the dome by at least \1/8\ inch chain or its
equivalent. Closures shall be made tight against leakage of vapor and
liquid by use of gaskets of suitable material.
(b) [Reserved]
Sec. 178.255-5 Bottom discharge outlets.
(a) Bottom discharge outlets prohibited, except on tanks used for
shipments of sludge acid and alkaline corrosive liquids.
(b) If installed, bottom outlets or bottom washout chambers shall be
of metal not subject to rapid deterioration by the lading, and each
shall be provided with a valve or plug at its upper end and liquid-tight
closure at it lower end. Each valve or plug shall be designed to insure
against unseating due to stresses or shocks incident to transportation.
Bottom outlets shall be adequately protected against handling damage and
outlet equipment must not extend to within less than one inch of the
bottom bearing surface of the skids or tank mounting.
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967,
as amended by Amdt. 178-104, 59 FR 49135, Sept. 26, 1994]
Sec. 178.255-6 Loading and unloading accessories.
(a) When installed, gauging, loading and air inlet devices,
including their valves, shall be provided with adequate means for their
secure closure; and means shall also be provided for the closing of pipe
connections of valves.
(b) Interior heater coils, if installed, must be of extra heavy pipe
and so constructed that breaking off of exterior connections will not
cause leakage of tanks.
[[Page 105]]
Sec. 178.255-7 Protection of valves and accessories.
(a) All valves, fittings, accessories, safety devices, gauging
devices, and the like shall be adequately protected against mechanical
damage by a housing closed with a cover plate.
(b) Protective housing shall comply with the requirements under
which the tanks are fabricated with respect to design and construction,
and shall be designed with a minimum factor of safety of four to
withstand loadings in any direction equal to two times the weight of the
tank and attachments when filled with water.
Sec. 178.255-8 Safety devices.
(a) See Sec. 173.315(i) of this subchapter.
(b) [Reserved]
[Amdt. 178-83, 50 FR 11066, Mar. 19, 1985]
Sec. 178.255-9 Compartments.
(a) When the interior of the tank is divided into compartments, each
compartment shall be designed, constructed and tested as a separate
tank. Thickness of shell and compartment heads shall be determined on
the basis of total tank capacity.
(b) [Reserved]
Sec. 178.255-10 Lining.
(a) If a lining is required, the material used for lining the tank
shall be homogeneous, nonporous, imperforate when applied, not less
elastic than the metal of the tank proper. It shall be of substantially
uniform thickness, not less than \1/32\ inch thick if metallic, and not
less than \1/16\ inch thick if nonmetallic, and shall be directly bonded
or attached by other equally satisfactory means. Rubber lining shall be
not less than \3/16\ inch thick. Joints and seams in the lining shall be
made by fusing the material together or by other equally satisfactory
means. The interior of the tank shall be free from scale, oxidation,
moisture and all foreign matter during the lining operation.
(b) [Reserved]
Sec. 178.255-11 Tank mountings.
(a) Tanks shall be designed and fabricated with mountings to provide
a secure base in transit. ``Skids'' or similar devices shall be deemed
to comply with this requirement.
(b) All tank mountings such as skids, fastenings, brackets, cradles,
lifting lugs, etc., intended to carry loadings shall be permanently
secured to tanks in accordance with the requirements under which the
tanks are fabricated, and shall be designed with a factor of safety of
four, and built to withstand loadings in any direction equal to two
times the weight of the tanks and attachments when filled to the maximum
permissible loaded weight.
(c) Lifting lugs or side hold-down lugs shall be provided on the
tank mountings in a manner suitable for attaching lifting gear and hold-
down devices. Lifting lugs and hold-down lugs welded directly to the
tank shall be of the pad-eye type. Doubling plates welded to the tank
and located at the points of support shall be deemed to comply with this
requirement.
(d) All tank mountings shall be so designed as to prevent the
concentration of excessive loads on the tank shell.
Sec. 178.255-12 Pressure test.
(a) Each completed portable tank prior to application of lining
shall be tested before being put into transportation service by
completely filling the tank with water or other liquid having a similar
viscosity, the temperature of which shall not exceed 100 [deg]F during
the test, and applying a pressure of 60 psig. The tank shall be capable
of holding the prescribed pressure for at least 10 minutes without
leakage, evidence of impending failure, or failure. All closures shall
be in place while the test is made and the pressure shall be gauged at
the top of the tank. Safety devices and/or vents shall be plugged during
this test.
(b) [Reserved]
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967,
as amended by Amdt. 178-104, 59 FR 49135, Sept. 26, 1994]
Sec. 178.255-13 Repair of tanks.
(a) Tanks failing to meet the test may be repaired and retested,
provided that repairs are made in complete compliance with the
requirements of this specification.
(b) [Reserved]
[[Page 106]]
Sec. 178.255-14 Marking.
(a) In addition to markings required by Section VIII of the ASME
Code (IBR, see Sec. 171.7 of this subchapter), every tank shall bear
permanent marks at least 1/8-inch high stamped into the metal near the
center of one of the tank heads or stamped into a plate permanently
attached to the tank by means of brazing or welding or other suitable
means as follows:
Manufacturer's name -------------- Serial No.___________________________
DOT specification_______________________________________________________
Nominal capacity -------------- (gallons)
Tare weight -------------- (pounds)
Date of manufacture_____________________________________________________
(b) [Reserved]
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967,
and amended by Amdt. 178-67, 46 FR 49906, Oct. 8, 1981; 68 FR 75750,
Dec. 31, 2003]
Sec. 178.255-15 Report.
(a) A copy of the manufacturer's data report required by Section
VIII of the ASME Code (IBR, see Sec. 171.7 of this subchapter) under
which the tank is fabricated must be furnished to the owner for each new
tank.
Place__________________________________________________________________
Date___________________________________________________________________
Portable tank
Manufactured for -------------- Company
Location________________________________________________________________
Manufactured by -------------- Company
Location________________________________________________________________
Consigned to ------------------ Company
Location________________________________________________________________
Size ------ feet outside diameter by ------ long.
Marks on tank as prescribed by Sec. 178.255-14 of this specification
are as follows:
Manufacturer's name_____________________________________________________
Serial number___________________________________________________________
Owner's serial number___________________________________________________
DOT specification_______________________________________________________
ASME Code Symbol (par U-201)____________________________________________
Date of manufacture_____________________________________________________
Nominal capacity -------------- gallons.
It is hereby certified that this tank is in complete compliance with
the requirements of DOT specification No. 60.
(Signed)_______________________________________________________________
Manufacturer or owner
(b) [Reserved]
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967,
and amended by Amdt. 178-83, 50 FR 11066, Mar. 19, 1985; 68 FR 75750,
Dec. 31, 2003]
Sec. 178.273 Approval of Specification UN portable tanks.
(a) Application for approval. (1) An owner or manufacturer of a
portable tank shall apply for approval to a designated approval agency
authorized to approve the portable tank in accordance with the
procedures in subpart E, part 107 of this subchapter.
(2) Each application for approval must contain the following
information:
(i) Two complete copies of all engineering drawings, calculations,
and test data necessary to ensure that the design meets the relevant
specification.
(ii) The manufacturer's serial number that will be assigned to each
portable tank.
(iii) A statement as to whether the design type has been examined by
any approval agency previously and judged unacceptable. Affirmative
statements must be documented with the name of the approval agency,
reason for nonacceptance, and the nature of modifications made to the
design type.
(b) Action by approval agency. The approval agency must perform the
following activities:
(1) Review the application for approval to determine whether it is
complete and conforms with the requirements of paragraph (a) of this
section. If an application is incomplete, it will be returned to the
applicant with an explanation as to why the application is incomplete.
(2) Review all drawings and calculations to ensure that the design
is in compliance with all requirements of the relevant specification. If
the application is approved, one set of the approved drawings,
calculations, and test data shall be returned to the applicant. The
second (inspector's copy) set of approved drawings, calculations, and
test data shall be retained by the approval agency. Maintain drawings
and approval records for as long as the portable tank remains in
service. The drawings and records must be provided to the Department of
Transportation (DOT) upon request.
(3) Witness all tests required for the approval of the portable tank
specified in this section and part 180, subpart G of this subchapter.
[[Page 107]]
(4) Ensure, through appropriate inspection that each portable tank
is fabricated in all respects in conformance with the approved drawings,
calculations, and test data.
(5) Determine and ensure that the portable tank is suitable for its
intended use and that it conforms to the requirements of this
subchapter.
(6) For UN portable tanks intended for non-refrigerated and
refrigerated liquefied gases and Division 6.1 liquids which meet the
inhalation toxicity criteria (Zone A or B) as defined in Sec. 173.132
of this subchapter, or that are designated as toxic by inhalation
materials in the Sec. 172.101 Table of this subchapter, the approval
agency must ensure that:
(i) The portable tank has been designed, constructed, certified, and
stamped in accordance with the requirements in Division 1 of Section
VIII of the ASME Code (IBR, see Sec. 171.7 of this subchapter). Other
design codes may be used if approved by the Associate Administrator (see
Sec. 178.274(b)(1));
(ii) All applicable provisions of the design and construction have
been met to the satisfaction of the designated approval agency in
accordance with the rules established in the ASME Code and that the
portable tank meets the requirements of the ASME Code and all the
applicable requirements specified in this subchapter;
(iii) The inspector has carried out all the inspections specified by
the rules established in the ASME Code; and
(iv) The portable tank is marked with a U stamp code symbol under
the authority of the authorized independent inspector.
(7) Upon successful completion of all requirements of this subpart,
the approval agency must:
(i) Apply its name, identifying mark or identifying number, and the
date upon which the approval was issued, to the metal identification
marking plate attached to the portable tank. Any approvals for UN
portable tanks authorizing design or construction alternatives
(Alternate Arrangements) approved by the Associate Administrator (see
Sec. 178.274(a)(2)) must be indicated on the plate as specified in
Sec. 178.274(i).
(ii) Issue an approval certificate for each portable tank or, in the
case of a series of identical portable tanks manufactured to a single
design type, for each series of portable tanks. The approval certificate
must include all the information required to be displayed on the metal
identification plate required by Sec. 178.274(i). The approval
certificate must certify that the approval agency designated to approve
the portable tank has approved the portable tank in accordance with the
procedures in subpart E of part 107 of this subchapter and that the
portable tank is suitable for its intended purpose and meets the
requirements of this subchapter. When a series of portable tanks is
manufactured without change in the design type, the certificate may be
valid for the entire series of portable tanks representing a single
design type. For UN portable tanks, the certificate must refer to the
prototype test report, the hazardous material or group of hazardous
materials allowed to be transported, the materials of construction of
the shell and lining (when applicable) and an approval number. The
approval number must consist of the distinguishing sign or mark of the
country (``USA'' for the United States of America) where the approval
was granted and a registration number.
(iii) Retain a copy of each approval certificate.
(8) For UN portable tanks, the approval certificate must also
include the following:
(i) The results of the applicable framework and rail impact test
specified in part 180, subpart G, of this subchapter; and
(ii) The results of the initial inspection and test in Sec.
178.274(j).
(9) The approval agency shall be independent from the manufacturer.
The approval agency and the authorized inspector may be the same entity.
(c) Manufacturers' responsibilities. The manufacturer is responsible
for compliance with the applicable specifications for the design and
construction of portable tanks. In addition to responsibility for
compliance, manufacturers are responsible for ensuring that the
contracted approval agency and authorized inspector, if applicable, are
qualified, reputable and competent. The manufacturer of a portable tank
shall--
[[Page 108]]
(1) Comply with all the applicable requirements of the ASME Code and
of this subpart including, but not limited to, ensuring that the quality
control, design calculations and required tests are performed and that
all aspects of the portable tank meet the applicable requirements.
(2) Obtain and use a designated approval agency, if applicable, and
obtain and use a DOT-designated approval agency to approve the design,
construction and certification of the portable tank.
(3) Provide a statement in the manufacturers' data report certifying
that each portable tank that is manufactured complies with the relevant
specification and all the applicable requirements of this subchapter.
(4) Maintain records of the qualification of portable tanks for at
least 5 years and provide copies to the approval agency, the owner or
lessee of the tank. Upon request, provide these records to a
representative of DOT.
(d) Denial of application for approval. If an approval agency finds
that a portable tank cannot be approved for any reason, it shall notify
the applicant in writing and shall provide the applicant with the
reasons for which the approval is denied. A copy of the notification
letter shall be provided to the Associate Administrator. An applicant
aggrieved by a decision of an approval agency may appeal the decision in
writing, within 90 days of receipt, to the Associate Administrator.
(e) Modifications to approved portable tanks. (1) Prior to
modification of any UN portable tank which may affect conformance and
the safe use of the portable tank, which may involve a change to the
design type or which may affect its ability to retain hazardous material
in transportation, the person desiring to make such modification shall
inform the approval agency that issued the initial approval of the
portable tank (or if unavailable, another approval agency) of the nature
of the modification and request approval of the modification. The person
desiring to modify the tank must supply the approval agency with three
sets of all revised drawings, calculations, and test data relative to
the intended modification.
(2) A statement as to whether the intended modification has been
examined and determined to be unacceptable by any approval agency. The
written statement must include the name of the approving agency, the
reason for nonacceptance, and the nature of changes made to the
modification since its original rejection.
(3) The approval agency shall review the request for modification,
and if it is determined that the proposed modification is in full
compliance with the relevant DOT specification, including a UN portable
tank, the request shall be approved and the approval agency shall
perform the following activities:
(i) Return one set of the approved revised drawings, calculations,
and test data to the applicant. The second and third sets of the
approved revised drawings, calculations, and data shall be retained by
the approval agency as required in Sec. 107.404(a)(3) of this
subchapter.
(ii) Ensure through appropriate inspection that all modifications
conform to the revised drawings, calculations, and test data.
(iii) Determine the extent to which retesting of the modified tank
is necessary based on the nature of the proposed modification, and
ensure that all required retests are satisfactorily performed.
(iv) If modification to an approved tank alters any information on
the approval certificate, issue a new approval certificate for the
modified tank and ensure that any necessary changes are made to the
metal identification plate. A copy of each newly issued approval
certificate shall be retained by the approval agency and by the owner of
each portable tank.
(4) If the approval agency determines that the proposed modification
is not in compliance with the relevant DOT specification, the approval
agency shall deny the request in accordance with paragraph (d) of this
section.
(f) Termination of Approval Certificate. (1) The Associate
Administrator may terminate an approval issued under this section if he
determines that--
(i) Information upon which the approval was based is fraudulent or
substantially erroneous; or
[[Page 109]]
(ii) Termination of the approval is necessary to adequately protect
against risks to life and property; or
(iii) The approval was not issued by the approval agency in good
faith; or
(iv) The portable tank does not meet the specification.
(2) Before an approval is terminated, the Associate Administrator
gives the interested party(ies):
(i) Written notice of the facts or conduct believed to warrant the
termination;
(ii) Opportunity to submit oral and written evidence; and
(iii) Opportunity to demonstrate or achieve compliance with the
applicable requirements.
(3) If the Associate Administrator determines that a certificate of
approval must be terminated to preclude a significant and imminent
adverse affect on public safety, he may terminate the certificate
immediately. In such circumstances, the opportunities of paragraphs
(f)(2) (ii) and (iii) of this section need not be provided prior to
termination of the approval, but shall be provided as soon as
practicable thereafter.
[66 FR 33439, June 21, 2001, as amended at 67 FR 61016, Sept. 27, 2002;
68 FR 75748, 75751, Dec. 31, 2003; 72 FR 55695, Oct. 1, 2007]
Sec. 178.274 Specifications for UN portable tanks.
(a) General. (1) Each UN portable tank must meet the requirements of
this section. In addition to the requirements of this section,
requirements specific to UN portable tanks used for liquid and solid
hazardous materials, non-refrigerated liquefied gases and refrigerated
liquefied gases are provided in Sec. Sec. 178.275, 178.276 and 178.277,
respectively. Requirements for approval, maintenance, inspection,
testing and use are provided in Sec. 178.273 and part 180, subpart G,
of this subchapter. Any portable tank which meets the definition of a
``container'' within the terms of the International Convention for Safe
Containers (CSC) must meet the requirements of the CSC as amended and 49
CFR parts 450 through 453 and must have a CSC safety approval plate.
(2) In recognition of scientific and technological advances, the
technical requirements applicable to UN portable tanks may be varied if
approved by the Associate Administrator and the portable tank is shown
to provide a level of safety equal to or exceeding the requirements of
this subchapter. Portable tanks approved to alternative technical
requirements must be marked ``Alternative Arrangement'' as specified in
paragraph (i) of this section.
(3) Definitions. The following definitions apply for the purposes of
design and construction of UN portable tanks under this subpart:
Alternate Arrangement portable tank means a UN portable tank that
has been approved to alternative technical requirements or testing
methods other than those specified for UN portable tanks in part 178 or
part 180 of this subchapter.
Approval agency means the designated approval agency authorized to
approve the portable tank in accordance with the procedures in subpart E
of part 107 of this subchapter.
Design pressure is defined according to the hazardous materials
intended to be transported in the portable tank. See Sec. Sec. 178.275,
178.276 and 178.277, as applicable.
Design type means a portable tank or series of portable tanks made
of materials of the same material specifications and thicknesses,
manufactured by a single manufacturer, using the same fabrication
techniques (for example, welding procedures) and made with equivalent
structural equipment, closures, and service equipment.
Fine grain steel means steel that has a ferritic grain size of 6 or
finer when determined in accordance with ASTM E 112-96 (IBR, see Sec.
171.7 of this subchapter).
Fusible element means a non-reclosing pressure relief device that is
thermally activated and that provides protection against excessive
pressure buildup in the portable tank developed by exposure to heat,
such as from a fire (see Sec. 178.275(g)).
Jacket means the outer insulation cover or cladding which may be
part of the insulation system.
Leakage test means a test using gas to subject the shell and its
service equipment to an internal pressure.
[[Page 110]]
Maximum allowable working pressure (MAWP) is defined according to
the hazardous materials intended to be transported in the portable tank.
See Sec. Sec. 178.275, 178.276 and 178.277, as applicable.
Maximum permissible gross mass (MPGM) means the sum of the tare mass
of the portable tank and the heaviest hazardous material authorized for
transportation.
Mild steel means a steel with a guaranteed minimum tensile strength
of 360 N/mm\2\ to 440 N/mm\2\ and a guaranteed minimum elongation at
fracture as specified in paragraph (c)(10) of this section.
Offshore portable tank means a portable tank specially designed for
repeated use in the transportation of hazardous materials to, from and
between offshore facilities. An offshore portable tank is designed and
constructed in accordance with the Guidelines for the Approval of
Containers Handled in Open Seas specified in the IMDG Code (IBR, see
Sec. 171.7 of this subchapter).
Reference steel means a steel with a tensile strength of 370 N/mm\2\
and an elongation at fracture of 27%.
Service equipment means measuring instruments and filling,
discharge, venting, safety, heating, cooling and insulating devices.
Shell means the part of the portable tank which retains the
hazardous materials intended for transportation, including openings and
closures, but does not include service equipment or external structural
equipment.
Structural equipment means the reinforcing, fastening, protective
and stabilizing members external to the shell.
Test pressure means the maximum gauge pressure at the top of the
shell during the hydraulic pressure test equal to not less than 1.5
times the design pressure for liquids and 1.3 for liquefied compressed
gases and refrigerated liquefied gases. In some instances a pneumatic
test is authorized as an alternative to the hydraulic test. The minimum
test pressures for portable tanks intended for specific liquid and solid
hazardous materials are specified in the applicable portable tank T
codes (such as T1-T23) assigned to these hazardous materials in the
Sec. 172.101 Table of this subchapter.
(b) General design and construction requirements. (1) The design
temperature range for the shell must be -40 [deg]C to 50 [deg]C (-40
[deg]F to 122 [deg]F) for hazardous materials transported under normal
conditions of transportation, except for portable tanks used for
refrigerated liquefied gases where the minimum design temperature must
not be higher than the lowest (coldest) temperature (for example,
service temperature) of the contents during filling, discharge or
transportation. For hazardous materials handled under elevated
temperature conditions, the design temperature must not be less than the
maximum temperature of the hazardous material during filling, discharge
or transportation. More severe design temperatures must be considered
for portable tanks subjected to severe climatic conditions (for example,
portable tanks transported in arctic regions). Shells must be designed
and constructed in accordance with the requirements in Section VIII of
the ASME Code (IBR, see Sec. 171.7 of this subchapter), except as
limited or modified in this subchapter. For portable tanks used for
liquid or solid hazardous materials, a design code other than the ASME
Code may be used if approved by the Associate Administrator. Portable
tanks must have an ASME certification and U stamp when used for Hazard
Zone A or B toxic by inhalation liquids, or when used for non-
refrigerated or refrigerated liquefied compressed gases. Shells must be
made of metallic materials suitable for forming. Non-metallic materials
may be used for the attachments and supports between the shell and
jacket, provided their material properties at the minimum and maximum
design temperatures are proven to be sufficient. For welded shells, only
a material whose weldability has been fully demonstrated may be used.
Welds must be of high quality and conform to a level of integrity at
least equivalent to the welding requirements specified in Section VIII
of the ASME Code for the welding of pressure vessels. When the
manufacturing process or the materials make it necessary, the shells
must be suitably heat-treated to guarantee adequate toughness in the
weld and in the heat-affected zones. In choosing the
[[Page 111]]
material, the design temperature range must be taken into account with
respect to risk of brittle fracture, stress corrosion cracking,
resistance to impact, and suitability for the hazardous materials
intended for transportation in the portable tank. When fine grain steel
is used, the guaranteed value of the yield strength must be not more
than 460 N/mm\2\ and the guaranteed value of the upper limit of the
tensile strength must be not more than 725 N/mm\2\ according to the
material specification. Aluminum may not be used as a construction
material for the shells of portable tanks intended for the transport of
non-refrigerated liquefied gases. For portable tanks intended for the
transport of liquid or solid hazardous materials, aluminum may only be
used as a construction material for portable tank shells if approved by
the Associate Administrator. Portable tank materials must be suitable
for the external environment where they will be transported, taking into
account the determined design temperature range. Portable tanks shall be
designed to withstand, without loss of contents, at least the internal
pressure due to the contents and the static, dynamic and thermal loads
during normal conditions of handling and transportation. The design must
take into account the effects of fatigue, caused by repeated application
of these loads through the expected life of the portable tank.
(2) Portable tank shells, fittings, and pipework shall be
constructed from materials that are:
(i) Compatible with the hazardous materials intended to be
transported; or
(ii) Properly passivated or neutralized by chemical reaction, if
applicable; or
(iii) For portable tanks used for liquid and solid materials, lined
with corrosion-resistant material directly bonded to the shell or
attached by equivalent means.
(3) Gaskets and seals shall be made of materials that are compatible
with the hazardous materials intended to be transported.
(4) When shells are lined, the lining must be compatible with the
hazardous materials intended to be transported, homogeneous, non-porous,
free from perforations, sufficiently elastic and compatible with the
thermal expansion characteristics of the shell. The lining of every
shell, shell fittings and piping must be continuous and must extend
around the face of any flange. Where external fittings are welded to the
tank, the lining must be continuous through the fitting and around the
face of external flanges. Joints and seams in the lining must be made by
fusing the material together or by other equally effective means.
(5) Contact between dissimilar metals which could result in damage
by galvanic action must be prevented by appropriate measures.
(6) The construction materials of the portable tank, including any
devices, gaskets, linings and accessories, must not adversely affect or
react with the hazardous materials intended to be transported in the
portable tank.
(7) Portable tanks must be designed and constructed with supports
that provide a secure base during transportation and with suitable
lifting and tie-down attachments.
(c) Design criteria. (1) Portable tanks and their fastenings must,
under the maximum permissible loads and maximum permissible working
pressures, be capable of absorbing the following separately applied
static forces (for calculation purposes, acceleration due to gravity (g)
=9.81m/s\2\):
(i) In the direction of travel: 2g (twice the MPGM multiplied by the
acceleration due to gravity);
(ii) Horizontally at right angles to the direction of travel: 1g
(the MPGM multiplied by the acceleration due to gravity);
(iii) Vertically upwards: 1g (the MPGM multiplied by the
acceleration due to gravity); and
(iv) Vertically downwards: 2g (twice the MPGM multiplied by the
acceleration due to gravity).
(2) Under each of the forces specified in paragraph (c)(1) of this
section, the safety factor must be as follows:
(i) For metals having a clearly defined yield point, a design margin
of 1.5 in relation to the guaranteed yield strength; or
(ii) For metals with no clearly defined yield point, a design margin
of 1.5 in relation to the guaranteed 0.2%
[[Page 112]]
proof strength and, for austenitic steels, the 1% proof strength.
(3) The values of yield strength or proof strength must be the
values according to recognized material standards. When austenitic
steels are used, the specified minimum values of yield strength or proof
strength according to the material standards may be increased by up to
15% for portable tanks used for liquid and solid hazardous materials,
other than toxic by inhalation liquids meeting the criteria of Hazard
Zone A or Hazard Zone B (see Sec. 173.133 of this subchapter), when
these greater values are attested in the material inspection
certificate.
(4) Portable tanks must be capable of being electrically grounded to
prevent dangerous electrostatic discharge when they are used for Class 2
flammable gases or Class 3 flammable liquids, including elevated
temperature materials transported at or above their flash point.
(5) For shells of portable tanks used for liquefied compressed
gases, the shell must consist of a circular cross section. Shells must
be of a design capable of being stress-analyzed mathematically or
experimentally by resistance strain gauges as specified in UG-101 of
Section VIII of the ASME Code, or other methods approved by the
Associate Administrator.
(6) Shells must be designed and constructed to withstand a hydraulic
test pressure of not less than 1.5 times the design pressure for
portable tanks used for liquids and 1.3 times the design pressure for
portable tanks used for liquefied compressed gases. Specific
requirements are provided for each hazardous material in the applicable
T Code or portable tank special provision specified in the Sec. 172.101
Table of this subchapter. The minimum shell thickness requirements must
also be taken into account.
(7) For metals exhibiting a clearly defined yield point or
characterized by a guaranteed proof strength (0.2% proof strength,
generally, or 1% proof strength for austenitic steels), the primary
membrane stress [sigma] (sigma) in the shell must not exceed 0.75 Re or
0.50 Rm, whichever is lower, at the test pressure, where:
Re = yield strength in N/mm\2\, or 0.2% proof strength or, for
austenitic steels, 1% proof strength;
Rm = minimum tensile strength in N/mm\2\.
(8) The values of Re and Rm to be used must be the specified minimum
values according to recognized material standards. When austenitic
steels are used, the specified minimum values for Re and Rm according to
the material standards may be increased by up to 15% when greater values
are attested in the material inspection certificate.
(9) Steels which have a Re/Rm ratio of more than 0.85 are not
allowed for the construction of welded shells. The values of Re and Rm
to be used in determining this ratio must be the values specified in the
material inspection certificate.
(10) Steels used in the construction of shells must have an
elongation at fracture, in percentage, of not less than 10,000/Rm with
an absolute minimum of 16% for fine grain steels and 20% for other
steels.
(11) For the purpose of determining actual values for materials for
sheet metal, the axis of the tensile test specimen must be at right
angles (transversely) to the direction of rolling. The permanent
elongation at fracture must be measured on test specimens of rectangular
cross sections in accordance with ISO 6892 (IBR, see Sec. 171.7 of this
subchapter), using a 50 mm gauge length.
(d) Minimum shell thickness. (1) The minimum shell thickness must be
the greatest thickness of the following:
(i) the minimum thickness determined in accordance with the
requirements of paragraphs (d)(2) through (d)(7) of this section;
(ii) the minimum thickness determined in accordance with Section
VIII of the ASME Code or other approved pressure vessel code; or
(iii) the minimum thickness specified in the applicable T code or
portable tank special provision indicated for each hazardous material in
the Sec. 172.101 Table of this subchapter.
(2) Shells (cylindrical portions, heads and manhole covers) not more
than 1.80 m in diameter may not be less than 5 mm thick in the reference
steel or of
[[Page 113]]
equivalent thickness in the metal to be used. Shells more than 1.80 m in
diameter may not be less than 6 mm (0.2 inches) thick in the reference
steel or of equivalent thickness in the metal to be used. For portable
tanks used only for the transportation of powdered or granular solid
hazardous materials of Packing Group II or III, the minimum thickness
requirement may be reduced to 5 mm in the reference steel or of
equivalent thickness in the metal to be used regardless of the shell
diameter. For vacuum-insulated tanks, the aggregate thickness of the
jacket and the shell must correspond to the minimum thickness prescribed
in this paragraph, with the thickness of the shell itself not less than
the minimum thickness prescribed in paragraph (d)(3) of this section.
(3) When additional protection against shell damage is provided in
the case of portable tanks used for liquid and solid hazardous materials
requiring test pressures less than 2.65 bar (265.0 kPa), subject to
certain limitations specified in the UN Recommendations (IBR, see Sec.
171.7 of this subchapter), the Associate Administrator may approve a
reduced minimum shell thickness.
(4) The cylindrical portions, heads and manhole covers of all shells
must not be less than 3 mm (0.1 inch) thick regardless of the material
of construction, except for portable tanks used for liquefied compressed
gases where the cylindrical portions, ends (heads) and manhole covers of
all shells must not be less than 4 mm (0.2 inch) thick regardless of the
material of construction.
(5) When steel is used, that has characteristics other than that of
reference steel, the equivalent thickness of the shell and heads must be
determined according to the following formula:
[GRAPHIC] [TIFF OMITTED] TN21JN01.005
Where:
e1 = required equivalent thickness (in mm) of the metal to be
used;
e0 = minimum thickness (in mm) of the reference steel
specified in the applicable T code or portable tank special provision
indicated for each material in the Sec. 172.101 Table of this
subchapter;
d1 = 1.8m, unless the formula is used to determine the
equivalent minimum thickness for a portable tank shell that is required
to have a minimum thickness of 8mm or 10mm according to the applicable T
code indicated in the Sec. 172.101 Table of this subchapter. When
reference steel thicknesses of 8mm or 10mm are specified, d1
is equal to the actual diameter of the shell but not less than 1.8m;
Rm1 = guaranteed minimum tensile strength (in N/mm \2\) of
the metal to be used;
A1 = guaranteed minimum elongation at fracture (in %) of the
metal to be used according to recognized material standards.
(6) The wall and all parts of the shell may not have a thickness
less than that prescribed in paragraphs (d)(2), (d)(3) and (d)(4) of
this section. This thickness must be exclusive of any corrosion
allowance.
(7) There must be no sudden change of plate thickness at the
attachment of the heads to the cylindrical portion of the shell.
(e) Service equipment. (1) Service equipment must be arranged so
that it is protected against the risk of mechanical damage by external
forces during handling and transportation. When the connections between
the frame and the shell allow relative movement between the sub-
assemblies, the equipment must be fastened to allow such movement
without risk of damage to any working part. The external discharge
fittings (pipe sockets, shut-off devices) and the internal stop-valve
and its seating must be protected against mechanical damage by external
forces (for example, by using shear sections). Each internal self-
closing stop-valve must be protected by a shear section or sacrificial
device located outboard of the valve. The shear section or sacrificial
device must break at no more than 70% of the load that would cause
failure of the internal self-closing stop valve. The filling and
discharge devices (including flanges or threaded plugs) and any
protective caps must be capable of being secured against unintended
opening.
(2) Each filling or discharge opening of a portable tank must be
clearly marked to indicate its function.
(3) Each stop-valve or other means of closure must be designed and
constructed to a rated pressure not less than the MAWP of the shell
taking
[[Page 114]]
into account the temperatures expected during transport. All stop-valves
with screwed spindles must close by a clockwise motion of the handwheel.
For other stop-valves, the position (open and closed) and direction of
closure must be clearly indicated. All stop-valves must be designed to
prevent unintentional opening.
(4) Piping must be designed, constructed and installed to avoid the
risk of damage due to thermal expansion and contraction, mechanical
shock and vibration. All piping must be of a suitable metallic material.
Welded pipe joints must be used wherever possible.
(5) Joints in copper tubing must be brazed or have an equally strong
metal union. The melting point of brazing materials must be no lower
than 525 [deg]C (977 [deg]F). The joints must not decrease the strength
of the tubing, such as may happen when cutting threads. Brazed joints
are not authorized for portable tanks intended for refrigerated
liquefied gases.
(6) The burst pressure of all piping and pipe fittings must be
greater than the highest of four times the MAWP of the shell or four
times the pressure to which it may be subjected in service by the action
of a pump or other device (except pressure relief devices).
(7) Ductile metals must be used in the construction of valves and
accessories.
(f) Pressure relief devices--(1) Marking of pressure relief devices.
Every pressure relief device must be clearly and permanently marked with
the following:
(i) the pressure (in bar or kPa) or temperature for fusible elements
(in [deg]C) at which it is set to discharge;
(ii) the allowable tolerance at the discharge pressure for reclosing
devices;
(iii) the reference temperature corresponding to the rated pressure
for frangible discs;
(iv) the allowable temperature tolerance for fusible elements;
(v) The rated flow capacity of the spring loaded pressure relief
devices, frangible disc or fusible elements in standard cubic meters of
air per second (m\3\/s). For spring loaded pressure relief device the
rated flow capacity shall be determined according to ISO 4126-1 (IBR,
see Sec. 171.7 of this subchapter); and
(vi) when practicable, the device must show the manufacturer's name
and product number.
(2) Connections to pressure relief devices. Connections to pressure
relief devices must be of sufficient size to enable the required
discharge to pass unrestricted to the safety device. No stop-valve may
be installed between the shell and the pressure relief devices except
where duplicate devices are provided for maintenance or other reasons
and the stop-valves serving the devices actually in use are locked open
or the stop-valves are interlocked so that at least one of the devices
is always in use. There must be no obstruction in an opening leading to
a vent or pressure relief device which might restrict or cut-off the
flow from the shell to that device. Vents or pipes from the pressure
relief device outlets, when used, must deliver the relieved vapor or
liquid to the atmosphere in conditions of minimum back-pressure on the
relieving devices.
(3) Location of pressure relief devices. (i) Each pressure relief
device inlet must be situated on top of the shell in a position as near
the longitudinal and transverse center of the shell as reasonably
practicable. All pressure relief device inlets must, under maximum
filling conditions, be situated in the vapor space of the shell and the
devices must be so arranged as to ensure that any escaping vapor is not
restricted in any manner. For flammable hazardous materials, the
escaping vapor must be directed away from the shell in such a manner
that it cannot impinge upon the shell. For refrigerated liquefied gases,
the escaping vapor must be directed away from the tank and in such a
manner that it cannot impinge upon the tank. Protective devices which
deflect the flow of vapor are permissible provided the required relief-
device capacity is not reduced.
(ii) Provisions must be implemented to prevent unauthorized persons
from access to the pressure relief devices and to protect the devices
from damage caused by the portable tank overturning.
(g) Gauging devices. Unless a portable tank is intended to be filled
by weight, it must be equipped with one or more gauging devices. Glass
level-gauges and
[[Page 115]]
gauges made of other fragile material, which are in direct communication
with the contents of the tank are prohibited. A connection for a vacuum
gauge must be provided in the jacket of a vacuum-insulated portable
tank.
(h) Portable tank supports, frameworks, lifting and tie-down
attachments. (1) Portable tanks must be designed and constructed with a
support structure to provide a secure base during transport. The forces
and safety factors specified in paragraphs (c)(1) and (c)(2) of this
section, respectively, must be taken into account in this aspect of the
design. Skids, frameworks, cradles or other similar structures are
acceptable.
(2) The combined stresses caused by portable tank mountings (for
example, cradles, framework, etc.) and portable tank lifting and tie-
down attachments must not cause stress that would damage the shell in a
manner that would compromise its lading retention capability. Permanent
lifting and tie-down attachments must be fitted to all portable tanks.
Preferably they should be fitted to the portable tank supports but may
be secured to reinforcing plates located on the shell at the points of
support. Each portable tank must be designed so that the center of
gravity of the filled tank is approximately centered within the points
of attachment for lifting devices.
(3) In the design of supports and frameworks, the effects of
environmental corrosion must be taken into account.
(4) Forklift pockets must be capable of being closed off. The means
of closing forklift pockets must be a permanent part of the framework or
permanently attached to the framework. Single compartment portable tanks
with a length less than 3.65 m (12 ft.) need not have forklift pockets
that are capable of being closed off provided that:
(i) The shell, including all the fittings, are well protected from
being hit by the forklift blades; and
(ii) The distance between forklift pockets (measured from the center
of each pocket) is at least half of the maximum length of the portable
tank.
(5) During transport, portable tanks must be adequately protected
against damage to the shell, and service equipment resulting from
lateral and longitudinal impact and overturning, or the shell and
service equipment must be constructed to withstand the forces resulting
from impact or overturning. External fittings must be protected so as to
preclude the release of the shell contents upon impact or overturning of
the portable tank on its fittings. Examples of protection include:
(i) Protection against lateral impact which may consist of
longitudinal bars protecting the shell on both sides at the level of the
median line;
(ii) Protection of the portable tank against overturning which may
consist of reinforcement rings or bars fixed across the frame;
(iii) Protection against rear impact which may consist of a bumper
or frame;
(iv) Protection of the shell against damage from impact or
overturning by use of an ISO frame in accordance with ISO 1496-3 (IBR,
see Sec. 171.7 of this subchapter); and
(v) Protection of the portable tank from impact or damage that may
result from overturning by an insulation jacket.
(i) Marking. (1) Every portable tank must be fitted with a corrosion
resistant metal plate permanently attached to the portable tank in a
conspicuous place and readily accessible for inspection. When the plate
cannot be permanently attached to the shell, the shell must be marked
with at least the information required by Section VIII of the ASME Code.
At a minimum, the following information must be marked on the plate by
stamping or by any other equivalent method:
Country of manufacture
U N
Approval Country
Approval Number
Alternative Arrangements (see Sec. 178.274(a)(2)) ``AA''
Manufacturer's name or mark
Manufacturer's serial number
Approval Agency (Authorized body for the design approval)
Owner's registration number
Year of manufacture
Pressure vessel code to which the shell is designed
Test pressure--------bar gauge.
MAWP--------bar gauge.
[[Page 116]]
External design pressure (not required for portable tanks used for
refrigerated liquefied gases)--------bar gauge.
Design temperature range-------- [deg]C to-------- [deg]C. (For portable
tanks used for refrigerated liquefied gases, the minimum design
temperature must be marked.)
Water capacity at 20 [deg]C/--------liters.
Water capacity of each compartment at 20 [deg]C--------liters.
Initial pressure test date and witness identification.
MAWP for heating/cooling system--------bar gauge.
Shell material(s) and material standard reference(s).
Equivalent thickness in reference steel--------mm.
Lining material (when applicable).
Date and type of most recent periodic test(s).
Month--------Year-------- Test pressure--------bar gauge.
Stamp of approval agency that performed or witnessed the most recent
test.
For portable tanks used for refrigerated liquefied gases:
Either ``thermally insulated'' or ``vacuum insulated''--------.
Effectiveness of the insulation system (heat influx)--------Watts (W).
Reference holding time--------days or hours and initial pressure--------
bar/kPa gauge and degree of filling--------in kg for each refrigerated
liquefied gas permitted for transportation.
(2) The following information must be marked either on the portable
tank itself or on a metal plate firmly secured to the portable tank:
Name of the operator.
Name of hazardous materials being transported and maximum mean bulk
temperature (except for refrigerated liquefied gases, the name and
temperature are only required when the maximum mean bulk temperature is
higher than 50 [deg]C).
Maximum permissible gross mass (MPGM)--------kg.
Unladen (tare) mass--------kg.
Note to paragraph (i)(2): For the identification of the hazardous
materials being transported refer to part 172 of this subchapter.
(3) If a portable tank is designed and approved for open seas
operations, such as offshore oil exploration, in accordance with the
IMDG Code, the words ``OFFSHORE PORTABLE TANK'' must be marked on the
identification plate.
(j) Initial inspection and test. The initial inspection and test of
a portable tank must include the following:
(1) A check of the design characteristics.
(2) An internal and external examination of the portable tank and
its fittings, taking into account the hazardous materials to be
transported. For UN portable tanks used for refrigerated liquefied
gases, a pressure test using an inert gas may be conducted instead of a
hydrostatic test. An internal inspection is not required for a portable
tank used for the dedicated transportation of refrigerated liquefied
gases that are not filled with an inspection opening.
(3) A pressure test as specified in paragraph (i) of this section.
(4) A leakage test.
(5) A test of the satisfactory operation of all service equipment
including pressure relief devices must also be performed. When the shell
and its fittings have been pressure-tested separately, they must be
subjected to a leakage test after reassembly. All welds, subject to full
stress level in the shell, must be inspected during the initial test by
radiographic, ultrasonic, or another suitable non-destructive test
method. This does not apply to the jacket.
(6) Effective January 1, 2008, each new UN portable tank design type
meeting the definition of ``container'' in the Convention for Safe
Containers (CSC) (see 49 CFR 450.3(a)(2)) must be subjected to the
dynamic longitudinal impact test prescribed in Part IV, Section 40 of
the UN Manual of Tests and Criteria (see IBR, Sec. 171.7 of this
subchapter). A UN portable tank design type impact-tested prior to
January 1, 2008, in accordance with the requirements of this section in
effect on October 1, 2005, need not be retested. UN portable tanks used
for the dedicated transportation of ``Helium, refrigerated liquid,''
UN1963, and ``Hydrogen, refrigerated liquid,'' UN1966, that are marked
``NOT FOR RAIL TRANSPORT'' in letters of a minimum height of 10 cm (4
inches) on at least two sides of the portable tank are excepted from the
dynamic longitudinal impact test.
(7) The following tests must be completed on a portable tank or a
series of portable tanks designed and constructed to a single design
type that is also a CSC container without leakage or deformation that
would render the
[[Page 117]]
portable tank unsafe for transportation and use:
(i) Longitudinal inertia. The portable tank loaded to its maximum
gross weight must be positioned with its longitudinal axis vertical. It
shall be held in this position for five minutes by support at the lower
end of the base structure providing vertical and lateral restraint and
by support at the upper end of the base structure providing lateral
restraint only.
(ii) Lateral inertia. The portable tank loaded to its maximum gross
weight must be positioned for five minutes with its transverse axis
vertical. It shall be held in this position for five minutes by support
at the lower side of the base structure providing vertical and lateral
restraint and by support at the upper side of the base structure
providing lateral restraint only.
[66 FR 33440, June 21, 2001, as amended at 67 FR 15744, Apr. 3, 2002; 68
FR 45041, July 31, 2003; 68 FR 57633, Oct. 6, 2003; 68 FR 75751, Dec.
31, 2003; 69 FR 76185, Dec. 20, 2004; 70 FR 34399, June 14, 2005; 71 FR
78634, Dec. 29, 2006; 72 FR 55696, Oct. 1, 2007; 73 FR 4719, Jan. 28,
2008]
Editorial Note: At 68 FR 57633, Oct. 6, 2003, Sec. 178.274 was
amended in paragraph (b)(1); however, the amendment could not be
incorporated due to inaccurate amendatory instruction.
Sec. 178.275 Specification for UN Portable Tanks intended for the
transportation of liquid and solid hazardous materials.
(a) In addition to the requirements of Sec. 178.274, this section
sets forth definitions and requirements that apply to UN portable tanks
intended for the transportation of liquid and solid hazardous materials.
(b) Definitions and requirements--(1) Design pressure means the
pressure to be used in calculations required by the recognized pressure
vessel code. The design pressure must not be less than the highest of
the following pressures:
(i) The maximum effective gauge pressure allowed in the shell during
filling or discharge; or
(ii) The sum of--
(A) The absolute vapor pressure (in bar) of the hazardous material
at 65 [deg]C, minus 1 bar (149 [deg]F, minus 100 kPa);
(B) The partial pressure (in bar) of air or other gases in the
ullage space, resulting from their compression during filling without
pressure relief by a maximum ullage temperature of 65 [deg]C (149
[deg]F) and a liquid expansion due to an increase in mean bulk
temperature of 35 [deg]C (95 [deg]F); and
(C) A head pressure determined on the basis of the forces specified
in Sec. 178.274(c) of this subchapter, but not less than 0.35 bar (35
kPa).
(2) Maximum allowable working pressure (MAWP) means a pressure that
must not be less than the highest of the following pressures measured at
the top of the shell while in operating position:
(i) The maximum effective gauge pressure allowed in the shell during
filling or discharge; or
(ii) The maximum effective gauge pressure to which the shell is
designed which must be not less than the design pressure.
(c) Service equipment. (1) In addition to the requirements specified
in Sec. 178.274, for service equipment, all openings in the shell,
intended for filling or discharging the portable tank must be fitted
with a manually operated stop-valve located as close to the shell as
reasonably practicable. Other openings, except for openings leading to
venting or pressure relief devices, must be equipped with either a stop-
valve or another suitable means of closure located as close to the shell
as reasonably practicable.
(2) All portable tanks must be fitted with a manhole or other
inspection openings of a suitable size to allow for internal inspection
and adequate access for maintenance and repair of the interior.
Compartmented portable tanks must have a manhole or other inspection
openings for each compartment.
(3) For insulated portable tanks, top fittings must be surrounded by
a spill collection reservoir with suitable drains.
(4) Piping must be designed, constructed and installed to avoid the
risk of damage due to thermal expansion and contraction, mechanical
shock and vibration. All piping must be of a suitable metallic material.
Welded pipe joints must be used wherever possible.
[[Page 118]]
(d) Bottom openings. (1) Certain hazardous materials may not be
transported in portable tanks with bottom openings. When the applicable
T code or portable tank special provision, as referenced for materials
in the Sec. 172.101 Table of this subchapter, specifies that bottom
openings are prohibited, there must be no openings below the liquid
level of the shell when it is filled to its maximum permissible filling
limit. When an existing opening is closed, it must be accomplished by
internally and externally welding one plate to the shell.
(2) Bottom discharge outlets for portable tanks carrying certain
solid, crystallizable or highly viscous hazardous materials must be
equipped with at least two serially fitted and mutually independent
shut-off devices. Use of only two shut-off devices is only authorized
when this paragraph is referenced in the applicable T Code indicated for
each hazardous material in the Sec. 172.101 Table of this subchapter.
The design of the equipment must be to the satisfaction of the approval
agency and must include:
(i) An external stop-valve fitted as close to the shell as
reasonably practicable; and
(ii) A liquid tight closure at the end of the discharge pipe, which
may be a bolted blank flange or a screw cap.
(3) Except as provided in paragraph (d)(2) of this section, every
bottom discharge outlet must be equipped with three serially fitted and
mutually independent shut-off devices. The design of the equipment must
include:
(i) A self-closing internal stop-valve, which is a stop-valve within
the shell or within a welded flange or its companion flange, such that:
(A) The control devices for the operation of the valve are designed
to prevent any unintended opening through impact or other inadvertent
act;
(B) The valve is operable from above or below;
(C) If possible, the setting of the valve (open or closed) must be
capable of being verified from the ground;
(D) Except for portable tanks having a capacity less than 1,000
liters (264.2 gallons), it must be possible to close the valve from an
accessible position on the portable tank that is remote from the valve
itself within 30 seconds of actuation; and
(E) The valve must continue to be effective in the event of damage
to the external device for controlling the operation of the valve;
(ii) An external stop-valve fitted as close to the shell as
reasonably practicable;
(iii) A liquid tight closure at the end of the discharge pipe, which
may be a bolted blank flange or a screw cap; and
(iv) For UN portable tanks, with bottom outlets, used for the
transportation of liquid hazardous materials that are Class 3, PG I or
II, or PG III with a flash point of less than 100 [deg]F (38 [deg]C);
Division 5.1, PG I or II; or Division 6.1, PG I or II, the remote means
of closure must be capable of thermal activation. The thermal means of
activation must activate at a temperature of not more than 250 [deg]F
(121 [deg]C).
(e) Pressure relief devices. All portable tanks must be fitted with
at least one pressure relief device. All relief devices must be
designed, constructed and marked in accordance with the requirements of
this subchapter.
(f) Vacuum-relief devices. (1) A shell which is to be equipped with
a vacuum-relief device must be designed to withstand, without permanent
deformation, an external pressure of not less than 0.21 bar (21.0 kPa).
The vacuum-relief device must be set to relieve at a vacuum setting not
greater than -0.21 bar (-21.0 kPa) unless the shell is designed for a
higher external over pressure, in which case the vacuum-relief pressure
of the device to be fitted must not be greater than the tank design
vacuum pressure. A shell that is not fitted with a vacuum-relief device
must be designed to withstand, without permanent deformation, an
external pressure of not less than 0.4 bar (40.0 kPa).
(2) Vacuum-relief devices used on portable tanks intended for the
transportation of hazardous materials meeting the criteria of Class 3,
including elevated temperature hazardous materials transported at or
above their flash point, must prevent the immediate passage of flame
into the shell or the portable tank must have a shell capable of
withstanding, without leakage, an internal explosion resulting
[[Page 119]]
from the passage of flame into the shell.
(g) Pressure relief devices. (1) Each portable tank with a capacity
not less than 1,900 liters (501.9 gallons) and every independent
compartment of a portable tank with a similar capacity, must be provided
with one or more pressure relief devices of the reclosing type. Such
portable tanks may, in addition, have a frangible disc or fusible
element in parallel with the reclosing devices, except when the
applicable T code assigned to a hazardous material requires that the
frangible disc precede the pressure relief device, according to
paragraph (g)(3) of this section, or when no bottom openings are
allowed. The pressure relief devices must have sufficient capacity to
prevent rupture of the shell due to over pressurization or vacuum
resulting from filling, discharging, heating of the contents or fire.
(2) Pressure relief devices must be designed to prevent the entry of
foreign matter, the leakage of liquid and the development of any
dangerous excess pressure.
(3) When required for certain hazardous materials by the applicable
T code or portable tank special provision specified for a hazardous
material in the Sec. 172.101 Table of this subchapter, portable tanks
must have a pressure relief device consistent with the requirements of
this subchapter. Except for a portable tank in dedicated service that is
fitted with an approved relief device constructed of materials
compatible with the hazardous material, the relief device system must
include a frangible disc preceding (such as, between the lading and the
reclosing pressure relief device) a reclosing pressure relief device. A
pressure gauge or suitable tell-tale indicator for the detection of disc
rupture, pin-holing or leakage must be provided in the space between the
frangible disc and the pressure relief device to allow the portable tank
operator to check to determine if the disc is leak free. The frangible
disc must rupture at a nominal pressure 10% above the start-to-discharge
pressure of the reclosable pressure relief device.
(4) Every portable tank with a capacity less than 1,900 liters
(501.9 gallons) must be fitted with a pressure relief device which,
except as provided in paragraph (g)(3) of this section, may be a
frangible disc when this disc is set to rupture at a nominal pressure
equal to the test pressure at any temperature within the design
temperature range.
(5) When the shell is fitted for pressure discharge, a suitable
pressure relief device must provide the inlet line to the portable tank
and set to operate at a pressure not higher than the MAWP of the shell,
and a stop-valve must be fitted as close to the shell as practicable to
minimize the potential for damage.
(6) Setting of pressure relief devices. (i) Pressure relief devices
must operate only in conditions of excessive rise in temperature. The
shell must not be subject to undue fluctuations of pressure during
normal conditions of transportation.
(ii) The required pressure relief device must be set to start to
discharge at a nominal pressure of five-sixths of the test pressure for
shells having a test pressure of not more than 4.5 bar (450 kPa) and
110% of two-thirds of the test pressure for shells having a test
pressure of more than 4.5 bar (450 kPa). A self-closing relief device
must close at a pressure not more than 10% below the pressure at which
the discharge starts. The device must remain closed at all lower
pressures. This requirement does not prevent the use of vacuum-relief or
combination pressure relief and vacuum-relief devices.
(h) Fusible elements. Fusible elements must operate at a temperature
between 110 [deg]C (230 [deg]F) and 149 [deg]C (300.2 [deg]F), provided
that the pressure in the shell at the fusing temperature will not exceed
the test pressure. They must be placed at the top of the shell with
their inlets in the vapor space and in no case may they be shielded from
external heat. Fusible elements must not be utilized on portable tanks
with a test pressure which exceeds 2.65 bar (265.0 kPa); however,
fusible elements are authorized on portable tanks for the transportation
of certain organometallic materials in accordance with Sec. 172.102,
special provision TP36 of this subchapter. Fusible elements used on
portable tanks intended for the transport of elevated temperature
hazardous materials
[[Page 120]]
must be designed to operate at a temperature higher than the maximum
temperature that will be experienced during transport and must be
designed to the satisfaction of the approval agency.
(i) Capacity of pressure relief devices. (1) The reclosing pressure
relief device required by paragraph (g)(1) of this section must have a
minimum cross sectional flow area equivalent to an orifice of 31.75 mm
(1.3 inches) diameter. Vacuum-relief devices, when used, must have a
cross sectional flow area not less than 284 mm \2\ (11.2 inches \2\).
(2) The combined delivery capacity of the pressure relief system
(taking into account the reduction of the flow when the portable tank is
fitted with frangible-discs preceding spring-loaded pressure-relief
devices or when the spring-loaded pressure-relief devices are provided
with a device to prevent the passage of the flame), in condition of
complete fire engulfment of the portable tank must be sufficient to
limit the pressure in the shell to 20% above the start to discharge
pressure limiting device (pressure relief device). The total required
capacity of the relief devices may be determined using the formula in
paragraph (i)(2)(i)(A) of this section or the table in paragraph
(i)(2)(iii) of this section.
(i)(A) To determine the total required capacity of the relief
devices, which must be regarded as being the sum of the individual
capacities of all the contributing devices, the following formula must
be used:
[GRAPHIC] [TIFF OMITTED] TR01OC08.000
Where:
Q = minimum required rate of discharge in cubic meters of air per second
(m\3\/s) at conditions: 1 bar and 0 [deg]C (273 [deg]K);
F = for uninsulated shells: 1; for insulated shells: U(649-t)/13.6 but
in no case is less than 0.25
Where:
U = thermal conductance of the insulation, in kW
m-2K-1, at 38 [deg]C (100 [deg]F); and t = actual
temperature of the hazardous material during filling (in [deg]C) or when
this temperature is unknown, let t = 15 [deg]C (59 [deg]F). The value of
F given in this paragraph (i)(2)(i)(A) for insulated shells may only be
used if the insulation is in conformance with paragraph (i)(2)(iv) of
this section;
A = total external surface area of shell in square meters;
Z = the gas compressibility factor in the accumulating condition (when
this factor is unknown, let Z equal 1.0);
T = absolute temperature in Kelvin ( [deg]C + 273) above the pressure
relief devices in the accumulating condition;
L = the latent heat of vaporization of the liquid, in kJ/kg, in the
accumulating condition;
M = molecular weight of the hazardous material.
(B) The constant C, as shown in the formula in paragraph
(i)(2)(i)(A) of this section, is derived from one of the following
formulas as a function of the ratio k of specific heats:
[GRAPHIC] [TIFF OMITTED] TR01OC08.001
Where:
cp is the specific heat at constant pressure; and
cv is the specific heat at constant volume.
(C) When k 1:
[GRAPHIC] [TIFF OMITTED] TR01OC08.002
(D) When k = 1 or k is unknown, a value of 0.607 may be used for the
constant C. C may also be taken from the following table:
C Constant Value Table
------------------------------------------------------------------------
k C
------------------------------------------------------------------------
1.00 0.607
1.02 0.611
1.04 0.615
1.06 0.620
1.08 0.624
1.10 0.628
1.12 0.633
1.14 0.637
1.16 0.641
1.18 0.645
1.20 0.649
1.22 0.652
1.24 0.656
1.26 0.660
1.28 0.664
1.30 0.667
1.32 0.671
1.34 0.674
1.36 0.678
1.38 0.681
1.40 0.685
1.42 0.688
1.44 0.691
[[Page 121]]
1.46 0.695
1.48 0.698
1.50 0.701
1.52 0.704
1.54 0.707
1.56 0.710
1.58 0.713
1.60 0.716
1.62 0.719
1.64 0.722
1.66 0.725
1.68 0.728
1.70 0.731
2.00 0.770
2.20 0.793
------------------------------------------------------------------------
(ii) As an alternative to the formula in paragraph (i)(2)(i)(A) of
this section, relief devices for shells used for transporting liquids
may be sized in accordance with the table in paragraph (i)(2)(iii) of
this section. The table in paragraph (i)(2)(iii) of this section assumes
an insulation value of F = 1 and must be adjusted accordingly when the
shell is insulated. Other values used in determining the table in
paragraph (i)(2)(iii) of this section are: L = 334.94 kJ/kg; M = 86.7; T
= 394 [deg]K; Z = 1; and C = 0.607.
(iii) Minimum emergency vent capacity, Q, in cubic meters of air per
second at 1 bar and 0 [deg]C (273 [deg]K) shown in the following table:
Minimum Emergency Vent Capacity
[Q Values]
------------------------------------------------------------------------
Q (Cubic meters Q (Cubic meters
A Exposed area of air per A Exposed area of air per
(square meters) second) (square meters) second)
------------------------------------------------------------------------
2 0.230 37.5 2.539
3 0.320 40 2.677
4 0.405 42.5 2.814
5 0.487 45 2.949
6 0.565 47.5 3.082
7 0.641 50 3.215
8 0.715 52.5 3.346
9 0.788 55 3.476
10 0.859 57.5 3.605
12 0.998 60 3.733
14 1.132 62.5 3.860
16 1.263 65 3.987
18 1.391 67.5 4.112
20 1.517 70 4.236
22.5 1.670 75 4.483
25 1.821 80 4.726
27.5 1.969 85 4.967
30 2.115 90 5.206
32.5 2.258 95 5.442
35 2.400 100 5.676
------------------------------------------------------------------------
(iv) Insulation systems, used for the purpose of reducing venting
capacity, must be specifically approved by the approval agency. In all
cases, insulation systems approved for this purpose must--
(A) Remain effective at all temperatures up to 649 [deg]C (1200
[deg]F); and
(B) Be jacketed with a material having a melting point of 700 [deg]C
(1292 [deg]F) or greater.
(j) Approval, inspection and testing. Approval procedures for UN
portable tanks are specified in Sec. 178.273. Inspection and testing
requirements are specified in Sec. 180.605 of this subchapter.
[66 FR 33445, June 21, 2001, as amended at 68 FR 32414, May 30, 2003; 69
FR 76185, Dec. 20, 2004; 73 FR 57006, Oct. 1, 2008; 76 FR 3388, Jan. 19,
2011]
Sec. 178.276 Requirements for the design, construction, inspection and
testing of portable tanks intended for the transportation of non-refrigerated
liquefied compressed gases.
(a) In addition to the requirements of Sec. 178.274 applicable to
UN portable tanks, the following requirements apply to UN portable tanks
used for non-refrigerated liquefied compressed gases. In addition to the
definitions in Sec. 178.274, the following definitions apply:
(1) Design pressure means the pressure to be used in calculations
required by the ASME Code, Section VIII (IBR, see Sec. 171.7 of this
subchapter). The design pressure must be not less than the highest of
the following pressures:
(i) The maximum effective gauge pressure allowed in the shell during
filling or discharge; or
(ii) The sum of:
(A) The maximum effective gauge pressure to which the shell is
designed as defined in this paragraph under ``MAWP''; and
(B) A head pressure determined on the basis of the dynamic forces
specified in paragraph (h) of this section, but not less than 0.35 bar
(35 kPa).
(2) Design reference temperature means the temperature at which the
vapor pressure of the contents is determined for the purpose of
calculating the MAWP. The value for each portable tank type is as
follows:
(i) Shell with a diameter of 1.5 meters (4.9 ft.) or less: 65 [deg]C
(149 [deg]F); or
[[Page 122]]
(ii) Shell with a diameter of more than 1.5 meters (4.9 ft.):
(A) Without insulation or sun shield: 60 [deg]C (140 [deg]F);
(B) With sun shield: 55 [deg]C (131 [deg]F); and
(C) With insulation: 50 [deg]C (122 [deg]F).
(3) Filling density means the average mass of liquefied compressed
gas per liter of shell capacity (kg/l).
(4) Maximum allowable working pressure (MAWP) means a pressure that
must be not less than the highest of the following pressures measured at
the top of the shell while in operating position, but in no case less
than 7 bar (700 kPa):
(i) The maximum effective gauge pressure allowed in the shell during
filling or discharge; or
(ii) The maximum effective gauge pressure to which the shell is
designed, which must be:
(A) Not less than the pressure specified for each liquefied
compressed gas listed in the UN Portable Tank Table for Liquefied
Compressed Gases in Sec. 173.313; and
(B) Not less than the sum of:
(1) The absolute vapor pressure (in bar) of the liquefied compressed
gas at the design reference temperature minus 1 bar; and
(2) The partial pressure (in bar) of air or other gases in the
ullage space which is determined by the design reference temperature and
the liquid phase expansion due to the increase of the mean bulk
temperature of tr-tf (tf = filling
temperature, usually 15 [deg]C, tr = 50 [deg]C maximum mean
bulk temperature).
(b) General design and construction requirements. (1) Shells must be
of seamless or welded steel construction, or combination of both, and
have a water capacity greater than 450 liters (118.9 gallons). Shells
must be designed, constructed, certified and stamped in accordance with
the ASME Code, Section VIII.
(2) Portable tanks must be postweld heat-treated and radiographed as
prescribed in Section VIII of the ASME Code, except that each portable
tank constructed in accordance with part UHT of the ASME Code must be
postweld heat-treated. Where postweld heat treatment is required, the
portable tank must be treated as a unit after completion of all the
welds in and/or to the shell and heads. The method must be as prescribed
in the ASME Code. Welded attachments to pads may be made after postweld
heat treatment is made. A portable tank used for anhydrous ammonia must
be postweld heat-treated. The postweld heat treatment must be as
prescribed in the ASME Code, but in no event at less than 1050 [deg]F
tank metal temperature. Additionally, portable tanks constructed in
accordance with part UHT of the ASME Code must conform to the following
requirements:
(i) Welding procedure and welder performance tests must be made
annually in accordance with Section IX of the ASME Code. In addition to
the essential variables named therein, the following must be considered
to be essential variables: number of passes, thickness of plate, heat
input per pass, and manufacturer's identification of rod and flux. The
number of passes, thickness of plate and heat input per pass may not
vary more than 25 percent from the qualified procedure. Records of the
qualification must be retained for at least 5 years by the portable tank
manufacturer or his designated agent and, upon request, made available
to a representative of the Department of Transportation or the owner of
the tank.
(ii) Impact tests must be made on a lot basis. A lot is defined as
100 tons or less of the same heat and having a thickness variation no
greater than plus or minus 25 percent. The minimum impact required for
full-sized specimens shall be 20 foot-pounds (or 10 foot-pounds for
half-sized specimens) at 0 [deg]F (-17.8 [deg]F) Charpy V-Notch in both
the longitudinal and transverse direction. If the lot test does not pass
this requirement, individual plates may be accepted if they individually
meet this impact requirement.
(3) When the shells intended for the transportation of non-
refrigerated liquefied compressed gases are equipped with thermal
insulation, a device must be provided to prevent any dangerous pressure
from developing in the insulating layer in the event of a leak, when the
protective covering is closed it must be gas tight. The thermal
insulation must not inhibit access to the
[[Page 123]]
fittings and discharge devices. In addition, the thermal insulation
systems must satisfy the following requirements:
(i) consist of a shield covering not less than the upper third, but
not more than the upper half of the surface of the shell, and separated
from the shell by an air space of approximately 40 mm (1.7 inches)
across; or
(ii) consist of a complete cladding of insulating materials. The
insulation must be of adequate thickness and constructed to prevent the
ingress of moisture and damage to the insulation. The insulation and
cladding must have a thermal conductance of not more than 0.67
(W[middot]m-2[middot]K-1) under normal conditions
of transportation.
(c) Service equipment. (1) Each opening with a diameter of more than
1.5 mm (0.1 inch) in the shell of a portable tank, except openings for
pressure-relief devices, inspection openings and closed bleed holes,
must be fitted with at least three mutually independent shut-off devices
in series: the first being an internal stop-valve, excess flow valve,
integral excess flow valve, or excess flow feature (see Sec. 178.337-
1(g)), the second being an external stop-valve and the third being a
blank flange, thread cap, plug or equivalent tight liquid closure
device.
(2) When a portable tank is fitted with an excess flow valve, the
excess flow valve must be so fitted that its seating is inside the shell
or inside a welded flange or, when fitted externally, its mountings must
be designed so that in the event of impact it maintains its
effectiveness. The excess flow valves must be selected and fitted so as
to close automatically when the rated flow, specified by the
manufacturer, is reached. Connections and accessories leading to or from
such a valve must have a capacity for a flow more than the excess flow
valve's rated flow.
(3) For filling and discharge openings that are located below the
liquid level, the first shut-off device must be an internal stop-valve
and the second must be a stop-valve placed in an accessible position on
each discharge and filling pipe.
(4) For filling and discharge openings located below the liquid
level of portable tanks intended for the transportation of flammable
and/or toxic liquefied compressed gases, the internal stop-valve must be
a self-closing safety device that fully closes automatically during
filling or discharge in the event of fire engulfment. The device shall
fully close within 30 seconds of actuation and the thermal means of
closure must actuate at a temperature of not more than 121 [deg]C (250
[deg]F). Except for portable tanks having a capacity less than 1,000
liters (264.2 gallons), this device must be operable by remote control.
(5) In addition to filling, discharge and gas pressure equalizing
orifices, shells may have openings in which gauges, thermometers and
manometers can be fitted. Connections for such instruments must be made
by suitable welded nozzles or pockets and may not be connected by
screwed connections through the shell.
(6) All portable tanks must be fitted with manholes or other
inspection openings of suitable size to allow for internal inspection
and adequate access for maintenance and repair of the interior.
(7) Inlets and discharge outlets on chlorine portable tanks. The
inlet and discharge outlets on portable tanks used to transport chlorine
must meet the requirements of Sec. 178.337-1(c)(2) and must be fitted
with an internal excess flow valve. In addition to the internal excess
flow valve, the inlet and discharge outlets must be equipped with an
external stop valve (angle valve). Excess flow valves must conform to
the standards of The Chlorine Institute, Inc. (IBR, see Sec. 171.7 of
this subchapter) as follows:
(i) A valve conforming to Drawing 101-7, dated July 1993, must be
installed under each liquid angle valve.
(ii) A valve conforming to Drawing 106-6, dated July 1993, must be
installed under each gas angle valve. For portable tanks used to
transport non-refrigerated liquefied gases.
(8) External fittings must be grouped together as close as
reasonably practicable. The following openings may be installed at
locations other than on the top or end of the tank:
(i) The openings for liquid level gauging devices, pressure gauges,
or for
[[Page 124]]
safety devices, may be installed separately at the other location or in
the side of the shell;
(ii) One plugged opening of 2-inch National Pipe Thread or less
provided for maintenance purposes may be located elsewhere;
(iii) An opening of 3-inch National Pipe Size or less may be
provided at another location, when necessary, to facilitate installation
of condensing coils.
(9) Filling and discharge connections are not required to be grouped
and may be installed below the normal liquid level of the tank if:
(i) The portable tank is permanently mounted in a full framework for
containerized transport;
(ii) For each portable tank design, a prototype portable tank, meets
the requirements of parts 450 through 453 of this title for compliance
with the requirements of Annex II of the International Convention for
Safe Containers; and
(iii) Each filling and discharge outlet meets the requirements of
paragraph (c)(4) of this section.
(d) Bottom openings. Bottom openings are prohibited on portable
tanks when the UN Portable Tank Table for Liquefied Compressed Gases in
Sec. 173.313 of this subchapter indicates that bottom openings are not
allowed. In this case, there may be no openings located below the liquid
level of the shell when it is filled to its maximum permissible filling
limit.
(e) Pressure relief devices. (1) Portable tanks must be provided
with one or more reclosing pressure relief devices. The pressure relief
devices must open automatically at a pressure not less than the MAWP and
be fully open at a pressure equal to 110% of the MAWP. These devices
must, after discharge, close at a pressure not less than 10% below the
pressure at which discharge starts and must remain closed at all lower
pressures. The pressure relief devices must be of a type that will
resist dynamic forces including liquid surge. A frangible disc may only
be used in series with a reclosing pressure relief device.
(2) Pressure relief devices must be designed to prevent the entry of
foreign matter, the leakage of gas and the development of any dangerous
excess pressure.
(3) A portable tank intended for the transportation of certain
liquefied compressed gases identified in the UN Portable Tank Table for
Liquefied Compressed Gases in Sec. 173.313 of this subchapter must have
a pressure relief device which conforms to the requirements of this
subchapter. Unless a portable tank, in dedicated service, is fitted with
a relief device constructed of materials compatible with the hazardous
material, the relief device must be comprised of a frangible disc
preceded by a reclosing device. The space between the frangible disc and
the device must be provided with a pressure gauge or a suitable tell-
tale indicator. This arrangement must facilitate the detection of disc
rupture, pinholing or leakage which could cause a malfunction of the
pressure relief device. The frangible disc must rupture at a nominal
pressure 10% above the start-to-discharge pressure of the relief device.
(4) In the case of portable tanks used for more than one gas, the
pressure relief devices must open at a pressure indicated in paragraph
(e)(1) of this section for the gas having the highest maximum allowable
pressure of the gases allowed to be transported in the portable tank.
(f) Capacity of relief devices. The combined delivery capacity of
the relief devices must be sufficient so that, in the event of total
fire engulfment, the pressure inside the shell cannot exceed 120% of the
MAWP. Reclosing relief devices must be used to achieve the full relief
capacity prescribed. In the case of portable tanks used for more than
gas, the combined delivery capacity of the pressure relief devices must
be taken for the liquefied compressed gas which requires the highest
delivery capacity of the liquefied compressed gases allowed to be
transported in the portable tank. The total required capacity of the
relief devices must be determined according to the requirements in Sec.
178.275(i). These requirements apply only to liquefied compressed gases
which have critical temperatures well above the temperature at the
accumulating condition. For gases that have critical temperatures near
or below the temperature at the
[[Page 125]]
accumulating condition, the calculation of the pressure relief device
delivery capacity must consider the additional thermodynamic properties
of the gas, for example see CGA S-1.2 (IBR, see Sec. 171.7 of this
subchapter).
[66 FR 33448, June 21, 2001, as amended at 68 FR 75748, 75752, Dec. 31,
2003; 69 FR 54046, Sept. 7, 2004; 69 FR 76185, Dec. 20, 2004]
Sec. 178.277 Requirements for the design, construction, inspection and
testing of portable tanks intended for the transportation of refrigerated
liquefied gases.
(a) In addition to the requirements of Sec. 178.274 applicable to
UN portable tanks, the following requirements and definitions apply to
UN portable tanks used for refrigerated liquefied gases:
Design pressure For the purpose of this section the term ``design
pressure'' is consistent with the definition for design pressure in the
ASME Code, Section VIII (IBR, see Sec. 171.7 of this subchapter).
Holding time is the time, as determined by testing, that will elapse
from loading until the pressure of the contents, under equilibrium
conditions, reaches the lowest set pressure of the pressure limiting
device(s) (for example, pressure control valve or pressure relief
device). Holding time must be determined as specified in Sec. 178.338-
9.
Maximum allowable working pressure (MAWP) means the maximum
effective gauge pressure permissible at the top of the shell of a loaded
portable tank in its operating position including the highest effective
pressure during filling and discharge;
Minimum design temperature means the temperature which is used for
the design and construction of the shell not higher than the lowest
(coldest) service temperature of the contents during normal conditions
of filling, discharge and transportation.
Shell means the part of the portable tank which retains the
refrigerated liquefied gas intended for transport, including openings
and their closures, but does not include service equipment or external
structural equipment.
Tank means a construction which normally consists of either:
(1) A jacket and one or more inner shells where the space between
the shell(s) and the jacket is exhausted of air (vacuum insulation) and
may incorporate a thermal insulation system; or
(2) A jacket and an inner shell with an intermediate layer of solid
thermally insulating material (for example, solid foam).
(b) General design and construction requirements. (1) Portable tanks
must be of seamless or welded steel construction and have a water
capacity of more than 450 liters (118.9 gallons). Portable tanks must be
designed, constructed, certified and stamped in accordance with Section
VIII of the ASME Code.
(2) Portable tanks must be postweld heat treated and radiographed as
prescribed in Sections V and VIII of the ASME Code except that each tank
constructed in accordance with part UHT in Section VIII of the ASME Code
must be postweld heat treated. Where postweld heat treatment is
required, the tank must be treated as a unit after completion of all the
welds to the shell and heads. The method must be as prescribed in the
ASME Code. Welded attachments to pads may be made after postweld heat
treatment is made. The postweld heat treatment must be as prescribed in
Section VIII of the ASME Code, but in no event at less than 1,050 [deg]F
tank metal temperature.
(3) Welding procedure and welder performance tests must be made
annually in accordance with Section IX of the ASME Code (IBR, see Sec.
171.7 of this subchapter). In addition to the essential variables named
in the ASME Code, the following must be considered as essential
variables: number of passes, thickness of plate, heat input per pass,
and the specified rod and flux. The number of passes, thickness of plate
and heat input per pass may not vary more than 25% from the procedure
qualification. Records of the qualification must be retained for at
least 5 years by the portable tank manufacturer and made available to
the approval agency and the owner of the portable tank as specified in
Sec. 178.273.
(4) Shells and jackets must be made of metallic materials suitable
for forming. Jackets must be made of steel. Non-metallic materials may
be used for the attachments and supports between the shell and jacket,
provided
[[Page 126]]
their material properties at the minimum design temperature are proven
to be sufficient. In choosing the material, the minimum design
temperature must be taken into account with respect to risk of brittle
fracture, to hydrogen embrittlement, to stress corrosion cracking and to
resistance to impact.
(5) Any part of a portable tank, including fittings, gaskets and
pipe-work, which can be expected normally to come into contact with the
refrigerated liquefied gas transported must be compatible with that
refrigerated liquefied gas.
(6) The thermal insulation system must include a complete covering
of the shell with effective insulating materials. External insulation
must be protected by a jacket so as to prevent the ingress of moisture
and other damage under normal transport conditions.
(7) When a jacket is so closed as to be gas-tight, a device must be
provided to prevent any dangerous pressure from developing in the
insulation space.
(8) Materials which may react with oxygen or oxygen enriched
atmospheres in a dangerous manner may not be used in portable tanks
intended for the transport of refrigerated liquefied gases having a
boiling point below minus 182 [deg]C at atmospheric pressure in
locations with the thermal insulation where there is a risk of contact
with oxygen or with oxygen enriched fluid.
(9) Insulating materials must not deteriorate to an extent that the
effectiveness of the insulation system, as determined in accordance with
paragraph (b)(11) of this section, would be reduced in service.
(10) A reference holding time must be determined for each
refrigerated liquefied gas intended for transport in a portable tank.
The reference holding time must be determined by testing in accordance
with the requirements of Sec. 178.338-9, considering the following
factors:
(i) The effectiveness of the insulation system, determined in
accordance with paragraph (b)(11) of this section;
(ii) The lowest set pressure of the pressure limiting device;
(iii) The initial filling conditions;
(iv) An assumed ambient temperature of 30 [deg]C (86 [deg]F);
(v) The physical properties of the individual refrigerated liquefied
gas intended to be transported.
(11) The effectiveness of the insulation system (heat influx in
watts) may be determined by type testing the portable tank in accordance
with a procedure specified in Sec. 178.338-9(c) or by using the holding
time test in Sec. 178.338-9(b). This test must consist of either:
(i) A constant pressure test (for example, at atmospheric pressure)
when the loss of refrigerated liquefied gas is measured over a period of
time; or
(ii) A closed system test when the rise in pressure in the shell is
measured over a period of time.
(12) When performing the constant pressure test, variations in
atmospheric pressure must be taken into account. When performing either
test, corrections must be made for any variation of the ambient
temperature from the assumed ambient temperature reference value of 30
[deg]C (86 [deg]F).
(13) The jacket of a vacuum-insulated double-wall tank must have
either an external design pressure not less than 100 kPa (1 bar) gauge
pressure calculated in accordance with Section VIII of the ASME Code or
a calculated critical collapsing pressure of not less than 200 kPa (2
bar) gauge pressure. Internal and external reinforcements may be
included in calculating the ability of the jacket to resist the external
pressure.
Note to paragraph (b): For the determination of the actual holding
time, as indicated by paragraphs (b)(10), (11), (12), and (13), before
each journey, refer to Sec. 178.338-9(b).
(c) Design criteria. For shells with vacuum insulation, the test
pressure must not be less than 1.3 times the sum of the MAWP and 100 kPa
(1 bar). In no case may the test pressure be less than 300 kPa (3 bar)
gauge pressure.
(d) Service equipment. (1) Each filling and discharge opening in
portable tanks used for the transport of flammable refrigerated
liquefied gases must be fitted with at least three mutually independent
shut-off devices in series: the first being a stop-valve situated as
close as reasonably practicable to the jacket, the second being a stop-
valve
[[Page 127]]
and the third being a blank flange or equivalent device. The shut-off
device closest to the jacket must be a self-closing device, which is
capable of being closed from an accessible position on the portable tank
that is remote from the valve within 30 seconds of actuation. This
device must actuate at a temperature of not more than 121 [deg]C (250
[deg]F).
(2) Each filling and discharge opening in portable tanks used for
the transport of non-flammable refrigerated liquefied gases must be
fitted with at least two mutually independent shut-off devices in
series: the first being a stop-valve situated as close as reasonably
practicable to the jacket and the second a blank flange or equivalent
device.
(3) For sections of piping which can be closed at both ends and
where liquid product can be trapped, a method of automatic pressure
relief must be provided to prevent excess pressure build-up within the
piping.
(4) Each filling and discharge opening on a portable tank must be
clearly marked to indicate its function.
(5) When pressure-building units are used, the liquid and vapor
connections to that unit must be provided with a valve as close to the
jacket as reasonably practicable to prevent the loss of contents in case
of damage to the pressure-building unit. A check valve may be used for
this purpose if it is located on the vapor side of the pressure build-up
coil.
(6) The materials of construction of valves and accessories must
have satisfactory properties at the lowest operating temperature of the
portable tank.
(7) Vacuum insulated portable tanks are not required to have an
inspection opening.
(e) Pressure relief devices. (1) Every shell must be provided with
not less than two independent reclosing pressure relief devices. The
pressure relief devices must open automatically at a pressure not less
than the MAWP and be fully open at a pressure equal to 110% of the MAWP.
These devices must, after discharge, close at a pressure not lower than
10% below the pressure at which discharge starts and must remain closed
at all lower pressures. The pressure relief devices must be of the type
that will resist dynamic forces including surge.
(2) Except for portable tanks used for oxygen, portable tanks for
non-flammable refrigerated liquefied gases (except oxygen) and hydrogen
may in addition have frangible discs in parallel with the reclosing
devices as specified in paragraphs (e)(4)(ii) and (e)(4)(iii) of this
section.
(3) Pressure relief devices must be designed to prevent the entry of
foreign matter, the leakage of gas and the development of any dangerous
excess pressure.
(4) Capacity and setting of pressure relief devices. (i) In the case
of the loss of vacuum in a vacuum-insulated tank or of loss of 20% of
the insulation of a portable tank insulated with solid materials, the
combined capacity of all pressure relief devices installed must be
sufficient so that the pressure (including accumulation) inside the
shell does not exceed 120% of the MAWP.
(ii) For non-flammable refrigerated liquefied gases (except oxygen)
and hydrogen, this capacity may be achieved by the use of frangible
discs in parallel with the required safety-relief devices. Frangible
discs must rupture at nominal pressure equal to the test pressure of the
shell.
(iii) Under the circumstances described in paragraphs (e)(4)(i) and
(e)(4)(ii) of this section, together with complete fire engulfment, the
combined capacity of all pressure relief devices installed must be
sufficient to limit the pressure in the shell to the test pressure.
(iv) The required capacity of the relief devices must be calculated
in accordance with CGA Pamphlet S-1.2 (IBR, see Sec. 171.7 of this
subchapter).
[66 FR 33450, June 21, 2001, as amended at 68 FR 75748, 75752, Dec. 31,
2003]
Subpart I [Reserved]
Subpart J_Specifications for Containers for Motor Vehicle Transportation
Source: 29 FR 18975, Dec. 29, 1964, unless otherwise noted.
Redesignated at 32 FR 5606, Apr. 5, 1967.
[[Page 128]]
Sec. 178.318 Specification MC 201; container for detonators and percussion
caps.
Sec. 178.318-1 Scope.
(a) This specification pertains to a container to be used for the
transportation of detonators and percussion caps in connection with the
transportation of liquid nitroglycerin, desensitized liquid
nitroglycerin or diethylene glycol dinitrate, where any or all of such
types of caps may be used for the detonation of liquid nitroglycerin,
desentitized liquid nitroglycerin or diethylene glycol dinitrate in
blasting operations. This specification is not intended to take the
place of any shipping or packing requirements of this Department where
the caps in question are themselves articles of commerce.
(b) [Reserved]
[29 FR 18975, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967,
and amended by Amdt. 178-60, 44 FR 70733, Dec. 10, 1979]
Sec. 178.318-2 Container.
(a) Every container for detonators and percussion caps coming within
the scope of this specification shall be constructed entirely of hard
rubber, phenolresinous or other resinous material, or other nonmetallic,
nonsparking material, except that metal parts may be used in such
locations as not in any event to come in contact with any of the caps.
Space shall be provided so that each detonator of whatever nature may be
inserted in an individual cell in the body of the container, into which
each such cap shall snugly fit. There shall be provided no more than
twenty (20) such cellular spaces. Space may be provided into which a
plurality of percussion caps may be carried, provided that such space
may be closed with a screw cap, and further provided that each or any
such space is entirely separate from any space provided for any
detonator. Each cellular space into which a detonator is to be inserted
and carried shall be capable of being covered by a rotary cover so
arranged as to expose not more than one cell at any time, and capable of
rotation to such a place that all cells will be covered at the same
time, at which place means shall be provided to lock the cover in place.
Means shall be provided to lock in place the cover for the cells
provided for the carrying of detonators. The requirement that not more
than one cell be exposed at one time need not apply in the case of
detonators, although spaces for such caps and detonators shall be
separate. Sufficient annular space shall be provided inside the cover
for such detonators that, when the cover is closed, there will be
sufficient space to accommodate the wires customarily attached to such
caps. If the material is of such a nature as to require treatment to
prevent the absorption of moisture, such treatment shall be applied as
shall be necessary in order to provide against the penetration of water
by permeation. A suitable carrying handle shall be provided, except for
which handle no part of the container may project beyond the exterior of
the body.
(b) Exhibited in plates I and II are line drawings of a container
for detonators and percussion caps, illustrative of the requirements set
forth in Sec. 178.318-2(a). These plates shall not be construed as a
part of this specification.
[[Page 129]]
[GRAPHIC] [TIFF OMITTED] TC02MR91.076
Sec. 178.318-3 Marking.
Each container must be marked as prescribed in Sec. 178.2(b).
[Amdt. 178-40, 41 FR 38181, Sept. 9, 1976, as amended at 66 FR 45185,
Aug. 28, 2001]
Sec. 178.320 General requirements applicable to all DOT specification cargo
tank motor vehicles.
(a) Definitions. For the purpose of this subchapter:
Appurtenance means any attachment to a cargo tank that has no lading
retention or containment function and provides no structural support to
the cargo tank.
Baffle means a non-liquid-tight transverse partition device that
deflects, checks or regulates fluid motion in a tank.
Bulkhead means a liquid-tight transverse closure at the ends of or
between cargo tanks.
Cargo tank means a bulk packaging that:
(1) Is a tank intended primarily for the carriage of liquids, gases,
solids, or
[[Page 130]]
semi-solids and includes appurtenances, reinforcements, fittings, and
closures (for tank, see Sec. Sec. 178.337-1, 178.338-1, or 178.345-1,
as applicable);
(2) Is permanently attached to or forms a part of a motor vehicle,
or is not permanently attached to a motor vehicle but that, by reason of
its size, construction, or attachment to a motor vehicle, is loaded or
unloaded without being removed from the motor vehicle; and
(3) Is not fabricated under a specification for cylinders,
intermediate bulk containers, multi-unit tank car tanks, portable tanks,
or tank cars.
Cargo tank motor vehicle means a motor vehicle with one or more
cargo tanks permanently attached to or forming an integral part of the
motor vehicle.
Cargo tank wall means those parts of the cargo tank that make up the
primary lading retention structure, including shell, bulkheads, and
fittings and, when closed, yield the minimum volume of a completed cargo
tank motor vehicle.
Charging line means a hose, tube, pipe, or a similar device used to
pressurize a tank with material other than the lading.
Companion flange means one of two mating flanges where the flange
faces are in contact or separated only by a thin leak-sealing gasket and
are secured to one another by bolts or clamps.
Connecting structure means the structure joining two cargo tanks.
Constructed and certified in accordance with the ASME Code means a
cargo tank is constructed and stamped in accordance with Section VIII of
the ASME Code (IBR, see Sec. 171.7 of this subchapter), and is
inspected and certified by an Authorized Inspector.
Constructed in accordance with the ASME Code means a cargo tank is
constructed in accordance with Section VIII of the ASME Code with
authorized exceptions (see Sec. Sec. 178.346 through 178.348) and is
inspected and certified by a Registered Inspector.
Design type means one or more cargo tanks that are made--
(1) To the same specification;
(2) By the same manufacturer;
(3) To the same engineering drawings and calculations, except for
minor variations in piping that do not affect the lading retention
capability of the cargo tank;
(4) Of the same materials of construction;
(5) To the same cross-sectional dimensions;
(6) To a length varying by no more than 5 percent;
(7) With the volume varying by no more than 5 percent (due to a
change in length only); and
(8) For the purposes of Sec. 178.338 only, with the same insulation
system.
External self-closing stop valve means a self-closing stop valve
designed so that the self-stored energy source is located outside the
cargo tank and the welded flange.
Extreme dynamic loading means the maximum loading a cargo tank motor
vehicle may experience during its expected life, excluding accident
loadings resulting from an accident, such as overturn or collision.
Flange means the structural ring for guiding or attachment of a pipe
or fitting with another flange (companion flange), pipe, fitting or
other attachment.
Inspection pressure means the pressure used to determine leak
tightness of the cargo tank when testing with pneumatic pressure.
Internal self-closing stop valve means a self-closing stop valve
designed so that the self-stored energy source is located inside the
cargo tank or cargo tank sump, or within the welded flange, and the
valve seat is located within the cargo tank or within one inch of the
external face of the welded flange or sump of the cargo tank.
Lading means the hazardous material contained in a cargo tank.
Loading/unloading connection means the fitting in the loading/
unloading line farthest from the loading/unloading outlet to which the
loading/unloading hose, pipe, or device is attached.
Loading/unloading outlet means a cargo tank outlet used for normal
loading/unloading operations.
Loading/unloading stop valve means the stop valve farthest from the
cargo tank loading/unloading outlet to which
[[Page 131]]
the loading/unloading connection is attached.
Manufacturer means any person engaged in the manufacture of a DOT
specification cargo tank, cargo tank motor vehicle, or cargo tank
equipment that forms part of the cargo tank wall. This term includes
attaching a cargo tank to a motor vehicle or to a motor vehicle
suspension component that involves welding on the cargo tank wall. A
manufacturer must register with the Department in accordance with
subpart F of part 107 in subpart A of this chapter.
Maximum allowable working pressure or MAWP means the maximum
pressure allowed at the top of the tank in its normal operating
position. The MAWP must be calculated as prescribed in Section VIII of
the ASME Code. In use, the MAWP must be greater than or equal to the
maximum lading pressure conditions prescribed in Sec. 173.33 of this
subchapter for each material transported.
Maximum lading pressure. See Sec. 173.33(c).
Minimum thickness means the minimum required shell and head (and
baffle and bulkhead when used as tank reinforcement) thickness needed to
meet the specification. The minimum thickness is the greatest of the
following values: (1)(i) For MC 330, MC 331, and MC 338 cargo tanks, the
specified minimum thickness found the applicable specification(s); or
(ii) For DOT 406, DOT 407 and DOT 412 cargo tanks, the specified
minimum thickness found in Tables I and II of the applicable
specification(s); or
(iii) For MC 300, MC 301, MC 302, MC 303, MC 304, MC 305, MC 306, MC
307, MC 310, MC 311, and MC 312 cargo tanks, the in-service minimum
thickness prescribed in Tables I and II of Sec. 180.407(i)(5) of this
subchapter, for the minimum thickness specified by Tables I and II of
the applicable specification(s); or
(2) The thickness necessary to meet with the structural integrity
and accident damage requirements of the applicable specification(s); or
(3) The thickness as computed per the ASME Code requirements (if
applicable).
Multi-specification cargo tank motor vehicle means a cargo tank
motor vehicle equipped with two or more cargo tanks fabricated to more
than one cargo tank specification.
Normal operating loading means the loading a cargo tank motor
vehicle may be expected to experience routinely in operation.
Nozzle means a subassembly consisting of a pipe or tubular section
with or without a welded or forged flange on one end.
Outlet means any opening in the shell or head of a cargo tank,
(including the means for attaching a closure), except that the following
are not outlets: a threaded opening securely closed during
transportation with a threaded plug or a threaded cap, a flanged opening
securely closed during transportation with a bolted or welded blank
flange, a manhole, a gauging device, a thermometer well, or a pressure
relief device.
Outlet stop valve means the stop valve at a cargo tank loading or
unloading outlet.
Pipe coupling means a fitting with internal threads on both ends.
Rear bumper means the structure designed to prevent a vehicle or
object from under-riding the rear of another motor vehicle. See Sec.
393.86 of this title.
Rear-end tank protection device means the structure designed to
protect a cargo tank and any lading retention piping or devices in case
of a rear end collision.
Self-closing stop valve means a stop valve held in the closed
position by means of self-stored energy, that opens only by application
of an external force and that closes when the external force is removed.
Shell means the circumferential portion of a cargo tank defined by
the basic design radius or radii excluding the bulkheads.
Stop valve means a valve that stops the flow of lading.
Sump means a protrusion from the bottom of a cargo tank shell
designed to facilitate complete loading and unloading of lading.
Tank means a container, consisting of a shell and heads, that forms
a pressure tight vessel having openings designed to accept pressure
tight fittings
[[Page 132]]
or closures, but excludes any appurtenances, reinforcements, fittings,
or closures.
Test pressure means the pressure to which a tank is subjected to
determine structural integrity.
Toughness of material means the capability of a material to absorb
energy represented by the area under a stress strain curve (indicating
the energy absorbed per unit volume of the material) up to the point of
rupture.
Vacuum cargo tank means a cargo tank that is loaded by reducing the
pressure in the cargo tank to below atmospheric pressure.
Variable specification cargo tank means a cargo tank that is
constructed in accordance with one specification, but that may be
altered to meet another specification by changing relief device,
closures, lading discharge devices, and other lading retention devices.
Void means the space between tank heads or bulkheads and a
connecting structure.
Welded flange means a flange attached to the tank by a weld joining
the tank shell to the cylindrical outer surface of the flange, or by a
fillet weld joining the tank shell to a flange shaped to fit the shell
contour.
(b) Design certification. (1) Each cargo tank or cargo tank motor
vehicle design type, including its required accident damage protection
device, must be certified to conform to the specification requirements
by a Design Certifying Engineer who is registered in accordance with
subpart F of part 107 of this title. An accident damage protection
device is a rear-end protection, overturn protection, or piping
protection device.
(2) The Design Certifying Engineer shall furnish to the manufacturer
a certificate to indicate compliance with the specification
requirements. The certificate must include the sketches, drawings, and
calculations used for certification. Each certificate, including
sketches, drawings, and calculations, shall be signed by the Design
Certifying Engineer.
(3) The manufacturer shall retain the design certificate at his
principal place of business for as long as he manufactures DOT
specification cargo tanks.
(c) Exceptions to the ASME Code. Unless otherwise specified, when
exceptions are provided in this subpart from compliance with certain
paragraphs of the ASME Code, compliance with those paragraphs is not
prohibited.
[Amdt. 178-89, 55 FR 37055, Sept. 7, 1990, as amended by Amdt. 178-98,
58 FR 33306, June 16, 1993; Amdt. 178-118, 61 FR 51339, Oct. 1, 1996; 68
FR 19277, Apr. 18, 2003; 68 FR 52370, Sept. 3, 2003; 68 FR 75752, Dec.
31, 2003; 76 FR 43532, July 20, 2011]
Sec. 178.337 Specification MC 331; cargo tank motor vehicle primarily for
transportation of compressed gases as defined in subpart G of part 173 of this
subchapter.
Sec. 178.337-1 General requirements.
(a) ASME Code construction. Tanks must be--
(1) Seamless or welded construction, or a combination of both;
(2) Designed, constructed, certified, and stamped in accordance with
Section VIII of the ASME Code (IBR, see Sec. 171.7 of this subchapter);
(3) Made of steel or aluminum; however, if aluminum is used, the
cargo tank must be insulated and the hazardous material to be
transported must be compatible with the aluminum (see Sec. Sec.
178.337-1(e)(2), 173.315(a) table, and 178.337-2(a)(1) of this
subchapter); and
(4) Covered with a steel jacket if the cargo tank is insulated and
used to transport a flammable gas (see Sec. 173.315(a) table Note 11 of
this subchapter).
(b) Design pressure. The design pressure of a cargo tank authorized
under this specification shall be not less than the vapor pressure of
the commodity contained therein at 115 [deg]F. or as prescribed for a
particular commodity in Sec. 173.315(a) of this subchapter, except that
in no case shall the design pressure of any cargo tank be less than 100
p.s.i.g. nor more than 500 p.s.i.g.
Note 1: The term design pressure as used in this specification, is
identical to the term MAWP as used in the ASME Code.
(c) Openings. (1) Excess pressure relief valves shall be located in
the top of the cargo tank or heads.
(2) A chlorine cargo tank shall have only one opening. That opening
shall be in the top of the cargo tank and
[[Page 133]]
shall be fitted with a nozzle that meets the following requirements:
(i) On a cargo tank manufactured on or before December 31, 1974, the
nozzle shall be protected by a dome cover plate which conforms to either
the standard of The Chlorine Institute, Inc., Dwg. 103-3, dated January
23, 1958, or to the standard specified in paragraph (c) (2) (ii) of this
section.
(ii) On a cargo tank manufactured on or after January 1, 1975, the
nozzle shall be protected by a manway cover which conforms to the
standard of The Chlorine Institute, Inc., Dwg. 103-4, dated September 1,
1971.
(d) Reflective design. Every uninsulated cargo tank permanently
attached to a cargo tank motor vehicle shall, unless covered with a
jacket made of aluminum, stainless steel, or other bright nontarnishing
metal, be painted a white, aluminum or similar reflecting color on the
upper two-thirds of area of the cargo tank.
(e) Insulation. (1) Each cargo tank required to be insulated must
conform with the use and performance requirements contained in
Sec. Sec. 173.315(a) table and 178.337-1 (a)(3) and (e)(2) of this
subchapter.
(2) Each cargo tank intended for chlorine; carbon dioxide,
refrigerated liquid; or nitrous oxide, refrigerated liquid service must
have suitable insulation of such thickness that the overall thermal
conductance is not more than 0.08 Btu per square foot per [deg]F
differential per hour. The conductance must be determined at 60 [deg]F.
Insulation material used on cargo tanks for nitrous oxide, refrigerated
liquid must be noncombustible. Insulating material used on cargo tanks
for chlorine must be corkboard or polyurethane foam, with a minimum
thickness of 4 inches, or 2 inches minimum thickness of ceramic fiber/
fiberglass of 4 pounds per cubic foot minimum density covered by 2
inches minimum thickness of fiber.
(f) Postweld heat treatment. Postweld heat treatment must be as
prescribed in the ASME Code except that each cargo tank constructed in
accordance with Part UHT of Section VIII of the ASME Code must be
postweld heat treated. Each chlorine cargo tank must be fully
radiographed and postweld heat treated in accordance with the provisions
in Section VIII of the ASME Code under which it is constructed. Where
postweld heat treatment is required, the cargo tank must be treated as a
unit after completion of all the welds in and/or to the shells and
heads. The method must be as prescribed in Section VIII of the ASME
Code. Welded attachments to pads may be made after postweld heat
treatment. A cargo tank used for anhydrous ammonia must be postweld heat
treated. The postweld heat treatment must be as prescribed in Section
VIII of the ASME Code, but in no event at less than 1,050 Sec. F cargo
tank metal temperature.
(g) Definitions. The following definitions apply to Sec. Sec.
178.337-1 through 178.337-18:
Emergency discharge control means the ability to stop a cargo tank
unloading operation in the event of an unintentional release. Emergency
discharge control can utilize passive or off-truck remote means to stop
the unloading operation. A passive means of emergency discharge control
automatically shuts off the flow of product without the need for human
intervention within 20 seconds of an unintentional release caused by a
complete separation of the liquid delivery hose. An off-truck remote
means of emergency discharge control permits a qualified person
attending the unloading operation to close the cargo tank's internal
self-closing stop valve and shut off all motive and auxiliary power
equipment at a distance from the cargo tank motor vehicle.
Excess flow valve, integral excess flow valve, or excess flow
feature means a component that will close automatically if the flow rate
of a gas or liquid through the component reaches or exceeds the rated
flow of gas or liquid specified by the original valve manufacturer when
piping mounted directly on the valve is sheared off before the first
valve, pump, or fitting downstream from the valve.
Internal self-closing stop valve means a primary shut off valve
installed in a product discharge outlet of a cargo tank and designed to
be kept closed by self-stored energy.
Primary discharge control system means a primary shut-off installed
at a product discharge outlet of a cargo
[[Page 134]]
tank consisting of an internal self-closing stop valve that may include
an integral excess flow valve or an excess flow feature, together with
linkages that must be installed between the valve and remote actuator to
provide manual and thermal on-truck remote means of closure.
[Order 59-B, 30 FR 579, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Editorial Note: For Federal Register citations affecting Sec.
178.337-1, see the List of CFR Sections Affected which appears in the
Finding Aids section of the printed volume and at www.fdsys.gov.
Sec. 178.337-2 Material.
(a) General. (1) All material used for construction of the cargo
tank and appurtenances must be suitable for use with the commodities to
be transported therein and must conform to the requirements in Section
II of the ASME Code (IBR, see Sec. 171.7 of this subchapter) and/or
requirements of the American Society for Testing and Materials in all
respects.
(2) Impact tests are required on steel used in the fabrication of
each cargo tank constructed in accordance with part UHT in Section VIII
of the ASME Code. The tests must be made on a lot basis. A lot is
defined as 100 tons or less of the same heat treatment processing lot
having a thickness variation no greater than plus or minus 25 percent.
The minimum impact required for full size specimens must be 20 foot-
pounds in the longitudinal direction at -30 [deg]F., Charpy V-Notch and
15 foot-pounds in the transverse direction at -30 [deg]F., Charpy V-
Notch. The required values for subsize specimens must be reduced in
direct proportion to the cross-sectional area of the specimen beneath
the notch. If a lot does not meet this requirement, individual plates
may be accepted if they individually meet this requirement.
(3) The fabricator shall record the heat, and slab numbers, and the
certified Charpy impact values, where required, of each plate used in
each cargo tank on a sketch showing the location of each plate in the
shell and heads of the cargo tank. Copies of each sketch shall be
provided to the owner and retained for at least five years by the
fabricator and made available to duly identified representatives of the
Department of Transportation.
(4) The direction of final rolling of the shell material shall be
the circumferential orientation of the cargo tank shell.
(b) For a chlorine cargo tank. Plates, the manway nozzle, and
anchorage shall be made of carbon steel which meets the following
requirements:
(1) For a cargo tank manufactured on or before December 31, 1974--
(i) Material shall conform to ASTM A 300, ``Steel Plates for
Pressure Vessels for Service at Low Temperatures'' (IBR, see Sec. 171.7
of this subchapter);
(ii) Material shall be Class 1, Grade A, flange or firebox quality;
(iii) Plate impact test specimens, as required under paragraph (a)
of this section, shall be of the Charpy keyhole notch type; and
(iv) Plate impact test specimens shall meet the impact test
requirements in paragraph (a) of this section in both the longitudinal
and transverse directions of rolling at a temperature of minus 45.5 C.
(-50 [deg]F.).
(2) For a cargo tank manufactured on or after January 1, 1975--
(i) Material shall conform to ASTM A 612 (IBR, see Sec. 171.7 of
this subchapter), Grade B or A 516/A 516M (IBR, see Sec. 171.7 of this
subchapter), Grade 65 or 70;
(ii) Material shall meet the Charpy V-notch test requirements of
ASTM A 20/A 20M (IBR, see Sec. 171.7 of this subchapter); and
(iii) Plate impact test specimens shall meet the impact test
requirements in paragraph (a) of this section in both the longitudinal
and transverse directions of rolling at a temperature of minus 40
[deg]C. (-40 [deg]F.).
(c) A cargo tank in anhydrous ammonia service must be constructed of
steel. The use of copper, silver, zinc or their alloys is prohibited.
Baffles made from aluminum may be used only if joined to the cargo tank
by a process not requiring postweld heat treatment of the cargo tank.
[Order 59-B, 30 FR 579, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Editorial Note: For Federal Register citations affecting Sec.
178.337-2, see the List of CFR Sections Affected which appears in the
Finding Aids section of the printed volume and at www.fdsys.gov.
[[Page 135]]
Sec. 178.337-3 Structural integrity.
(a) General requirements and acceptance criteria. (1) Except as
provided in paragraph (d) of this section, the maximum calculated design
stress at any point in the cargo tank may not exceed the maximum
allowable stress value prescribed in Section VIII of the ASME Code (IBR,
see Sec. 171.7 of this subchapter), or 25 percent of the tensile
strength of the material used.
(2) The relevant physical properties of the materials used in each
cargo tank may be established either by a certified test report from the
material manufacturer or by testing in conformance with a recognized
national standard. In either case, the ultimate tensile strength of the
material used in the design may not exceed 120 percent of the ultimate
tensile strength specified in either the ASME Code or the ASTM standard
to which the material is manufactured.
(3) The maximum design stress at any point in the cargo tank must be
calculated separately for the loading conditions described in paragraphs
(b), (c), and (d) of this section. Alternate test or analytical methods,
or a combination thereof, may be used in place of the procedures
described in paragraphs (b), (c), and (d) of this section, if the
methods are accurate and verifiable.
(4) Corrosion allowance material may not be included to satisfy any
of the design calculation requirements of this section.
(b) Static design and construction. (1) The static design and
construction of each cargo tank must be in accordance with Section VIII
of the ASME Code. The cargo tank design must include calculation of
stresses generated by design pressure, the weight of lading, the weight
of structure supported by the cargo tank wall, and the effect of
temperature gradients resulting from lading and ambient temperature
extremes. When dissimilar materials are used, their thermal coefficients
must be used in calculation of thermal stresses.
(2) Stress concentrations in tension, bending and torsion which
occur at pads, cradles, or other supports must be considered in
accordance with appendix G in Section VIII of the ASME Code.
(c) Shell design. Shell stresses resulting from static or dynamic
loadings, or combinations thereof, are not uniform throughout the cargo
tank motor vehicle. The vertical, longitudinal, and lateral normal
operating loadings can occur simultaneously and must be combined. The
vertical, longitudinal and lateral extreme dynamic loadings occur
separately and need not be combined.
(1) Normal operating loadings. The following procedure addresses
stress in the tank shell resulting from normal operating loadings. The
effective stress (the maximum principal stress at any point) must be
determined by the following formula:
S = 0.5(Sy + Sx) [0.25(Sy - Sx)\2\ +
Ss2]\0.5\
Where:
(i) S = effective stress at any given point under the combination of
static and normal operating loadings that can occur at the same time, in
psi.
(ii) Sy = circumferential stress generated by the MAWP
and external pressure, when applicable, plus static head, in psi.
(iii) Sx = The following net longitudinal stress
generated by the following static and normal operating loading
conditions, in psi:
(A) The longitudinal stresses resulting from the MAWP and external
pressure, when applicable, plus static head, in combination with the
bending stress generated by the static weight of the fully loaded cargo
tank motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall;
(B) The tensile or compressive stress resulting from normal
operating longitudinal acceleration or deceleration. In each case, the
forces applied must be 0.35 times the vertical reaction at the
suspension assembly, applied at the road surface, and as transmitted to
the cargo tank wall through the suspension assembly of a trailer during
deceleration; or the horizontal pivot of the truck tractor or converter
dolly fifth wheel, or the drawbar hinge on the fixed dolly during
acceleration; or anchoring and support members of a truck during
acceleration and deceleration, as applicable. The vertical reaction must
be calculated based on the
[[Page 136]]
static weight of the fully loaded cargo tank motor vehicle, all
structural elements, equipment and appurtenances supported by the cargo
tank wall. The following loadings must be included:
(1) The axial load generated by a decelerative force;
(2) The bending moment generated by a decelerative force;
(3) The axial load generated by an accelerative force; and
(4) The bending moment generated by an accelerative force; and
(C) The tensile or compressive stress generated by the bending
moment resulting from normal operating vertical accelerative force equal
to 0.35 times the vertical reaction at the suspension assembly of a
trailer; or the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or anchoring and support members of a truck, as applicable.
The vertical reaction must be calculated based on the static weight of
the fully loaded cargo tank motor vehicle, all structural elements,
equipment and appurtenances supported by the cargo tank wall.
(iv) Ss = The following shear stresses generated by the
following static and normal operating loading conditions, in psi:
(A) The static shear stress resulting from the vertical reaction at
the suspension assembly of a trailer, and the horizontal pivot of the
upper coupler (fifth wheel) or turntable; or anchoring and support
members of a truck, as applicable. The vertical reaction must be
calculated based on the static weight of the fully loaded cargo tank
motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall;
(B) The vertical shear stress generated by a normal operating
accelerative force equal to 0.35 times the vertical reaction at the
suspension assembly of a trailer; or the horizontal pivot of the upper
coupler (fifth wheel) or turntable; or anchoring and support members of
a truck, as applicable. The vertical reaction must be calculated based
on the static weight of the fully loaded cargo tank motor vehicle, all
structural elements, equipment and appurtenances supported by the cargo
tank wall;
(C) The lateral shear stress generated by a normal operating lateral
accelerative force equal to 0.2 times the vertical reaction at each
suspension assembly of a trailer, applied at the road surface, and as
transmitted to the cargo tank wall through the suspension assembly of a
trailer, and the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or anchoring and support members of a truck, as applicable.
The vertical reaction must be calculated based on the static weight of
the fully loaded cargo tank motor vehicle, all structural elements,
equipment and appurtenances supported by the cargo tank wall; and
(D) The torsional shear stress generated by the same lateral forces
as described in paragraph (c)(1)(iv)(C) of this section.
(2) Extreme dynamic loadings. The following procedure addresses
stress in the tank shell resulting from extreme dynamic loadings. The
effective stress (the maximum principal stress at any point) must be
determined by the following formula:
S = 0.5(Sy + Sx) [0.25(Sy - Sx)\2\ +
Ss2]\0.5\
Where:
(i) S = effective stress at any given point under a combination of
static and extreme dynamic loadings that can occur at the same time, in
psi.
(ii) Sy = circumferential stress generated by MAWP and
external pressure, when applicable, plus static head, in psi.
(iii) Sx = the following net longitudinal stress
generated by the following static and extreme dynamic loading
conditions, in psi:
(A) The longitudinal stresses resulting from the MAWP and external
pressure, when applicable, plus static head, in combination with the
bending stress generated by the static weight of the fully loaded cargo
tank motor vehicle, all structural elements, equipment and appurtenances
supported by the tank wall;
(B) The tensile or compressive stress resulting from extreme
longitudinal acceleration or deceleration. In each case the forces
applied must be 0.7 times the vertical reaction at the suspension
assembly, applied at the road surface, and as transmitted to the
[[Page 137]]
cargo tank wall through the suspension assembly of a trailer during
deceleration; or the horizontal pivot of the truck tractor or converter
dolly fifth wheel, or the drawbar hinge on the fixed dolly during
acceleration; or the anchoring and support members of a truck during
acceleration and deceleration, as applicable. The vertical reaction must
be calculated based on the static weight of the fully loaded cargo tank
motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall. The following loadings must be
included:
(1) The axial load generated by a decelerative force;
(2) The bending moment generated by a decelerative force;
(3) The axial load generated by an accelerative force; and
(4) The bending moment generated by an accelerative force; and
(C) The tensile or compressive stress generated by the bending
moment resulting from an extreme vertical accelerative force equal to
0.7 times the vertical reaction at the suspension assembly of a trailer,
and the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or the anchoring and support members of a truck, as
applicable. The vertical reaction must be calculated based on the static
weight of the fully loaded cargo tank motor vehicle, all structural
elements, equipment and appurtenances supported by the cargo tank wall.
(iv) Ss = The following shear stresses generated by
static and extreme dynamic loading conditions, in psi:
(A) The static shear stress resulting from the vertical reaction at
the suspension assembly of a trailer, and the horizontal pivot of the
upper coupler (fifth wheel) or turntable; or anchoring and support
members of a truck, as applicable. The vertical reaction must be
calculated based on the static weight of the fully loaded cargo tank
motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall;
(B) The vertical shear stress generated by an extreme vertical
accelerative force equal to 0.7 times the vertical reaction at the
suspension assembly of a trailer, and the horizontal pivot of the upper
coupler (fifth wheel) or turntable; or anchoring and support members of
a truck, as applicable. The vertical reaction must be calculated based
on the static weight of the fully loaded cargo tank motor vehicle, all
structural elements, equipment and appurtenances supported by the cargo
tank wall;
(C) The lateral shear stress generated by an extreme lateral
accelerative force equal to 0.4 times the vertical reaction at the
suspension assembly of a trailer, applied at the road surface, and as
transmitted to the cargo tank wall through the suspension assembly of a
trailer, and the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or anchoring and support members of a truck, as applicable.
The vertical reaction must be calculated based on the static weight of
the fully loaded cargo tank motor vehicle, all structural elements,
equipment and appurtenances supported by the cargo tank wall; and
(D) The torsional shear stress generated by the same lateral forces
as described in paragraph (c)(2)(iv)(C) of this section.
(d) In order to account for stresses due to impact in an accident,
the design calculations for the cargo tank shell and heads must include
the load resulting from the design pressure in combination with the
dynamic pressure resulting from a longitudinal deceleration of ``2g''.
For this loading condition the stress value used may not exceed the
lesser of the yield strength or 75 percent of the ultimate tensile
strength of the material of construction. For cargo tanks constructed of
stainless steel the maximum design stress may not exceed 75 percent of
the ultimate tensile strength of the type steel used.
(e) The minimum metal thickness for the shell and heads on tanks
with a design pressure of 100 psig or more must be 4.75 mm (0.187 inch)
for steel and 6.86 mm (0.270 inch) for aluminum, except for chlorine and
sulfur dioxide tanks. In all cases, the minimum thickness of the tank
shell and head shall be determined using structural design requirements
in Section VIII of the ASME Code or 25% of the tensile strength of the
material used. For a cargo tank
[[Page 138]]
used in chlorine or sulfur dioxide service, the cargo tank must be made
of steel. A corrosion allowance of 20 percent or 2.54 mm (0.10 inch),
whichever is less, must be added to the thickness otherwise required for
sulfur dioxide and chlorine tank material. In chlorine cargo tanks, the
wall thickness must be at least 1.59 cm (0.625 inch), including
corrosion allowance.
(f) Where a cargo tank support is attached to any part of the cargo
tank wall, the stresses imposed on the cargo tank wall must meet the
requirements in paragraph (a) of this section.
(g) The design, construction, and installation of an attachment,
appurtenance to the cargo tank, structural support member between the
cargo tank and the vehicle or suspension component, or accident
protection device must conform to the following requirements:
(1) Structural members, the suspension sub-frame, accident
protection structures, and external circumferential reinforcement
devices must be used as sites for attachment of appurtenances and other
accessories to the cargo tank, when practicable.
(2) A lightweight attachment to the cargo tank wall such as a
conduit clip, brake line clip, skirting structure, lamp mounting
bracket, or placard holder must be of a construction having lesser
strength than the cargo tank wall materials and may not be more than 72
percent of the thickness of the material to which it is attached. The
lightweight attachment may be secured directly to the cargo tank wall if
the device is designed and installed in such a manner that, if damaged,
it will not affect the lading retention integrity of the tank. A
lightweight attachment must be secured to the cargo tank shell or head
by a continuous weld or in such a manner as to preclude formation of
pockets which may become sites for corrosion. Attachments meeting the
requirements of this paragraph are not authorized for cargo tanks
constructed under part UHT in Section VIII of the ASME Code.
(3) Except as prescribed in paragraphs (g)(1) and (g)(2) of this
section, the welding of any appurtenance to the cargo tank wall must be
made by attachment of a mounting pad so that there will be no adverse
effect upon the lading retention integrity of the cargo tank if any
force less than that prescribed in paragraph (b)(1) of this section is
applied from any direction. The thickness of the mounting pad may not be
less than that of the shell wall or head wall to which it is attached,
and not more than 1.5 times the shell or head thickness. However, a pad
with a minimum thickness of 0.25 inch may be used when the shell or head
thickness is over 0.25 inch. If weep holes or tell-tale holes are used,
the pad must be drilled or punched at the lowest point before it is
welded to the tank. Each pad must--
(i) Be fabricated from material determined to be suitable for
welding to both the cargo tank material and the material of the
appurtenance or structural support member; a Design Certifying Engineer
must make this determination considering chemical and physical
properties of the materials and must specify filler material conforming
to the requirements in Section VIII of the ASME Code (IBR, see Sec.
171.7 of this subchapter).
(ii) Be preformed to an inside radius no greater than the outside
radius of the cargo tank at the attachment location.
(iii) Extend at least 2 inches in each direction from any point of
attachment of an appurtenance or structural support member. This
dimension may be measured from the center of the attached structural
member.
(iv) Have rounded corners, or otherwise be shaped in a manner to
minimize stress concentrations on the shell or head.
(v) Be attached by continuous fillet welding. Any fillet weld
discontinuity may only be for the purpose of preventing an intersection
between the fillet weld and a tank or jacket seam weld.
[Amdt. 178-89, 55 FR 37056, Sept. 7, 1990, as amended by Amdt. 178-104,
59 FR 49135, Sept. 26, 1994; Amdt. 178-105, 60 FR 17401, Apr. 5, 1995;
Amdt. 178-118, 61 FR 51340, Oct. 1, 1996; 65 FR 58631, Sept. 29, 2000;
68 FR 19279, Apr. 18, 2003; 68 FR 52370, Sept. 3, 2003; 68 FR 75753,
Dec. 31, 2003]
[[Page 139]]
Sec. 178.337-4 Joints.
(a) Joints shall be as required in Section VIII of the ASME Code
(IBR, see Sec. 171.7 of this subchapter), with all undercutting in
shell and head material repaired as specified therein.
(b) Welding procedure and welder performance must be in accordance
with Section IX of the ASME Code. In addition to the essential variables
named therein, the following must be considered as essential variables:
Number of passes; thickness of plate; heat input per pass; and
manufacturer's identification of rod and flux. When fabrication is done
in accordance with part UHT in Section VIII of the ASME Code, filler
material containing more than 0.08 percent vanadium must not be used.
The number of passes, thickness of plate, and heat input per pass may
not vary more than 25 percent from the procedure or welder
qualifications. Records of the qualifications must be retained for at
least 5 years by the cargo tank manufacturer and must be made available
to duly identified representatives of the Department and the owner of
the cargo tank.
(c) All longitudinal shell welds shall be located in the upper half
of the cargo tank.
(d) Edge preparation of shell and head components may be by machine
heat processes, provided such surfaces are remelted in the subsequent
welding process. Where there will be no subsequent remelting of the
prepared surface as in a tapered section, the final 0.050 inch of
material shall be removed by mechanical means.
(e) The maximum tolerance for misalignment and butting up shall be
in accordance with the requirement in Section VIII of the ASME Code.
(f) Substructures shall be properly fitted before attachment, and
the welding sequence shall be such as to minimize stresses due to
shrinkage of welds.
[Order 59-B, 30 FR 580, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Editorial Note: For Federal Register citations affecting Sec.
178.337-4, see the List of CFR Sections Affected which appears in the
Finding Aids section of the printed volume and at www.fdsys.gov.
Sec. 178.337-5 Bulkheads, baffles and ring stiffeners.
(a) Not a specification requirement.
(b) [Reserved]
[Order 59-B, 30 FR 580, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Sec. 178.337-6 Closure for manhole.
(a) Each cargo tank marked or certified after April 21, 1994, must
be provided with a manhole conforming to paragraph UG-46(g)(1) and other
applicable requirements in Section VIII of the ASME Code (IBR, see Sec.
171.7 of this subchapter), except that a cargo tank constructed of NQT
steel having a capacity of 3,500 water gallons or less may be provided
with an inspection opening conforming to paragraph UG-46 and other
applicable requirements of the ASME Code instead of a manhole.
(b) The manhole assembly of cargo tanks constructed after June 30,
1979, may not be located on the front head of the cargo tank.
[Amdt. 178-7, 34 FR 18250, Nov. 14, 1969, as amended by Amdt. 178-52, 43
FR 58820, Dec. 18, 1978; Amdt. 178-89, 54 FR 25017, June 12, 1989; 55 FR
21038, May 22, 1990; 56 FR 27876, June 17, 1991; 58 FR 12905, March 8,
1993; Amdt. 178-118, 61 FR 51340, Oct. 1, 1996; 68 FR 75753, Dec. 31,
2003]
Sec. 178.337-7 Overturn protection.
(a) See Sec. 178.337-10.
(b) [Reserved]
[Order 59-B, 30 FR 580, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Sec. 178.337-8 Openings, inlets, and outlets.
(a) General. The requirements in this paragraph (a) apply to MC 331
cargo tanks except for those used to transport chlorine. The
requirements for inlets and outlets on chlorine cargo tanks are in
paragraph (b) of this section.
(1) An opening must be provided on each cargo tank used for the
transportation of liquefied materials to permit complete drainage.
(2) Except for gauging devices, thermometer wells, pressure relief
valves, manhole openings, product inlet openings, and product discharge
openings, each opening in a cargo tank must be
[[Page 140]]
closed with a plug, cap, or bolted flange.
(3) Except as provided in paragraph (b) of this section, each
product inlet opening, including vapor return lines, must be fitted with
a back flow check valve or an internal self-closing stop valve located
inside the cargo tank or inside a welded nozzle that is an integral part
of the cargo tank. The valve seat must be located inside the cargo tank
or within 2.54 cm (one inch) of the external face of the welded flange.
Damage to parts exterior to the cargo tank or mating flange must not
prevent effective seating of the valve. All parts of a valve inside a
cargo tank or welded flange must be made of material that will not
corrode or deteriorate in the presence of the lading.
(4) Except as provided in paragraphs (a)(5), (b), and (c) of this
section, each liquid or vapor discharge outlet must be fitted with a
primary discharge control system as defined in Sec. 178.337-1(g).
Thermal remote operators must activate at a temperature of 121.11[deg]C
(250 [deg]F) or less. Linkages between closures and remote operators
must be corrosion resistant and effective in all types of environmental
conditions incident to discharging of product.
(i) On a cargo tank over 13,247.5 L (3,500 gallons) water capacity,
thermal and mechanical means of remote closure must be installed at the
ends of the cargo tank in at least two diagonally opposite locations. If
the loading/unloading connection at the cargo tank is not in the general
vicinity of one of the two locations specified in the first sentence of
this paragraph (a)(4)(i), additional means of thermal remote closure
must be installed so that heat from a fire in the loading/unloading
connection area or the discharge pump will activate the primary
discharge control system. The loading/unloading connection area is where
hoses or hose reels are connected to the permanent metal piping.
(ii) On a cargo tank of 13,247.5 L (3,500 gallons) water capacity or
less, a thermal means of remote closure must be installed at or near the
internal self-closing stop valve. A mechanical means of remote closure
must be installed on the end of the cargo tank furthest away from the
loading/unloading connection area. The loading/unloading connection area
is where hoses or hose reels are connected to the permanent metal
piping. Linkages between closures and remote operators must be corrosion
resistant and effective in all types of environmental conditions
incident to discharge of product.
(iii) All parts of a valve inside a cargo tank or within a welded
flange must be made of material that will not corrode or deteriorate in
the presence of the lading.
(iv) An excess flow valve, integral excess flow valve, or excess
flow feature must close if the flow reaches the rated flow of a gas or
liquid specified by the original valve manufacturer when piping mounted
directly on the valve is sheared off before the first valve, pump, or
fitting downstream from the excess flow valve, integral excess flow
valve, or excess flow feature.
(v) An integral excess flow valve or the excess flow feature of an
internal self-closing stop valve may be designed with a bypass, not to
exceed 0.1016 cm (0.040 inch) diameter opening, to allow equalization of
pressure.
(vi) The internal self-closing stop valve must be designed so that
the self-stored energy source and the valve seat are located inside the
cargo tank or within 2.54 cm (one inch) of the external face of the
welded flange. Damage to parts exterior to the cargo tank or mating
flange must not prevent effective seating of the valve.
(5) A primary discharge control system is not required on the
following:
(i) A vapor or liquid discharge opening of less than 1\1/4\ NPT
equipped with an excess flow valve together with a manually operated
external stop valve in place of an internal self-closing stop valve.
(ii) An engine fuel line on a truck-mounted cargo tank of not more
than \3/4\ NPT equipped with a valve having an integral excess flow
valve or excess flow feature.
(iii) A cargo tank motor vehicle used to transport refrigerated
liquids such as argon, carbon dioxide, helium, krypton, neon, nitrogen,
and xenon, or mixtures thereof.
[[Page 141]]
(6) In addition to the internal self-closing stop valve, each
filling and discharge line must be fitted with a stop valve located in
the line between the internal self-closing stop valve and the hose
connection. A back flow check valve or excess flow valve may not be used
to satisfy this requirement.
(7) An excess flow valve may be designed with a bypass, not to
exceed a 0.1016 centimeter (0.040 inch) diameter opening, to allow
equalization of pressure.
(b) Inlets and discharge outlets on chlorine tanks. The inlet and
discharge outlets on a cargo tank used to transport chlorine must meet
the requirements of Sec. 178.337-1(c)(2) and must be fitted with an
internal excess flow valve. In addition to the internal excess flow
valve, the inlet and discharge outlets must be equipped with an external
stop valve (angle valve). Excess flow valves must conform to the
standards of The Chlorine Institute, Inc., as follows:
(1) A valve conforming to The Chlorine Institute, Inc., Dwg. 101-7
(IBR, see Sec. 171.7 of this subchapter), must be installed under each
liquid angle valve.
(2) A valve conforming to The Chlorine Institute, Inc., Dwg. 106-6
(IBR, see Sec. 171.7 of this subchapter), must be installed under each
gas angle valve.
(c) Discharge outlets on carbon dioxide, refrigerated liquid, cargo
tanks. A discharge outlet on a cargo tank used to transport carbon
dioxide, refrigerated liquid is not required to be fitted with an
internal self-closing stop valve.
[64 FR 28049, May 24, 1999, as amended at 66 FR 45387, Aug. 28, 2001; 68
FR 19279, Apr. 18, 2003; 68 FR 75753, Dec. 31, 2003]
Sec. 178.337-9 Pressure relief devices, piping, valves, hoses, and fittings.
(a) Pressure relief devices. (1) See Sec. 173.315(i) of this
subchapter.
(2) On cargo tanks for carbon dioxide or nitrous oxide see Sec.
173.315 (i) (9) and (10) of this subchapter.
(3) Each valve must be designed, constructed, and marked for a rated
pressure not less than the cargo tank design pressure at the temperature
expected to be encountered.
(b) Piping, valves, hose, and fittings. (1) The burst pressure of
all piping, pipe fittings, hose and other pressure parts, except for
pump seals and pressure relief devices, must be at least 4 times the
design pressure of the cargo tank. Additionally, the burst pressure may
not be less than 4 times any higher pressure to which each pipe, pipe
fitting, hose or other pressure part may be subjected to in service. For
chlorine service, see paragraph (b)(7) of this section.
(2) Pipe joints must be threaded, welded, or flanged. If threaded
pipe is used, the pipe and fittings must be Schedule 80 weight or
heavier, except for sacrificial devices. Malleable metal, stainless
steel, or ductile iron must be used in the construction of primary valve
body parts and fittings used in liquid filling or vapor equalization.
Stainless steel may be used for internal components such as shutoff
discs and springs except where incompatible with the lading to be
transported. Where copper tubing is permitted, joints must be brazed or
be of equally strong metal union type. The melting point of the brazing
material may not be lower than 538 [deg]C (1,000 [deg]F). The method of
joining tubing may not reduce the strength of the tubing.
(3) Each hose coupling must be designed for a pressure of at least
120 percent of the hose design pressure and so that there will be no
leakage when connected.
(4) Piping must be protected from damage due to thermal expansion
and contraction, jarring, and vibration. Slip joints are not authorized
for this purpose.
(5) [Reserved]
(6) Cargo tank manufacturers and fabricators must demonstrate that
all piping, valves, and fittings on a cargo tank are free from leaks. To
meet this requirement, the piping, valves, and fittings must be tested
after installation at not less than 80 percent of the design pressure
marked on the cargo tank.
(7) A hose assembler must:
(i) Permanently mark each hose assembly with a unique identification
number.
(ii) Demonstrate that each hose assembly is free from leaks by
performing the tests and inspections in Sec. 180.416(f) of this
subchapter.
[[Page 142]]
(iii) Mark each hose assembly with the month and year of its
original pressure test.
(8) Chlorine cargo tanks. Angle valves on cargo tanks intended for
chlorine service must conform to the standards of the Chlorine
Institute, Inc., Dwg. 104-8 or ``Section 3, Pamphlet 166, Angle Valve
Guidelines for Chlorine Bulk Transportation.'' (IBR, see Sec. 171.7 of
this subchapter). Before installation, each angle valve must be tested
for leakage at not less than 225 psig using dry air or inert gas.
(c) Marking inlets and outlets. Except for gauging devices,
thermometer wells, and pressure relief valves, each cargo tank inlet and
outlet must be marked ``liquid'' or ``vapor'' to designate whether it
communicates with liquid or vapor when the cargo tank is filled to the
maximum permitted filling density. A filling line that communicates with
vapor may be marked ``spray-fill'' instead of ``vapor.''
(d) Refrigeration and heating coils. (1) Refrigeration and heating
coils must be securely anchored with provisions for thermal expansion.
The coils must be pressure tested externally to at least the cargo tank
test pressure, and internally to either the tank test pressure or twice
the working pressure of the heating/refrigeration system, whichever is
higher. A cargo tank may not be placed in service if any leakage occurs
or other evidence of damage is found. The refrigerant or heating medium
to be circulated through the coils must not be capable of causing any
adverse chemical reaction with the cargo tank lading in the event of
leakage. The unit furnishing refrigeration may be mounted on the motor
vehicle.
(2) Where any liquid susceptible to freezing, or the vapor of any
such liquid, is used for heating or refrigeration, the heating or
refrigeration system shall be arranged to permit complete drainage.
[Order 59-B, 30 FR 580, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Editorial Note: For Federal Register citations affecting Sec.
178.337-9, see the List of CFR Sections Affected which appears in the
Finding Aids section of the printed volume and at www.fdsys.gov.
Sec. 178.337-10 Accident damage protection.
(a) All valves, fittings, pressure relief devices, and other
accessories to the tank proper shall be protected in accordance with
paragraph (b) of this section against such damage as could be caused by
collision with other vehicles or objects, jack-knifing and overturning.
In addition, pressure relief valves shall be so protected that in the
event of overturn of the vehicle onto a hard surface, their opening will
not be prevented and their discharge will not be restricted.
(b) The protective devices or housing must be designed to withstand
static loading in any direction equal to twice the weight of the tank
and attachments when filled with the lading, using a safety factor of
not less than four, based on the ultimate strength of the material to be
used, without damage to the fittings protected, and must be made of
metal at least \3/16\-inch thick.
(c) Rear-end tank protection. Rear-end tank protection devices must:
(1) Consist of at least one rear bumper designed to protect the
cargo tank and all valves, piping and fittings located at the rear of
the cargo tank from damage that could result in loss of lading in the
event of a rear end collision. The bumper design must transmit the force
of the collision directly to the chassis of the vehicle. The rear bumper
and its attachments to the chassis must be designed to withstand a load
equal to twice the weight of the loaded cargo tank motor vehicle and
attachments, using a safety factor of four based on the tensile strength
of the materials used, with such load being applied horizontally and
parallel to the major axis of the cargo tank. The rear bumper dimensions
must also meet the requirements of Sec. 393.86 of this title; or
(2) Conform to the requirements of Sec. 178.345-8(d).
(d) Chlorine tanks. A chlorine tank must be equipped with a
protective housing and a manway cover to permit the use of standard
emergency kits for controlling leaks in fittings on the dome cover
plate. For tanks manufactured on or after October 1, 2009, the
[[Page 143]]
housing and manway cover must conform to the Chlorine Institute, Inc.,
Dwg. 137-5 (IBR, see Sec. 171.7 of this subchapter).
(e) Piping and fittings. Piping and fittings must be grouped in the
smallest practicable space and protected from damage as required in this
section.
(f) Shear section. A shear section or sacrificial device is required
for the valves specified in the following locations:
(1) A section that will break under strain must be provided adjacent
to or outboard of each valve specified in Sec. 178.337-8(a)(3) and (4).
(2) Each internal self-closing stop valve, excess flow valve, and
check valve must be protected by a shear section or other sacrificial
device. The sacrificial device must be located in the piping system
outboard of the stop valve and within the accident damage protection to
prevent any accidental loss of lading. The failure of the sacrificial
device must leave the protected lading protection device and its
attachment to the cargo tank wall intact and capable of retaining
product.
[Order 59-B, 30 FR 581, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Editorial Note: For Federal Register citations affecting Sec.
178.337-10, see the List of CFR Sections Affected which appears in the
Finding Aids section of the printed volume and at www.fdsys.gov.
Sec. 178.337-11 Emergency discharge control.
(a) Emergency discharge control equipment. Emergency discharge
control equipment must be installed in a liquid discharge line as
specified by product and service in Sec. 173.315(n) of this subchapter.
The performance and certification requirements for emergency discharge
control equipment are specified in Sec. 173.315(n) of this subchapter
and are not a part of the cargo tank motor vehicle certification made
under this specification.
(b) Engine fuel lines. On a truck-mounted cargo tank, emergency
discharge control equipment is not required on an engine fuel line of
not more than \3/4\ NPT equipped with a valve having an integral excess
flow valve or excess flow feature.
[64 FR 28050, May 24, 1999]
Sec. 178.337-12 [Reserved]
Sec. 178.337-13 Supporting and anchoring.
(a) A cargo tank that is not permanently attached to or integral
with a vehicle chassis must be secured by the use of restraining devices
designed to prevent relative motion between the cargo tank and the
vehicle chassis when the vehicle is in operation. Such restraining
devices must be readily accessible for inspection and maintenance.
(b) On a cargo tank motor vehicle designed and constructed so that
the cargo tank constitutes in whole or in part the structural member
used in place of a motor vehicle frame, the cargo tank must be supported
by external cradles. A cargo tank mounted on a motor vehicle frame must
be supported by external cradles or longitudinal members. Where used,
the cradles must subtend at least 120 degrees of the shell
circumference.
(c) The design calculations of the support elements must satisfy the
requirements of Sec. 178.337-3, (a), (b), (c), and (d).
(d) Where any cargo tank support is attached to any part of a cargo
tank head, the stresses imposed upon the head must be provided for as
required in paragraph (c) of this section.
[68 FR 19280, Apr. 18, 2003]
Sec. 178.337-14 Gauging devices.
(a) Liquid level gauging devices. See Sec. 173.315(h) of this
subchapter.
(b) Pressure gauges. (1) See Sec. 173.315(h) of this subchapter.
(2) Each cargo tank used in carbon dioxide, refrigerated liquid or
nitrous oxide, refrigerated liquid service must be provided with a
suitable pressure gauge. A shut-off valve must be installed between the
pressure gauge and the cargo tank.
(c) Orifices. See Sec. 173.315(h) (3) and (4) of this subchapter.
[Amdt. 178-29, 38 FR 27599, Oct. 5, 1973, as amended by Amdt. 178-89, 54
FR 25018, June 12, 1989; Amdt. 178-118, 61 FR 51340, Oct. 1, 1996]
[[Page 144]]
Sec. 178.337-15 Pumps and compressors.
(a) Liquid pumps or gas compressors, if used, must be of suitable
design, adequately protected against breakage by collision, and kept in
good condition. They may be driven by motor vehicle power take-off or
other mechanical, electrical, or hydraulic means. Unless they are of the
centrifugal type, they shall be equipped with suitable pressure actuated
by-pass valves permitting flow from discharge to suction or to the cargo
tank.
(b) A liquid chlorine pump may not be installed on a cargo tank
intended for the transportation of chlorine.
[Amdt. 178-89, 54 FR 25018, June 12, 1989, as amended by Amdt. 178-118,
61 FR 51340, Oct. 1, 1996]
Sec. 178.337-16 Testing.
(a) Inspection and tests. Inspection of materials of construction of
the cargo tank and its appurtenances and original test and inspection of
the finished cargo tank and its appurtenances must be as required by
Section VIII of the ASME Code (IBR, see Sec. 171.7 of this subchapter)
and as further required by this specification, except that for cargo
tanks constructed in accordance with part UHT in Section VIII of the
ASME Code the original test pressure must be at least twice the cargo
tank design pressure.
(b) Weld testing and inspection. (1) Each cargo tank constructed in
accordance with part UHT in Section VIII of the ASME Code must be
subjected, after postweld heat treatment and hydrostatic tests, to a wet
fluorescent magnetic particle inspection to be made on all welds in or
on the cargo tank shell and heads both inside and out. The method of
inspection must conform to appendix 6 in Section VIII of the ASME Code
except that permanent magnets shall not be used.
(2) On cargo tanks of over 3,500 gallons water capacity other than
those described in paragraph (b)(1) of this section unless fully
radiographed, a test must be made of all welds in or on the shell and
heads both inside and outside by either the wet fluorescent magnetic
particle method conforming to appendix U in Section VIII of the ASME
Code, liquid dye penetrant method, or ultrasonic testing in accordance
with appendix 12 in Section VIII of the ASME Code. Permanent magnets
must not be used to perform the magnetic particle inspection.
(c) All defects found shall be repaired, the cargo tanks shall then
again be postweld heat treated, if such heat treatment was previously
performed, and the repaired areas shall again be tested.
[Order 59-B, 30 FR 582, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967, and amended by Amdt. 178-7, 34 FR 18250, Nov. 14, 1969; Amdt.
178-99, 58 FR 51534, Oct. 1, 1993; Amdt. 178-118, 61 FR 51340, Oct. 1,
1996; 68 FR 75753, Dec. 31, 2003]
Sec. 178.337-17 Marking.
(a) General. Each cargo tank certified after October 1, 2004 must
have a corrosion-resistant metal name plate (ASME Plate) and
specification plate permanently attached to the cargo tank by brazing,
welding, or other suitable means on the left side near the front, in a
place accessible for inspection. If the specification plate is attached
directly to the cargo tank wall by welding, it must be welded to the
tank before the cargo tank is postweld heat treated.
(1) The plates must be legibly marked by stamping, embossing, or
other means of forming letters into the metal of the plate, with the
information required in paragraphs (b) and (c) of this section, in
addition to that required by the ASME Code, in characters at least 3/16
inch high (parenthetical abbreviations may be used). All plates must be
maintained in a legible condition.
(2) Each insulated cargo tank must have additional plates, as
described, attached to the jacket in the location specified unless the
specification plate is attached to the chassis and has the information
required in paragraphs (b) and (c) of this section.
(3) The information required for both the name and specification
plate may be displayed on a single plate. If the information required by
this section is displayed on a plate required by the ASME, the
information need not be repeated on the name and specification plates.
[[Page 145]]
(4) The specification plate may be attached to the cargo tank motor
vehicle chassis rail by brazing, welding, or other suitable means on the
left side near the front head, in a place accessible for inspection. If
the specification plate is attached to the chassis rail, then the cargo
tank serial number assigned by the cargo tank manufacturer must be
included on the plate.
(b) Name plate. The following information must be marked on the name
plate in accordance with this section:
(1) DOT-specification number MC 331 (DOT MC 331).
(2) Original test date (Orig. Test Date).
(3) MAWP in psig.
(4) Cargo tank design temperature (Design Temp. Range) ------ [deg]F
to ------ [deg]F.
(5) Nominal capacity (Water Cap.), in pounds.
(6) Maximum design density of lading (Max. Lading density), in
pounds per gallon.
(7) Material specification number--shell (Shell matl, yyy***), where
``yyy'' is replaced by the alloy designation and ``***'' is replaced by
the alloy type.
(8) Material specification number--heads (Head matl. yyy***), where
``yyy'' is replaced by the alloy designation and ``***'' by the alloy
type.
(9) Minimum Thickness--shell (Min. Shell-thick), in inches. When
minimum shell thicknesses are not the same for different areas, show
(top----, side----, bottom----, in inches).
(10) Minimum thickness--heads (Min. heads thick.), in inches.
(11) Manufactured thickness--shell (Mfd. Shell thick.), top----,
side----, bottom----, in inches. (Required when additional thickness is
provided for corrosion allowance.)
(12) Manufactured thickness--heads (Mfd. Heads thick.), in inches.
(Required when additional thickness is provided for corrosion
allowance.)
(13) Exposed surface area, in square feet.
Note to paragraph (b): When the shell and head materials are the
same thickness, they may be combined, (Shell&head matl, yyy***).
(c) Specification plate. The following information must be marked on
the specification plate in accordance with this section:
(1) Cargo tank motor vehicle manufacturer (CTMV mfr.).
(2) Cargo tank motor vehicle certification date (CTMV cert. date).
(3) Cargo tank manufacturer (CT mfr.).
(4) Cargo tank date of manufacture (CT date of mfr.), month and
year.
(5) Maximum weight of lading (Max. Payload), in pounds
(6) Lining materials (Lining), if applicable.
(7) Heating system design pressure (Heating sys. press.), in psig,
if applicable.
(8) Heating system design temperature (Heating sys. temp.), in
[deg]F, if applicable.
(9) Cargo tank serial number, assigned by cargo tank manufacturer
(CT serial), if applicable.
Note 1 to paragraph (c): See Sec. 173.315(a) of this chapter
regarding water capacity.
Note 2 to paragraph (c): When the shell and head materials are the
same thickness, they may be combined (Shell & head matl, yyy***).
(d) The design weight of lading used in determining the loading in
Sec. Sec. 178.337-3(b), 178.337-10(b) and (c), and 178.337-13(a) and
(b), must be shown as the maximum weight of lading marking required by
paragraph (c) of this section.
[68 FR 19280, Apr. 18, 2003; 68 FR 52370, Sept. 3, 2003, as amended at
68 FR 57633, Oct. 6, 2003]
Sec. 178.337-18 Certification.
(a) At or before the time of delivery, the cargo tank motor vehicle
manufacturer must supply and the owner must obtain, a cargo tank motor
vehicle manufacturer's data report as required by Section VIII of the
ASME Code (IBR, see Sec. 171.7 of this subchapter), and a certificate
stating that the completed cargo tank motor vehicle conforms in all
respects to Specification MC 331 and the ASME Code. The registration
numbers of the manufacturer, the Design Certifying Engineer, and the
Registered Inspector, as appropriate, must appear on the certificates
(see subpart F, part 107 in subchapter A of this chapter).
[[Page 146]]
(1) For each design type, the certificate must be signed by a
responsible official of the manufacturer and a Design Certifying
Engineer; and
(2) For each cargo tank motor vehicle, the certificate must be
signed by a responsible official of the manufacturer and a Registered
Inspector.
(3) When a cargo tank motor vehicle is manufactured in two or more
stages, each manufacturer who performs a manufacturing function or
portion thereof on the incomplete cargo tank motor vehicle must provide
to the succeeding manufacturer, at or before the time of delivery, a
certificate that states the function performed by the manufacturer,
including any certificates received from previous manufacturers,
Registered Inspectors, and Design Certifying Engineers.
(4) Specification shortages. When a cargo tank motor vehicle is
manufactured in two or more stages, the manufacturer of the cargo tank
must attach the name plate and specification plate as required by Sec.
178.337-17(a) and (b) without the original date of certification stamped
on the specification plate. Prior manufacturers must list the
specification requirements that are not completed on the Certificate of
Compliance. When the cargo tank motor vehicle is brought into full
compliance with the applicable specification, the cargo tank motor
vehicle manufacturer must have a Registered Inspector stamp the date of
certification on the specification plate and issue a Certificate of
Compliance to the owner of the cargo tank motor vehicle. The Certificate
of Compliance must list the actions taken to bring the cargo tank motor
vehicle into full compliance. In addition, the certificate must include
the date of certification and the person (manufacturer, carrier or
repair organization) accomplishing compliance.
(5) The certificate must state whether or not it includes
certification that all valves, piping, and protective devices conform to
the requirements of the specification. If it does not so certify, the
installer of any such valve, piping, or device shall supply and the
owner shall obtain a certificate asserting complete compliance with
these specifications for such devices. The certificate, or certificates,
will include sufficient sketches, drawings, and other information to
indicate the location, make, model, and size of each valve and the
arrangement of all piping associated with the cargo tank.
(6) The certificate must contain a statement indicating whether or
not the cargo tank was postweld heat treated for anhydrous ammonia as
specified in Sec. 178.337-1(f).
(b) The owner shall retain the copy of the data report and
certificates and related papers in his files throughout his ownership of
the cargo tank motor vehicle and for at least one year thereafter; and
in the event of change in ownership, retention by the prior owner of
nonfading photographically reproduced copies will be deemed to satisfy
this requirement. Each motor carrier using the cargo tank motor vehicle,
if not the owner thereof, shall obtain a copy of the data report and
certificate and retain them in his files during the time he uses the
cargo tank motor vehicle and for at least one year thereafter.
[Order 59-B, 30 FR 583, Jan. 16, 1965. Redesignated at 32 FR 5606, Apr.
5, 1967]
Editorial Note: For Federal Register citations affecting Sec.
178.337-18, see the List of CFR Sections Affected which appears in the
Finding Aids section of the printed volume and at www.fdsys.gov.
Sec. 178.338 Specification MC-338; insulated cargo tank motor vehicle.
Sec. 178.338-1 General requirements.
(a) For the purposes of this section--
(1) Design pressure means the ``MAWP'' as used in Section VIII of
the ASME Code (IBR, see Sec. 171.7 of this subchapter), and is the
gauge pressure at the top of the tank.
(2) Design service temperature means the coldest temperature for
which the tank is suitable (see Sec. Sec. 173.318 (a)(1) and (f) of
this subchapter).
(b) Each cargo tank must consist of a suitably supported welded
inner vessel enclosed within an outer shell or jacket, with insulation
between the inner vessel and outer shell or jacket, and having piping,
valves, supports and other appurtenances as specified in this
subchapter. For the purpose of this specification, tank means inner
vessel
[[Page 147]]
and jacket means either the outer shell or insulation cover.
(c) Each tank must be designed, constructed, certified, and stamped
in accordance with Section VIII of the ASME Code.
(d) The exterior surface of the tank must be insulated with a
material compatible with the lading.
(1) Each cargo tank must have an insulation system that will prevent
the tank pressure from exceeding the pressure relief valve set pressure
within the specified holding time when the tank is loaded with the
specific cryogenic liquid at the design conditions of--
(i) The specified temperature and pressure of the cryogenic liquid,
and
(ii) The exposure of the filled cargo tank to an average ambient
temperature of 85 [deg]F.
(2) For a cargo tank used to transport oxygen, the insulation may
not sustain combustion in a 99.5 percent oxygen atmosphere at
atmospheric pressure when contacted with a continuously heated glowing
platinum wire. The cargo tank must be marked in accordance with Sec.
178.338-18(b)(7).
(3) Each vacuum-insulated cargo tank must be provided with a
connection for a vacuum gauge to indicate the absolute pressure within
the insulation space.
(e) The insulation must be completely covered by a metal jacket. The
jacket or the insulation must be so constructed and sealed as to prevent
moisture from coming into contact with the insulation (see Sec.
173.318(a)(3) of this subchapter). Minimum metal thicknesses are as
follows:
------------------------------------------------------------------------
Jacket Jacket not
evacuated evacuated
Type metal --------------------------------
Gauge Inches Gauge Inches
------------------------------------------------------------------------
Stainless steel........................ 18 0.0428 22 0.0269
Low carbon mild steel.................. 12 0.0946 14 0.0677
Aluminum............................... ...... 0.125 ...... 0.1000
------------------------------------------------------------------------
(f) An evacuated jacket must be in compliance with the following
requirements:
(1) The jacket must be designed to sustain a minimum critical
collapsing pressure of 30 psig.
(2) If the jacket also supports additional loads, such as the weight
of the tank and lading, the combined stress, computed according to the
formula in Sec. 178.338-3(b), may not exceed 25 percent of the minimum
specified tensile strength.
[Amdt. 178-77, 48 FR 27703, June 16, 1983, as amended at 49 FR 24316,
June 12, 1984; Amdt. 178-104, 59 FR 49135, Sept. 26, 1994; 66 FR 45387,
Aug. 28, 2001; 68 FR 75754, Dec. 31, 2003]
Sec. 178.338-2 Material.
(a) All material used in the construction of a tank and its
appurtenances that may come in contact with the lading must be
compatible with the lading to be transported. All material used for tank
pressure parts must conform to the requirements in Section II of the
ASME Code (IBR, see Sec. 171.7 of this subchapter). All material used
for evacuated jacket pressure parts must conform to the chemistry and
steelmaking practices of one of the material specifications of Section
II of the ASME Code or the following ASTM Specifications (IBR, see Sec.
171.7 of this subchapter): A 242, A 441, A 514, A 572, A 588, A 606, A
633, A 715, A 1008/A 1008M, A 1011/A 1011M.
(b) All tie-rods, mountings, and other appurtenances within the
jacket and all piping, fittings and valves must be of material suitable
for use at the lowest temperature to be encountered.
(c) Impact tests are required on all tank materials, except
materials that are excepted from impact testing by the ASME Code, and
must be performed using the procedure prescribed in Section VIII of the
ASME Code.
(d) The direction of final rolling of the shell material must be the
circumferential orientation of the tank shell.
(e) Each tank constructed in accordance with part UHT in Section
VIII of the ASME Code must be postweld heat treated as a unit after
completion of all welds to the shell and heads. Other tanks must be
postweld heat treated as required in Section VIII of the ASME Code. For
all tanks the method must be as prescribed in the ASME Code. Welded
attachments to pads may be made after postweld heat treatment.
(f) The fabricator shall record the heat and slab numbers and the
certified Charpy impact values of each plate used in the tank on a
sketch showing the location of each plate in the shell and heads of the
tank. A copy of the sketch must be provided to the owner
[[Page 148]]
of the cargo tank and a copy must be retained by the fabricator for at
least five years and made available, upon request, to any duly
identified representative of the Department.
(Approved by the Office of Management and Budget under control number
2137-0017)
[Amdt. 178-77, 48 FR 27703 and 27713, June 16, 1983, as amended at 49 FR
24316, June 12, 1984; 68 FR 19281, Apr. 18, 2003; 68 FR 75754, Dec. 31,
2003; 70 FR 34076, June 13, 2005]
Sec. 178.338-3 Structural integrity.
(a) General requirements and acceptance criteria. (1) Except as
permitted in paragraph (d) of this section, the maximum calculated
design stress at any point in the tank may not exceed the lesser of the
maximum allowable stress value prescribed in section VIII of the ASME
Code, or 25 percent of the tensile strength of the material used.
(2) The relevant physical properties of the materials used in each
tank may be established either by a certified test report from the
material manufacturer or by testing in conformance with a recognized
national standard. In either case, the ultimate tensile strength of the
material used in the design may not exceed 120 percent of the minimum
ultimate tensile strength specified in either the ASME Code or the ASTM
standard to which the material is manufactured.
(3) The maximum design stress at any point in the tank must be
calculated separately for the loading conditions described in paragraphs
(b), (c), and (d) of this section. Alternate test or analytical methods,
or a combination thereof, may be used in lieu of the procedures
described in paragraphs (b), (c), and (d) of this section, if the
methods are accurate and verifiable.
(4) Corrosion allowance material may not be included to satisfy any
of the design calculation requirements of this section.
(b) Static design and construction. (1) The static design and
construction of each tank must be in accordance with appendix G in
Section VIII of the ASME Code (IBR, see Sec. 171.7 of this subchapter).
The tank design must include calculation of stress due to the design
pressure, the weight of lading, the weight of structures supported by
the tank wall, and the effect of temperature gradients resulting from
lading and ambient temperature extremes. When dissimilar materials are
used, their thermal coefficients must be used in calculation of the
thermal stresses.
(2) Stress concentrations in tension, bending, and torsion which
occur at pads, cradles, or other supports must be considered in
accordance with appendix G in Section VIII of the ASME Code.
(c) Stresses resulting from static and dynamic loadings, or a
combination thereof, are not uniform throughout the cargo tank motor
vehicle. The following is a simplified procedure for calculating the
effective stress in the tank resulting from static and dynamic loadings.
The effective stress (the maximum principal stress at any point) must be
determined by the following formula:
S = 0.5 (Sy + Sx) (0.25(Sy - Sx)\2\ +
Ss2) \0.5\
Where:
(1) S = effective stress at any given point under the most severe
combination of static and dynamic loadings that can occur at the same
time, in psi.
(2) Sy = circumferential stress generated by internal and
external pressure when applicable, in psi.
(3) Sx = the net longitudinal stress, in psi, generated
by the following loading conditions:
(i) The longitudinal tensile stress generated by internal pressure;
(ii) The tensile or compressive stress generated by the axial load
resulting from a decelerative force applied independently to each
suspension assembly at the road surface using applicable static loadings
specified in Sec. 178.338-13 (b);
(iii) The tensile or compressive stress generated by the bending
moment resulting from a decelerative force applied independently to each
suspension assembly at the road surface using applicable static loadings
specified in Sec. 178.338-13 (b);
(iv) The tensile or compressive stress generated by the axial load
resulting from an accelerative force applied to the horizontal pivot of
the fifth wheel supporting the vehicle using applicable static loadings
specified in Sec. 178.338-13 (b);
[[Page 149]]
(v) The tensile or compressive stress generated by the bending
moment resulting from an accelerative force applied to the horizontal
pivot of the fifth wheel supporting the vehicle using applicable static
loadings specified in Sec. 178.338-13 (b); and
(vi) The tensile or compressive stress generated by a bending moment
produced by a vertical force using applicable static loadings specified
in Sec. 178.338-13 (b).
(4) Ss = The following shear stresses that apply, in
psi,: The vectorial sum of the applicable shear stresses in the plane
under consideration, including direct shear generated by the static
vertical loading; direct lateral and torsional shear generated by a
lateral accelerative force applied at the road surface, using applicable
static loads specified in Sec. 178.338-13 (b)
(d) In order to account for stresses due to impact in an accident,
the design calculations for the tank shell and heads must include the
load resulting from the design pressure in combination with the dynamic
pressure resulting from a longitudinal deceleration of ``2g''. For this
loading condition the stress value used may not exceed the lesser of the
yield strength or 75 percent of the ultimate tensile strength of the
material of construction. For a cargo tank constructed of stainless
steel, the maximum design stress may not exceed 75 percent of the
ultimate tensile strength of the type steel used.
(e) The minimum thickness of the shell or heads of the tank must be
0.187 inch for steel and 0.270 inch for aluminum. However, the minimum
thickness for steel may be 0.110 inches provided the cargo tank is:
(1) Vacuum insulated, or
(2) Double walled with a load bearing jacket designed to carry a
proportionate amount of structural loads prescribed in this section.
(f) Where a tank support is attached to any part of the tank wall,
the stresses imposed on the tank wall must meet the requirements in
paragraph (a) of this section.
(g) The design, construction and installation of an attachment,
appurtenance to the cargo tank or structural support member between the
cargo tank and the vehicle or suspension component or accident
protection device must conform to the following requirements:
(1) Structural members, the suspension subframe, accident protection
structures and external circumferential reinforcement devices must be
used as sites for attachment of appurtenances and other accessories to
the cargo tank, when practicable.
(2) A lightweight attachment to the cargo tank wall such as a
conduit clip, brakeline clip, skirting structure, lamp mounting bracket,
or placard holder must be of a construction having lesser strength than
the cargo tank wall materials and may not be more than 72 percent of the
thickness of the material to which it is attached. The lightweight
attachment may be secured directly to the cargo tank wall if the device
is designed and installed in such a manner that, if damaged, it will not
affect the lading retention integrity of the tank. A lightweight
attachment must be secured to the cargo tank shell or head by a
continuous weld or in such a manner as to preclude formation of pockets
that may become sites for corrosion. Attachments meeting the
requirements of this paragraph are not authorized for cargo tanks
constructed under part UHT in Section VIII of the ASME Code.
(3) Except as prescribed in paragraphs (g)(1) and (g)(2) of this
section, the welding of any appurtenance the cargo tank wall must be
made by attachment of a mounting pad so that there will be no adverse
effect upon the lading retention integrity of the cargo tank if any
force less than that prescribed in paragraph (b)(1) of this section is
applied from any direction. The thickness of the mounting pad may not be
less than that of the shell or head to which it is attached, and not
more than 1.5 times the shell or head thickness. However, a pad with a
minimum thickness of 0.187 inch may be used when the shell or head
thickness is over 0.187 inch. If weep holes or tell-tale holes are used,
the pad must be drilled or punched at the lowest point before it is
welded to the tank. Each pad must:
(i) Be fabricated from material determined to be suitable for
welding to both the cargo tank material and the
[[Page 150]]
material of the appurtenance or structural support member; a Design
Certifying Engineer must make this determination considering chemical
and physical properties of the materials and must specify filler
material conforming to the requirements in Section IX of the ASME Code
(IBR, see Sec. 171.7 of this subchapter).
(ii) Be preformed to an inside radius no greater than the outside
radius of the cargo tank at the attachment location.
(iii) Extend at least 2 inches in each direction from any point of
attachment of an appurtenance or structural support member. This
dimension may be measured from the center of the attached structural
member.
(iv) Have rounded corners, or otherwise be shaped in a manner to
minimize stress concentrations on the shell or head.
(v) Be attached by continuous fillet welding. Any fillet weld
discontinuity may only be for the purpose of preventing an intersection
between the fillet weld and a tank or jacket seam weld.
[Amdt. 178-89, 55 FR 37057, Sept. 7, 1990, as amended by Amdt. 178-89,
56 FR 27876, June 17, 1991; 56 FR 46354, Sept. 11, 1991; 68 FR 19281,
Apr. 18, 2003; 68 FR 57633, Oct. 6, 2003; 68 FR 75754, Dec. 31, 2003]
Sec. 178.338-4 Joints.
(a) All joints in the tank, and in the jacket if evacuated, must be
as prescribed in Section VIII of the ASME Code (IBR, see Sec. 171.7 of
this subchapter), except that a butt weld with one plate edge offset is
not authorized.
(b) Welding procedure and welder performance tests must be made in
accordance with Section IX of the ASME Code. Records of the
qualification must be retained by the tank manufacturer for at least
five years and must be made available, upon request, to any duly
identified representative of the Department, or the owner of the cargo
tank.
(c) All longitudinal welds in tanks and load bearing jackets must be
located so as not to intersect nozzles or supports other than load rings
and stiffening rings.
(d) Substructures must be properly fitted before attachment and the
welding sequence must minimize stresses due to shrinkage of welds.
(e) Filler material containing more than 0.05 percent vanadium may
not be used with quenched and tempered steel.
(f) All tank nozzle-to-shell and nozzle-to-head welds must be full
penetration welds.
(Approved by the Office of Management and Budget under control number
2137-0017)
[Amdt. 178-77, 48 FR 27704 and 27713, June 16, 1983, as amended at 49 FR
24316, June 12, 1984; 68 FR 75754, Dec. 31, 2003]
Sec. 178.338-5 Stiffening rings.
(a) A tank is not required to be provided with stiffening rings,
except as prescribed in Section VIII of the ASME Code (IBR, see Sec.
171.7 of this subchapter).
(b) If a jacket is evacuated, it must be constructed in compliance
with Sec. 178.338-1(f). Stiffening rings may be used to meet these
requirements.
[Amdt. 178-77, 48 FR 27704, June 16, 1983, as amended at 68 FR 75754,
Dec. 31, 2003]
Sec. 178.338-6 Manholes.
(a) Each tank in oxygen service must be provided with a manhole as
prescribed in Section VIII of the ASME Code (IBR, see Sec. 171.7 of
this subchapter).
(b) Each tank having a manhole must be provided with a means of
entrance and exit through the jacket, or the jacket must be marked to
indicate the manway location on the tank.
(c) A manhole with a bolted closure may not be located on the front
head of the tank.
[Amdt. 178-77, 48 FR 27704, June 16, 1983, as amended at 49 FR 24316,
June 12, 1984; 68 FR 75754, Dec. 31, 2003]
Sec. 178.338-7 Openings.
(a) The inlet to the liquid product discharge opening of each tank
intended for flammable ladings must be at the bottom centerline of the
tank.
(b) If the leakage of a single valve, except a pressure relief
valve, pressure control valve, full trycock or gas phase manual vent
valve, would permit loss of flammable material, an additional closure
that is leak tight at the tank
[[Page 151]]
design pressure must be provided outboard of such valve.
[Amdt. 178-77, 48 FR 27704, June 16, 1983]
Sec. 178.338-8 Pressure relief devices, piping, valves, and fittings.
(a) Pressure relief devices. Each tank pressure relief device must
be designed, constructed, and marked in accordance with Sec. 173.318(b)
of this subchapter.
(b) Piping, valves, and fittings. (1) The burst pressure of all
piping, pipe fittings, hoses and other pressure parts, except for pump
seals and pressure relief devices, must be at least 4 times the design
pressure of the tank. Additionally, the burst pressure may not be less
than 4 times any higher pressure to which each pipe, pipe fitting, hose
or other pressure part may be subjected to in service.
(2) Pipe joints must be threaded, welded or flanged. If threaded
pipe is used, the pipe and fittings must be Schedule 80 weight or
heavier. Malleable metals must be used in the construction of valves and
fittings. Where copper tubing is permitted, joints shall be brazed or be
of equally strong metal union type. The melting point of the brazing
materials may not be lower than 1000 [deg]F. The method of joining
tubing may not reduce the strength of the tubing, such as by the cutting
of threads.
(3) Each hose coupling must be designed for a pressure of at least
120 percent of the hose design pressure and so that there will be no
leakage when connected.
(4) Piping must be protected from damage due to thermal expansion
and contraction, jarring, and vibration. Slip joints are not authorized
for this purpose.
(5) All piping, valves and fittings on a cargo tank must be proved
free from leaks. This requirement is met when such piping, valves, and
fittings have been tested after installation with gas or air and proved
leak tight at not less than the design pressure marked on the cargo
tank. This requirement is applicable to all hoses used in a cargo tank,
except that hose may be tested before or after installation on the tank.
(6) Each valve must be suitable for the tank design pressure at the
tank design service temperature.
(7) All fittings must be rated for the maximum tank pressure and
suitable for the coldest temperature to which they will be subjected in
actual service.
(8) All piping, valves, and fittings must be grouped in the smallest
practicable space and protected from damage as required by Sec.
178.338-10.
(9) When a pressure-building coil is used on a tank designed to
handle oxygen or flammable ladings, the vapor connection to that coil
must be provided with a valve or check valve as close to the tank shell
as practicable to prevent the loss of vapor from the tank in case of
damage to the coil. The liquid connection to that coil must also be
provided with a valve.
[Amdt. 178-77, 48 FR 27704, June 16, 1983, as amended by Amdt. 178-89,
54 FR 25019, June 12, 1989]
Sec. 178.338-9 Holding time.
(a) ``Holding time'' is the time, as determined by testing, that
will elapse from loading until the pressure of the contents, under
equilibrium conditions, reaches the level of the lowest pressure control
valve or pressure relief valve setting.
(b) Holding time test. (1) The test to determine holding time must
be performed by charging the tank with a cryogenic liquid having a
boiling point, at a pressure of one atmosphere, absolute, no lower than
the design service temperature of the tank. The tank must be charged to
its maximum permitted filling density with that liquid and stabilized to
the lowest practical pressure, which must be equal to or less than the
pressure to be used for loading. The cargo tank together with its
contents must then be exposed to ambient temperature.
(2) The tank pressure and ambient temperature must be recorded at 3-
hour intervals until the pressure level of the contents reaches the set-
to-discharge pressure of the pressure control valve or pressure relief
valve with the lowest setting. This total time lapse in hours represents
the measured holding time at the actual average ambient temperature.
This measured holding time for the test cryogenic liquid must be
adjusted to an equivalent holding time for each cryogenic liquid that is
[[Page 152]]
to be identified on or adjacent to the specification plate, at an
average ambient temperature of 85 [deg]F. This is the rated holding time
(RHT). The marked rated holding time (MRHT) displayed on or adjacent to
the specification plate (see Sec. 178.338-18(c)(10)) may not exceed
this RHT.
(c) Optional test regimen. (1) If more than one cargo tank is made
to the same design, only one cargo tank must be subjected to the full
holding time test at the time of manufacture. However, each subsequent
cargo tank made to the same design must be performance tested during its
first trip. The holding time determined in this test may not be less
than 90 percent of the marked rated holding time. This test must be
performed in accordance with Sec. Sec. 173.318(g)(3) and 177.840(h) of
this subchapter, regardless of the classification of the cryogenic
liquid.
(2) Same design. The term ``same design'' as used in this section
means cargo tanks made to the same design type. See Sec. 178.320(a) for
definition of ``design type''.
(3) For a cargo tank used in nonflammable cryogenic liquid service,
in place of the holding time tests prescribed in paragraph (b) of this
section, the marked rated holding time (MRHT) may be determined as
follows:
(i) While the cargo tank is stationary, the heat transfer rate must
be determined by measuring the normal evaporation rate (NER) of the test
cryogenic liquid (preferably the lading, where feasible) maintained at
approximately one atmosphere. The calculated heat transfer rate must be
determined from:
q = [n([Delta] h)(85-t1)] / [ts - tf]
Where:
q = calculated heat transfer rate to cargo tank with lading, Btu/hr.
n = normal evaporation rate (NER), which is the rate of evaporation,
determined by the test of a test cryogenic liquid in a cargo tank
maintained at a pressure of approximately one atmosphere, absolute, lb/
hr.
[Delta] h = latent heat of vaporization of test fluid at test pressure,
Btu/lb.
ts = average temperature of outer shell during test, [deg]F.
t1 = equilibrium temperature of lading at maximum loading
pressure, [deg]F.
tf = equilibrium temperature of test fluid at one atmosphere,
[deg]F.
(ii) The rated holding time (RHT) must be calculated as follows:
RHT = [(U2 - U1) W] / q
Where:
RHT = rated holding time, in hours
U1 and U2 = internal energy for the combined
liquid and vapor lading at the pressure offered for transportation, and
the set pressure of the applicable pressure control valve or pressure
relief valve, respectively, Btu/lb.
W = total weight of the combined liquid and vapor lading in the cargo
tank, pounds.
q = calculated heat transfer rate to cargo tank with lading, Btu/hr.
(iii) The MRHT (see Sec. 178.338-18(b)(9) of this subchapter) may
not exceed the RHT.
[Amdt. 178-77, 48 FR 27704, June 16, 1983; 48 FR 50442, Nov. 1, 1983, as
amended at 49 FR 24316, June 12, 1984; 49 FR 43965, Nov. 1, 1984; 59 FR
55173, Nov. 3, 1994; Amdt. 178-118, 61 FR 51340, Oct. 1, 1996; 68 FR
57634, Oct. 6, 2003; 71 FR 54397, Sept. 14, 2006]
Sec. 178.338-10 Accident damage protection.
(a) All valves, fittings, pressure relief devices and other
accessories to the tank proper, which are not isolated from the tank by
closed intervening shut-off valves or check valves, must be installed
within the motor vehicle framework or within a suitable collision
resistant guard or housing, and appropriate ventilation must be
provided. Each pressure relief device must be protected so that in the
event of the upset of the vehicle onto a hard surface, the device's
opening will not be prevented and its discharge will not be restricted.
(b) Each protective device or housing, and its attachment to the
vehicle structure, must be designed to withstand static loading in any
direction that it may be loaded as a result of front, rear, side, or
sideswipe collision, or the overturn of the vehicle. The static loading
shall equal twice the loaded weight of the tank and attachments. A
safety factor of four, based on the tensile strength of the material,
shall be used. The protective device or the housing must be made of
steel at least \3/16\-inch thick, or other material of equivalent
strength.
(c) Rear-end tank protection. Rear-end tank protections devices
must:
[[Page 153]]
(1) Consist of at least one rear bumper designed to protect the
cargo tank and piping in the event of a rear-end collision. The rear-end
tank protection device design must transmit the force of the collision
directly to the chassis of the vehicle. The rear-end tank protection
device and its attachments to the chassis must be designed to withstand
a load equal to twice the weight of the loaded cargo tank and
attachments, using a safety factor of four based on the tensile strength
of the materials used, with such load being applied horizontally and
parallel to the major axis of the cargo tank. The rear-end tank
protection device dimensions must meet the requirements of Sec. 393.86
of this title and extend vertically to a height adequate to protect all
valves and fittings located at the rear of the cargo tank from damage
that could result in loss of lading; or
(2) Conform to the requirements of Sec. 178.345-8(b).
(d) Every part of the loaded cargo tank, and any associated valve,
pipe, enclosure, or protective device or structure (exclusive of wheel
assemblies), must be at least 14 inches above level ground.
[Amdt. 178-77, 48 FR 27705, June 16, 1983, as amended at 49 FR 24316,
June 12, 1984; Amdt. 178-99, 58 FR 51534, Oct. 1, 1993; 68 FR 19282,
Apr. 18, 2003; 68 FR 52371, Sept. 3, 2003]
Sec. 178.338-11 Discharge control devices.
(a) Excess-flow valves are not required.
(b) Each liquid filling and liquid discharge line must be provided
with a shut-off valve located as close to the tank as practicable.
Unless this valve is manually operable at the valve, the line must also
have a manual shut-off valve.
(c) Except for a cargo tank that is used to transport argon, carbon
dioxide, helium, krypton, neon, nitrogen, xenon, or mixtures thereof,
each liquid filling and liquid discharge line must be provided with an
on-vehicle remotely controlled self-closing shutoff valve.
(1) If pressure from a reservoir or from an engine-driven pump or
compressor is used to open this valve, the control must be of fail-safe
design and spring-biased to stop the admission of such pressure into the
cargo tank. If the jacket is not evacuated, the seat of the valve must
be inside the tank, in the opening nozzle or flange, or in a companion
flange bolted to the nozzle. If the jacket is evacuated, the remotely
controlled valve must be located as close to the tank as practicable.
(2) Each remotely controlled shut off valve must be provided with
on-vehicle remote means of automatic closure, both mechanical and
thermal. One means may be used to close more than one remotely
controlled valve. Cable linkage between closures and remote operators
must be corrosion resistant and effective in all types of environment
and weather. The thermal means must consist of fusible elements actuated
at a temperature not exceeding 121 [deg]C (250 [deg]F), or equivalent
devices. The loading/unloading connection area is where hoses are
connected to the permanent metal piping. The number and location of
remote operators and thermal devices shall be as follows:
(i) On a cargo tank motor vehicle over 3,500 gallons water capacity,
remote means of automatic closure must be installed at the ends of the
cargo tank in at least two diagonally opposite locations. If the
loading/unloading connection at the cargo tank is not in the general
vicinity of one of these locations, at least one additional thermal
device must be installed so that heat from a fire in the loading/
unloading connection area will activate the emergency control system.
(ii) On a cargo tank motor vehicle of 3,500 gallons water capacity
or less, at least one remote means of automatic closure must be
installed on the end of the cargo tank farthest away from the loading/
unloading connection area. At least one thermal device must be installed
so that heat from a fire in the loading/unloading connection area will
activate the emergency control system.
[Amdt. 178-77, 48 FR 27705, June 16, 1983, as amended by Amdt. 178-105,
59 FR 55173, Nov. 3, 1994; 60 FR 17402, Apr. 5, 1995; 68 FR 19282, Apr.
18, 2003]
Sec. 178.338-12 Shear section.
Unless the valve is located in a rear cabinet forward of and
protected by the
[[Page 154]]
bumper (see Sec. 178.338-10(c)), the design and installation of each
valve, damage to which could result in loss of liquid or vapor, must
incorporate a shear section or breakage groove adjacent to, and outboard
of, the valve. The shear section or breakage groove must yield or break
under strain without damage to the valve that would allow the loss of
liquid or vapor. The protection specified in Sec. 178.338-10 is not a
substitute for a shear section or breakage groove.
[Amdt. 178-77, 49 FR 24316, June 12, 1984]
Sec. 178.338-13 Supporting and anchoring.
(a) On a cargo tank motor vehicle designed and constructed so that
the cargo tank constitutes in whole or in part the structural member
used in place of a motor vehicle frame, the cargo tank or the jacket
must be supported by external cradles or by load rings. For a cargo tank
mounted on a motor vehicle frame, the tank or jacket must be supported
by external cradles, load rings, or longitudinal members. If cradles are
used, they must subtend at least 120 degrees of the cargo tank
circumference. The design calculations for the supports and load-bearing
tank or jacket, and the support attachments must include beam stress,
shear stress, torsion stress, bending moment, and acceleration stress
for the loaded vehicle as a unit, using a safety factor of four, based
on the tensile strength of the material, and static loading that uses
the weight of the cargo tank and its attachments when filled to the
design weight of the lading (see appendix G in Section VIII of the ASME
Code) (IBR, see Sec. 171.7 of this subchapter), multiplied by the
following factors. The effects of fatigue must also be considered in the
calculations. Minimum static loadings must be as follows:
(1) For a vacuum-insulated cargo tank--
(i) Vertically downward of 2;
(ii) Vertically upward of 2;
(iii) Longitudinally of 2; and
(iv) Laterally of 2.
(2) For any other insulated cargo tank--
(i) Vertically downward of 3;
(ii) Vertically upward of 2;
(iii) Longitudinally of 2; and
(iv) Laterally of 2.
(b) When a loaded tank is supported within the vacuum jacket by
structural members, the design calculations for the tank and its
structural members must be based on a safety factor of four and the
tensile strength of the material at ambient temperature. The enhanced
tensile strength of the material at actual operating temperature may be
substituted for the tensile strength at ambient temperature to the
extent recognized in the ASME Code for static loadings. Static loadings
must take into consideration the weight of the tank and the structural
members when the tank is filled to the design weight of lading (see
Appendix G of Section VIII, Division 1 of the ASME Code), multiplied by
the following factors. Static loadings must take into consideration the
weight of the tank and the structural members when the tank is filled to
the design weight of lading (see appendix G in Section VIII of the ASME
Code), multiplied by the following factors. When load rings in the
jacket are used for supporting the tank, they must be designed to carry
the fully loaded tank at the specified static loadings, plus external
pressure. Minimum static loadings must be as follows:
(1) Vertically downward of 2;
(2) Vertically upward of 1\1/2\;
(3) Longitudinally of 1\1/2\; and, (4) Laterally of 1\1/2\.
[68 FR 19282, Apr. 18, 2003, as amended at 68 FR 75754, Dec. 31, 2003]
Sec. 178.338-14 Gauging devices.
(a) Liquid level gauging devices. (1) Unless a cargo tank is
intended to be filled by weight, it must be equipped with one or more
gauging devices, which accurately indicate the maximum permitted liquid
level at the loading pressure, in order to provide a minimum of two
percent outage below the inlet of the pressure control valve or pressure
relief valve at the condition of incipient opening of that valve. A
fixed-length dip tube, a fixed trycock line, or a differential pressure
liquid level gauge must be used as the primary control for filling.
Other gauging devices, except gauge glasses, may be used, but not as the
primary control for filling.
[[Page 155]]
(2) The design pressure of each liquid level gauging device must be
at least that of the tank.
(3) If a fixed length dip tube or trycock line gauging device is
used, it must consist of a pipe or tube of small diameter equipped with
a valve at or near the jacket and extending into the cargo tank to a
specified filling height. The fixed height at which the tube ends in the
cargo tank must be such that the device will function when the liquid
reaches the maximum level permitted in loading.
(4) The liquid level gauging device used as a primary control for
filling must be designed and installed to accurately indicate the
maximum filling level at the point midway of the tank both
longitudinally and laterally.
(b) Pressure gauges. Each cargo tank must be provided with a
suitable pressure gauge indicating the lading pressure and located on
the front of the jacket so it can be read by the driver in the rear view
mirror. Each gauge must have a reference mark at the cargo tank design
pressure or the set pressure of the pressure relief valve or pressure
control valve, whichever is lowest.
(c) Orifices. All openings for dip tube gauging devices and pressure
gauges in flammable cryogenic liquid service must be restricted at or
inside the jacket by orifices no larger than 0.060-inch diameter.
Trycock lines, if provided, may not be greater than \1/2\-inch nominal
pipe size.
[Amdt. 178-77, 48 FR 27706, June 16, 1983, as amended at 49 FR 24317,
June 12, 1984]
Sec. 178.338-15 Cleanliness.
A cargo tank constructed for oxygen service must be thoroughly
cleaned to remove all foreign material in accordance with CGA G-4.1
(IBR, see Sec. 171.7 of this subchapter). All loose particles from
fabrication, such as weld beads, dirt, grinding wheel debris, and other
loose materials, must be removed prior to the final closure of the
manhole of the tank. Chemical or solvent cleaning with a material
compatible with the intending lading must be performed to remove any
contaminants likely to react with the lading.
[68 FR 75755, Dec. 31, 2003]
Sec. 178.338-16 Inspection and testing.
(a) General. The material of construction of a tank and its
appurtenances must be inspected for conformance to Section VIII of the
ASME Code (IBR, see Sec. 171.7 of this subchapter). The tank must be
subjected to either a hydrostatic or pneumatic test. The test pressure
must be one and one-half times the sum of the design pressure, plus
static head of lading, plus 101.3 kPa (14.7 psi) if subjected to
external vacuum, except that for tanks constructed in accordance with
Part UHT in Section VIII of the ASME Code the test pressure must be
twice the design pressure.
(b) Additional requirements for pneumatic test. A pneumatic test may
be used in place of the hydrostatic test. Due regard for protection of
all personnel should be taken because of the potential hazard involved
in a pneumatic test. The pneumatic test pressure in the tank must be
reached by gradually increasing the pressure to one-half of the test
pressure. Thereafter, the test pressure must be increased in steps of
approximately one-tenth of the test pressure until the required test
pressure has been reached. Then the pressure must be reduced to a value
equal to four-fifths of the test pressure and held for a sufficient time
to permit inspection of the cargo tank for leaks.
(c) Weld inspection. All tank shell or head welds subject to
pressure shall be radiographed in accordance with Section VIII of the
ASME Code. A tank which has been subjected to inspection by the magnetic
particle method, the liquid penetrant method, or any method involving a
material deposit on the interior tank surface, must be cleaned to remove
any such residue by scrubbing or equally effective means, and all such
residue and cleaning solution must be removed from the tank prior to
final closure of the tank.
(d) Defect repair. All cracks and other defects must be repaired as
prescribed in Section VIII of the ASME Code. The welder and the welding
procedure must be qualified in accordance with Section IX of the ASME
Code (IBR, see Sec. 171.7 of this subchapter). After repair, the tank
must again be postweld heat-treated, if such heat treatment was
previously
[[Page 156]]
performed, and the repaired areas must be retested.
(e) Verification must be made of the interior cleanliness of a tank
constructed for oxygen service by means that assure that all
contaminants that are likely to react with the lading have been removed
as required by Sec. 178.338-15.
[Amdt. 178-77, 48 FR 27706, June 16, 1983, as amended at 49 FR 24317,
June 12, 1984; 49 FR 42736, Oct. 24, 1984; 68 FR 75755, Dec. 31, 2003]
Sec. 178.338-17 Pumps and compressors.
(a) Liquid pumps and gas compressors, if used, must be of suitable
design, adequately protected against breakage by collision, and kept in
good condition. They may be driven by motor vehicle power take-off or
other mechanical, electrical, or hydraulic means. Unless they are of the
centrifugal type, they shall be equipped with suitable pressure actuated
by-pass valves permitting flow from discharge to suction to the tank.
(b) A valve or fitting made of aluminum with internal rubbing or
abrading aluminum parts that may come in contact with oxygen (cryogenic
liquid) may not be installed on any cargo tank used to transport oxygen
(cryogenic liquid) unless the parts are anodized in accordance with ASTM
B 580 (IBR, see Sec. 171.7 of this subchapter).
[Amdt. 178-89, 54 FR 25020, June 12, 1989, as amended at 55 FR 37058,
Sept. 7, 1990; 67 FR 61016, Sept. 27, 2002; 68 FR 75755, Dec. 31, 2003]
Sec. 178.338-18 Marking.
(a) General. Each cargo tank certified after October 1, 2004 must
have a corrosion-resistant metal name plate (ASME Plate) and
specification plate permanently attached to the cargo tank by brazing,
welding, or other suitable means on the left side near the front, in a
place accessible for inspection. If the specification plate is attached
directly to the cargo tank wall by welding, it must be welded to the
tank before the cargo tank is postweld heat treated.
(1) The plates must be legibly marked by stamping, embossing, or
other means of forming letters into the metal of the plate, with the
information required in paragraphs (b) and (c) of this section, in
addition to that required by Section VIII of the ASME Code (IBR, see
Sec. 171.7 of this subchapter), in characters at least 3/16 inch high
(parenthetical abbreviations may be used). All plates must be maintained
in a legible condition.
(2) Each insulated cargo tank must have additional plates, as
described, attached to the jacket in the location specified unless the
specification plate is attached to the chassis and has the information
required in paragraphs (b) and (c) of this section.
(3) The information required for both the name and specification
plate may be displayed on a single plate. If the information required by
this section is displayed on a plate required by Section VIII of the
ASME Code, the information need not be repeated on the name and
specification plates.
(4) The specification plate may be attached to the cargo tank motor
vehicle chassis rail by brazing, welding, or other suitable means on the
left side near the front head, in a place accessible for inspection. If
the specification plate is attached to the chassis rail, then the cargo
tank serial number assigned by the cargo tank manufacturer must be
included on the plate.
(b) Name plate. The following information must be marked on the name
plate in accordance with this section:
(1) DOT-specification number MC 338 (DOT MC 338).
(2) Original test date (Orig, Test Date).
(3) MAWP in psig.
(4) Cargo tank test pressure (Test P), in psig.
(5) Cargo tank design temperature (Design Temp. Range) ---- [deg]F
to ---- [deg]F.
(6) Nominal capacity (Water Cap.), in pounds.
(7) Maximum design density of lading (Max. Lading density), in
pounds per gallon.
(8) Material specification number--shell (Shell matl, yyy * * *),
where ``yyy'' is replaced by the alloy designation and ``* * *'' is
replaced by the alloy type.
(9) Material specification number--heads (Head matl. yyy * * *),
where ``yyy'' is replaced by the alloy designation and ``* * *'' by the
alloy type.
[[Page 157]]
Note: When the shell and heads materials are the same thickness,
they may be combined, (Shell & head matl, yyy * * *).
(10) Weld material (Weld matl.).
(11) Minimum Thickness-shell (Min. Shell-thick), in inches. When
minimum shell thicknesses are not the same for different areas, show
(top ----, side ----, bottom ----, in inches).
(12) Minimum thickness-heads (Min heads thick.), in inches.
(13) Manufactured thickness-shell (Mfd. Shell thick.), top ----,
side ----, bottom ----, in inches. (Required when additional thickness
is provided for corrosion allowance.)
(14) Manufactured thickness-heads (Mfd. Heads thick.), in inches.
(Required when additional thickness is provided for corrosion
allowance.)
(15) Exposed surface area, in square feet.
(c) Specification plate. The following information must be marked on
the specification plate in accordance with this section:
(1) Cargo tank motor vehicle manufacturer (CTMV mfr.).
(2) Cargo tank motor vehicle certification date (CTMV cert. date).
(3) Cargo tank manufacturer (CT mfr.).
(4) Cargo tank date of manufacture (CT date of mfr.), month and
year.
(5) Maximum weight of lading (Max. Payload), in pounds.
(6) Maximum loading rate in gallons per minute (Max. Load rate,
GPM).
(7) Maximum unloading rate in gallons per minute (Max Unload rate).
(8) Lining materials (Lining), if applicable.
(9) ``Insulated for oxygen service'' or ``Not insulated for oxygen
service'' as appropriate.
(10) Marked rated holding time for at least one cryogenic liquid, in
hours, and the name of that cryogenic liquid (MRHT ---- hrs, name of
cryogenic liquid). Marked rated holding marking for additional cryogenic
liquids may be displayed on or adjacent to the specification plate.
(11) Cargo tank serial number (CT serial), as assigned by cargo tank
manufacturer, if applicable.
Note 1 to paragraph (c): See Sec. 173.315(a) of this chapter
regarding water capacity.
Note 2 to paragraph (c): When the shell and head materials are the
same thickness, they may be combined (Shell & head matl, yyy***).
(d) The design weight of lading used in determining the loading in
Sec. Sec. 178.338-3 (b), 178.338-10 (b) and (c), and 178.338-13 (b),
must be shown as the maximum weight of lading marking required by
paragraph (c) of this section.
[68 FR 19283, Apr. 18, 2003, as amended at 68 FR 57634, Oct. 6, 2003; 68
FR 75755, Dec. 31, 2003]
Sec. 178.338-19 Certification.
(a) At or before the time of delivery, the manufacturer of a cargo
tank motor vehicle shall furnish to the owner of the completed vehicle
the following:
(1) The tank manufacturer's data report as required by the ASME Code
(IBR, see Sec. 171.7 of this subchapter), and a certificate bearing the
manufacturer's vehicle serial number stating that the completed cargo
tank motor vehicle conforms to all applicable requirements of
Specification MC 338, including Section VIII of the ASME Code (IBR, see
Sec. 171.7 of this subchapter) in effect on the date (month, year) of
certification. The registration numbers of the manufacturer, the Design
Certifying Engineer, and the Registered Inspector, as appropriate, must
appear on the certificates (see subpart F, part 107 in subchapter B of
this chapter).
(2) A photograph, pencil rub, or other facsimile of the plates
required by paragraphs (a) and (b) of Sec. 178.338-18.
(b) In the case of a cargo tank vehicle manufactured in two or more
stages, each manufacturer who performs a manufacturing operation on the
incomplete vehicle or portion thereof shall furnish to the succeeding
manufacturer, at or before the time of delivery, a certificate covering
the particular operation performed by that manufacturer, and any
certificates received from previous manufacturers, Registered
Inspectors, and Design Certifying Engineers. The certificates must
include sufficient sketches, drawings, and other information to indicate
the location, make, model and size of each valve and the arrangement of
all piping associated with the tank. Each certificate must be signed by
an official of
[[Page 158]]
the manufacturing firm responsible for the portion of the complete cargo
tank vehicle represented thereby, such as basic tank fabrication,
insulation, jacket, or piping. The final manufacturer shall furnish the
owner with all certificates, as well as the documents required by
paragraph (a) of this section.
(c) The owner shall retain the data report, certificates, and
related papers throughout his ownership of the cargo tank. In the event
of change of ownership, the prior owner shall retain non-fading
photographically reproduced copies of these documents for at least one
year. Each operator using the cargo tank vehicle, if not the owner
thereof, shall obtain a copy of the data report and the certificate or
certificates and retain them during the time he uses the cargo tank and
for at least one year thereafter.
(Approved by the Office of Management and Budget under control number
2137-0017)
[Amdt. 178-77, 48 FR 27707 and 27713, June 16, 1983, as amended by Amdt.
178-89, 55 FR 37058, Sept. 7, 1990; Amdt. 178-99, 58 FR 51534, Oct. 1,
1993; 62 FR 51561, Oct. 1, 1997; 68 FR 75755, Dec. 31, 2003]
Sec. Sec. 178.340-178.343 [Reserved]
Sec. 178.345 General design and construction requirements applicable to
Specification DOT 406 (Sec. 178.346), DOT 407 (Sec. 178.347), and DOT 412
(Sec. 178.348) cargo tank motor vehicles.
Sec. 178.345-1 General requirements.
(a) Specification DOT 406, DOT 407 and DOT 412 cargo tank motor
vehicles must conform to the requirements of this section in addition to
the requirements of the applicable specification contained in Sec. Sec.
178.346, 178.347 or 178.348.
(b) All specification requirements are minimum requirements.
(c) Definitions. See Sec. 178.320(a) for the definition of certain
terms used in Sec. Sec. 178.345, 178.346, 178.347, and 178.348. In
addition, the following definitions apply to Sec. Sec. 178.345,
178.346, 178.347, and 178.348:
Appurtenance means any cargo tank accessory attachment that has no
lading retention or containment function and provides no structural
support to the cargo tank.
Baffle means a non-liquid-tight transverse partition device that
deflects, checks or regulates fluid motion in a tank.
Bulkhead means a liquid-tight transverse closure at the ends of or
between cargo tanks.
Charging line means a hose, tube, pipe, or similar device used to
pressurize a tank with material other than the lading.
Companion flange means one of two mating flanges where the flange
faces are in contact or separated only by a thin leak sealing gasket and
are secured to one another by bolts or clamps.
Connecting structure means the structure joining two cargo tanks.
Constructed and certified in conformance with the ASME Code means
the cargo tank is constructed and stamped in accordance with the ASME
Code, and is inspected and certified by an Authorized Inspector.
Constructed in accordance with the ASME Code means the cargo tank is
constructed in accordance with the ASME Code with the authorized
exceptions (see Sec. Sec. 178.346, 178.347, and 178.348) and is
inspected and certified by a Registered Inspector.
External self-closing stop-valve means a self-closing stop-valve
designed so that the self-stored energy source is located outside the
cargo tank and the welded flange.
Extreme dynamic loading means the maximum single-acting loading a
cargo tank motor vehicle may experience during its expected life,
excluding accident loadings.
Flange means the structural ring for guiding or attachment of a pipe
or fitting with another flange (companion flange), pipe, fitting or
other attachment.
Inspection pressure means the pressure used to determine leak
tightness of the cargo tank when testing with pneumatic pressure.
Internal self-closing stop-valve means a self-closing stop-valve
designed so that the self-stored energy source is located inside the
cargo tank or cargo tank sump, or within the welded flange, and the
valve seat is located within the cargo tank or within one inch of the
[[Page 159]]
external face of the welded flange or sump of the cargo tank.
Lading means the hazardous material contained in a cargo tank.
Loading/unloading connection means the fitting in the loading/
unloading line farthest from the loading/unloading outlet to which the
loading/unloading hose or device is attached.
Loading/unloading outlet means the cargo tank outlet used for normal
loading/unloading operations.
Loading/unloading stop-valve means the stop valve farthest from the
cargo tank loading/unloading outlet to which the loading/unloading
connection is attached.
MAWP. See Sec. 178.320(a).
Multi-specification cargo tank motor vehicle means a cargo tank
motor vehicle equipped with two or more cargo tanks fabricated to more
than one cargo tank specification.
Normal operating loading means the loading a cargo tank motor
vehicle may be expected to experience routinely in operation.
Nozzle means the subassembly consisting of a pipe or tubular section
with or without a welded or forged flange on one end.
Outlet means any opening in the shell or head of a cargo tank,
(including the means for attaching a closure), except that the following
are not outlets: A threaded opening securely closed during
transportation with a threaded plug or a threaded cap, a flanged opening
securely closed during transportation with a bolted or welded blank
flange, a manhole, or gauging devices, thermometer wells, and safety
relief devices.
Outlet stop-valve means the stop-valve at the cargo tank loading/
unloading outlet.
Pipe coupling means a fitting with internal threads on both ends.
Rear bumper means the structure designed to prevent a vehicle or
object from under-riding the rear of a motor vehicle. See Sec. 393.86
of this title.
Rear-end tank protection device means the structure designed to
protect a cargo tank and any lading retention piping or devices in case
of a rear end collision.
Sacrificial device means an element, such as a shear section,
designed to fail under a load in order to prevent damage to any lading
retention part or device. The device must break under strain at no more
than 70 percent of the strength of the weakest piping element between
the cargo tank and the sacrificial device. Operation of the sacrificial
device must leave the remaining piping and its attachment to the cargo
tank intact and capable of retaining lading.
Self-closing stop-valve means a stop-valve held in the closed
position by means of self-stored energy, which opens only by application
of an external force and which closes when the external force is
removed.
Shear section means a sacrificial device fabricated in such a manner
as to abruptly reduce the wall thickness of the adjacent piping or valve
material by at least 30 percent.
Shell means the circumferential portion of a cargo tank defined by
the basic design radius or radii excluding the closing heads.
Stop-valve means a valve that stops the flow of lading.
Sump means a protrusion from the bottom of a cargo tank shell
designed to facilitate complete loading and unloading of lading.
Tank means a container, consisting of a shell and heads, that forms
a pressure tight vessel having openings designed to accept pressure
tight fittings or closures, but excludes any appurtenances,
reinforcements, fittings, or closures.
Test pressure means the pressure to which a tank is subjected to
determine pressure integrity.
Toughness of material means the capability of a material to absorb
the energy represented by the area under the stress strain curve
(indicating the energy absorbed per unit volume of the material) up to
the point of rupture.
Vacuum cargo tank means a cargo tank that is loaded by reducing the
pressure in the cargo tank to below atmospheric pressure.
Variable specification cargo tank means a cargo tank that is
constructed in accordance with one specification, but which may be
altered to meet another specification by changing relief
[[Page 160]]
device, closures, lading discharge devices, and other lading retention
devices.
Void means the space between tank heads or bulkheads and a
connecting structure.
Welded flange means a flange attached to the tank by a weld joining
the tank shell to the cylindrical outer surface of the flange, or by a
fillet weld joining the tank shell to a flange shaped to fit the shell
contour.
(d) A manufacturer of a cargo tank must hold a current ASME
certificate of authorization and must be registered with the Department
in accordance with part 107, subpart F of this chapter.
(e) All construction must be certified by an Authorized Inspector or
by a Registered Inspector as applicable to the cargo tank.
(f) Each cargo tank must be designed and constructed in conformance
with the requirements of the applicable cargo tank specification. Each
DOT 412 cargo tank with a ``MAWP'' greater than 15 psig, and each DOT
407 cargo tank with a maximum allowable working pressure greater than 35
psig must be ``constructed and certified in conformance with Section
VIII of the ASME Code'' (IBR, see Sec. 171.7 of this subchapter) except
as limited or modified by the applicable cargo tank specification. Other
cargo tanks must be ``constructed in accordance with Section VIII of the
ASME Code,'' except as limited or modified by the applicable cargo tank
specification.
(g) Requirements relating to parts and accessories on motor
vehicles, which are contained in part 393 of the Federal Motor Carrier
Safety Regulations of this title, are incorporated into these
specifications.
(h) Any additional requirements prescribed in part 173 of this
subchapter that pertain to the transportation of a specific lading are
incorporated into these specifications.
(i) Cargo tank motor vehicle composed of multiple cargo tanks. (1) A
cargo tank motor vehicle composed of more than one cargo tank may be
constructed with the cargo tanks made to the same specification or to
different specifications. Each cargo tank must conform in all respects
with the specification for which it is certified.
(2) The strength of the connecting structure joining multiple cargo
tanks in a cargo tank motor vehicle must meet the structural design
requirements in Sec. 178.345-3. Any void within the connecting
structure must be equipped with a drain located on the bottom centerline
that is accessible and kept open at all times. For carbon steel, self-
supporting cargo tanks, the drain configuration may consist of a single
drain of at least 1.0 inch diameter, or two or more drains of at least
0.5 inch diameter, 6.0 inches apart, one of which is located as close to
the bottom centerline as practicable. Vapors trapped in a void within
the connecting structure must be allowed to escape to the atmosphere
either through the drain or a separate vent.
(j) Variable specification cargo tank. A cargo tank that may be
physically altered to conform to another cargo tank specification must
have the required physical alterations to convert from one specification
to another clearly indicated on the variable specification plate.
[Amdt. 178-89, 54 FR 25020, June 12, 1989, as amended at 55 FR 37058,
Sept. 7, 1990; Amdt. 178-105, 59 FR 55173, Nov. 3, 1994; Amdt. 178-118,
61 FR 51340, Oct. 1, 1996; 66 FR 45387, 45389, Aug. 28, 2001; 68 FR
19283, Apr. 18, 2003; 68 FR 52371, Sept. 3, 2003; 68 FR 75755, Dec. 31,
2003; 70 FR 56099, Sept. 23, 2005; 76 FR 43532, July 20, 2011]
Sec. 178.345-2 Material and material thickness.
(a) All material for shell, heads, bulkheads, and baffles must
conform to Section II of the ASME Code (IBR, see Sec. 171.7 of this
subchapter) except as follows:
(1) The following steels are also authorized for cargo tanks
``constructed in accordance with the ASME Code'', Section VIII.
ASTM A 569
ASTM A 570
ASTM A 572
ASTM A 622
ASTM A 656
ASTM A 715
ASTM A 1008/ A 1008M, ASTM A 1011/A 1011M
(2) Aluminum alloys suitable for fusion welding and conforming with
the 0, H32 or H34 tempers of one of the following ASTM specifications
may be
[[Page 161]]
used for cargo tanks ``constructed in accordance with the ASME Code'':
ASTM B-209 Alloy 5052
ASTM B-209 Alloy 5086
ASTM B-209 Alloy 5154
ASTM B-209 Alloy 5254
ASTM B-209 Alloy 5454
ASTM B-209 Alloy 5652
All heads, bulkheads and baffles must be of 0 temper (annealed) or
stronger tempers. All shell materials shall be of H 32 or H 34 tempers
except that the lower ultimate strength tempers may be used if the
minimum shell thicknesses in the tables are increased in inverse
proportion to the lesser ultimate strength.
(b) Minimum thickness. The minimum thickness for the shell and heads
(or baffles and bulkheads when used as tank reinforcement) must be no
less than that determined under criteria for minimum thickness specified
in Sec. 178.320(a).
(c) Corrosion or abrasion protection. When required by 49 CFR part
173 for a particular lading, a cargo tank or a part thereof, subject to
thinning by corrosion or mechanical abrasion due to the lading, must be
protected by providing the tank or part of the tank with a suitable
increase in thickness of material, a lining or some other suitable
method of protection.
(1) Corrosion allowance. Material added for corrosion allowance need
not be of uniform thickness if different rates of attack can reasonably
be expected for various areas of the cargo tank.
(2) Lining. Lining material must consist of a nonporous, homogeneous
material not less elastic than the parent metal and substantially immune
to attack by the lading. The lining material must be bonded or attached
by other appropriate means to the cargo tank wall and must be
imperforate when applied. Any joint or seam in the lining must be made
by fusing the materials together, or by other satisfactory means.
[Amdt. 178-89, 54 FR 25021, June 12, 1989, as amended at 55 FR 37059,
Sept. 7, 1990; 56 FR 27876, June 17, 1991; Amdt. 178-97, 57 FR 45465,
Oct. 1, 1992; Amdt. 178-118, 61 FR 51341, Oct. 1, 1996; 68 FR 19283,
Apr. 18, 2003; 68 FR 75755, Dec. 31, 2003; 70 FR 34076, June 13, 2005]
Sec. 178.345-3 Structural integrity.
(a) General requirements and acceptance criteria. (1) The maximum
calculated design stress at any point in the cargo tank wall may not
exceed the maximum allowable stress value prescribed in Section VIII of
the ASME Code (IBR, see Sec. 171.7 of this subchapter), or 25 percent
of the tensile strength of the material used at design conditions.
(2) The relevant physical properties of the materials used in each
cargo tank may be established either by a certified test report from the
material manufacturer or by testing in conformance with a recognized
national standard. In either case, the ultimate tensile strength of the
material used in the design may not exceed 120 percent of the minimum
ultimate tensile strength specified in either the ASME Code or the ASTM
standard to which the material is manufactured.
(3) The maximum design stress at any point in the cargo tank must be
calculated separately for the loading conditions described in paragraphs
(b) and (c) of this section. Alternate test or analytical methods, or a
combination thereof, may be used in place of the procedures described in
paragraphs (b) and (c) of this section, if the methods are accurate and
verifiable. TTMA RP 96-01, Structural Integrity of DOT 406, DOT 407, and
DOT 412 Cylindrical Cargo Tanks, may be used as guidance in performing
the calculations.
(4) Corrosion allowance material may not be included to satisfy any
of the design calculation requirements of this section.
(b) ASME Code design and construction. The static design and
construction of each cargo tank must be in accordance with Section VIII
of the ASME Code. The cargo tank design must include calculation of
stresses generated by the MAWP, the weight of the lading, the weight of
structures supported by the cargo tank wall and the effect of
temperature gradients resulting from lading and ambient temperature
extremes. When dissimilar materials are used, their thermal coefficients
must be used in the calculation of thermal stresses.
(1) Stress concentrations in tension, bending and torsion which
occur at
[[Page 162]]
pads, cradles, or other supports must be considered in accordance with
appendix G in Section VIII of the ASME Code.
(2) Longitudinal compressive buckling stress for ASME certified
vessels must be calculated using paragraph UG-23(b) in Section VIII of
the ASME Code. For cargo tanks not required to be certified in
accordance with the ASME Code, compressive buckling stress may be
calculated using alternative analysis methods which are accurate and
verifiable. When alternative methods are used, calculations must include
both the static loads described in this paragraph and the dynamic loads
described in paragraph (c) of this section.
(3) Cargo tank designers and manufacturers must consider all of the
conditions specified in Sec. 173.33(c) of this subchapter when matching
a cargo tank's performance characteristic to the characteristic of each
lading transported.
(c) Shell design. Shell stresses resulting from static or dynamic
loadings, or combinations thereof, are not uniform throughout the cargo
tank motor vehicle. The vertical, longitudinal, and lateral normal
operating loadings can occur simultaneously and must be combined. The
vertical, longitudinal and lateral extreme dynamic loadings occur
separately and need not be combined.
(1) Normal operating loadings. The following procedure addresses
stress in the cargo tank shell resulting from normal operating loadings.
The effective stress (the maximum principal stress at any point) must be
determined by the following formula:
S = 0.5(Sy + Sx) [0.25(Sy-Sx)\2\ +
SS2]\0.5\
Where:
(i) S = effective stress at any given point under the combination of
static and normal operating loadings that can occur at the same time, in
psi.
(ii) Sy = circumferential stress generated by the MAWP
and external pressure, when applicable, plus static head, in psi.
(iii) Sx = The following net longitudinal stress
generated by the following static and normal operating loading
conditions, in psi:
(A) The longitudinal stresses resulting from the MAWP and external
pressure, when applicable, plus static head, in combination with the
bending stress generated by the static weight of the fully loaded cargo
tank motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall;
(B) The tensile or compressive stress resulting from normal
operating longitudinal acceleration or deceleration. In each case, the
forces applied must be 0.35 times the vertical reaction at the
suspension assembly, applied at the road surface, and as transmitted to
the cargo tank wall through the suspension assembly of a trailer during
deceleration; or the horizontal pivot of the truck tractor or converter
dolly fifth wheel, or the drawbar hinge on the fixed dolly during
acceleration; or anchoring and support members of a truck during
acceleration and deceleration, as applicable. The vertical reaction must
be calculated based on the static weight of the fully loaded cargo tank
motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall. The following loadings must be
included:
(1) The axial load generated by a decelerative force;
(2) The bending moment generated by a decelerative force;
(3) The axial load generated by an accelerative force; and
(4) The bending moment generated by an accelerative force; and
(C) The tensile or compressive stress generated by the bending
moment resulting from normal operating vertical accelerative force equal
to 0.35 times the vertical reaction at the suspension assembly of a
trailer; or the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or anchoring and support members of a truck, as applicable.
The vertical reaction must be calculated based on the static weight of
the fully loaded cargo tank motor vehicle, all structural elements,
equipment and appurtenances supported by the cargo tank wall.
(iv) SS = The following shear stresses generated by the
following static and normal operating loading conditions, in psi:
[[Page 163]]
(A) The static shear stress resulting from the vertical reaction at
the suspension assembly of a trailer, and the horizontal pivot of the
upper coupler (fifth wheel) or turntable; or anchoring and support
members of a truck, as applicable. The vertical reaction must be
calculated based on the static weight of the fully loaded cargo tank
motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall;
(B) The vertical shear stress generated by a normal operating
accelerative force equal to 0.35 times the vertical reaction at the
suspension assembly of a trailer; or the horizontal pivot of the upper
coupler (fifth wheel) or turntable; or anchoring and support members of
a truck, as applicable. The vertical reaction must be calculated based
on the static weight of the fully loaded cargo tank motor vehicle, all
structural elements, equipment and appurtenances supported by the cargo
tank wall;
(C) The lateral shear stress generated by a normal operating lateral
accelerative force equal to 0.2 times the vertical reaction at each
suspension assembly of a trailer, applied at the road surface, and as
transmitted to the cargo tank wall through the suspension assembly of a
trailer, and the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or anchoring and support members of a truck, as applicable.
The vertical reaction must be calculated based on the static weight of
the fully loaded cargo tank motor vehicle, all structural elements,
equipment and appurtenances supported by the cargo tank wall; and
(D) The torsional shear stress generated by the same lateral forces
as described in paragraph (c)(1)(iv)(C) of this section.
(2) Extreme dynamic loadings. The following procedure addresses
stress in the cargo tank shell resulting from extreme dynamic loadings.
The effective stress (the maximum principal stress at any point) must be
determined by the following formula:
S = 0.5(Sy + Sx) [0.25(Sy - Sx)\2\ +
SS\2\]\0.5\
Where:
(i) S = effective stress at any given point under a combination of
static and extreme dynamic loadings that can occur at the same time, in
psi.
(ii) Sy = circumferential stress generated by MAWP and
external pressure, when applicable, plus static head, in psi.
(iii) Sx = the following net longitudinal stress
generated by the following static and extreme dynamic loading
conditions, in psi:
(A) The longitudinal stresses resulting from the MAWP and external
pressure, when applicable, plus static head, in combination with the
bending stress generated by the static weight of the fully loaded cargo
tank motor vehicle, all structural elements, equipment and appurtenances
supported by the tank wall;
(B) The tensile or compressive stress resulting from extreme
longitudinal acceleration or deceleration. In each case the forces
applied must be 0.7 times the vertical reaction at the suspension
assembly, applied at the road surface, and as transmitted to the cargo
tank wall through the suspension assembly of a trailer during
deceleration; or the horizontal pivot of the truck tractor or converter
dolly fifth wheel, or the drawbar hinge on the fixed dolly during
acceleration; or the anchoring and support members of a truck during
acceleration and deceleration, as applicable. The vertical reaction must
be calculated based on the static weight of the fully loaded cargo tank
motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall. The following loadings must be
included:
(1) The axial load generated by a decelerative force;
(2) The bending moment generated by a decelerative force;
(3) The axial load generated by an accelerative force; and
(4) The bending moment generated by an accelerative force; and
(C) The tensile or compressive stress generated by the bending
moment resulting from an extreme vertical accelerative force equal to
0.7 times the vertical reaction at the suspension assembly of a trailer,
and the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or the anchoring and support members of a truck, as
applicable.
[[Page 164]]
The vertical reaction must be calculated based on the static weight of
the fully loaded cargo tank motor vehicle, all structural elements,
equipment and appurtenances supported by the cargo tank wall.
(iv) SS = The following shear stresses generated by
static and extreme dynamic loading conditions, in psi:
(A) The static shear stress resulting from the vertical reaction at
the suspension assembly of a trailer, and the horizontal pivot of the
upper coupler (fifth wheel) or turntable; or anchoring and support
members of a truck, as applicable. The vertical reaction must be
calculated based on the static weight of the fully loaded cargo tank
motor vehicle, all structural elements, equipment and appurtenances
supported by the cargo tank wall;
(B) The vertical shear stress generated by an extreme vertical
accelerative force equal to 0.7 times the vertical reaction at the
suspension assembly of a trailer, and the horizontal pivot of the upper
coupler (fifth wheel) or turntable; or anchoring and support members of
a truck, as applicable. The vertical reaction must be calculated based
on the static weight of the fully loaded cargo tank motor vehicle, all
structural elements, equipment and appurtenances supported by the cargo
tank wall;
(C) The lateral shear stress generated by an extreme lateral
accelerative force equal to 0.4 times the vertical reaction at the
suspension assembly of a trailer, applied at the road surface, and as
transmitted to the cargo tank wall through the suspension assembly of a
trailer, and the horizontal pivot of the upper coupler (fifth wheel) or
turntable; or anchoring and support members of a truck, as applicable.
The vertical reaction must be calculated based on the static weight of
the fully loaded cargo tank motor vehicle, all structural elements,
equipment and appurtenances supported by the cargo tank wall; and
(D) The torsional shear stress generated by the same lateral forces
as described in paragraph (c)(2)(iv)(C) of this section.
(d) In no case may the minimum thickness of the cargo tank shells
and heads be less than that prescribed in Sec. 178.346-2, Sec.
178.347-2, or Sec. 178.348-2, as applicable.
(e) For a cargo tank mounted on a frame or built with integral
structural supports, the calculation of effective stresses for the
loading conditions in paragraph (c) of this section may include the
structural contribution of the frame or the integral structural
supports.
(f) The design, construction, and installation of an attachment,
appurtenance to a cargo tank, structural support member between the
cargo tank and the vehicle or suspension component must conform to the
following requirements:
(1) Structural members, the suspension sub-frame, accident
protection structures and external circumferential reinforcement devices
must be used as sites for attachment of appurtenances and other
accessories to the cargo tank, when practicable.
(2) A lightweight attachment to a cargo tank wall such as a conduit
clip, brake line clip, skirting structure, lamp mounting bracket, or
placard holder must be of a construction having lesser strength than the
cargo tank wall materials and may not be more than 72 percent of the
thickness of the material to which it is attached. The lightweight
attachment may be secured directly to the cargo tank wall if the device
is designed and installed in such a manner that, if damaged, it will not
affect the lading retention integrity of the tank. A lightweight
attachment must be secured to the cargo tank shell or head by continuous
weld or in such a manner as to preclude formation of pockets which may
become sites for corrosion.
(3) Except as prescribed in paragraphs (f)(1) and (f)(2) of this
section, the welding of any appurtenance to the cargo tank wall must be
made by attachment of a mounting pad so that there will be no adverse
effect upon the lading retention integrity of the cargo tank if any
force less than that prescribed in paragraph (b)(1) of this section is
applied from any direction. The thickness of the mounting pad may not be
less than that of the shell or head to which it is attached, and not
more than 1.5 times the shell or head thickness. However, a pad with a
minimum
[[Page 165]]
thickness of 0.187 inch may be used when the shell or head thickness is
over 0.187 inch. If weep holes or tell-tale holes are used, the pad must
be drilled or punched at the lowest point before it is welded to the
tank. Each pad must:
(i) Be fabricated from material determined to be suitable for
welding to both the cargo tank material and the material of the
appurtenance or structural support member; a Design Certifying Engineer
must make this determination considering chemical and physical
properties of the materials and must specify filler material conforming
to the requirements of the ASME Code (incorporated by reference; see
Sec. 171.7 of this subchapter).
(ii) Be preformed to an inside radius no greater than the outside
radius of the cargo tank at the attachment location.
(iii) Extend at least 2 inches in each direction from any point of
attachment of an appurtenance or structural support member. This
dimension may be measured from the center of the structural member
attached.
(iv) Have rounded corners, or otherwise be shaped in a manner to
minimize stress concentrations on the shell or head.
(v) Be attached by continuous fillet welding. Any fillet weld
discontinuity may only be for the purpose of preventing an intersection
between the fillet weld and the tank or jacket seam weld.
[Amdt. 178-89, 55 FR 37059, Sept. 7, 1990, as amended by Amdt. 178-89,
56 FR 27876, June 17, 1991; Amdt. 178-104, 59 FR 49135, Sept. 26, 1994;
Amdt. 178-105, 59 FR 55173, 55174 and 55175, Nov. 3, 1994; 60 FR 17402,
Apr. 5, 1995; Amdt. 178-118, 61 FR 51341, Oct. 1, 1996; 65 FR 58631,
Sept. 29, 2000; 68 FR 19283, Apr. 18, 2003; 68 FR 75755, Dec. 31, 2003;
74 FR 16143, Apr. 9, 2009]
Sec. 178.345-4 Joints.
(a) All joints between the cargo tank shell, heads, baffles, baffle
attaching rings, and bulkheads must be welded in conformance with
Section VIII of the ASME Code (IBR, see Sec. 171.7 of this subchapter).
(b) Where practical all welds must be easily accessible for
inspection.
[Amdt. 178-89, 54 FR 25022, June 12, 1989, as amended by Amdt. 178-118,
61 FR 51341, Oct. 1, 1996; 68 FR 75756, Dec. 31, 2003]
Sec. 178.345-5 Manhole assemblies.
(a) Each cargo tank with capacity greater than 400 gallons must be
accessible through a manhole at least 15 inches in diameter.
(b) Each manhole, fill opening and washout assembly must be
structurally capable of withstanding, without leakage or permanent
deformation that would affect its structural integrity, a static
internal fluid pressure of at least 36 psig, or cargo tank test
pressure, whichever is greater. The manhole assembly manufacturer shall
verify compliance with this requirement by hydrostatically testing at
least one percent (or one manhole closure, whichever is greater) of all
manhole closures of each type produced each 3 months, as follows:
(1) The manhole, fill opening, or washout assembly must be tested
with the venting devices blocked. Any leakage or deformation that would
affect the product retention capability of the assembly shall constitute
a failure.
(2) If the manhole, fill opening, or washout assembly tested fails,
then five more covers from the same lot must be tested. If one of these
five covers fails, then all covers in the lot from which the tested
covers were selected are to be 100% tested or rejected for service.
(c) Each manhole, filler and washout cover must be fitted with a
safety device that prevents the cover from opening fully when internal
pressure is present.
(d) Each manhole and fill cover must be secured with fastenings that
will prevent opening of the covers as a result of vibration under normal
transportation conditions or shock impact due to a rollover accident on
the roadway or shoulder where the fill cover is not struck by a
substantial obstacle.
(e) On cargo tank motor vehicles manufactured after October 1, 2004,
each manhole assembly must be permanently marked on the outside by
stamping or other means in a location
[[Page 166]]
visible without opening the manhole assembly or fill opening, with:
(1) Manufacturer's name;
(2) Test pressure ---- psig;
(3) A statement certifying that the manhole cover meets the
requirements in Sec. 178.345-5.
(f) All components mounted on a manhole cover that form part of the
lading retention structure of the cargo tank wall must withstand the
same static internal fluid pressure as that required for the manhole
cover. The component manufacturer shall verify compliance using the same
test procedure and frequency of testing as specified in Sec. 178.345-
5(b).
[Amdt. 178-89, 54 FR 25022, June 12, 1989, as amended by Amdt. 178-105,
59 FR 55175, Nov. 3, 1994; 68 FR 19284, Apr. 18, 2003; 74 FR 16144, Apr.
9, 2009]
Sec. 178.345-6 Supports and anchoring.
(a) A cargo tank with a frame not integral to the cargo tank must
have the tank secured by restraining devices to eliminate any motion
between the tank and frame that may abrade the tank shell due to the
stopping, starting, or turning of the cargo tank motor vehicle. The
design calculations of the support elements must include the stresses
indicated in Sec. 178.345-3(b) and as generated by the loads described
in Sec. 178.345-3(c). Such restraining devices must be readily
accessible for inspection and maintenance, except that insulation and
jacketing are permitted to cover the restraining devices.
(b) A cargo tank designed and constructed so that it constitutes, in
whole or in part, the structural member used in lieu of a frame must be
supported in such a manner that the resulting stress levels in the cargo
tank do not exceed those specified in Sec. 178.345-3(a). The design
calculations of the support elements must include the stresses indicated
in Sec. 178.345-3(b) and as generated by the loads described in Sec.
178.345-3(c).
[Amdt. 178-89, 54 FR 25023, June 12, 1989, as amended by Amdt. 178-105,
59 FR 55175, Nov. 3, 1994; Amdt. 178-118, 61 FR 51341, Oct. 1, 1996]
Sec. 178.345-7 Circumferential reinforcements.
(a) A cargo tank with a shell thickness of less than \3/8\ inch must
be circumferentially reinforced with bulkheads, baffles, ring
stiffeners, or any combination thereof, in addition to the cargo tank
heads.
(1) Circumferential reinforcement must be located so that the
thickness and tensile strength of the shell material in combination with
the frame and reinforcement produces structural integrity at least equal
to that prescribed in Sec. 178.345-3 and in such a manner that the
maximum unreinforced portion of the shell does not exceed 60 inches. For
cargo tanks designed to be loaded by vacuum, spacing of circumferential
reinforcement may exceed 60 inches provided the maximum unreinforced
portion of the shell conforms with the requirements in Section VIII of
the ASME Code (IBR, see Sec. 171.7 of this subchapter).
(2) Where circumferential joints are made between conical shell
sections, or between conical and cylindrical shell sections, and the
angle between adjacent sections is less than 160 degrees,
circumferential reinforcement must be located within one inch of the
shell joint, unless otherwise reinforced with structural members capable
of maintaining shell stress levels authorized in Sec. 178.345-3. When
the joint is formed by the large ends of adjacent conical shell
sections, or by the large end of a conical shell and a cylindrical shell
section, this angle is measured inside the shell; when the joint is
formed by the small end of a conical shell section and a cylindrical
shell section, it is measured outside the shell.
(b) Except for doubler plates and knuckle pads, no reinforcement may
cover any circumferential joint.
(c) When a baffle or baffle attachment ring is used as a
circumferential reinforcement member, it must produce structural
integrity at least equal to that prescribed in Sec. 178.345-3 and must
be circumferentially welded to the cargo tank shell. The welded portion
may not be less than 50 percent of the total circumference of the cargo
tank and the length of any unwelded space on the joint may not exceed 40
[[Page 167]]
times the shell thickness unless reinforced external to the cargo tank.
(d) When a ring stiffener is used as a circumferential reinforcement
member, whether internal or external, reinforcement must be continuous
around the circumference of the cargo tank shell and must be in
accordance with the following:
(1) The section modulus about the neutral axis of the ring section
parallel to the shell must be at least equal to that derived from the
applicable formula:
I/C = 0.00027WL, for MS, HSLA and SS; or
I/C = 0.000467WL, for aluminum alloys;
Where:
I/C = Section modulus in inches \3\
W = Tank width, or diameter, inches
L = Spacing of ring stiffener, inches; i.e., the maximum longitudinal
distance from the midpoint of the unsupported shell on one side of the
ring stiffener to the midpoint of the unsupported shell on the opposite
side of the ring stiffener.
(2) If a ring stiffener is welded to the cargo tank shell, a portion
of the shell may be considered as part of the ring section for purposes
of computing the ring section modulus. This portion of the shell may be
used provided at least 50 percent of the total circumference of the
cargo tank is welded and the length of any unwelded space on the joint
does not exceed 40 times the shell thickness. The maximum portion of the
shell to be used in these calculations is as follows:
------------------------------------------------------------------------
Number of circumferential ring
stiffener-to-shell welds J \1\ Shell section
------------------------------------------------------------------------
1................................ .................... 20t
2................................ Less than 20t....... 20t+J
2................................ 20t or more......... 40t
------------------------------------------------------------------------
\1\ where:
t=Shell thickness, inches;
J=Longitudinal distance between parallel circumferential ring stiffener-
to-shell welds.
(3) When used to meet the vacuum requirements of this section, ring
stiffeners must be as prescribed in Section VIII of the ASME Code.
(4) If configuration of internal or external ring stiffener encloses
an air space, this air space must be arranged for venting and be
equipped with drainage facilities which must be kept operative at all
times.
(5) Hat shaped or open channel ring stiffeners which prevent visual
inspection of the cargo tank shell are prohibited on cargo tank motor
vehicles constructed of carbon steel.
[Amdt. 178-89, 55 FR 37060, Sept. 7, 1990, as amended by Amdt. 178-89,
56 FR 27876, June 17, 1991; 56 FR 46354, Sept. 11, 1991; Amdt. 178-104,
59 FR 49135, Sept. 26, 1994; Amdt. 178-118, 61 FR 51341, Oct. 1, 1996;
68 FR 75756, Dec. 31, 2003]
Sec. 178.345-8 Accident damage protection.
(a) General. Each cargo tank motor vehicle must be designed and
constructed in accordance with the requirements of this section and the
applicable individual specification to minimize the potential for the
loss of lading due to an accident.
(1) Any dome, sump, or washout cover plate projecting from the cargo
tank wall that retains lading in any tank orientation, must be as strong
and tough as the cargo tank wall and have a thickness at least equal to
that specified by the appropriate cargo tank specification. Any such
projection located in the lower \1/3\ of the tank circumference (or
cross section perimeter for non-circular cargo tanks) that extends more
than half its diameter at the point of attachment to the tank or more
than 4 inches from the cargo tank wall, or located in the upper \2/3\ of
the tank circumference (or cross section perimeter for non-circular
cargo tanks) that extends more than \1/4\ its diameter or more than 2
inches from the point of attachment to the tank must have accident
damage protection devices that are:
(i) As specified in this section;
(ii) 125 percent as strong as the otherwise required accident damage
protection device; or
(iii) Attached to the cargo tank in accordance with the requirements
of paragraph (a)(3) of this section.
(2) Outlets, valves, closures, piping, or any devices that if
damaged in an accident could result in a loss of lading from the cargo
tank must be protected by accident damage protection devices as
specified in this section.
(3) Accident damage protection devices attached to the wall of a
cargo
[[Page 168]]
tank must be able to withstand or deflect away from the cargo tank the
loads specified in this section. They must be designed, constructed and
installed so as to maximize the distribution of loads to the cargo tank
wall and to minimize the possibility of adversely affecting the lading
retention integrity of the cargo tank. Accident induced stresses
resulting from the appropriate accident damage protection device
requirements in combination with the stresses from the cargo tank
operating at the MAWP may not result in a cargo tank wall stress greater
than the ultimate strength of the material of construction using a
safety factor of 1.3. Deformation of the protection device is acceptable
provided the devices being protected are not damaged when loads
specified in this section are applied.
(4) Any piping that extends beyond an accident damage protection
device must be equipped with a stop-valve and a sacrificial device such
as a shear section. The sacrificial device must be located in the piping
system outboard of the stop-valve and within the accident damage
protection device to prevent any accidental loss of lading. The device
must break at no more than 70 percent of the load that would be required
to cause the failure of the protected lading retention device, part or
cargo tank wall. The failure of the sacrificial device must leave the
protected lading retention device and its attachment to the cargo tank
wall intact and capable of retaining product.
(5) Minimum road clearance. The minimum road clearance of any cargo
tank motor vehicle component or protection device located between any
two adjacent axles on a vehicle or vehicle combination must be at least
one-half inch for each foot separating the component or device from the
nearest axle of the adjacent pair, but in no case less than twelve (12)
inches, except that the minimum road clearance for landing gear or other
attachments within ten (10) feet of an axle must be no less than ten
(10) inches. These measurements must be calculated at the gross vehicle
weight rating of the cargo tank motor vehicle.
(b) Each outlet, projection or piping located in the lower \1/3\ of
the cargo tank circumference (or cross section perimeter for non-
circular cargo tanks) that could be damaged in an accident that may
result in the loss of lading must be protected by a bottom damage
protection device, except as provided by paragraph (a)(1) of this
section and Sec. 173.33(e) of this subchapter. Outlets, projections and
piping may be grouped or clustered together and protected by a single
protection device.
(1) Any bottom damage protection device must be able to withstand a
force of 155,000 pounds (based on the ultimate strength of the material)
from the front, side, or rear, uniformly distributed over each surface
of the device, over an area not to exceed 6 square feet, and a width not
to exceed 6 feet. Suspension components and structural mounting members
may be used to provide all, or part, of this protection. The device must
extend no less than 6 inches beyond any component that may contain
lading in transit.
(2) A lading discharge opening equipped with an internal self-
closing stop-valve need not conform to paragraph (b)(1) of this section
provided it is protected so as to reasonably assure against the
accidental loss of lading. This protection must be provided by a
sacrificial device located outboard of each internal self-closing stop-
valve and within 4 inches of the major radius of the cargo tank shell or
within 4 inches of a sump, but in no case more than 8 inches from the
major radius of the tank shell. The device must break at no more than 70
percent of the load that would be required to cause the failure of the
protected lading retention device, part or cargo tank wall. The failure
of the sacrificial device must leave the protected lading retention
device or part and its attachment to the cargo tank wall intact and
capable of retaining product.
(c) Each closure for openings, including but not limited to the
manhole, filling or inspection openings, and each valve, fitting,
pressure relief device, vapor recovery stop valve or lading retaining
fitting located in the upper \2/3\ of a cargo tank circumference (or
cross section perimeter for non-circular tanks) must be protected by
being located within or between adjacent rollover damage protection
devices, or by
[[Page 169]]
being 125 percent of the strength that would be provided by the
otherwise required damage protection device.
(1) A rollover damage protection device on a cargo tank motor
vehicle must be designed and installed to withstand loads equal to twice
the weight of the loaded cargo tank motor vehicle applied as follows:
normal to the cargo tank shell (perpendicular to the cargo tank
surface); and tangential (perpendicular to the normal load) from any
direction. The stresses shall not exceed the ultimate strength of the
material of construction. These design loads may be considered to be
uniformly distributed and independently applied. If more than one
rollover protection device is used, each device must be capable of
carrying its proportionate share of the required loads and in each case
at least one-fourth the total tangential load. The design must be proven
capable of carrying the required loads by calculations, tests or a
combination of tests and calculations.
(2) A rollover damage protection device that would otherwise allow
the accumulation of liquid on the top of the cargo tank, must be
provided with a drain that directs the liquid to a safe point of
discharge away from any structural component of the cargo tank motor
vehicle.
(d) Rear-end tank protection. Each cargo tank motor vehicle must be
provided with a rear-end tank protection device to protect the cargo
tank and piping in the event of a rear-end collision and reduce the
likelihood of damage that could result in the loss of lading. Nothing in
this paragraph relieves the manufacturer of responsibility for complying
with the requirements of Sec. 393.86 of this title and, if applicable,
paragraph (b) of this section. The rear-end tank protection device must
conform to the following requirements:
(1) The rear-end cargo tank protection device must be designed so
that it can deflect at least 6 inches horizontally forward with no
contact between any part of the cargo tank motor vehicle which contains
lading during transit and with any part of the rear-end protection
device, or with a vertical plane passing through the outboard surface of
the protection device.
(2) The dimensions of the rear-end cargo tank protection device
shall conform to the following:
(i) The bottom surface of the rear-end protection device must be at
least 4 inches below the lower surface of any part at the rear of the
cargo tank motor vehicle which contains lading during transit and not
more than 60 inches from the ground when the vehicle is empty.
(ii) The maximum width of a notch, indentation, or separation
between sections of a rear-end cargo tank protection device may not
exceed 24 inches. A notched, indented, or separated rear-end protection
device may be used only when the piping at the rear of the cargo tank is
equipped with a sacrificial device outboard of a shut-off valve.
(iii) The widest part of the motor vehicle at the rear may not
extend more than 18 inches beyond the outermost ends of the device or
(if separated) devices on either side of the vehicle.
(3) The structure of the rear-end protection device and its
attachment to the vehicle must be designed to satisfy the conditions
specified in paragraph (d)(1) of this section when subjected to an
impact of the cargo tank motor vehicle at rated payload, at a
deceleration of 2 ``g''. Such impact must be considered as being
uniformly applied in the horizontal plane at an angle of 10 degrees or
less to the longitudinal axis of the vehicle.
(e) Longitudinal deceleration protection. In order to account for
stresses due to longitudinal impact in an accident, the cargo tank shell
and heads must be able to withstand the load resulting from the design
pressure in combination with the dynamic pressure resulting from a
longitudinal deceleration of 2 ``g''. For this loading condition, the
allowable stress value used may not exceed the ultimate strength of the
material of construction using a safety factor of 1.3. Performance
testing, analytical methods, or a combination thereof, may be used to
prove this capability provided the methods are accurate and verifiable.
For cargo tanks with internal baffles, the decelerative force may be
reduced by 0.25 ``g'' for each baffle assembly,
[[Page 170]]
but in no case may the total reduction in decelerative force exceed 1.0
``g''.
[Amdt. 178-89, 54 FR 25023, June 12, 1989, as amended at 55 FR 37061,
Sept. 7, 1990; Amdt. 178-105, 59 FR 55175, Nov. 3, 1994; Amdt. 178-118,
61 FR 51341, Oct. 1, 1996; 68 FR 19284, Apr. 18, 2003]
Sec. 178.345-9 Pumps, piping, hoses and connections.
(a) Suitable means must be provided during loading or unloading
operations to ensure that pressure within a cargo tank does not exceed
test pressure.
(b) Each hose, piping, stop-valve, lading retention fitting and
closure must be designed for a bursting pressure of the greater of 100
psig or four times the MAWP.
(c) Each hose coupling must be designed for a bursting pressure of
the greater of 120 psig or 4.8 times the MAWP of the cargo tank, and
must be designed so that there will be no leakage when connected.
(d) Suitable provision must be made to allow for and prevent damage
due to expansion, contraction, jarring, and vibration. Slip joints may
not be used for this purpose in the lading retention system.
(e) Any heating device, when installed, must be so constructed that
the breaking of its external connections will not cause leakage of the
cargo tank lading.
(f) Any gauging, loading or charging device, including associated
valves, must be provided with an adequate means of secure closure to
prevent leakage.
(g) The attachment and construction of each loading/unloading or
charging line must be of sufficient strength, or be protected by a
sacrificial device, such that any load applied by loading/unloading or
charging lines connected to the cargo tank cannot cause damage resulting
in loss of lading from the cargo tank.
(h) Use of a nonmetallic pipe, valve or connection that is not as
strong and heat resistant as the cargo tank material is authorized only
if such attachment is located outboard of the lading retention system.
[Amdt. 178-89, 54 FR 25025, June 12, 1989, as amended at 55 FR 37061,
Sept. 7, 1990, Amdt. 178-89, 56 FR 27877, June 17, 1991; Amdt. 178-118,
61 FR 51341, Oct. 1, 1996]
Sec. 178.345-10 Pressure relief.
(a) Each cargo tank must be equipped to relieve pressure and vacuum
conditions in conformance with this section and the applicable
individual specification. The pressure and vacuum relief system must be
designed to operate and have sufficient capacity to prevent cargo tank
rupture or collapse due to over-pressurization or vacuum resulting from
loading, unloading, or from heating and cooling of lading. Pressure
relief systems are not required to conform to the ASME Code.
(b) Type and construction of relief systems and devices. (1) Each
cargo tank must be provided with a primary pressure relief system
consisting of one or more reclosing pressure relief valves. A secondary
pressure relief system consisting of another pressure relief valve in
parallel with the primary pressure relief system may be used to augment
the total venting capacity of the cargo tank. Non-reclosing pressure
relief devices are not authorized in any cargo tank except when in
series with a reclosing pressure relief device. Gravity actuated
reclosing valves are not authorized on any cargo tank.
(2) When provided by Sec. 173.33(c)(1)(iii) of this subchapter,
cargo tanks may be equipped with a normal vent. Such vents must be set
to open at not less than 1 psig and must be designed to prevent loss of
lading through the device in case of vehicle overturn.
(3) Each pressure relief system must be designed to withstand
dynamic pressure surges in excess of the design set pressure as
specified in paragraphs (b)(3) (i) and (ii) of this section. Set
pressure is a function of MAWP as set forth in paragraph (d) of this
section.
(i) Each pressure relief device must be able to withstand dynamic
pressure surge reaching 30 psig above the design set pressure and
sustained above the set pressure for at least 60 milliseconds with a
total volume of liquid released
[[Page 171]]
not exceeding one gallon before the relief device recloses to a leak-
tight condition. This requirement must be met regardless of vehicle
orientation. This capability must be demonstrated by testing. An
acceptable method is outlined in TTMA RP No. 81-97 ``Performance of
Spring Loaded Pressure Relief Valves on MC 306, MC 307, MC 312, DOT 406,
DOT 407, and DOT 412 Tanks'' (incorporated by reference; see Sec. 171.7
of this subchapter).
(ii) After August 31, 1995, each pressure relief device must be able
to withstand a dynamic pressure surge reaching 30 psig above the design
set pressure and sustained above the design set pressure for at least 60
milliseconds with a total volume of liquid released not exceeding 1 L
before the relief valve recloses to a leak-tight condition. This
requirement must be met regardless of vehicle orientation. This
capability must be demonstrated by testing. TTMA RP No. 81, cited in
paragraph (b)(3)(i) of this section, is an acceptable test procedure.
(4) Each reclosing pressure relief valve must be constructed and
installed in such a manner as to prevent unauthorized adjustment of the
relief valve setting.
(5) No shut-off valve or other device that could prevent venting
through the pressure relief system may be installed in a pressure relief
system.
(6) The pressure relief system must be mounted, shielded and
drainable so as to minimize the accumulation of material that could
impair the operation or discharge capability of the system by freezing,
corrosion or blockage.
(c) Location of relief devices. Each pressure relief device must
communicate with the vapor space above the lading as near as practicable
to the center of the vapor space. For example, on a cargo tank designed
to operate in a level attitude, the device should be positioned at the
horizontal and transverse center of the cargo tank; on cargo tanks
sloped to the rear, the device should be located in the forward half of
the cargo tank. The discharge from any device must be unrestricted.
Protective devices which deflect the flow of vapor are permissible
provided the required vent capacity is maintained.
(d) Settings of pressure relief system. The set pressure of the
pressure relief system is the pressure at which it starts to open,
allowing discharge.
(1) Primary pressure relief system. The set pressure of each primary
relief valve must be no less than 120 percent of the MAWP, and no more
than 132 percent of the MAWP. The valve must reclose at not less than
108 percent of the MAWP and remain closed at lower pressures.
(2) Secondary pressure relief system. The set pressure of each
pressure relief valve used as a secondary relief device must be not less
than 120 percent of the MAWP.
(e) Venting capacity of pressure relief systems. The pressure relief
system (primary and secondary, including piping) must have sufficient
venting capacity to limit the cargo tank internal pressure to not more
than the cargo tank test pressure. The total venting capacity, rated at
not more than the cargo tank test pressure, must be at least that
specified in table I, except as provided in Sec. 178.348-4.
Table I--Minimum Emergency Vent Capacity
[In cubic feet free air/hour at 60 [deg]F and 1 atm.]
------------------------------------------------------------------------
Cubic feet
Exposed area in square feet free air
per hour
------------------------------------------------------------------------
20......................................................... 15,800
30......................................................... 23,700
40......................................................... 31,600
50......................................................... 39,500
60......................................................... 47,400
70......................................................... 55,300
80......................................................... 63,300
90......................................................... 71,200
100........................................................ 79,100
120........................................................ 94,900
140........................................................ 110,700
160........................................................ 126,500
180........................................................ 142,300
200........................................................ 158,100
225........................................................ 191,300
250........................................................ 203,100
275........................................................ 214,300
300........................................................ 225,100
350........................................................ 245,700
400........................................................ 265,000
450........................................................ 283,200
500........................................................ 300,600
550........................................................ 317,300
600........................................................ 333,300
650........................................................ 348,800
700........................................................ 363,700
750........................................................ 378,200
800........................................................ 392,200
850........................................................ 405,900
900........................................................ 419,300
[[Page 172]]
950........................................................ 432,300
1,000...................................................... 445,000
------------------------------------------------------------------------
Note 1: Interpolate for intermediate sizes.
(1) Primary pressure relief system. Unless otherwise specified in
the applicable individual specification, the primary relief system must
have a minimum venting capacity of 12,000 SCFH per 350 square feet of
exposed cargo tank area, but in any case at least one fourth the
required total venting capacity for the cargo tank.
(2) Secondary pressure relief system. If the primary pressure relief
system does not provide the required total venting capacity, additional
capacity must be provided by a secondary pressure relief system.
(f) Certification of pressure relief devices. The manufacturer of
any pressure relief device, including valves, frangible (rupture) disks,
vacuum vents and combination devices must certify that the device model
was designed and tested in accordance with this section and the
appropriate cargo tank specification. The certificate must contain
sufficient information to describe the device and its performance. The
certificate must be signed by a responsible official of the manufacturer
who approved the flow capacity certification.
(g) Rated flow capacity certification test. Each pressure relief
device model must be successfully flow capacity certification tested
prior to first use. Devices having one design, size and set pressure are
considered to be one model. The testing requirements are as follows:
(1) At least 3 devices of each specific model must be tested for
flow capacity at a pressure not greater than the test pressure of the
cargo tank. For a device model to be certified, the capacities of the
devices tested must fall within a range of plus or minus 5 percent of
the average for the devices tested.
(2) The rated flow capacity of a device model may not be greater
than 90 percent of the average value for the devices tested.
(3) The rated flow capacity derived for each device model must be
certified by a responsible official of the device manufacturer.
(h) Marking of pressure relief devices. Each pressure relief device
must be permanently marked with the following:
(1) Manufacturer's name;
(2) Model number;
(3) Set pressure, in psig; and
(4) Rated flow capacity, in SCFH at the rating pressure, in psig.
[Amdt. 178-89, 54 FR 25025, June 12, 1989, as amended at 55 FR 21038,
May 22, 1990; 55 FR 37062, Sept. 7, 1990; Amdt. 178-89, 56 FR 27877,
June 17, 1991; Amdt. 178-105, 59 FR 55175, Nov. 3, 1994; Amdt. 178-118,
61 FR 51341, Oct. 1, 1996; 65 FR 58631, Sept. 29, 2000; 66 FR 45389,
Aug. 28, 2001; 68 FR 19284, Apr. 18, 2003]
Sec. 178.345-11 Tank outlets.
(a) General. As used in this section, ``loading/unloading outlet''
means any opening in the cargo tank wall used for loading or unloading
of lading, as distinguished from outlets such as manhole covers, vents,
vapor recovery devices, and similar closures. Cargo tank outlets,
closures and associated piping must be protected in accordance with
Sec. 178.345-8.
(b) Each cargo tank loading/unloading outlet must be equipped with
an internal self-closing stop-valve, or alternatively, with an external
stop-valve located as close as practicable to the cargo tank wall. Each
cargo tank loading/unloading outlet must be in accordance with the
following provisions:
(1) Each loading/unloading outlet must be fitted with a self-closing
system capable of closing all such outlets in an emergency within 30
seconds of actuation. During normal operations the outlets may be closed
manually. The self-closing system must be designed according to the
following:
(i) Each self-closing system must include a remotely actuated means
of closure located more than 10 feet from the loading/unloading outlet
where vehicle length allows, or on the end of the cargo tank farthest
away from the
[[Page 173]]
loading/unloading outlet. The actuating mechanism must be corrosion-
resistant and effective in all types of environment and weather.
(ii) If the actuating system is accidentally damaged or sheared off
during transportation, each loading/unloading outlet must remain
securely closed and capable of retaining lading.
(iii) When required by part 173 of this subchapter for materials
which are flammable, pyrophoric, oxidizing, or Division 6.1 (poisonous
liquid) materials, the remote means of closure must be capable of
thermal activation. The means by which the self-closing system is
thermally activated must be located as close as practicable to the
primary loading/unloading connection and must actuate the system at a
temperature not over 250 [deg]F. In addition, outlets on these cargo
tanks must be capable of being remotely closed manually or mechanically.
(2) Bottom loading outlets which discharge lading into the cargo
tank through fixed internal piping above the maximum liquid level of the
cargo tank need not be equipped with a self-closing system.
(c) Any loading/unloading outlet extending beyond an internal self-
closing stop-valve, or beyond the innermost external stop-valve which is
part of a self-closing system, must be fitted with another stop-valve or
other leak-tight closure at the end of such connection.
(d) Each cargo tank outlet that is not a loading/unloading outlet
must be equipped with a stop-valve or other leak-tight closure located
as close as practicable to the cargo tank outlet. Any connection
extending beyond this closure must be fitted with another stop-valve or
other leak-tight closure at the end of such connection.
[Amdt. 178-89, 56 FR 27877, June 17, 1991, as amended by Amdt. 178-97,
57 FR 45465, Oct. 1, 1992; Amdt. 178-118, 61 FR 51341, Oct. 1, 1996]
Sec. 178.345-12 Gauging devices.
Each cargo tank, except a cargo tank intended to be filled by
weight, must be equipped with a gauging device that indicates the
maximum permitted liquid level to within 0.5 percent of the nominal
capacity as measured by volume or liquid level. Gauge glasses are not
permitted.
[Amdt. 178-89, 55 FR 37062, Sept. 7, 1990, as amended by Amdt. 178-118,
61 FR 51342, Oct. 1, 1996]
Sec. 178.345-13 Pressure and leakage tests.
(a) Each cargo tank must be pressure and leakage tested in
accordance with this section and Sec. Sec. 178.346-5, 178.347-5, or
178.348-5.
(b) Pressure test. Each cargo tank or cargo tank compartment must be
tested hydrostatically or pneumatically. Each cargo tank of a multi-
cargo tank motor vehicle must be tested with the adjacent cargo tanks
empty and at atmospheric pressure. Each closure, except pressure relief
devices and loading/unloading venting devices rated at less than the
prescribed test pressure, must be in place during the test. If the
venting device is not removed during the test, such device must be
rendered inoperative by a clamp, plug or other equally effective
restraining device, which may not prevent the detection of leaks, or
damage the device. Restraining devices must be removed immediately after
the test is completed.
(1) Hydrostatic method. Each cargo tank, including its domes, must
be filled with water or other liquid having similar viscosity, the
temperature of which may not exceed 100 [deg]F. The cargo tank must then
be pressurized as prescribed in the applicable specification. The
pressure must be gauged at the top of the cargo tank. The prescribed
test pressure must be maintained for at least 10 minutes during which
time the cargo tank must be inspected for leakage, bulging, or other
defect.
(2) Pneumatic method. A pneumatic test may be used in place of the
hydrostatic test. However, pneumatic pressure testing may involve higher
risk than hydrostatic testing. Therefore, suitable safeguards must be
provided to protect personnel and facilities should failure occur during
the test. The cargo tank must be pressurized with air or an inert gas.
Test pressure must be reached gradually by increasing the pressure to
one half of test pressure. Thereafter, the pressure must be increased in
steps of approximately one tenth of the test pressure until test
[[Page 174]]
pressure is reached. Test pressure must be held for at least 5 minutes.
The pressure must then be reduced to the inspection pressure which must
be maintained while the entire cargo tank surface is inspected for
leakage and other sign of defects. The inspection method must consist of
coating all joints and fittings with a solution of soap and water or
other equally sensitive method.
(c) Leakage test. The cargo tank with all its accessories in place
and operable must be leak tested at not less than 80 percent of tank's
MAWP with the pressure maintained for at least 5 minutes.
(d) Any cargo tank that leaks, bulges or shows any other sign of
defect must be rejected. Rejected cargo tanks must be suitably repaired
and retested successfully prior to being returned to service. The retest
after any repair must use the same method of test under which the cargo
tank was originally rejected.
[Amdt. 178-89, 54 FR 25026, June 12, 1989, as amended at 55 FR 37063,
Sept. 7, 1990; Amdt. 178-105, 59 FR 55176, Nov. 3, 1994; Amdt. 178-118,
61 FR 51342, Oct. 1, 1996; 65 FR 58631, Sept. 29, 2000; 68 FR 19284,
Apr. 18, 2003]
Sec. 178.345-14 Marking.
(a) General. The manufacturer shall certify that each cargo tank
motor vehicle has been designed, constructed and tested in accordance
with the applicable Specification DOT 406, DOT 407 or DOT 412
(Sec. Sec. 178.345, 178.346, 178.347, 178.348) cargo tank requirements
and, when applicable, with Section VIII of the ASME Code (IBR, see Sec.
171.7 of this subchapter). The certification shall be accomplished by
marking the cargo tank as prescribed in paragraphs (b) and (c) of this
section, and by preparing the certificate prescribed in Sec. 178.345-
15. Metal plates prescribed by paragraphs (b), (c), (d) and (e) of this
section, must be permanently attached to the cargo tank or its integral
supporting structure, by brazing, welding or other suitable means. These
plates must be affixed on the left side of the vehicle near the front of
the cargo tank (or the frontmost cargo tank of a multi-cargo tank motor
vehicle), in a place readily accessible for inspection. The plates must
be permanently and plainly marked in English by stamping, embossing or
other means in characters at least \3/16\ inch high. The information
required by paragraphs (b) and (c) of this section may be combined on
one specification plate.
(b) Nameplate. Each cargo tank must have a corrosion resistant
nameplate permanently attached to it. The following information, in
addition to any applicable information required by the ASME Code, must
be marked on the tank nameplate (parenthetical abbreviations may be
used):
(1) DOT-specification number DOT XXX (DOT XXX) where ``XXX'' is
replaced with the applicable specification number. For cargo tanks
having a variable specification plate, the DOT-specification number is
replaced with the words ``See variable specification plate.''
(2) Original test date, month and year (Orig. Test Date).
(3) Tank MAWP in psig.
(4) Cargo tank test pressure (Test P), in psig.
(5) Cargo tank design temperature range (Design temp. range),--
[deg]F to -- [deg]F.
(6) Nominal capacity (Water cap.), in gallons.
(7) Maximum design density of lading (Max. lading density), in
pounds per gallon.
(8) Material specification number--shell (Shell matl, yyy***), where
``yyy'' is replaced by the alloy designation and ``***'' by the alloy
type.
(9) Material specification number--heads (Head matl, yyy***), where
``yyy'' is replaced by the alloy designation and ``***'' by the alloy
type.
Note: When the shell and heads materials are the same thickness,
they may be combined, (Shell&head matl, yyy***).
(10) Weld material (Weld matl.).
(11) Minimum thickness--shell (Min. shell-thick), in inches. When
minimum shell thicknesses are not the same for different areas, show
(top --, side --, bottom --, in inches).
(12) Minimum thickness--heads (Min. heads thick.), in inches.
(13) Manufactured thickness--shell (Mfd. shell thick.), top --, side
--, bottom --, in inches. (Required when additional thickness is
provided for corrosion allowance.)
[[Page 175]]
(14) Manufactured thickness--heads (Mfd. heads thick.), in inches.
(Required when additional thickness is provided for corrosion
allowance.)
(15) Exposed surface area, in square feet.
(c) Specification plate. Each cargo tank motor vehicle must have an
additional corrosion resistant metal specification plate attached to it.
The specification plate must contain the following information
(parenthetical abbreviations may be used):
(1) Cargo tank motor vehicle manufacturer (CTMV mfr.).
(2) Cargo tank motor vehicle certification date (CTMV cert. date),
if different from the cargo tank certification date.
(3) Cargo tank manufacturer (CT mfr.).
(4) Cargo tank date of manufacture (CT date of mfr.), month and
year.
(5) Maximum weight of lading (Max. Payload), in pounds.
(6) Maximum loading rate in gallons per minute (Max. Load rate,
GPM).
(7) Maximum unloading rate in gallons per minute (Max. Unload rate).
(8) Lining material (Lining), if applicable.
(9) Heating system design pressure (Heating sys. press.), in psig,
if applicable.
(10) Heating system design temperature (Heating sys. temp.), in
[deg]F, if applicable.
(d) Multi-cargo tank motor vehicle. For a multi-cargo tank motor
vehicle having all its cargo tanks not separated by any void, the
information required by paragraphs (b) and (c) of this section may be
combined on one specification plate. When separated by a void, each
cargo tank must have an individual nameplate as required in paragraph
(b) of this section, unless all cargo tanks are made by the same
manufacturer with the same materials, manufactured thickness, minimum
thickness and to the same specification. The cargo tank motor vehicle
may have a combined nameplate and specification plate. When only one
plate is used, the plate must be visible and not covered by insulation.
The required information must be listed on the plate from front to rear
in the order of the corresponding cargo tank location.
(e) Variable specification cargo tank. Each variable specification
cargo tank must have a corrosion resistant metal variable specification
plate attached to it. The mounting of this variable specification plate
must be such that only the plate identifying the applicable
specification under which the tank is being operated is legible.
(1) The following information must be included (parenthetical
abbreviations are authorized):
Specification DOT XXX (DOT XXX), where ``XXX'' is replaced with the
applicable specification number.
Equipment required Required rating \1\
Pressure relief devices:
Pressure actuated type............... ------------
Frangible type....................... ------------
Lading discharge devices............. ------------
Top.................................. ------------
Bottom............................... ------------
Pressure unloading fitting........... ------------
Closures:
Manhole.............................. ------------
Fill openings........................ ------------
Discharge openings................... ------------
\1\ Required rating--to meet the applicable specification.
(2) If no change of information in the specification plate is
required, the letters ``NC'' must follow the rating required. If the
cargo tank is not so equipped, the word ``None'' must be inserted.
(3) Those parts to be changed or added must be stamped with the
appropriate MC or DOT Specification markings.
(4) The alterations that must be made in order for the tank to be
modified from one specification to another must be clearly indicated on
the manufacturer's certificate and on the variable specification plate.
[Amdt. 178-89, 54 FR 25027, June 12, 1989, as amended at 55 FR 37063,
Sept. 7, 1990; Amdt. 178-99, 58 FR 51534, Oct. 1, 1993; Amdt. 178-104,
59 FR 49135, Sept. 26, 1994; Amdt. 178-105, 59 FR 55176, Nov. 3, 1994;
60 FR 17402, Apr. 5, 1995; Amdt. 178-118, 61 FR 51342, Oct. 1, 1996; 66
FR 45389, Aug. 28, 2001; 68 FR 19284, Apr. 18, 2003; 68 FR 52371, Sept.
3, 2003; 68 FR 75756, Dec. 31, 2003]
[[Page 176]]
Sec. 178.345-15 Certification.
(a) At or before the time of delivery, the manufacturer of a cargo
tank motor vehicle must provide certification documents to the owner of
the cargo tank motor vehicle. The registration numbers of the
manufacturer, the Design Certifying Engineer, and the Registered
Inspector, as appropriate, must appear on the certificates (see subpart
F, part 107 in subchapter A of this chapter).
(b) The manufacturer of a cargo tank motor vehicle made to any of
these specifications must provide:
(1) For each design type, a certificate signed by a responsible
official of the manufacturer and a Design Certifying Engineer certifying
that the cargo tank motor vehicle design meets the applicable
specification; and
(2) For each ASME cargo tank, a cargo tank manufacturer's data
report as required by Section VIII of the ASME Code (IBR, see Sec.
171.7 of this subchapter). For each cargo tank motor vehicle, a
certificate signed by a responsible official of the manufacturer and a
Registered Inspector certifying that the cargo tank motor vehicle is
constructed, tested and completed in conformance with the applicable
specification.
(c) The manufacturer of a variable specification cargo tank motor
vehicle must provide:
(1) For each design type, a certificate signed by a responsible
official of the manufacturer and a Design Certifying Engineer certifying
that the cargo tank motor vehicle design meets the applicable
specifications; and
(2) For each variable specification cargo tank motor vehicle, a
certificate signed by a responsible official of the manufacturer and a
Registered Inspector certifying that the cargo tank motor vehicle is
constructed, tested and completed in conformance with the applicable
specifications. The certificate must include all the information
required and marked on the variable specification plate.
(d) In the case of a cargo tank motor vehicle manufactured in two or
more stages, each manufacturer who performs a manufacturing operation on
the incomplete vehicle or portion thereof shall provide to the
succeeding manufacturer, at or before the time of delivery, a
certificate covering the particular operation performed by that
manufacturer, including any certificates received from previous
manufacturers, Registered Inspectors, and Design Certifying Engineers.
Each certificate must indicate the portion of the complete cargo tank
motor vehicle represented thereby, such as basic cargo tank fabrication,
insulation, jacket, lining, or piping. The final manufacturer shall
provide all applicable certificates to the owner.
(e) Specification shortages. If a cargo tank is manufactured which
does not meet all applicable specification requirements, thereby
requiring subsequent manufacturing involving the installation of
additional components, parts, appurtenances or accessories, the cargo
tank manufacturer may affix the name plate and specification plate, as
required by Sec. 178.345-14 (b) and (c), without the original date of
certification stamped on the specification plate. The manufacturer shall
state the specification requirements not complied with on the
manufacturer's Certificate of Compliance. When the cargo tank is brought
into full compliance with the applicable specification, the Registered
Inspector shall stamp the date of compliance on the specification plate.
The Registered Inspector shall issue a Certificate of Compliance stating
details of the particular operations performed on the cargo tank, and
the date and person (manufacturer, carrier, or repair organization)
accomplishing the compliance.
[Amdt. 178-89, 55 FR 37063, Sept. 7, 1990, as amended by Amdt. 178-98,
58 FR 33306, June 16, 1993; Amdt. 178-105, 59 FR 55176, Nov. 3, 1994;
Amdt. 178-118, 61 FR 51342, Oct. 1, 1996; 68 FR 75756, Dec. 31, 2003]
Sec. 178.346 Specification DOT 406; cargo tank motor vehicle.
Sec. 178.346-1 General requirements.
(a) Each Specification DOT 406 cargo tank motor vehicle must meet
the general design and construction requirements in Sec. 178.345, in
addition to the specific requirements contained in this section.
[[Page 177]]
(b) MAWP: The MAWP of each cargo tank must be no lower than 2.65
psig and no higher than 4 psig.
(c) Vacuum loaded cargo tanks must not be constructed to this
specification.
(d) Each cargo tank must be ``constructed in accordance with Section
VIII of the ASME Code'' (IBR, see Sec. 171.7 of this subchapter) except
as modified herein:
(1) The record-keeping requirements contained in the ASME Code
Section VIII do not apply. Parts UG-90 through 94 in Section VIII do not
apply. Inspection and certification must be made by an inspector
registered in accordance with subpart F of part 107.
(2) Loadings must be as prescribed in Sec. 178.345-3.
(3) The knuckle radius of flanged heads must be at least three times
the material thickness, and in no case less than 0.5 inch. Stuffed
(inserted) heads may be attached to the shell by a fillet weld. The
knuckle radius and dish radius versus diameter limitations of UG-32 do
not apply. Shell sections of cargo tanks designed with a non-circular
cross section need not be given a preliminary curvature, as prescribed
in UG-79(b).
(4) Marking, certification, data reports, and nameplates must be as
prescribed in Sec. Sec. 178.345-14 and 178.345-15.
(5) Manhole closure assemblies must conform to Sec. Sec. 178.345-5
and 178.346-5.
(6) Pressure relief devices must be as prescribed in Sec. 178.346-
3.
(7) The hydrostatic or pneumatic test must be as prescribed in Sec.
178.346-5.
(8) The following paragraphs in parts UG and UW in Section VIII of
the ASME Code do not apply: UG-11, UG-12, UG-22(g), UG-32(e), UG-34, UG-
35, UG-44, UG-76, UG-77, UG-80, UG-81, UG-96, UG-97, UW-13(b)(2), UW-
13.1(f) and the dimensional requirements found in Figure UW-13.1.
(9) Single full fillet lap joints without plug welds may be used for
arc or gas welded longitudinal seams without radiographic examination
under the following conditions:
(i) For a truck-mounted cargo tank, no more than two such joints may
be used on the top half of the tank and no more than two joints may be
used on the bottom half. They may not be located farther from the top
and bottom centerline than 16 percent of the shell's circumference.
(ii) For a self-supporting cargo tank, no more than two such joints
may be used on the top of the tank. They may not be located farther from
the top centerline than 12.5 percent of the shell's circumference.
(iii) Compliance test. Two test specimens of the material to be used
in the manufacture of a cargo tank must be tested to failure in tension.
The test specimens must be of the same thicknesses and joint
configuration as the cargo tank, and joined by the same welding
procedures. The test specimens may represent all the tanks that are made
of the same materials and welding procedures, have the same joint
configuration, and are made in the same facility within 6 months after
the tests are completed. Before welding, the fit-up of the joints on the
test specimens must represent production conditions that would result in
the least joint strength. Evidence of joint fit-up and test results must
be retained at the manufacturers' facility.
(iv) Weld joint efficiency. The lower value of stress at failure
attained in the two tensile test specimens shall be used to compute the
efficiency of the joint as follows: Determine the failure ratio by
dividing the stress at failure by the mechanical properties of the
adjacent metal; this value, when multiplied by 0.75, is the design weld
joint efficiency.
(10) The requirements of paragraph UW-9(d) in Section VIII of the
ASME Code do not apply.
[Amdt. 178-89, 54 FR 25028, June 12, 1989, as amended at 55 FR 37063,
Sept. 7, 1990; Amdt. 178-89, 56 FR 27877, June 17, 1991; Amdt. 178-105,
59 FR 55176, Nov. 3, 1994; 65 FR 58631, Sept. 29, 2000; 66 FR 45387,
Aug. 28, 2001; 68 FR 19285, Apr. 18, 2003; 68 FR 75756, Dec. 31, 2003]
Sec. 178.346-2 Material and thickness of material.
The type and thickness of material for DOT 406 specification cargo
tanks must conform to Sec. 178.345-2, but in no case may the thickness
be less than that determined by the minimum thickness requirements in
Sec. 178.320(a). The following Tables I and II identify
[[Page 178]]
the specified minimum thickness values to be employed in that
determination.
Table I--Specified Minimum Thickness of Heads (or Bulkheads and Baffles When Used as Tank Reinforcement) Using
Mild Steel (MS), High Strength Low Alloy Steel (HSLA), Austenitic Stainless Steel (SS), or Aluminum (AL)--
Expressed in Decimals of an Inch After Forming
----------------------------------------------------------------------------------------------------------------
Volume capacity in gallons per inch of length
--------------------------------------------------------------------------------
Material 14 or less Over 14 to 23 Over 23
--------------------------------------------------------------------------------
MS HSLA SS AL MS HSLA SS AL MS HSLA SS AL
----------------------------------------------------------------------------------------------------------------
Thickness...................... .100 .100 .160 .115 .115 .173 .129 .129 .187
----------------------------------------------------------------------------------------------------------------
Table II--Specified Minimum Thickness of Shell Using Mild Steel (MS),
High Strength Low Alloy Steel (HSLA), Austenitic Stainless Steel (SS),
or Aluminum (AL)--Expressed in Decimals of an Inch After Forming \1\
------------------------------------------------------------------------
Cargo tank motor vehicle rated capacity
(gallons) MS SS/HSLA AL
------------------------------------------------------------------------
More than 0 to at least 4,500............ 0.100 0.100 0.151
More than 4,500 to at least 8,000........ 0.115 0.100 0.160
More than 8,000 to at least 14,000....... 0.129 0.129 0.173
More than 14,000......................... 0.143 0.143 0.187
------------------------------------------------------------------------
\1\ Maximum distance between bulkheads, baffles, or ring stiffeners
shall not exceed 60 inches.
[Amdt. 178-89, 54 FR 25028, June 12, 1989, as amended at 55 FR 37064,
Sept. 7, 1990; Amdt. 178-105, 59 FR 55176, Nov. 3, 1994; 68 FR 19285,
Apr. 18, 2003]
Sec. 178.346-3 Pressure relief.
(a) Each cargo tank must be equipped with a pressure relief system
in accordance with Sec. 178.345-10 and this section.
(b) Type and construction. In addition to the pressure relief
devices required in Sec. 178.345-10:
(1) Each cargo tank must be equipped with one or more vacuum relief
devices;
(2) When intended for use only for lading meeting the requirements
of Sec. 173.33(c)(1)(iii) of this subchapter, the cargo tank may be
equipped with a normal vent. Such vents must be set to open at not less
than 1 psig and must be designed to prevent loss of lading through the
device in case of vehicle upset; and
(3) Notwithstanding the requirements in Sec. 178.345-10(b), after
August 31, 1996, each pressure relief valve must be able to withstand a
dynamic pressure surge reaching 30 psig above the design set pressure
and sustained above the set pressure for at least 60 milliseconds with a
total volume of liquid released not exceeding 1 L before the relief
valve recloses to a leak-tight condition. This requirement must be met
regardless of vehicle orientation. This capability must be demonstrated
by testing. TTMA RP No. 81 (IBR, see Sec. 171.7 of this subchapter),
cited at Sec. 178.345-10(b)(3)(i), is an acceptable test procedure.
(c) Pressure settings of relief valves. (1) Notwithstanding the
requirements in Sec. 178.345-10(d), the set pressure of each primary
relief valve must be not less than 110 percent of the MAWP or 3.3 psig,
whichever is greater, and not more than 138 percent of the MAWP. The
valve must close at not less than the MAWP and remain closed at lower
pressures.
(2) Each vacuum relief device must be set to open at no more than 6
ounces vacuum.
(d) Venting capacities. (1) Notwithstanding the requirements in
Sec. 178.345-10 (e) and (g), the primary pressure relief valve must
have a venting capacity of at least 6,000 SCFH, rated at not greater
than 125 percent of the tank test pressure and not greater than 3
[[Page 179]]
psig above the MAWP. The venting capacity required in Sec. 178.345-
10(e) may be rated at these same pressures.
(2) Each vacuum relief system must have sufficient capacity to limit
the vacuum to 1 psig.
(3) If pressure loading or unloading devices are provided, the
relief system must have adequate vapor and liquid capacity to limit the
tank pressure to the cargo tank test pressure at maximum loading or
unloading rate. The maximum loading and unloading rates must be included
on the metal specification plate.
[Amdt. 178-89, 54 FR 25029, June 12, 1989, as amended at 55 FR 37064,
Sept. 7, 1990; Amdt. 178-105, 59 FR 55176, Nov. 3, 1994. Redesignated by
Amdt. 178-112, 61 FR 18934, Apr. 29, 1996; 66 FR 45389, Aug. 28, 2001;
68 FR 75756, Dec. 31, 2003]
Sec. 178.346-4 Outlets.
(a) All outlets on each tank must conform to Sec. 178.345-11 and
this section.
(b) External self-closing stop-valves are not authorized as an
alternative to internal self-closing stop-valves on loading/unloading
outlets.
[Amdt. 178-89, 54 FR 25029, June 12, 1989. Redesignated by Amdt. 178-
112, 61 FR 18934, Apr. 29, 1996]
Sec. 178.346-5 Pressure and leakage tests.
(a) Each cargo tank must be tested in accordance with Sec. 178.345-
13 and this section.
(b) Pressure test. Test pressure must be as follows:
(1) Using the hydrostatic test method, the test pressure must be the
greater of 5.0 psig or 1.5 times the cargo tank MAWP.
(2) Using the pneumatic test method, the test pressure must be the
greater of 5.0 psig or 1.5 times the cargo tank MAWP, and the inspection
pressure must be the cargo tank MAWP.
(c) Leakage test. A cargo tank used to transport a petroleum
distillate fuel that is equipped with vapor recovery equipment may be
leakage tested in accordance with 40 CFR 63.425(e). To satisfy the
leakage test requirements of this paragraph, the test specified in 40
CFR 63.425(e)(1) must be conducted using air. The hydrostatic test
alternative permitted under Appendix A to 40 CFR Part 60 (``Method 27--
Determination of Vapor Tightness of Gasoline Delivery Tank Using
Pressure-Vacuum Test'') may not be used to satisfy the leakage test
requirements of this paragraph. A cargo tank tested in accordance with
40 CFR 63.425(e) may be marked as specified in Sec. 180.415 of this
subchapter.
[Amdt. 178-89, 54 FR 25029, June 12, 1989, as amended at 55 FR 37064,
Sept. 7, 1990; Amdt. 178-105, 59 FR 55176, Nov. 3, 1994. Redesignated by
Amdt. 178-112, 61 FR 18934, Apr. 29, 1996; 68 FR 19285, Apr. 18, 2003]
Sec. 178.347 Specification DOT 407; cargo tank motor vehicle.
Sec. 178.347-1 General requirements.
(a) Each specification DOT 407 cargo tank motor vehicle must conform
to the general design and construction requirements in Sec. 178.345 in
addition to the specific requirements contained in this section.
(b) Each tank must be of a circular cross-section and have an MAWP
of at least 25 psig.
(c) Any cargo tank motor vehicle built to this specification with a
MAWP greater than 35 psig or any cargo tank motor vehicle built to this
specification designed to be loaded by vacuum must be constructed and
certified in accordance with Section VIII of the ASME Code (IBR, see
Sec. 171.7 of this subchapter). The external design pressure for a
cargo tank loaded by vacuum must be at least 15 psi.
(d) Any cargo tank motor vehicle built to this specification with a
MAWP of 35 psig or less or any cargo tank motor vehicle built to this
specification designed to withstand full vacuum but not equipped to be
loaded by vacuum must be constructed in accordance with Section VIII of
the ASME Code.
(1) The record-keeping requirements contained in Section VIII of the
ASME Code do not apply. The inspection requirements of parts UG-90
through 94 do not apply. Inspection and certification must be made by an
inspector registered in accordance with subpart F of part 107.
(2) Loadings must be as prescribed in Sec. 178.345-3.
(3) The knuckle radius of flanged heads must be at least three times
the
[[Page 180]]
material thickness, and in no case less than 0.5 inch. Stuffed
(inserted) heads may be attached to the shell by a fillet weld. The
knuckle radius and dish radius versus diameter limitations of UG-32 do
not apply for cargo tank motor vehicles with a MAWP of 35 psig or less.
(4) Marking, certification, data reports and nameplates must be as
prescribed in Sec. Sec. 178.345-14 and 178.345-15.
(5) Manhole closure assemblies must conform to Sec. 178.347-3.
(6) Pressure relief devices must be as prescribed in Sec. 178.347-
4.
(7) The hydrostatic or pneumatic test must be as prescribed in Sec.
178.347-5.
(8) The following paragraphs in parts UG and UW in Section VIII the
ASME Code do not apply: UG-11, UG-12, UG-22(g), UG-32(e), UG-34, UG-35,
UG-44, UG-76, UG-77, UG-80, UG-81, UG-96, UG-97, UW-12, UW-13(b)(2), UW-
13.1(f), and the dimensional requirements found in Figure UW-13.1.
(9) UW-12 in Section VIII of the ASME Code does not apply to a weld
seam in a bulkhead that has not been radiographically examined, under
the following conditions:
(i) The strength of the weld seam is assumed to be 0.85 of the
strength of the bulkhead.
(ii) The welded seam must be a full penetration butt weld.
(iii) No more than one seam may be used per bulkhead.
(iv) The welded seam must be completed before forming the dish
radius and knuckle radius.
(v) Compliance test: Two test specimens of materials representative
of those to be used in the manufacture of a cargo tank bulkhead must be
tested to failure in tension. The test specimen must be of the same
thickness and joined by the same welding procedure. The test specimens
may represent all the tanks that are made in the same facility within 6
months after the tests are completed. Before welding, the fit-up of the
joints on the test specimens must represent production conditions that
would result in the least joint strength. Evidence of joint fit-up and
test results must be retained at the manufacturer's facility for at
least 5 years.
(vi) Acceptance criteria: The ratio of the actual tensile stress at
failure to the actual tensile strength of the adjacent material of all
samples of a test lot must be greater than 0.85.
[Amdt. 178-89, 54 FR 25029, June 12, 1989, as amended at 55 FR 37064,
Sept. 7, 1990; Amdt. 178-89, 56 FR 27877, June 17, 1991; 65 FR 58632,
Sept. 29, 2000; 66 FR 45387, Aug. 28, 2001; 68 FR 19285, Apr. 18, 2003;
68 FR 75756, Dec. 31, 2003; 76 FR 3388, Jan. 19, 2011; 76 FR 43532, July
20, 2011]
Sec. 178.347-2 Material and thickness of material.
(a) The type and thickness of material for DOT 407 specification
cargo tanks must conform to Sec. 178.345-2, but in no case may the
thickness be less than that determined by the minimum thickness
requirements in Sec. 178.320(a). Tables I and II identify the specified
minimum thickness values to be employed in that the determination:
Table I--Specified Minimum Thickness of Heads (or Bulkheads and Baffles When Used as Tank Reinforcement) Using
Mild Steel (MS), High Strength Low Alloy Steel (HSLA), Austenitic Stainless Steel (SS), or Aluminum (AL)--
Expressed in Decimals of an Inch After Forming
----------------------------------------------------------------------------------------------------------------
10 or Over 10 Over 14 Over 18 Over 22 Over 26
Volume capacity in gallons per inch less to 14 to 18 to 22 to 26 to 30 Over 30
----------------------------------------------------------------------------------------------------------------
Thickness (MS)............................ 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (HSLA).......................... 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (SS)............................ 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (AL)............................ 0.160 0.160 0.173 0.187 0.194 0.216 0.237
----------------------------------------------------------------------------------------------------------------
[[Page 181]]
Table II--Specified Minimum Thickness of Shell Using Mild Steel (MS), High Strength Low Alloy Steel (HSLA),
Austenitic Stainless Steel (SS), or Aluminum (AL)--Expressed in Decimals of an Inch After Forming
----------------------------------------------------------------------------------------------------------------
10 or Over 10 Over 14 Over 18 Over 22 Over 26
Volume capacity in gallons per inch less to 14 to 18 to 22 to 26 to 30 Over 30
----------------------------------------------------------------------------------------------------------------
Thickness (MS)............................ 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (HSLA).......................... 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (SS)............................ 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (AL)............................ 0.151 0.151 0.160 0.173 0.194 0.216 0.237
----------------------------------------------------------------------------------------------------------------
(b) [Reserved]
[Amdt. 178-89, 54 FR 25030, June 12, 1989, as amended at 55 FR 37064,
Sept. 7, 1990; Amdt. 178-104, 59 FR 49135, Sept. 26, 1994; 68 FR 19285,
Apr. 18, 2003]
Sec. 178.347-3 Manhole assemblies.
Each manhole assembly must conform to Sec. 178.345-5, except that
each manhole assembly must be capable of withstanding internal fluid
pressures of 40 psig or test pressure of the tank, whichever is greater.
[Amdt. 178-89, 54 FR 25030, June 12, 1989. Redesignated by Amdt. 178-
112, 61 FR 18934, Apr. 29, 1996]
Sec. 178.347-4 Pressure relief.
(a) Each cargo tank must be equipped with a pressure and vacuum
relief system in accordance with Sec. 178.345-10 and this section.
(b) Type and construction. Vacuum relief devices are not required
for cargo tank motor vehicles that are designed to be loaded by vacuum
in accordance with Sec. 178.347-1(c) or built to withstand full vacuum
in accordance with Sec. 178.347-1(d).
(c) Pressure settings of relief valves. The setting of pressure
relief valves must be in accordance with Sec. 178.345-10(d).
(d) Venting capacities. (1) The vacuum relief system must limit the
vacuum to less than 80 percent of the design vacuum capability of the
cargo tank.
(2) If pressure loading or unloading devices are provided, the
relief system must have adequate vapor and liquid capacity to limit the
tank pressure to the cargo tank test pressure at maximum loading or
unloading rate. The maximum loading or unloading rate must be included
on the metal specification plate.
[Amdt. 178-89, 54 FR 25030, June 12, 1989, as amended at 55 FR 37064,
Sept. 7, 1990. Redesignated by Amdt. 178-112, 61 FR 18934, Apr. 29,
1996; 76 FR 43532, July 20, 2011]
Sec. 178.347-5 Pressure and leakage test.
(a) Each cargo tank must be tested in accordance with Sec. 178.345-
13 and this section.
(b) Pressure test. Test pressure must be as follows:
(1) Using the hydrostatic test method, the test pressure must be at
least 40 psig or 1.5 times tank MAWP, whichever is greater.
(2) Using the pneumatic test method, the test pressure must be 40
psig or 1.5 times tank MAWP, whichever is greater, and the inspection
pressure is tank MAWP.
[Amdt. 178-89, 54 FR 25030, June 12, 1989. Redesignated by Amdt. 178-
112, 61 FR 18934, Apr. 29, 1996]
Sec. 178.348 Specification DOT 412; cargo tank motor vehicle.
Sec. 178.348-1 General requirements.
(a) Each specification DOT 412 cargo tank motor vehicle must conform
to the general design and construction requirements in Sec. 178.345 in
addition to the specific requirements of this section.
(b) The MAWP of each cargo tank must be at least 5 psig.
(c) The MAWP for each cargo tank designed to be loaded by vacuum
must
[[Page 182]]
be at least 25 psig internal and 15 psig external.
(d) Each cargo tank having a MAWP greater than 15 psig must be of
circular cross-section.
(e) Each cargo tank having a--
(1) MAWP greater than 15 psig must be ``constructed and certified in
conformance with Section VIII of the ASME Code'' (IBR, see Sec. 171.7
of this subchapter); or
(2) MAWP of 15 psig or less must be ``constructed in accordance with
Section VIII of the ASME Code,'' except as modified herein:
(i) The recordkeeping requirements contained in Section VIII of the
ASME Code do not apply. Parts UG-90 through 94 in Section VIII do not
apply. Inspection and certification must be made by an inspector
registered in accordance with subpart F of part 107.
(ii) Loadings must be as prescribed in Sec. 178.345-3.
(iii) The knuckle radius of flanged heads must be at least three
times the material thickness, and in no case less than 0.5 inch. Stuffed
(inserted) heads may be attached to the shell by a fillet weld. The
knuckle radius and dish radius versus diameter limitations of UG-32 do
not apply for cargo tank motor vehicles with a MAWP of 15 psig or less.
Shell sections of cargo tanks designed with a non-circular cross section
need not be given a preliminary curvature, as prescribed in UG-79(b).
(iv) Marking, certification, data reports, and nameplates must be as
prescribed in Sec. Sec. 178.345-14 and 178.345-15.
(v) Manhole closure assemblies must conform to Sec. Sec. 178.345-5.
(vi) Pressure relief devices must be as prescribed in Sec. 178.348-
4.
(vii) The hydrostatic or pneumatic test must be as prescribed in
Sec. 178.348-5.
(viii) The following paragraphs in parts UG and UW in Section VIII
of the ASME Code do not apply: UG-11, UG-12, UG-22(g), UG-32(e), UG-34,
UG-35, UG-44, UG-76, UG-77, UG-80, UG-81, UG-96, UG-97, UW-13(b)(2), UW-
13.1(f), and the dimensional requirements found in Figure UW-13.1.
[Amdt. 178-89, 54 FR 25031, June 12, 1989, as amended at 55 FR 37065,
Sept. 7, 1990; Amdt. 178-89, 56 FR 27877, June 17, 1991; 65 FR 58632,
Sept. 29, 2000; 68 FR 19285, Apr. 18, 2003; 68 fR 75756, Dec. 31, 2003]
Sec. 178.348-2 Material and thickness of material.
(a) The type and thickness of material for DOT 412 specification
cargo tanks must conform to Sec. 178.345-2, but in no case may the
thickness be less than that determined by the minimum thickness
requirements in Sec. 178.320(a). The following Tables I and II identify
the ``Specified Minimum Thickness'' values to be employed in that
determination.
[[Page 183]]
Table I--Specified Minimum Thickness of Heads (or Bulkheads and Baffles When Used as Tank Reinforcement) Using Mild Steel (MS), High Strength Low Alloy
Steel (HSLA), Austenitic Stainless Steel (SS), or Aluminum (AL)--Expressed in Decimals of an Inch After Forming
--------------------------------------------------------------------------------------------------------------------------------------------------------
Volume capacity (gallons per inch) 10 or less Over 10 to 14 Over 14 to 18 18 and over
--------------------------------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------------------------------
Lading density at 60 [deg]F in pounds 10 lbs Over Over Over 10 lbs Over Over Over 10 lbs Over Over 10 lbs Over Over
per gallon............................. and 10 to 13 to 16 lbs and 10 to 13 to 16 lbs and 10 to 13 to and 10 to 13 to
less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs
Thickness (inch), steel................. .100 .129 .157 .187 .129 .157 .187 .250 .157 .250 .250 .157 .250 .312
Thickness (inch), aluminum.............. .144 .187 .227 .270 .187 .227 .270 .360 .227 .360 .360 .227 .360 .450
--------------------------------------------------------------------------------------------------------------------------------------------------------
Table II--Specified Minimum Thickness of Shell Using Mild Steel (MS), High Strength Low Alloy Steel (HSLA), Austenitic Stainless Steel (SS), or Aluminum
(AL)--Expressed in Decimals of an Inch After Forming
--------------------------------------------------------------------------------------------------------------------------------------------------------
Volume capacity in gallons per inch 10 or less Over 10 to 14 Over 14 to 18 18 and over
--------------------------------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------------------------------
Lading density at 60 [deg]F in pounds 10 lbs Over Over Over 10 lbs Over Over Over 10 lbs Over Over 10 lbs Over Over
per gallon............................. and 10 to 13 to 16 lbs and 10 to 13 to 16 lbs and 10 to 13 to and 10 to 13 to
less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs
Thickness (steel):
Distances between heads (and
bulkheads baffles and ring
stiffeners when used as tank
reinforcement):
36 in. or less.................. .100 .129 .157 .187 .100 .129 .157 .187 .100 .129 .157 .129 .157 .187
Over 36 in. to 54 inches........ .100 .129 .157 .187 .100 .129 .157 .187 .129 .157 .187 .157 .250 .250
Over 54 in. to 60 inches........ .100 .129 .157 .187 .129 .157 .187 .250 .157 .250 .250 .187 .250 .312
Thickness (aluminum):
Distances between heads (and
bulkheads baffles and ring
stiffeners when used as tank
reinforcement):
36 in. or less.................. .144 .187 .227 .270 .144 .187 .227 .270 .144 .187 .227 .187 .227 .270
Over 36 in. to 54 inches........ .144 .187 .227 .270 .144 .187 .227 .270 .187 .227 .270 .157 .360 .360
Over 54 in. to 60 inches........ .144 .187 .227 .270 .187 .227 .270 .360 .227 .360 .360 .270 .360 .450
--------------------------------------------------------------------------------------------------------------------------------------------------------
[[Page 184]]
(b) [Reserved]
[Amdt. 178-89, 54 FR 25031, June 12, 1989; 54 FR 28750, July 7, 1989, as
amended at 55 FR 37065, Sept. 7, 1990; 68 FR 19285, Apr. 18, 2003]
Sec. 178.348-3 Pumps, piping, hoses and connections.
Each pump and all piping, hoses and connections on each cargo tank
motor vehicle must conform to Sec. 178.345-9, except that the use of
nonmetallic pipes, valves, or connections are authorized on DOT 412
cargo tanks.
[Amdt. 178-89, 55 FR 37065, Sept. 7, 1990. Redesignated by Amdt. 178-
112, 61 FR 18934, Apr. 29, 1996]
Sec. 178.348-4 Pressure relief.
(a) Each cargo tank must be equipped with a pressure and vacuum
relief system in accordance with Sec. 178.345-10 and this section.
(b) Type and construction. Vacuum relief devices are not required
for cargo tanks designed to be loaded by vacuum or built to withstand
full vacuum.
(c) Pressure settings of relief valves. The setting of the pressure
relief devices must be in accordance with Sec. 178.345-10(d), except as
provided in paragraph (d)(3) of this section.
(d) Venting capacities. (1) The vacuum relief system must limit the
vacuum to less than 80 percent of the design vacuum capability of the
cargo tank.
(2) If pressure loading or unloading devices are provided, the
pressure relief system must have adequate vapor and liquid capacity to
limit tank pressure to the cargo tank test pressure at the maximum
loading or unloading rate. The maximum loading and unloading rates must
be included on the metal specification plate.
(3) Cargo tanks used in dedicated service for materials classed as
corrosive material, with no secondary hazard, may have a total venting
capacity which is less than required by Sec. 178.345-10(e). The minimum
total venting capacity for these cargo tanks must be determined in
accordance with the following formula (use of approximate values given
for the formula is acceptable):
Formula in Nonmetric Units
Q = 37,980,000 A0.82 (ZT)0.5 /
(LC)(M0.5)
Where:
Q = The total required venting capacity, in cubic meters of air per hour
at standard conditions of 15.6 [deg]C and 1 atm (cubic feet of air per
hour at standard conditions of 60 [deg]F and 14.7 psia);
T = The absolute temperature of the vapor at the venting conditions--
degrees Kelvin ( [deg]C+273) [degrees Rankine ( [deg]F+460)];
A = The exposed surface area of tank shell--square meters (square feet);
L = The latent heat of vaporization of the lading--calories per gram
(BTU/lb);
Z = The compressibility factor for the vapor (if this factor is unknown,
let Z equal 1.0);
M = The molecular weight of vapor;
C = A constant derived from (K), the ratio of specific heats of the
vapor. If (K) is unknown, let C = 315.
C = 520[K(2/(K+1))[(K+1)/(K-1)]]\0.5\
Where:
K = Cp / Cv
Cp = The specific heat at constant pressure, in -calories per
gram degree centigrade (BTU/lb [deg]F.); and
Cv = The specific heat at constant volume, in -calories per
gram degree centigrade (BTU/lb [deg]F.).
[Amdt. 178-89, 54 FR 25032, June 12, 1989, as amended at 55 FR 37065,
Sept. 7, 1990; Amdt. 178-104, 59 FR 49135, Sept. 26, 1994. Redesignated
by Amdt. 178-112, 61 FR 18934, Apr. 29, 1996; 72 FR 55696, Oct. 1, 2007;
72 FR 59146, Oct. 18, 2007]
Sec. 178.348-5 Pressure and leakage test.
(a) Each cargo tank must be tested in accordance with Sec. 178.345-
13 and this section.
(b) Pressure test. Test pressure must be as follows:
(1) Using the hydrostatic test method, the test pressure must be at
least 1.5 times MAWP.
(2) Using the pneumatic test method, the test pressure must be at
least 1.5 times tank MAWP, and the inspection pressure is tank MAWP.
[Amdt. 178-89, 54 FR 25032, June 12, 1989. Redesignated by Amdt. 178-
112, 61 FR 18934, Apr. 29, 1996]
[[Page 185]]
Subpart K_Specifications for Packagings for Class 7 (Radioactive)
Materials
Sec. 178.350 Specification 7A; general packaging, Type A.
(a) Each packaging must meet all applicable requirements of subpart
B of part 173 of this subchapter and be designed and constructed so that
it meets the requirements of Sec. Sec. 173.403, 173.410, 173.412,
173.415 and 173.465 of this subchapter for Type A packaging.
(b) Each Specification 7A packaging must be marked on the outside
``USA DOT 7A Type A.''
(c) Each Specification 7A packaging must comply with the marking
requirements of Sec. 178.3. In paragraph 178.3(a)(2), the term
``packaging manufacturer'' means the person certifying that the package
meets all requirements of this section.
[Amdt. 178-109, 60 FR 50336, Sept. 28, 1995; 60 FR 54409, Oct. 23, 1995,
as amended at 69 FR 3696, Jan. 26, 2004; 70 FR 56099, Sept. 23, 2005]
Sec. 178.356 Specification 20PF phenolic-foam insulated, metal overpack.
Sec. 178.356-1 General requirements.
(a) Each overpack must meet all of the applicable requirements of
Sec. 173.24 of this subchapter.
(b) The maximum gross weight of the package, including the inner
cylinder and its contents, must not exceed the following:
(1) Specification 20PF-1--138 kg (300 pounds).
(2) Specification 20PF-2--320 kg (700 pounds).
(3) Specification 20PF-3--455 kg (1000 pounds).
(c) The general configuration of the overpack must be a right
cylinder, consisting of an insulated base section, a steel liner lid,
and an insulated top section. The inner liner and outer shell must be at
least 16-gauge and 18-gauge steel, respectively, with the intervening
cavity filled with a molded-in-place, fire-resistant, phenolic-foam
insulation interspersed with wooden members for bracing and support Wood
pieces must be securely attached to both the liner and shell. No hole is
permitted in the liner. Each joint between sections must be stepped a
minimum of 5 cm (2 inches) and gaps between mating surfaces must not
exceed 5 mm (0.2 inch). Gaps between foam surface of top section and
liner lid must not exceed 1 cm (0.4 inch) or 5 cm (2 inches) where taper
is required for mold stripping. For the specification 20PF-1, the top
section may consist of a plug of foam insulation and a steel cover. The
liner and shell closures must each be gasketed against moisture
penetration. The liner must have a bolted flange closure. Shell closure
must conform to paragraph (d) of this section.
(d) Drums over 5 gallons capacity must be closed by means of 12-
gauge bolted ring with drop forged lugs, one of which is threaded, and
having 3/8 inch bolt and nut for drums not over 30 gallons capacity and
5/8 inch bolt and nut for drums over 30 gallons capacity. Five gallon
drums must be of lug type closure with cover having at least 16 lugs.
(e) Drawings in DOE CAPE-1662, Rev. 1 and Supplement 1 (IBR, see
Sec. 171.7 of this subchapter), which include bills of material, are a
part of this specification.
[Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Redesignated by Amdt. 178-97,
55 FR 52716, Dec. 21, 1990; 65 FR 58632, Sept. 29, 2000; 66 FR 45386,
45389, Aug. 28, 2001; 68 FR 75757, Dec. 31, 2003]
Sec. 178.356-2 Materials of construction and other requirements.
(a) Phenolic foam insulation must be fire-resistant and fabricated
in accordance with USDOE Material and Equipment Specification SP-9, Rev.
1 and Supplement (IBR, see Sec. 171.7 of this subchapter), which is a
part of this specification. (Note: Packagings manufactured under USAEC
Specification SP-9 and Rev. 1 thereto are authorized for continued
manufacture and use.) A 13.7 cm (5.4-inch) minimum thickness of foam
must be provided over the entire liner except:
(1) Where wood spacers replace the foam; or
(2) At protrusions of liner or shell, such as flanges, baffles,
etc., where minimum insulation thickness is 9 cm (3.5 inches); or
(3) Where alternate top section (specification 20PF-1) is used. Foam
must not interfere with proper seating of
[[Page 186]]
screws in inner liner flange assembly. Average density of insulation
must be 0.13 g/cc (8 pounds per cubic foot (pcf)) minimum for bottom
section and 0.16 g/cc (10 pcf) minimum for top section, except 0.1 g/cc
(6.5 pcf) for the specification 20PF-1 top section.
(b) Gaskets must be as follows:
(1) Inner liner flange--Neoprene rubber of 30 to 60 type A durometer
hardness or other equivalent gasket material which is compatible with
the specific contents.
(2) Outer shell--Synthetic rubber conforming to MIL-R-6855
(available from the Naval Publications Forms Center, 5801 Tabor Avenue,
Philadelphia, Pennsylvania 19120) class 2, grade 60.
(3) Support and pressure pads for inner liner top and bottom must be
sponge rubber or equivalent.
(c) Alternate top section (specification 20PF-1 only). Average
insulation density must be 0.16 g/cc (10 pcf minimum). Thickness of plug
must be 11 cm (4.3 inches) minimum, except thickness may be reduced to
10 cm (4 inches) to clear bolt heads. A flush mounted top lifting device
must be securely fastened to a wood block encapsulated by the foam.
(d) Vent holes 5 mm (0.2-inch) diameter must be drilled in the outer
shell to provide pressure relief during the insulation foaming and in
the event of a fire. These holes, which must be drilled in all areas of
the shell that mate with the foam insulation, must be spaced in
accordance with DOE CAPE-1662, Rev. 1 and Supplement 1 (IBR, see Sec.
171.7 of this subchapter).
(e) Welding must be by a fusion welding process in accordance with
American Welding Society Codes B-3.0 and D-1.0 (IBR, see Sec. 171.7 of
this subchapter). Body seams and joints for the liner or shell must be
continuous welds.
(f) Waterproofing. Each screw hole in the outer shell must be sealed
with appropriate resin-type sealing material, or equivalent, during
installation of the screw. All exposed foam surfaces, including any vent
hole, must be sealed with waterproofing material as prescribed in USDOE
Material and Equipment Specification SP-9, Rev. 1 and Supplement, or
equivalent.
[Amdt. 178-35, 39 FR 45247, Dec. 31, 1974, as amended by Amdt. 178-56,
44 FR 49458, Aug. 23, 1979. Redesignated by Amdt. 178-97, 55 FR 52716,
Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001; 68 FR 75757, Dec. 31, 2003]
Sec. 178.356-3 Tests.
(a) Leakage test--Each inner liner assembly must be tested for
leakage prior to installation. Seam welds of the liner must be covered
for a distance of at least 15 cm (6 inches) on either side of the seam
with soapsuds, heavy oil, or equivalent material, and interior air
pressure applied to at least 776 mm Hg (15 p.s.i.g.) above atmospheric
pressure must be held for at least 30 seconds. Liners failing to pass
this test may not be used until repairs are made, and retests
successfully passed.
(b) [Reserved]
[Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Redesignated by Amdt. 178-97,
55 FR 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001; 67 FR 61016,
Sept. 27, 2002]
Sec. 178.356-4 Required markings.
(a) Marking must be as prescribed in Sec. 178.3.
(b) Marking on the outside of each overpack must be as follows:
(1) ``USA-DOT-20PF-1'' or ``-2,'' as appropriate, and if the entire
liner is made of stainless steel, additional marking such as ``3041-SS''
to indicate the type of stainless steel used.
(2) ``TARE WT: xxx lbs.'' where xxx is the tare weight of the
assembled overpack without the inner container.
(3) Year of manufacture.
[Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Redesignated by Amdt. 178-97,
55 FR 52716, Dec. 21, 1990, as amended at 63 FR 37462, July 10, 1998]
Sec. 178.356-5 Typical assembly detail.
(a) Specifications 20PF-1.
[[Page 187]]
[GRAPHIC] [TIFF OMITTED] TC02MR91.077
(b) Specification 20PF-2.
[[Page 188]]
[GRAPHIC] [TIFF OMITTED] TC02MR91.078
(c) Specification 20PF-3.
[[Page 189]]
[GRAPHIC] [TIFF OMITTED] TC02MR91.079
[Amdt. 178-35, 39 FR 45247, Dec. 31, 1974. Redesignated by Amdt. 178-97,
55 FR 52716, Dec. 21, 1990]
[[Page 190]]
Sec. 178.358 Specification 21PF fire and shock resistant, phenolic-foam
insulated, metal overpack.
Sec. 178.358-1 General requirements.
(a) Each overpack must meet all of the applicable requirements of
Sec. Sec. 173.24, 173.411, and 173.412 of this subchapter.
(1) Specification 21PF-1 overpacks includes the series of 21PF-1,
21PF-1A, and 21PF-1B models. Details of the three models are included in
DOE CAPE-1662, Rev. 1 and Supplement 1 (IBR, see Sec. 171.7 of this
subchapter).
(2) Drawings in CAPE-1662, Rev. 1 and Supplement 1, that include
bills of materials, and KSS-471 (IBR, see Sec. 171.7 of this
subchapter), are a part of this specification.
(b) Each overpack is authorized for use in applications where the
maximum gross weight of the package, including the inner container and
contents does not exceed 3725 kg (8200 pounds), (horizontally-loaded
specification 21 PF-1 unit), or 3900 kg (8600 pounds), (end-loaded
specification 21 PF-2 unit).
(c) The general configuration of the overpack must be a right
cylinder, consisting of a steel inner liner (at least 16-gauge) and
steel outer shell (at least 14-gauge) with the intervening cavity filled
with a molded-in-place, fire-resistant, phenolic foam insulation and
interspersed wooden members for bracing and support. Two specific
configurations are authorized; a horizontal loading unit (specification
21PF-1) consisting of insulated base and top sections jointed in a
longitudinal peripheral closure joint; or an end-loading unit
(specification 21PF-2), consisting of an insulated main section, a steel
plate liner lid, and an insulated end cap. For either type each joint
between sections must be stepped at least 1.8 cm (0.75-inch) and gaps
between mating surfaces may not exceed 5 mm (0.2-inch). Bolted closures,
which must each be gasketed against moisture penetration, must be in
accordance with CAPE-1662. Each bolt must be equipped with a locking
device to prevent loosening from vibration. Outer steel bracing and
support framework must be attached to the shell to facilitate normal
handling.
(d) Specification 21PF-1 overpacks in use or under construction
before April 1, 1989, must be modified to Specification 21PF-1A before
April 1, 1991. All new construction to Specification 21PF-1 beginning
after March 31, 1989, must meet Specification 21PF-1B. Use of unmodified
21PF-1 overpacks after March 31, 1991, is prohibited.
[Amdt. 178-35, 39 FR 45250, Dec. 31, 1974; 40 FR 2435, Jan. 13, 1975, as
amended by Amdt. 178-90, 53 FR 36551, Sept. 20, 1988. Redesigntated by
Amdt. 178-97, 55 FR 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001; 68
FR 75757, Dec. 31, 2003]
Sec. 178.358-2 Materials of construction and other requirements.
(a) Phenolic foam insulation must be fire resistant and fabricated
in accordance with USDOE Material and Equipment Specification SP-9, Rev.
1 and Supplement (IBR, see Sec. 171.7 of this subchapter), which is a
part of this specification. (Note: Packagings manufactured under USAEC
Specification SP-9, and Rev. 1 thereto are authorized for continued
manufacture and use.) A 14 cm (5.5-inch) minimum thickness of foam must
be provided over the entire liner except where:
(1) Wood spacers replace the foam material; or
(2) At protrusions of liner or shell, such as flanges, baffles,
etc., where the minimum thickness of foam, wood, or a combination of
these is 10 cm (4 inches).
(3) Solid wood or laminated wood solidly glued may be used to
replace the foam between liner and shell (i.e., in ends of overpack). In
this case, minimum wood thickness is 10 cm (4 inches). Average density
of insulation must be 0.1g/cc (6.75 pounds per cubic foot (pcf))
minimum, except that 0.13 g/cc (8 pcf) is required in the removable end
cap of the specification 21PF-2, which must have a minimum foam
thickness of 12.7 cm (5 inches).
(b) Gaskets for inner liner, outer shell, or where otherwise
specified in DOE CAPE-1662, Rev. 1 (IBR, see Sec. 171.7 of this
subchapter), must be as specified in DOE CAPE-1662, Rev. 1.
(c) Support and pressure pads for the inner liner must be of
neoprene, sponge rubber, or equivalent.
[[Page 191]]
(d) Fire-retardant (intumescent) paint must be applied to any wood
blocking which is located at any joint in the shell.
(e) Vent holes 5 mm (0.2-inch) diameter must be drilled in the outer
shell to provide pressure relief during the insulation foaming and in
the event of a fire. These holes, which must be drilled in all areas of
the shell which made with the foam insulation, must be spaced in
accordance with CAPE-1662.
(f) Welding must be by a fusion process in accordance with the
American Welding Society Codes B-3.0 and D-1.0 (IBR, see Sec. 171.7 of
this subchapter). Body seams and joints for the liner and shell must be
continuous welds.
(g) Waterproofing. Each screw hole in the outer shell must be sealed
with appropriate resin-type sealing material, or equivalent, during
installation of the screw. All exposed foam surfaces, including any vent
hole, must be sealed with either:
(1) Waterproofing material as prescribed in USDOE Material and
Equipment Specification SP-9, Rev. 1 and Supplement, or
(2) As specified in CAPE-1662, Revision 1.
[Amdt. 178-35, 39 FR 45250, Dec. 31, 1974, as amended by Amdt. 178-56,
44 FR 49459, Aug. 23, 1979; Amdt. 178-90, 53 FR 36551, Sept. 20, 1988.
Redesigntated by Amdt. 178-97, 55 FR 52716, Dec. 21, 1990; 66 FR 45387,
Aug. 28, 2001; 68 FR 75757, Dec. 31, 2003]
Sec. 178.358-3 Modification of Specification 21PF-1 overpacks.
(a) Each Specification 21PF-1 overpack for which construction began
or was completed before April 1, 1989, in conformance with drawing E-S-
31536-J, Rev. 1 of DOE CAPE-1662 (IBR, see Sec. 171.7 of this
subchapter), must be modified in conformance with drawing S1E-31536-J1-D
of DOE CAPE-1662, Rev. 1, Supplement 1, before April 1, 1991.
(b) Each such existing Specification 21PF-1 overpack must be dried
and weighed in accordance with the following procedures:
(1) Drill out or otherwise clean the plug material from the vent
holes originally provided for foam expansion. See drawing S1E-31536-J1-D
of CAPE-1662, Revision 1, Supplement 1, for locations.
(2) Weigh each packaging element (top and bottom halves) separately
to an accuracy of 2.3 kg (5
pounds) and record the weights. If this measured weight exceeds the
initially measured weight at the time of fabrication by 11.3 kg (25
pounds) (indicating a significant retained water content), the packaging
element must be dried.
(3) Place overpack element in drying oven; maintain temperature
between 87.8-98.9 [deg]C (190[deg] and 210 [deg]F) for a minimum of 72
hours. The oven should have a provision for air exchange or other means
of removing moisture driven from the foam structure.
(4) Drying may be discontinued after 72 hours if the weight of the
packaging element does not exceed the initially measured tare weight of
that element at the time of fabrication by more than 11.3 kg (25
pounds). If the weight of the packaging element exceeds the initial
fabricated weight (indicating a significant remaining water content) by
more than 11.3 kg (25 pounds), drying must be continued until the weight
differential is not higher than 11.3 kg (25 pounds), or until the rate
of weight loss is less than 1.1 kg (2.5 pounds) per day.
(5) As an alternate moisture measurement, a calibrated moisture
meter reading for 20 percent maximum water content may be used to
indicate an end point in the drying cycle, which is detailed in report
``Renovation of DOT Specification 21PF-1 Protective Shipping Packages,''
Report No. K-2057, Revision 1, November 21, 1986, available from the
USDOE and part of USDOE Report No. KSS-471 (IBR, see Sec. 171.7 of this
subchapter).
(6) Following drying, each overpack element (top and bottom halves)
must be weighed and the weight in both pounds and kilograms must be
engraved on the identification plate required by Sec. 178.358-5(c).
(c) After modification as provided for herein, each Specification
21PF-1 overpack must be marked ``USA-DOT-21PF-
[[Page 192]]
1A''. See the marking requirements of Sec. 178.358-5.
[Amdt. 178-90, 53 FR 36551, Sept. 20, 1988. Redesigntated by Amdt. 178-
97, 55 FR 52716, Dec. 21, 1990; Amdt. 178-110, 60 FR 49111, Sept. 21,
1995; 63 FR 37462, July 10, 1998; 66 FR 45389, Aug. 28, 2001; 68 FR
75757, Dec. 31, 2003]
Sec. 178.358-4 Construction of Specification 21PF-1B overpacks.
(a) Each Specification 21PF-1 overpack for which construction began
after March 31, 1989, must meet the requirements of Specification 21PF-
1B, in conformance with drawings E-S-31536-J-P, and S1E-31536-J2-B of
DOE CAPE-1662, Rev. 1, Supplement 1 (IBR, see Sec. 171.7 of this
subchapter).
(b) With the exception of the closure nuts and bolts, all metal
parts of the Specification 21PF-1B must be of stainless steel as shown
on the drawings referred to in paragraph (a) of this section.
[Amdt. 178-90, 53 FR 36551, Sept. 20, 1988. Redesigntated by Amdt. 178-
97, 55 FR 52716, Dec. 21, 1990; 68 FR 75757, Dec. 31, 2003]
Sec. 178.358-5 Required markings.
(a) Markings must be as prescribed in Sec. 178.3.
(b) Specification marking on the outside of each overpack must be as
follows: ``USA-DOT-21PF-1'', ``1A'', ``1B'', or ``2'', as appropriate.
(1) For Specifications 21PF-1 and 21PF-2 only, if the inner shell is
constructed of stainless steel, additional marking such as ``304L-SS''
are to be marked on the outside of the overpack to indicate the type of
stainless steel used.
(2) For Specification 21PF-1 and 21PF-2 only, ``TARE WT: * * * lbs.
(* * * kg)'' where * * * is the tare weight in pounds and kilograms,
respectively, of the assembled overpack without the inner product
container.
(3) For Specification 21PF-1A and 21PF-1B only: ``TARE WT. of Cover:
* * * lbs (* * * kg) TARE WT. of BOTTOM: * * * lbs (* * * kg)'' where *
* * is the tare weight in pounds and kilograms, respectively, of the
separate halves of the overpack without the inner product container. For
Specification 21PF-1A overpacks, the previous tare weight must be
changed to reflect the modified tare weight value or must be covered or
removed.
(4) Year of manufacture followed by the year of modification, if
applicable.
(5) The name or symbol of maker or party certifying compliance with
specification requirements. A symbol, if used, must be registered with
the Associate Administrator.
(c) For Specification 21PF-1A and -1B only, the markings required by
this section must be affixed to each overpack by inscription upon a
metal identification plate 11 inches wide x 15 inches long (28 cm x 38
cm), fabricated of 16 to 20 gauge stainless steel sheet, ASTM A-240/A
240M (IBR, see Sec. 171.7 of this subchapter), Type 304L.
[Amdt. 178-90, 53 FR 36552, Sept. 20, 1988. Redesigntated by Amdt. 178-
97, 55 FR 52716, Dec. 21, 1990, and amended at Amdt. 178-97, 56 FR
66287, Dec. 20, 1991; 63 FR 37462, July 10, 1998; 66 FR 45386, Aug. 28,
2001; 67 FR 51660, Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003; 69 FR
54046, Sept. 7, 2004]
Sec. 178.358-6 Typical assembly detail.
(a) Specification 21PF-1 (horizontal loading overpack).
[[Page 193]]
[GRAPHIC] [TIFF OMITTED] TC02MR91.080
(b) Specification 21PF-1A and 21PF-1B (horizontal loading overpack).
[[Page 194]]
[GRAPHIC] [TIFF OMITTED] TC02MR91.081
(c) Specification 21PF-2 (end loading overpack).
[[Page 195]]
[GRAPHIC] [TIFF OMITTED] TC02MR91.082
[Amdt. 178-90, 53 FR 36552, Sept. 20, 1988. Redesignated by Amdt. 178-
97, 55 FR 52716, Dec. 21, 1990]
[[Page 196]]
Sec. 178.360 Specification 2R; inside containment vessel.
Sec. 178.360-1 General requirements.
(a) Each vessel must be made of stainless steel, malleable iron, or
brass, or other material having equivalent physical strength and fire
resistance.
(b) Each vessel must meet all of the applicable requirements of
Sec. 173.24 (c) and (d) of this subchapter. Letters and numerals at
least 6 mm (\1/4\-inch) in height are authorized for the marking of a
vessel not exceeding 5 cm (2 inches) inside diameter.
[Amdt. 178-35, 39 FR 45245, Dec. 31, 1974. Redesignated by Amdt. 178-97,
55 FR 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001]
Sec. 178.360-2 Manufacture.
The ends of the vessel must be fitted with screw-type closures or
flanges (see Sec. 178.360-4), except that one or both ends of the
vessel may be permanently closed by a welded or brazed plate. Welded or
brazed side seams are authorized.
[Amdt. 178-35, 39 FR 45245, Dec. 31, 1974. Redesignated by Amdt. 178-97,
55 FR 52716, Dec. 21, 1990, as amended at 63 FR 37462, July 10, 1998]
Sec. 178.360-3 Dimensions.
(a) The inside diameter of the vessel may not exceed 30 cm (12
inches) exclusive of flanges for handling or fastening devices and must
have wall thickness and length in accordance with the following:
----------------------------------------------------------------------------------------------------------------
Inside diameter Threaded closure Length maximum
maximum -------------------- -------------------
------------------- Wall thickness minimum--Flanged closure
Inches Cm Inches Mm Inches Cm
----------------------------------------------------------------------------------------------------------------
2 5 \3/32\ 2.5 Not less than that prescribed for schedule 40 pipe.. 16 41
6 15 \1/8\ 3.2 .................................................... 72 183
12 30 \1/4\ 6.5 .................................................... 72 183
----------------------------------------------------------------------------------------------------------------
(b) [Reserved]
[Amdt. 178-35, 39 FR 45245, Dec. 31, 1974. Redesignated by Amdt. 178-97,
55 FR 52716, Dec. 21, 1990; 66 FR 45387, Aug. 28, 2001]
Sec. 178.360-4 Closure devices.
(a) Each closure device must be as follows:
(1) Screw-type cap or plug; number of threads per inch must not be
less than United States standard pipe threads and must have sufficient
length of thread to engage at least 5 threads when securely tightened.
Pipe threads must be luted with an appropriate non-hardening compound
which must be capable of withstanding up to 149 [deg]C (300 [deg]F)
without loss of efficiency. Tightening torque must be adequate to
maintain leak tightness with the specific luting compound.
(2) An opening may be closed by a securely bolted flange and leak-
tight gasket. Each flange must be welded or brazed to the body of the 2R
vessel per (ANSI) Standard B16.5 or (AWWA) Standard C207-55, section 10
(IBR, see Sec. 171.7 of this subchapter). A torque wrench must be used
in securing the flange with a corresponding torque of no more than twice
the force necessary to seal the selected gasket. Gasket material must be
capable of withstanding up to 149 [deg]C (300 [deg]F) without loss of
efficiency. The flange, whether of ferrous or nonferrous metal, must be
constructed from the same metal as the vessel and must meet the
dimensional and fabrication specifications for welded construction as
follows:
(i) Pipe flanges described in Tables 13, 14, 16, 17, 19, 20, 22, 23,
25 and 26 of ANSI B16.5 (IBR, see Sec. 171.7 of this subchapter).
(ii) For nominal pipe sizes, 6, 8, 10, and 12 inches, AWWA Standard
C207-55, Table 1, class B, may be used in place of the tables prescribed
by paragraph (a)(2)(i) of this section.
[[Page 197]]
(iii) Sizes under 6 inches, nominal pipe size, the following table
with the same configuration as illustrated in AWWA C207-55, Table 1,
class B, may be used in place of paragraph (a)(2)(i) of this section.
----------------------------------------------------------------------------------------------------------------
Nominal pipe size Flange O.D. Bolt circle Diameter of bolts Flange thickness
------------------------------------------- Number diameter ---------------------------------------
of bolts --------------------
Inches Cm Inches Cm Inches Cm Inches Cm Inches Cm
----------------------------------------------------------------------------------------------------------------
2 5 6 15 4 4\3/4\ 11.8 \1/2\ 1.2 \5/8\ 1.6
2\1/2\ 6.2 7 17.5 4 5\1/2\ 13.8 \1/2\ ........ \5/8\ ........
3 7.5 7\1/2\ 18.8 4 6 15 \1/2\ ........ \5/8\ ........
3\1/2\ 8.8 8\1/2\ 21.3 8 7 17.5 \1/2\ ........ \5/8\ ........
4 10 9 22.5 8 7\1/2\ 18.8 \1/2\ ........ \5/8\ ........
5 12.6 10 25.4 8 8\1/2\ 21.3 \1/2\ ........ \5/8\ ........
----------------------------------------------------------------------------------------------------------------
(iv) Cast iron flanges prohibited.
(b) [Reserved]
[Amdt. 178-35, 39 FR 45245, Dec. 31, 1974; 40 FR 2435, Jan. 13, 1975, as
amended at 40 FR 44327, Sept. 26, 1975. Redesignated by Amdt. 178-97, 56
FR 66284, Dec. 20, 1991; 68 FR 75757, Dec. 31, 2003]
Subpart L_Non-bulk Performance-Oriented Packaging Standards
Source: Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, unless otherwise
noted.
Sec. 178.500 Purpose, scope and definitions.
(a) This subpart prescribes certain requirements for non-bulk
packagings for hazardous materials. Standards for these packagings are
based on the UN Recommendations.
(b) Terms used in this subpart are defined in Sec. 171.8 of this
subchapter.
Sec. 178.502 Identification codes for packagings.
(a) Identification codes for designating kinds of packagings consist
of the following:
(1) A numeral indicating the kind of packaging, as follows:
(i) ``1'' means a drum.
(ii) ``2'' means a wooden barrel.
(iii) ``3'' means a jerrican.
(iv) ``4'' means a box.
(v) ``5'' means a bag.
(vi) ``6'' means a composite packaging.
(vii) ``7'' means a pressure receptacle.
(2) A capital letter indicating the material of construction, as
follows:
(i) ``A'' means steel (all types and surface treatments).
(ii) ``B'' means aluminum.
(iii) ``C'' means natural wood.
(iv) ``D'' means plywood.
(v) ``F'' means reconstituted wood.
(vi) ``G'' means fiberboard.
(vii) ``H'' means plastic.
(viii) ``L'' means textile.
(ix) ``M'' means paper, multi-wall.
(x) ``N'' means metal (other than steel or aluminum).
(xi) ``P'' means glass, porcelain or stoneware.
(3) A numeral indicating the category of packaging within the kind
to which the packaging belongs. For example, for steel drums (``1A''),
``1'' indicates a non-removable head drum (i.e., ``1A1'') and ``2''
indicates a removable head drum (i.e., ``1A2'').
(b) For composite packagings, two capital letters are used in
sequence in the second position of the code, the first indicating the
material of the inner receptacle and the second, that of the outer
packaging. For example, a plastic receptacle in a steel drum is
designated ``6HA1''.
(c) For combination packagings, only the code number for the outer
packaging is used.
(d) Identification codes are set forth in the standards for
packagings in Sec. Sec. 178.504 through 178.523 of this subpart.
Note to Sec. 178.502: Plastics materials include other polymeric
materials such as rubber.
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended by Amdt. 178-106,
59 FR 67519, Dec. 29, 1994; 74 FR 2269, Jan. 14, 2009]
Sec. 178.503 Marking of packagings.
(a) A manufacturer must mark every packaging that is represented as
manufactured to meet a UN standard with the marks specified in this
section. The
[[Page 198]]
markings must be durable, legible and placed in a location and of such a
size relative to the packaging as to be readily visible, as specified in
Sec. 178.3(a). Except as otherwise provided in this section, every
reusable packaging liable to undergo a reconditioning process which
might obliterate the packaging marks must bear the marks specified in
paragraphs (a)(1) through (a)(6) and (a)(9) of this section in a
permanent form (e.g. embossed) able to withstand the reconditioning
process. A marking may be applied in a single line or in multiple lines
provided the correct sequence is used. As illustrated by the examples in
paragraph (e) of this section, the following information must be
presented in the correct sequence. Slash marks should be used to
separate this information. A packaging conforming to a UN standard must
be marked as follows:
(1) Except as provided in paragraph (e)(1)(ii) of this section, the
United Nations symbol as illustrated in paragraph (e)(1)(i) of this
section (for embossed metal receptacles, the letters ``UN'') may be
applied in place of the symbol;;
(2) A packaging identification code designating the type of
packaging, the material of construction and, when appropriate, the
category of packaging under Sec. Sec. 178.504 through 178.523 of this
subpart within the type to which the packaging belongs. The letter ``V''
must follow the packaging identification code on packagings tested in
accordance with Sec. 178.601(g)(2); for example, ``4GV''. The letter
``W'' must follow the packaging identification code on packagings when
required by an approval under the provisions of Sec. 178.601(h) of this
part;
(3) A letter identifying the performance standard under which the
packaging design type has been successfully tested, as follows:
(i) X--for packagings meeting Packing Group I, II and III tests;
(ii) Y--for packagings meeting Packing Group II and III tests; or
(iii) Z--for packagings only meeting Packing Group III tests;
(4) A designation of the specific gravity or mass for which the
packaging design type has been tested, as follows:
(i) For packagings without inner packagings intended to contain
liquids, the designation shall be the specific gravity rounded down to
the first decimal but may be omitted when the specific gravity does not
exceed 1.2; and
(ii) For packagings intended to contain solids or inner packagings,
the designation shall be the maximum gross mass in kilograms;
(5)(i) For single and composite packagings intended to contain
liquids, the test pressure in kilopascals rounded down to the nearest 10
kPa of the hydrostatic pressure test that the packaging design type has
successfully passed;
(ii) For packagings intended to contain solids or inner packagings,
the letter ``S'';
(6) The last two digits of the year of manufacture. Packagings of
types 1H and 3H shall also be marked with the month of manufacture in
any appropriate manner; this may be marked on the packaging in a
different place from the remainder of the markings;
(7) The state authorizing allocation of the mark. The letters `USA'
indicate that the packaging is manufactured and marked in the United
States in compliance with the provisions of this subchapter;
(8) The name and address or symbol of the manufacturer or the
approval agency certifying compliance with subpart L and subpart M of
this part. Symbols, if used, must be registered with the Associate
Administrator;
(9) For metal or plastic drums or jerricans intended for reuse or
reconditioning as single packagings or the outer packagings of a
composite packaging, the thickness of the packaging material, expressed
in mm (rounded to the nearest 0.1 mm), as follows:
(i) Metal drums or jerricans must be marked with the nominal
thickness of the metal used in the body. The marked nominal thickness
must not exceed the minimum thickness of the steel used by more than the
thickness tolerance stated in ISO 3574 (IBR, see Sec. 171.7 of this
subchapter). (See appendix C of this part.) The unit of measure is not
required to be marked. When the nominal thickness of either head of a
metal drum is thinner than that of the body, the nominal thickness of
the top
[[Page 199]]
head, body, and bottom head must be marked (e.g., ``1.0-1.2-1.0'' or
``0.9-1.0-1.0'').
(ii) Plastic drums or jerricans must be marked with the minimum
thickness of the packaging material. Minimum thicknesses of plastic must
be as determined in accordance with Sec. 173.28(b)(4). The unit of
measure is not required to be marked;
(10) In addition to the markings prescribed in paragraphs (a)(1)
through (a)(9) of this section, every new metal drum having a capacity
greater than 100 L must bear the marks described in paragraphs (a)(1)
through (a)(6), and (a)(9)(i) of this section, in a permanent form, on
the bottom. The markings on the top head or side of these packagings
need not be permanent, and need not include the thickness mark described
in paragraph (a)(9) of this section. This marking indicates a drum's
characteristics at the time it was manufactured, and the information in
paragraphs (a)(1) through (a)(6) of this section that is marked on the
top head or side must be the same as the information in paragraphs
(a)(1) through (a)(6) of this section permanently marked by the original
manufacturer on the bottom of the drum; and
(11) Rated capacity of the packaging expressed in liters may be
marked.
(b) For a packaging with a removable head, the markings may not be
applied only to the removable head.
(c) Marking of reconditioned packagings. (1) If a packaging is
reconditioned, it shall be marked by the reconditioner near the marks
required in paragraphs (a)(1) through (6) of this section with the
following additional information:
(i) The name of the country in which the reconditioning was
performed (in the United States, use the letters ``USA'');
(ii) The name and address or symbol of the reconditioner. Symbols,
if used, must be registered with the Associate Administrator;
(iii) The last two digits of the year of reconditioning;
(iv) The letter ``R''; and
(v) For every packaging successfully passing a leakproofness test,
the additional letter ``L''.
(2) When, after reconditioning, the markings required by paragraph
(a)(1) through (a)(5) of this section no longer appear on the top head
or the side of the metal drum, the reconditioner must apply them in a
durable form followed by the markings in paragraph (c)(1) of this
section. These markings may identify a different performance capability
than that for which the original design type had been tested and marked,
but may not identify a greater performance capability. The markings
applied in accordance with this paragraph may be different from those
which are permanently marked on the bottom of a drum in accordance with
paragraph (a)(10) of this section.
(d) Marking of remanufactured packagings. For remanufactured metal
drums, if there is no change to the packaging type and no replacement or
removal of integral structural components, the required markings need
not be permanent (e.g., embossed). Every other remanufactured drum must
bear the marks required in paragraphs (a)(1) through (a)(6) of this
section in a permanent form (e.g., embossed) on the top head or side. If
the metal thickness marking required in paragraph (a)(9)(i) of this
section does not appear on the bottom of the drum, or if it is no longer
valid, the remanufacturer also must mark this information in permanent
form.
(1)(i) The United Nations symbol is:
[[Page 200]]
[GRAPHIC] [TIFF OMITTED] TR02FE10.002
(ii) The circle that surrounds the letters ``u'' and ``n'' may have
small breaks provided the following provisions are met:
(A) The total gap space does not exceed 15 percent of the
circumference of the circle;
(B) There are no more than four gaps in the circle;
(C) The spacing between gaps is separated by no less than 20 percent
of the circumference of the circle (72 degrees); and
(D) The letters ``u'' and ``n'' appear exactly as depicted in Sec.
178.503(e)(1)(i) with no gaps.
(2) Examples of markings for a new packaging are as follows:
(i) For a fiberboard box designed to contain an inner packaging:
[GRAPHIC] [TIFF OMITTED] TC02MR91.087
(as in Sec. 178.503 (a)(1) through (a)(9) of this subpart).
(ii) For a steel drum designed to contain liquids:
[GRAPHIC] [TIFF OMITTED] TC02MR91.088
(as in Sec. 178.503 (a)(1) through (a)(10) of this subpart).
(iii) For a steel drum to transport solids or inner packagings:
[GRAPHIC] [TIFF OMITTED] TC02MR91.089
(as in Sec. 178.503 (a)(1) through (a)(8) of this subpart).
(3) Examples of markings for reconditioned packagings are as
follows:
[GRAPHIC] [TIFF OMITTED] TC02MR91.090
(as in Sec. 178.503(c)(1)).
(f) A manufacturer must mark every UN specification package
represented as manufactured to meet the requirements of Sec. 178.609
for packaging of infectious substances with the marks specified in this
section. The markings
[[Page 201]]
must be durable, legible, and must be readily visible, as specified in
Sec. 178.3(a). An infectious substance packaging that successfully
passes the tests conforming to the UN standard must be marked as
follows:
(1) The United Nations symbol as illustrated in paragraph (e) of
this section.
(2) The code designating the type of packaging and material of
construction according to the identification codes for packagings
specified in Sec. 178.502.
(3) The text ``CLASS 6.2''.
(4) The last two digits of the year of manufacture of the packaging.
(5) The country authorizing the allocation of the mark. The letters
``USA'' indicate the packaging is manufactured and marked in the United
States in compliance with the provisions of this subchapter.
(6) The name and address or symbol of the manufacturer or the
approval agency certifying compliance with subparts L and M of this
part. Symbols, if used, must be registered with the Associate
Administrator for Hazardous Materials Safety.
(7) For packagings meeting the requirements of Sec. 178.609(i)(3),
the letter ``U'' must be inserted immediately following the marking
designating the type of packaging and material required in paragraph
(f)(2) of this section.
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66284,
Dec. 20, 1991; Amdt. 178-102, 59 FR 28493, June 2, 1994; Amdt. 178-106,
59 FR 67520, 67521, Dec. 29, 1994; Amdt. 178-107, 60 FR 26806, May 18,
1995; 62 FR 51561, Oct. 1, 1997; 66 FR 45386, Aug. 28, 2001; 67 FR
61016, Sept. 27, 2002; 67 FR 53143, Aug. 14, 2002; 68 FR 75757, Dec. 31,
2003; 75 FR 5395, Feb 2, 2010; 75 FR 60339, Sept. 30, 2010]
Sec. 178.504 Standards for steel drums.
(a) The following are identification codes for steel drums:
(1) 1A1 for a non-removable head steel drum; and
(2) 1A2 for a removable head steel drum.
(b) Construction requirements for steel drums are as follows:
(1) Body and heads must be constructed of steel sheet of suitable
type and adequate thickness in relation to the capacity and intended use
of the drum. Minimum thickness and marking requirements in Sec. Sec.
173.28(b)(4) and 178.503(a)(9) of this subchapter apply to drums
intended for reuse.
(2) Body seams must be welded on drums designed to contain more than
40 L (11 gallons) of liquids. Body seams must be mechanically seamed or
welded on drums intended to contain only solids or 40 L (11 gallons) or
less of liquids.
(3) Chimes must be mechanically seamed or welded. Separate
reinforcing rings may be applied.
(4) The body of a drum of a capacity greater than 60 L (16 gallons)
may have at least two expanded rolling hoops or two separate rolling
hoops. If there are separate rolling hoops, they must be fitted tightly
on the body and so secured that they cannot shift. Rolling hoops may not
be spot-welded.
(5) Openings for filling, emptying and venting in the bodies or
heads of non-removable head (1A1) drums may not exceed 7.0 cm (3 inches)
in diameter. Drums with larger openings are considered to be of the
removable head type (1A2). Closures for openings in the bodies and heads
of drums must be so designed and applied that they will remain secure
and leakproof under normal conditions of transport. Closure flanges may
be mechanically seamed or welded in place. Gaskets or other sealing
elements must be used with closures unless the closure is inherently
leakproof.
(6) Closure devices for removable head drums must be so designed and
applied that they will remain secure and drums will remain leakproof
under normal conditions of transport. Gaskets or other sealing elements
must be used with all removable heads.
(7) If materials used for body, heads, closures, and fittings are
not in themselves compatible with the contents to be transported,
suitable internal protective coatings or treatments must be applied.
These coatings or treatments must retain their protective properties
under normal conditions of transport.
(8) Maximum capacity of drum: 450 L (119 gallons).
[[Page 202]]
(9) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66284,
Dec. 20, 1991; Amdt. 178-110, 60 FR 49111, Sept. 21, 1995]
Sec. 178.505 Standards for aluminum drums.
(a) The following are the identification codes for aluminum drums:
(1) 1B1 for a non-removable head aluminum drum; and
(2) 1B2 for a removable head aluminum drum.
(b) Construction requirements for aluminum drums are as follows:
(1) Body and heads must be constructed of aluminum at least 99
percent pure or an aluminum base alloy. Material must be of suitable
type and adequate thickness in relation to the capacity and the intended
use of the drum. Minimum thickness and marking requirements in
Sec. Sec. 173.28(b)(4) and 178.503(a)(9) of this subchapter apply to
drums intended for reuse.
(2) All seams must be welded. Chime seams, if any, must be
reinforced by the application of separate reinforcing rings.
(3) The body of a drum of a capacity greater than 60 L (16 gallons)
may have at least two expanded rolling hoops or two separate rolling
hoops. If there are separate rolling hoops, the hoops must be fitted
tightly on the body and so secured that they cannot shift. Rolling hoops
may not be spot-welded.
(4) Openings for filling, emptying, or venting in the bodies or
heads of non-removable head (1B1) drums may not exceed 7.0 cm (3 inches)
in diameter. Drums with larger openings are considered to be of the
removable head type (1B2). Closures for openings in the bodies and heads
of drums must be so designed and applied that they will remain secure
and leakproof under normal conditions of transport. Closure flanges may
be welded in place so that the weld provides a leakproof seam. Gaskets
or other sealing elements must be used with closures unless the closure
is inherently leakproof.
(5) Closure devices for removable head drums must be so designed and
applied that they remain secure and drums remain leakproof under normal
conditions of transport. Gaskets or other sealing elements must be used
with all removable heads.
(6) Maximum capacity of drum: 450 L (119 gallons).
(7) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66284,
Dec. 20, 1991; Amdt. 178-102, 59 FR 28494, June 2, 1994]
Sec. 178.506 Standards for metal drums other than steel or aluminum.
(a) The following are the identification codes for metal drums other
than steel or aluminum:
(1) 1N1 for a non-removable head metal drum; and
(2) 1N2 for a removable head metal drum.
(b) Construction requirements for metal drums other than steel or
aluminum are as follows:
(1) Body and heads must be constructed of metal (other than steel or
aluminum) of suitable type and adequate thickness in relation to the
capacity and the intended use of the drum. Minimum thickness and marking
requirements in Sec. Sec. 173.28(b)(4) and 178.503(a)(9) of this
subchapter apply to drums intended for reuse.
(2) All seams must be welded. Chime seams, if any, must be
reinforced by the application of separate reinforcing rings.
(3) The body of a drum of a capacity greater than 60 L (16 gallons)
may have at least two expanded rolling hoops or two separate rolling
hoops. If there are separate rolling hoops, the hoops must be fitted
tightly on the body and so secured that they cannot shift. Rolling hoops
may not be spot-welded.
(4) Openings for filling, emptying, or venting in the bodies or
heads of non-removable head (1N1) drums may not exceed 7.0 cm (3 inches)
in diameter. Drums with larger openings are considered to be of the
removable head type (1N2). Closures for openings in the bodies and heads
of drums must be so designed and applied that they will remain secure
and leakproof under normal conditions of transport. Closure flanges may
be welded in place so that the weld provides a leakproof seam. Gaskets
or other sealing elements must be used with closures unless the closure
is inherently leakproof.
[[Page 203]]
(5) Closure devices for removable head drums must be so designed and
applied that they remain secure and drums remain leakproof under normal
conditions of transport. Gaskets or other sealing elements must be used
with all removable heads.
(6) Maximum capacity of drum: 450 L (119 gallons).
(7) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66285,
Dec. 20, 1991; Amdt. 178-102, 59 FR 28494, June 2, 1994]
Sec. 178.507 Standards for plywood drums.
(a) The identification code for a plywood drum is 1D.
(b) Construction requirements for plywood drums are as follows:
(1) The wood used must be well-seasoned, commercially dry and free
from any defect likely to lessen the effectiveness of the drum for the
purpose intended. A material other than plywood, of at least equivalent
strength and durability, may be used for the manufacture of the heads.
(2) At least two-ply plywood must be used for the body and at least
three-ply plywood for the heads; the plies must be firmly glued
together, with their grains crosswise.
(3) The body and heads of the drum and their joints must be of a
design appropriate to the capacity of the drum and its intended use.
(4) In order to prevent sifting of the contents, lids must be lined
with kraft paper or some other equivalent material which must be
securely fastened to the lid and extend to the outside along its full
circumference.
(5) Maximum capacity of drum: 250 L (66 gallons).
(6) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 57 FR 45465,
Oct. 1, 1992]
Sec. 178.508 Standards for fiber drums.
(a) The identification code for a fiber drum is 1G.
(b) Construction requirements for fiber drums are as follows:
(1) The body of the drum must be constructed of multiple plies of
heavy paper or fiberboard (without corrugations) firmly glued or
laminated together and may include one or more protective layers of
bitumen, waxed kraft paper, metal foil, plastic material, or similar
materials.
(2) Heads must be of natural wood, fiberboard, metal, plywood,
plastics, or other suitable material and may include one or more
protective layers of bitumen, waxed kraft paper, metal foil, plastic
material, or similar material.
(3) The body and heads of the drum and their joints must be of a
design appropriate to the capacity and intended use of the drum.
(4) The assembled packaging must be sufficiently water-resistant so
as not to delaminate under normal conditions of transport.
(5) Maximum capacity of drum: 450 L (119 gallons).
(6) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended by Amdt. 178-106,
59 FR 67521, Dec. 29, 1994]
Sec. 178.509 Standards for plastic drums and jerricans.
(a) The following are identification codes for plastic drums and
jerricans:
(1) 1H1 for a non-removable head plastic drum;
(2) 1H2 for a removable head plastic drum;
(3) 3H1 for a non-removable head jerrican; and
(4) 3H2 for a removable head jerrican.
(b) Construction requirements for plastic drums and jerricans are as
follows:
(1) The packaging must be manufactured from suitable plastic
material and be of adequate strength in relation to its capacity and
intended use. No used material other than production residues or regrind
from the same manufacturing process may be used unless approved by the
Associate Administrator. The packaging must be adequately resistant to
aging and to degradation caused either by the substance contained or by
ultra-violet radiation. Any permeation of the substance contained may
not constitute a danger under normal conditions of transport.
[[Page 204]]
(2) If protection against ultra-violet radiation is required, it
must be provided by the addition of carbon black or other suitable
pigments or inhibitors. These additives must be compatible with the
contents and remain effective throughout the life of the packaging.
Where use is made of carbon black, pigments or inhibitors other than
those used in the manufacture of the design type, retesting may be
omitted if the carbon black content does not exceed 2 percent by mass or
if the pigment content does not exceed 3 percent by mass; the content of
inhibitors of ultra-violet radiation is not limited.
(3) Additives serving purposes other than protection against ultra-
violet radiation may be included in the composition of the plastic
material provided they do not adversely affect the chemical and physical
properties of the packaging material.
(4) The wall thickness at every point of the packaging must be
appropriate to its capacity and its intended use, taking into account
the stresses to which each point is liable to be exposed. Minimum
thickness and marking requirements in Sec. Sec. 173.28(b)(4) and
178.503(a)(9) of this subchapter apply to drums intended for reuse.
(5) Openings for filling, emptying and venting in the bodies or
heads of non-removable head (1H1) drums and jerricans (3H1) may not
exceed 7.0 cm (3 inches) in diameter. Drums and jerricans with larger
openings are considered to be of the removable head type (1H2 and 3H2).
Closures for openings in the bodies or heads of drums and jerricans must
be so designed and applied that they remain secure and leakproof under
normal conditions of transport. Gaskets or other sealing elements must
be used with closures unless the closure is inherently leakproof.
(6) Closure devices for removable head drums and jerricans must be
so designed and applied that they remain secure and leakproof under
normal conditions of transport. Gaskets must be used with all removable
heads unless the drum or jerrican design is such that when the removable
head is properly secured, the drum or jerrican is inherently leakproof.
(7) Maximum capacity of drums and jerricans: 1H1, 1H2: 450 L (119
gallons); 3H1, 3H2: 60 L (16 gallons).
(8) Maximum net mass: 1H1, 1H2: 400 kg (882 pounds); 3H1, 3H2: 120
kg (265 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended by Amdt. 178-102,
59 FR 28494, June 2, 1994; 64 FR 10782, Mar. 5, 1999; 66 FR 45386, Aug.
28, 2001]
Sec. 178.510 Standards for wooden barrels.
(a) The following are identification codes for wooden barrels:
(1) 2C1 for a bung type wooden barrel; and
(2) 2C2 for a slack type (removable head) wooden barrel.
(b) Construction requirements for wooden barrels are as follows:
(1) The wood used must be of good quality, straight-grained, well-
seasoned and free from knots, bark, rotten wood, sapwood or other
defects likely to lessen the effectiveness of the barrel for the purpose
intended.
(2) The body and heads must be of a design appropriate to the
capacity and intended use of the barrel.
(3) Staves and heads must be sawn or cleft with the grain so that no
annual ring extends over more than half the thickness of a stave or
head.
(4) Barrel hoops must be of steel or iron of good quality. The hoops
of 2C2 barrels may be of a suitable hardwood.
(5) For wooden barrels 2C1, the diameter of the bung-hole may not
exceed half the width of the stave in which it is placed.
(6) For wooden barrels 2C2, heads must fit tightly into crozes.
(7) Maximum capacity of barrel: 250 L (66 gallons).
(8) Maximum net mass: 400 kg (882 pounds).
Sec. 178.511 Standards for aluminum and steel jerricans.
(a) The following are identification codes for aluminum and steel
jerricans:
(1) 3A1 for a non-removable head steel jerrican;
(2) 3A2 for a removable head steel jerrican;
(3) 3B1 for a non-removable head aluminum jerrican; and
[[Page 205]]
(4) 3B2 for a removable head aluminum jerrican.
(b) Construction requirements for aluminum and steel jerricans are
as follows:
(1) For steel jerricans the body and heads must be constructed of
steel sheet of suitable type and adequate thickness in relation to the
capacity of the jerrican and its intended use. Minimum thickness and
marking requirements in Sec. Sec. 173.28(b)(4) and 178.503(a)(9) of
this subchapter apply to jerricans intended for reuse.
(2) For aluminum jerricans the body and heads must be constructed of
aluminum at least 99% pure or of an aluminum base alloy. Material must
be of a type and of adequate thickness in relation to the capacity of
the jerrican and to its intended use.
(3) Chimes of all jerricans must be mechanically seamed or welded.
Body seams of jerricans intended to carry more than 40 L (11 gallons) of
liquid must be welded. Body seams of jerricans intended to carry 40 L
(11 gallons) or less must be mechanically seamed or welded.
(4) Openings in jerricans (3A1) may not exceed 7.0 cm (3 inches) in
diameter. Jerricans with larger openings are considered to be of the
removable head type. Closures must be so designed that they remain
secure and leakproof under normal conditions of transport. Gaskets or
other sealing elements must be used with closures, unless the closure is
inherently leakproof.
(5) If materials used for body, heads, closures and fittings are not
in themselves compatible with the contents to be transported, suitable
internal protective coatings or treatments must be applied. These
coatings or treatments must retain their protective properties under
normal conditions of transport.
(6) Maximum capacity of jerrican: 60 L (16 gallons).
(7) Maximum net mass: 120 kg (265 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended by Amdt. 178-102,
59 FR 28494, June 2, 1994; Amdt. 178-119, 62 FR 24742, May 6, 1997]
Sec. 178.512 Standards for steel or aluminum boxes.
(a) The following are identification codes for steel or aluminum
boxes:
(1) 4A for a steel box; and
(2) 4B for an aluminum box.
(b) Construction requirements for steel or aluminum boxes are as
follows:
(1) The strength of the metal and the construction of the box must
be appropriate to the capacity and intended use of the box.
(2) Boxes must be lined with fiberboard or felt packing pieces or
must have an inner liner or coating of suitable material in accordance
with subpart C of part 173 of this subchapter. If a double seamed metal
liner is used, steps must be taken to prevent the ingress of materials,
particularly explosives, into the recesses of the seams.
(3) Closures may be of any suitable type, and must remain secure
under normal conditions of transport.
(4) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended by Amdt. 178-106,
59 FR 67521, Dec. 29, 1994]
Sec. 178.513 Standards for boxes of natural wood.
(a) The following are the identification codes for boxes of natural
wood:
(1) 4C1 for an ordinary box; and
(2) 4C2 for a box with sift-proof walls.
(b) Construction requirements for boxes of natural wood are as
follows:
(1) The wood used must be well-seasoned, commercially dry and free
from defects that would materially lessen the strength of any part of
the box. The strength of the material used and the method of
construction must be appropriate to the capacity and intended use of the
box. The tops and bottoms may be made of water-resistant reconstituted
wood such as hard board, particle board or other suitable type.
(2) Fastenings must be resistant to vibration experienced under
normal conditions of transportation. End grain nailing must be avoided
whenever practicable. Joints which are likely to be highly stressed must
be made using clenched or annular ring nails or equivalent fastenings.
[[Page 206]]
(3) Each part of the 4C2 box must be one piece or equivalent. Parts
are considered equivalent to one piece when one of the following methods
of glued assembly is used: Linderman joint, tongue and groove joint,
ship lap or rabbet joint, or butt joint with at least two corrugated
metal fasteners at each joint.
(4) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended by Amdt. 178-106,
59 FR 67521, Dec. 29, 1994]
Sec. 178.514 Standards for plywood boxes.
(a) The identification code for a plywood box is 4D.
(b) Construction requirements for plywood boxes are as follows:
(1) Plywood used must be at least 3 ply. It shall be made from well-
seasoned rotary cut, sliced or sawn veneer, commercially dry and free
from defects that would materially lessen the strength of the box. The
strength of the material used and the method of construction must be
appropriate to the capacity and intended use of the box. All adjacent
plies must be glued with water-resistant adhesive. Other suitable
materials may be used together with plywood in the construction of
boxes. Boxes must be nailed or secured to corner posts or ends or
assembled with other equally suitable devices.
(2) Maximum net mass: 400 kg (882 pounds).
Sec. 178.515 Standards for reconstituted wood boxes.
(a) The identification code for a reconstituted wood box is 4F.
(b) Construction requirements for reconstituted wood boxes are as
follows:
(1) The walls of boxes must be made of water-resistant,
reconstituted wood such as hardboard, particle board, or other suitable
type. The strength of the material used and the method of construction
must be appropriate to the capacity of the boxes and their intended use.
(2) Other parts of the box may be made of other suitable materials.
(3) Boxes must be securely assembled by means of suitable devices.
(4) Maximum net mass: 400 kg (882 pounds).
Sec. 178.516 Standards for fiberboard boxes.
(a) The identification code for a fiberboard box is 4G.
(b) Construction requirements for fiberboard boxes are as follows:
(1) Strong, solid or double-faced corrugated fiberboard (single or
multi-wall) must be used, appropriate to the capacity and intended use
of the box. The water resistance of the outer surface must be such that
the increase in mass, as determined in a test carried out over a period
of 30 minutes by the Cobb method of determining water absorption, is not
greater than 155 g per square meter (0.0316 pounds per square foot)--see
ISO 535 (IBR, see Sec. 171.7 of this subchapter). Fiberboard must have
proper bending qualities. Fiberboard must be cut, creased without
cutting through any thickness of fiberboard, and slotted so as to permit
assembly without cracking, surface breaks, or undue bending. The fluting
of corrugated fiberboard must be firmly glued to the facings.
(2) The ends of boxes may have a wooden frame or be entirely of wood
or other suitable material. Reinforcements of wooden battens or other
suitable material may be used.
(3) Manufacturing joints. (i) Manufacturing joints in the bodies of
boxes must be--
(A) Taped;
(B) Lapped and glued; or
(C) Lapped and stitched with metal staples.
(ii) Lapped joints must have an appropriate overlap.
(4) Where closing is effected by gluing or taping, a water resistant
adhesive must be used.
(5) Boxes must be designed so as to provide a snug fit to the
contents.
(6) Maximum net mass: 400 kg (882 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, and amended by Amdt. 178-99,
58 FR 51534, Oct. 1, 1993; Amdt. 178-106, 59 FR 67521, Dec. 29, 1994; 68
FR 75758, Dec. 31, 2003]
Sec. 178.517 Standards for plastic boxes.
(a) The following are identification codes for plastic boxes:
(1) 4H1 for an expanded plastic box; and
(2) 4H2 for a solid plastic box.
[[Page 207]]
(b) Construction requirements for plastic boxes are as follows:
(1) The box must be manufactured from suitable plastic material and
be of adequate strength in relation to its capacity and intended use.
The box must be adequately resistant to aging and to degradation caused
either by the substance contained or by ultra-violet radiation.
(2) An expanded plastic box must consist of two parts made of a
molded expanded plastic material: a bottom section containing cavities
for the inner receptacles, and a top section covering and interlocking
with the bottom section. The top and bottom sections must be so designed
that the inner receptacles fit snugly. The closure cap for any inner
receptacle may not be in contact with the inside of the top section of
the box.
(3) For transportation, an expanded plastic box must be closed with
a self-adhesive tape having sufficient tensile strength to prevent the
box from opening. The adhesive tape must be weather-resistant and its
adhesive compatible with the expanded plastic material of the box. Other
closing devices at least equally effective may be used.
(4) For solid plastic boxes, protection against ultra-violet
radiation, if required, must be provided by the addition of carbon black
or other suitable pigments or inhibitors. These additives must be
compatible with the contents and remain effective throughout the life of
the box. Where use is made of carbon black pigment or inhibitors other
than those used in the manufacture of the tested design type, retesting
may be waived if the carbon black content does not exceed 2 percent by
mass or if the pigment content does not exceed 3 percent by mass; the
content of inhibitors of ultra-violet radiation is not limited.
(5) Additives serving purposes other than protection against ultra-
violet radiation may be included in the composition of the plastic
material if they do not adversely affect the material of the box.
Addition of these additives does not change the design type.
(6) Solid plastic boxes must have closure devices made of a suitable
material of adequate strength and so designed as to prevent the box from
unintentionally opening.
(7) Maximum net mass 4H1: 60 kg (132 pounds); 4H2: 400 kg (882
pounds).
Sec. 178.518 Standards for woven plastic bags.
(a) The following are identification codes for woven plastic bags:
(1) 5H1 for an unlined or non-coated woven plastic bag;
(2) 5H2 for a sift-proof woven plastic bag; and
(3) 5H3 for a water-resistant woven plastic bag.
(b) Construction requirements for woven plastic fabric bags are as
follows:
(1) Bags must be made from stretched tapes or monofilaments of a
suitable plastic material. The strength of the material used and the
construction of the bag must be appropriate to the capacity and intended
use of the bag.
(2) If the fabric is woven flat, the bags must be made by sewing or
some other method ensuring closure of the bottom and one side. If the
fabric is tubular, the bag must be closed by sewing, weaving, or some
other equally strong method of closure.
(3) Bags, sift-proof, 5H2 must be made sift-proof by appropriate
means such as use of paper or a plastic film bonded to the inner surface
of the bag or one or more separate inner liners made of paper or plastic
material.
(4) Bags, water-resistant, 5H3: To prevent the entry of moisture,
the bag must be made waterproof by appropriate means, such as separate
inner liners of water-resistant paper (e.g., waxed kraft paper, double-
tarred kraft paper or plastic-coated kraft paper), or plastic film
bonded to the inner or outer surface of the bag, or one or more inner
plastic liners.
(5) Maximum net mass: 50 kg (110 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, and amended by Amdt. 178-99,
58 FR 51534, Oct. 1, 1993]
Sec. 178.519 Standards for plastic film bags.
(a) The identification code for a plastic film bag is 5H4.
(b) Construction requirements for plastic film bags are as follows:
[[Page 208]]
(1) Bags must be made of a suitable plastic material. The strength
of the material used and the construction of the bag must be appropriate
to the capacity and the intended use of the bag. Joints and closures
must be capable of withstanding pressures and impacts liable to occur
under normal conditions of transportation.
(2) Maximum net mass: 50 kg (110 pounds).
Sec. 178.520 Standards for textile bags.
(a) The following are identification codes for textile bags:
(1) 5L1 for an unlined or non-coated textile bag;
(2) 5L2 for a sift-proof textile bag; and
(3) 5L3 for a water-resistant textile bag.
(b) Construction requirements for textile bags are as follows:
(1) The textiles used must be of good quality. The strength of the
fabric and the construction of the bag must be appropriate to the
capacity and intended use of the bag.
(2) Bags, sift-proof, 5L2: The bag must be made sift-proof, by
appropriate means, such as by the use of paper bonded to the inner
surface of the bag by a water-resistant adhesive such as bitumen,
plastic film bonded to the inner surface of the bag, or one or more
inner liners made of paper or plastic material.
(3) Bags, water-resistant, 5L3: To prevent entry of moisture, the
bag must be made waterproof by appropriate means, such as by the use of
separate inner liners of water-resistant paper (e.g., waxed kraft paper,
tarred paper, or plastic-coated kraft paper), or plastic film bonded to
the inner surface of the bag, or one or more inner liners made of
plastic material or metalized film or foil.
(4) Maximum net mass: 50 kg (110 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66285,
Dec. 20, 1991]
Sec. 178.521 Standards for paper bags.
(a) The following are identification codes for paper bags:
(1) 5M1 for a multi-wall paper bag; and
(2) 5M2 for a multi-wall water-resistant paper bag.
(b) Construction requirements for paper bags are as follows:
(1) Bags must be made of a suitable kraft paper, or of an equivalent
paper with at least three plies. The strength of the paper and the
construction of the bag must be appropriate to the capacity and intended
use of the bag. Seams and closures must be sift-proof.
(2) Paper bags 5M2: To prevent the entry of moisture, a bag of four
plies or more must be made waterproof by the use of either a water-
resistant ply as one of the two outermost plies or a water-resistant
barrier made of a suitable protective material between the two outermost
plies. A 5M2 bag of three plies must be made waterproof by the use of a
water-resistant ply as the outermost ply. When there is danger of the
lading reacting with moisture, or when it is packed damp, a waterproof
ply or barrier, such as double-tarred kraft paper, plastics-coated kraft
paper, plastics film bonded to the inner surface of the bag, or one or
more inner plastics liners, must also be placed next to the substance.
Seams and closures must be waterproof.
(3) Maximum net mass: 50 kg (110 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended at 56 FR 66285,
Dec. 20, 1991; Amdt. 178-106, 59 FR 67521, Dec. 29, 1994]
Sec. 178.522 Standards for composite packagings with inner plastic
receptacles.
(a) The following are the identification codes for composite
packagings with inner plastic receptacles:
(1) 6HA1 for a plastic receptacle within a protective steel drum;
(2) 6HA2 for a plastic receptacle within a protective steel crate or
box;
(3) 6HB1 for a plastic receptacle within a protective aluminum drum.
(4) 6HB2 for a plastic receptacle within a protective aluminum crate
or box.
(5) 6HC for a plastic receptacle within a protective wooden box.
(6) 6HD1 for a plastic receptacle within a protective plywood drum;
(7) 6HD2 for a plastic receptacle within a protective plywood box;
(8) 6HG1 for a plastic receptacle within a protective fiber drum;
[[Page 209]]
(9) 6HG2 for a plastic receptacle within a protective fiberboard
box;
(10) 6HH1 for a plastic receptacle within a protective plastic drum;
and
(11) 6HH2 for a plastic receptacle within a protective plastic box.
(b) Construction requirements for composite packagings with inner
receptacles of plastic are as follows:
(1) Inner receptacles must be constructed under the applicable
construction requirements prescribed in Sec. 178.509(b) (1) through (7)
of this subpart.
(2) The inner plastic receptacle must fit snugly inside the outer
packaging, which must be free of any projections which may abrade the
plastic material.
(3) Outer packagings must be constructed as follows:
(i) 6HA1 or 6HB1: Protective packaging must conform to the
requirements for steel drums in Sec. 178.504(b) of this subpart, or
aluminum drums in Sec. 178.505(b) of this subpart.
(ii) 6HA2 or 6HB2: Protective packagings with steel or aluminum
crate must conform to the requirements for steel or aluminum boxes found
in Sec. 178.512(b) of this subpart.
(iii) 6HC protective packaging must conform to the requirements for
wooden boxes in Sec. 178.513(b) of this subpart.
(iv) 6HD1: Protective packaging must conform to the requirements for
plywood drums, in Sec. 178.507(b) of this subpart.
(v) 6HD2: Protective packaging must conform to the requirements of
plywood boxes, in Sec. 178.514(b) of this subpart.
(vi) 6HG1: Protective packaging must conform to the requirements for
fiber drums, in Sec. 178.508(b) of this subpart.
(vii) 6HG2: protective packaging must conform to the requirements
for fiberboard boxes, in Sec. 178.516(b) of this subpart.
(viii) 6HH1: Protective packaging must conform to the requirements
for plastic drums, in Sec. 178.509(b).
(ix) 6HH2: Protective packaging must conform to the requirements for
plastic boxes, in Sec. 178.517(b).
(4) Maximum capacity of inner receptacles is as follows: 6HA1, 6HB1,
6HD1, 6HG1, 6HH1--250 L (66 gallons); 6HA2, 6HB2, 6HC, 6HD2, 6HG2,
6HH2--60 L (16 gallons).
(5) Maximum net mass is as follows: 6HA1, 6HB1, 6HD1, 6HG1, 6HH1--
400kg (882 pounds); 6HB2, 6HC, 6HD2, 6HG2, 6HH2--75 kg (165 pounds).
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, as amended by Amdt. 178-106,
59 FR 67521, Dec. 29, 1994]
Sec. 178.523 Standards for composite packagings with inner glass, porcelain,
or stoneware receptacles.
(a) The following are identification codes for composite packagings
with inner receptacles of glass, porcelain, or stoneware:
(1) 6PA1 for glass, porcelain, or stoneware receptacles within a
protective steel drum;
(2) 6PA2 for glass, porcelain, or stoneware receptacles within a
protective steel crate or box;
(3) 6PB1 for glass, porcelain, or stoneware receptacles within a
protective aluminum drum;
(4) 6PB2 for glass, porcelain, or stoneware receptacles within a
protective aluminum crate or box;
(5) 6PC for glass, porcelain, or stoneware receptacles within a
protective wooden box;
(6) 6PD1 for glass, porcelain, or stoneware receptacles within a
protective plywood drum;
(7) 6PD2 for glass, porcelain, or stoneware receptacles within a
protective wickerwork hamper;
(8) 6PG1 for glass, porcelain, or stoneware receptacles within a
protective fiber drum;
(9) 6PG2 for glass, porcelain, or stoneware receptacles within a
protective fiberboard box;
(10) 6PH1 for glass, porcelain, or stoneware receptacles within a
protective expanded plastic packaging; and
(11) 6PH2 for glass, porcelain, or stoneware receptacles within a
protective solid plastic packaging.
(b) Construction requirements for composite packagings with inner
receptacles of glass, porcelain, or stoneware are as follows:
(1) Inner receptacles must conform to the following requirements:
(i) Receptacles must be of suitable form (cylindrical or pear-
shaped), be made of good quality materials free from any defect that
could impair their
[[Page 210]]
strength, and be firmly secured in the outer packaging.
(ii) Any part of a closure likely to come into contact with the
contents of the receptacle must be resistant to those contents. Closures
must be fitted so as to be leakproof and secured to prevent any
loosening during transportation. Vented closures must conform to Sec.
173.24(f) of this subchapter.
(2) Protective packagings must conform to the following
requirements:
(i) For receptacles with protective steel drum 6PAl, the drum must
comply with Sec. 178.504(b) of this subpart. However, the removable lid
required for this type of packaging may be in the form of a cap.
(ii) For receptacles with protective packaging of steel crate or
steel box 6PA2, the protective packaging must conform to the following:
(A) Section 178.512(b) of this subpart.
(B) In the case of cylindrical receptacles, the protective packaging
must, when upright, rise above the receptacle and its closure; and
(C) If the protective crate surrounds a pear-shaped receptacle and
is of matching shape, the protective packaging must be fitted with a
protective cover (cap).
(iii) For receptacles with protective aluminum drum 6PB1, the
requirements of Sec. 178.505(b) of this subpart apply to the protective
packaging.
(iv) For receptacles with protective aluminum box or crate 6PB2, the
requirements of Sec. 178.512(b) of this subpart apply to the protective
packaging.
(v) For receptacles with protective wooden box 6PC, the requirements
of Sec. 178.513(b) of this subpart apply to the protective packaging.
(vi) For receptacles with protective plywood drum 6PD1, the
requirements of Sec. 178.507(b) of this subpart apply to the protective
packaging.
(vii) For receptacles with protective wickerwork hamper 6PD2, the
wickerwork hamper must be properly made with material of good quality.
The hamper must be fitted with a protective cover (cap) so as to prevent
damage to the receptacle.
(viii) For receptacles with protective fiber drum 6PG1, the drum
must conform to the requirements of Sec. 178.508(b) of this subpart.
(ix) For receptacles with protective fiberboard box 6PG2, the
requirements of Sec. 178.516(b) of this subpart apply to the protective
packaging.
(x) For receptacles with protective solid plastic or expanded
plastic packaging 6PH1 or 6PH2, the requirements of Sec. 178.517(b) of
this subpart apply to the protective packaging. Solid protective plastic
packaging must be manufactured from high-density polyethylene from some
other comparable plastic material. The removable lid required for this
type of packaging may be a cap.
(3) Quantity limitations are as follows:
(i) Maximum net capacity for packaging for liquids: 60 L (16
gallons).
(ii) Maximum net mass for packagings for solids: 75 kg (165 pounds).
Subpart M_Testing of Non-bulk Packagings and Packages
Source: Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, unless otherwise
noted.
Sec. 178.600 Purpose and scope.
This subpart prescribes certain testing requirements for
performance-oriented packagings identified in subpart L of this part.
[Amdt. 178-97, 55 FR 52717, Dec. 21, 1990, and amended by Amdt. 178-99,
58 FR 51534, Oct. 1, 1993]
Sec. 178.601 General requirements.
(a) General. The test procedures prescribed in this subpart are
intended to ensure that packages containing hazardous materials can
withstand normal conditions of transportation and are considered minimum
requirements. Each packaging must be manufactured and assembled so as to
be capable of successfully passing the prescribed tests and of
conforming to the requirements of Sec. 173.24 of this subchapter at all
times while in transportation.
(b) Responsibility. It is the responsibility of the packaging
manufacturer to assure that each package is capable of passing the
prescribed tests. To the extent that a package assembly function,
including final closure, is performed by the person who offers a
hazardous material for transportation,
[[Page 211]]
that person is responsible for performing the function in accordance
with Sec. Sec. 173.22 and 178.2 of this subchapter.
(c) Definitions. For the purpose of this subpart:
(1) Design qualification testing is the performance of the tests
prescribed in Sec. 178.603, Sec. 178.604, Sec. 178.605, Sec.
178.606, Sec. 178.607, Sec. 178.608, or Sec. 178.609, as applicable,
for each new or different packaging, at the start of production of that
packaging.
(2) Periodic retesting is the performance of the drop,
leakproofness, hydrostatic pressure, and stacking tests, as applicable,
as prescribed in Sec. 178.603, Sec. 178.604, Sec. 178.605, or Sec.
178.606, respectively, at the frequency specified in paragraph (e) of
this section. For infectious substances packagings required to meet the
requirements of Sec. 178.609, periodic retesting is the performance of
the tests specified in Sec. 178.609 at the frequency specified in
paragraph (e) of this section.
(3) Production testing is the performance of the leakproofness test
prescribed in Sec. 178.604 of this subpart on each single or composite
packaging intended to contain a liquid.
(4) A different packaging is one that differs (i.e. is not
identical) from a previously produced packaging in structural design,
size, material of construction, wall thickness or manner of construction
but does not include:
(i) A packaging which differs only in surface treatment;
(ii) A combination packaging which differs only in that the outer
packaging has been successfully tested with different inner packagings.
A variety of such inner packagings may be assembled in this outer
packaging without further testing;
(iii) A plastic packaging which differs only with regard to
additives which conform to Sec. 178.509(b)(3) or Sec. 178.517(b) (4)
or (5) of this part;
(iv) A combination packaging with inner packagings conforming to the
provisions of paragraph (g) of this section;
(v) Packagings which differ from the design type only in their
lesser design height; or
(vi) For a steel drum, variations in design elements which do not
constitute a different design type under the provisions of paragraph
(g)(8) of this section.
(d) Design qualification testing. The packaging manufacturer shall
achieve successful test results for the design qualification testing at
the start of production of each new or different packaging.
(e) Periodic retesting. The packaging manufacturer must achieve
successful test results for the periodic retesting at intervals
established by the manufacturer of sufficient frequency to ensure that
each packaging produced by the manufacturer is capable of passing the
design qualification tests. Changes in retest frequency are subject to
the approval of the Associate Administrator for Hazardous Materials
Safety. For single or composite packagings, the periodic retests must be
conducted at least once every 12 months. For combination packagings, the
periodic retests must be conducted at least once every 24 months. For
infectious substances packagings, the periodic retests must be conducted
at least once every 24 months.
(f) Test samples. The manufacturer shall conduct the design
qualification and periodic tests prescribed in this subpart using random
samples of packagings, in the numbers specified in the appropriate test
section. In addition, the leakproofness test, when required, shall be
performed on each packaging produced by the manufacturer, and each
packaging prior to reuse under Sec. 173.28 of this subchapter, by the
reconditioner.
(g) Selective testing. The selective testing of packagings that
differ only in minor respects from a tested type is permitted as
described in this section. For air transport, packagings must comply
with Sec. 173.27(c)(1) and (c)(2) of this subchapter.
(1) Selective testing of combination packagings. Variation 1.
Variations are permitted in inner packagings of a tested combination
package, without further testing of the package, provided an equivalent
level of performance is maintained and, when a package is altered under
Variation 1 after October 1, 2010, the methodology used to determine
that the inner packaging,
[[Page 212]]
including closure, maintains an equivalent level of performance is
documented in writing by the person certifying compliance with this
paragraph and retained in accordance with paragraph (l) of this section.
Permitted variations are as follows:
(i) Inner packagings of equivalent or smaller size may be used
provided--
(A) The inner packagings are of similar design to the tested inner
packagings (i.e. shape--round, rectangular, etc.);
(B) The material of construction of the inner packagings (glass,
plastic, metal, etc.) offers resistance to impact and stacking forces
equal to or greater than that of the originally tested inner packaging;
(C) The inner packagings have the same or smaller openings and the
closure is of similar design (e.g., screw cap, friction lid, etc.);
(D) Sufficient additional cushioning material is used to take up
void spaces and to prevent significant moving of the inner packagings;
(E) Inner packagings are oriented within the outer packaging in the
same manner as in the tested package; and,
(F) The gross mass of the package does not exceed that originally
tested.
(ii) A lesser number of the tested inner packagings, or of the
alternative types of inner packagings identified in paragraph (g)(1)(i)
of this section, may be used provided sufficient cushioning is added to
fill void space(s) and to prevent significant moving of the inner
packagings.
(2) Selective testing of combination packagings. Variation 2.
Articles or inner packagings of any type, for solids or liquids, may be
assembled and transported without testing in an outer packaging under
the following conditions:
(i) The outer packaging must have been successfully tested in
accordance with Sec. 178.603 with fragile (e.g. glass) inner packagings
containing liquids at the Packing Group I drop height;
(ii) The total combined gross mass of inner packagings may not
exceed one-half the gross mass of inner packagings used for the drop
test;
(iii) The thickness of cushioning material between inner packagings
and between inner packagings and the outside of the packaging may not be
reduced below the corresponding thickness in the originally tested
packaging; and when a single inner packaging was used in the original
test, the thickness of cushioning between inner packagings may not be
less than the thickness of cushioning between the outside of the
packaging and the inner packaging in the original test. When either
fewer or smaller inner packagings are used (as compared to the inner
packagings used in the drop test), sufficient additional cushioning
material must be used to take up void spaces.
(iv) The outer packaging must have successfully passed the stacking
test set forth in Sec. 178.606 of this subpart when empty, i.e.,
without either inner packagings or cushioning materials. The total mass
of identical packages must be based on the combined mass of inner
packagings used for the drop test;
(v) Inner packagings containing liquids must be completely
surrounded with a sufficient quantity of absorbent material to absorb
the entire liquid contents of the inner packagings;
(vi) When the outer packaging is intended to contain inner
packagings for liquids and is not leakproof, or is intended to contain
inner packagings for solids and is not siftproof, a means of containing
any liquid or solid contents in the event of leakage must be provided in
the form of a leakproof liner, plastic bag, or other equally efficient
means of containment. For packagings containing liquids, the absorbent
material required in paragraph (g)(2)(v) of this section must be placed
inside the means of containing liquid contents; and
(vii) Packagings must be marked in accordance with Sec. 178.503 of
this part as having been tested to Packing Group I performance for
combination packagings. The marked maximum gross mass may not exceed the
sum of the mass of the outer packaging plus one half the mass of the
filled inner packagings of the tested combination packaging. In
addition, the marking required by Sec. 178.503(a)(2) of this part must
include the letter ``V''.
[[Page 213]]
(3) Variation 3. Packagings other than combination packagings which
are produced with reductions in external dimensions (i.e., length, width
or diameter) of up to 25 percent of the dimensions of a tested packaging
may be used without further testing provided an equivalent level of
performance is maintained. The packagings must, in all other respects
(including wall thicknesses), be identical to the tested design-type.
The marked gross mass (when required) must be reduced in proportion to
the reduction in volume.
(4) Variation 4. Variations are permitted in outer packagings of a
tested design-type combination packaging, without further testing,
provided an equivalent level of performance is maintained, as follows:
(i) Each external dimension (length, width and height) is less than
or equal to the corresponding dimension of the tested design-type;
(ii) The structural design of the tested outer packaging (i.e.
methods of construction, materials of construction, strength
characteristics of materials of construction, method of closure and
material thicknesses) is maintained;
(iii) The inner packagings are identical to the inner packagings
used in the tested design type except that their size and mass may be
less; and they are oriented within the outer packaging in the same
manner as in the tested packaging;
(iv) The same type or design of absorbent materials, cushioning
materials and any other components necessary to contain and protect
inner packagings, as used in the tested design type, are maintained. The
thickness of cushioning material between inner packagings and between
inner packagings and the outside of the packaging may not be less than
the thicknesses in the tested design type packaging; and
(v) Sufficient additional cushioning material is used to take up
void spaces and to prevent significant moving of the inner packagings.
An outer packaging qualifying for use in transport in accordance with
all of the above conditions may also be used without testing to
transport inner packagings substituted for the originally tested inner
packagings in accordance with the conditions set out in Variation 1 in
paragraph (g)(1) of this section.
(5) Variation 5. Single packagings (i.e., non-bulk packagings other
than combination packagings), that differ from a tested design type only
to the extent that the closure device or gasketing differs from that
used in the originally tested design type, may be used without further
testing, provided an equivalent level of performance is maintained,
subject to the following conditions (the qualifying tests):
(i) A packaging with the replacement closure devices or gasketing
must successfully pass the drop test specified in Sec. 178.603 in the
orientation which most severely tests the integrity of the closure or
gasket;
(ii) When intended to contain liquids, a packaging with the
replacement closure devices or gasketing must successfully pass the
leakproofness test specified in Sec. 178.604, the hydrostatic pressure
test specified in Sec. 178.605, and the stacking test specified in
Sec. 178.606.
Replacement closures and gasketings qualified under the above test
requirements are authorized without additional testing for packagings
described in paragraph (g)(3) of this section. Replacement closures and
gasketings qualified under the above test requirements also are
authorized without additional testing for different tested design types
packagings of the same type as the originally tested packaging, provided
the original design type tests are more severe or comparable to tests
which would otherwise be conducted on the packaging with the replacement
closures or gasketings. (For example: The packaging used in the
qualifying tests has a lesser packaging wall thickness than the
packaging with replacement closure devices or gasketing; the gross mass
of the packaging used in the qualifying drop test equals or exceeds the
mass for which the packaging with replacement closure devices or
gasketing was tested; the packaging used in the qualifying drop test was
dropped from the same or greater height than the height from which the
packaging with replacement closure devices or gasketing was dropped in
design type tests; and the specific gravity
[[Page 214]]
of the substance used in the qualifying drop test was the same or
greater than the specific gravity of the liquid used in the design type
tests of the packaging with replacement closure devices or gasketing.)
(6) The provisions in Variations 1, 2, and 4 in paragraphs (g)(1),
(2) and (4) of this section for combination packagings may be applied to
packagings containing articles, where the provisions for inner
packagings are applied analogously to the articles. In this case, inner
packagings need not comply with Sec. 173.27(c)(1) and (c)(2) of this
subchapter.
(7) Approval of selective testing. In addition to the provisions of
Sec. 178.601(g)(1) through (g)(6) of this subpart, the Associate
Administrator may approve the selective testing of packagings that
differ only in minor respects from a tested type.
(8) For a steel drum with a capacity greater than 12 L (3 gallons)
manufactured from low carbon, cold-rolled sheet steel meeting ASTM
designations A 366/A 366M or A 568/A 568M, variations in elements other
than the following design elements are considered minor and do not
constitute a different drum design type, or ``different packaging'' as
defined in paragraph (c) of this section for which design qualification
testing and periodic retesting are required. Minor variations authorized
without further testing include changes in the identity of the supplier
of component material made to the same specifications, or the original
manufacturer of a DOT specification or UN standard drum to be
remanufactured. A change in any one or more of the following design
elements constitutes a different drum design type:
(i) The packaging type and category of the original drum and the
remanufactured drum, i.e., 1A1 or 1A2;
(ii) The style, (i.e., straight-sided or tapered);
(iii) Except as provided in paragraph (g)(3) of this section, the
rated (marked) capacity and outside dimensions;
(iv) The physical state for which the packaging was originally
approved (e.g., tested for solids or liquids);
(v) An increase in the marked level of performance of the original
drum (i.e., to a higher packing group, hydrostatic test pressure, or
specific gravity to which the packaging has been tested);
(vi) Type of side seam welding;
(vii) Type of steel;
(viii) An increase greater than 10% or any decrease in the steel
thickness of the head, body, or bottom;
(ix) End seam type, (e.g., triple or double seam);
(x) A reduction in the number of rolling hoops (beads) which equal
or exceed the diameter over the chimes;
(xi) The location, type or size, and material of closures (other
than the cover of UN 1A2 drums);
(xii) The location (e.g., from the head to the body), type (e.g.,
mechanically seamed or welded flange), and materials of closure (other
than the cover of UN 1A2 drums); and
(xiii) For UN 1A2 drums:
(A) Gasket material (e.g., plastic), or properties affecting the
performance of the gasket;
(B) Configuration or dimensions of the gasket;
(C) Closure ring style including bolt size (e.g., square or round
back, 0.625 inches bolt); and
(D) Closure ring thickness,
(E) Width of lugs or extensions in crimp/lug cover.
(h) Approval of equivalent packagings. A packaging having
specifications different from those in Sec. Sec. 178.504-178.523 of
this part, or which is tested using methods or test intervals, other
than those specified in subpart M of this part, may be used if approved
by the Associate Administrator. Such packagings must be shown to be
equally effective, and testing methods used must be equivalent.
(i) Proof of compliance. Notwithstanding the periodic retest
intervals specified in paragraph (e) of this section, the Associate
Administrator may at any time require demonstration of compliance by a
manufacturer, through testing in accordance with this subpart, that
packagings meet the requirements of this subpart. As required by the
Associate Administrator, the manufacturer shall either--
(1) Conduct performance tests, or have tests conducted by an
independent testing facility, in accordance with this subpart; or
[[Page 215]]
(2) Supply packagings, in quantities sufficient to conduct tests in
accordance with this subpart, to the Associate Administrator or a
designated representative of the Associate Administrator.
(j) Coatings. If an inner treatment or coating of a packaging is
required for safety reasons, the manufacturer shall design the packaging
so that the treatment or coating retains its protective properties even
after withstanding the tests prescribed by this subpart.
(k) Number of test samples. Except as provided in this section, one
test sample must be used for each test performed under this subpart.
(1) Stainless steel drums. Provided the validity of the test results
is not affected, a person may perform the design qualification testing
of stainless steel drums using three (3) samples rather than the
specified eighteen (18) samples under the following provisions:
(i) The packaging must be tested in accordance with this subpart by
subjecting each of the three containers to the following sequence of
tests:
(A) The stacking test in Sec. 178.606,
(B) The leakproofness test in Sec. 178.604,
(C) The hydrostatic pressure test in Sec. 178.608, and
(D) Diagonal top chime and flat on the side drop tests in Sec.
178.603. Both drop tests may be conducted on the same sample.
(ii) For periodic retesting of stainless steel drums, a reduced
sample size of one container is authorized.
(2) Packagings other than stainless steel drums. Provided the
validity of the test results is not affected, several tests may be
performed on one sample with the approval of the Associate
Administrator.
(l) Record retention. Following each design qualification test and
each periodic retest on a packaging, a test report must be prepared. The
test report must be maintained at each location where the packaging is
manufactured and each location where the design qualification tests are
conducted, for as long as the packaging is produced and for at least two
years thereafter, and at each location where the periodic retests are
conducted until such tests are successfully performed again and a new
test report produced. In addition, a copy of the test report must be
maintained by a person certifying compliance with this part. The test
report must be made available to a user of a packaging or a
representative of the Department upon request. The test report, at a
minimum, must contain the following information:
(1) Name and address of test facility;
(2) Name and address of applicant (where appropriate);
(3) A unique test report identification;
(4) Date of the test report;
(5) Manufacturer of the packaging;
(6) Description of the packaging design type (e.g. dimensions,
materials, closures, thickness, etc.), including methods of manufacture
(e.g. blow molding) and which may include drawing(s) and/or
photograph(s);
(7) Maximum capacity;
(8) Characteristics of test contents, e.g. viscosity and relative
density for liquids and particle size for solids;
(9) Test descriptions and results; and
(10) Signed with the name and title of signatory.
[Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66285,
Dec. 20, 1991; 57 FR 45465, Oct. 1, 1992; Amdt. 178-102, 59 FR 28494,
June 2, 1994; Amdt. 178-106, 59 FR 67521, 67522, Dec. 29, 1994; Amdt.
178-117, 61 FR 50628, Sept. 26, 1996; 66 FR 45386, Aug. 28, 2001; 67 FR
53143, Aug. 14, 2002; 68 FR 75758, Dec. 31, 2003; 68 FR 61942, Oct. 30,
2003; 75 FR 5396, Feb 2, 2010; 75 FR 60339, Sept. 30, 2010]
Sec. 178.602 Preparation of packagings and packages for testing.
(a) Except as otherwise provided in this subchapter, each packaging
and package must be closed in preparation for testing and tests must be
carried out in the same manner as if prepared for transportation,
including inner packagings in the case of combination packagings.
(b) For the drop and stacking test, inner and single-unit
receptacles other than bags must be filled to not less than 95% of
maximum capacity (see Sec. 171.8 of this subchapter) in the case of
solids and not less than 98% of maximum in the case of liquids. Bags
containing solids shall be filled to the maximum mass at which they may
be used. The material to be transported in the packagings may be
replaced by a non-hazardous material, except for
[[Page 216]]
chemical compatibility testing or where this would invalidate the
results of the tests.
(c) If the material to be transported is replaced for test purposes
by a non-hazardous material, the material used must be of the same or
higher specific gravity as the material to be carried, and its other
physical properties (grain, size, viscosity) which might influence the
results of the required tests must correspond as closely as possible to
those of the hazardous material to be transported. Water may also be
used for the liquid drop test under the conditions specified in Sec.
178.603(e) of this subpart. It is permissible to use additives, such as
bags of lead shot, to achieve the requisite total package mass, so long
as they are placed so that the test results are not affected.
(d) Paper or fiberboard packagings must be conditioned for at least
24 hours immediately prior to testing in an atmosphere maintained--
(1) At 50 percent 2 percent relative humidity,
and at a temperature of 23 [deg]C2 [deg]C (73
[deg]F4 [deg]F). Average values should fall within
these limits. Short-term fluctuations and measurement limitations may
cause individual measurements to vary by up to 5
percent relative humidity without significant impairment of test
reproducibility;
(2) At 65 percent 2 percent relative humidity,
and at a temperature of 20 [deg]C2 [deg]C (68
[deg]F4 [deg]F), or 27 [deg]C2 [deg]C (81 [deg]F4 [deg]F).
Average values should fall within these limits. Short-term fluctuations
and measurement limitations may cause individual measurements to vary by
up to 5 percent relative humidity without
significant impairment of test reproducibility; or
(3) For testing at periodic intervals only (i.e., other than initial
design qualification testing), at ambient conditions.
(e) Except as otherwise provided, each packaging must be closed in
preparation for testing in the same manner as if prepared for actual
shipment. All closures must be installed using proper techniques and
torques.
(f) Bung-type barrels made of natural wood must be left filled with
water for at least 24 hours before the tests.
[Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286,
Dec. 20, 1991; Amdt. 178-106, 59 FR 67522, Dec. 29, 1994; 69 FR 76186,
Dec. 20, 2004; 71 FR 78635, Dec. 29, 2006]
Sec. 178.603 Drop test.
(a) General. The drop test must be conducted for the qualification
of all packaging design types and performed periodically as specified in
Sec. 178.601(e). For other than flat drops, the center of gravity of
the test packaging must be vertically over the point of impact. Where
more than one orientation is possible for a given drop test, the
orientation most likely to result in failure of the packaging must be
used. The number of drops required and the packages' orientations are as
follows:
------------------------------------------------------------------------
No. of tests Drop orientation of
Packaging (samples) samples
------------------------------------------------------------------------
Steel drums, Aluminum drums, Six--(three for First drop (using three
Metal drums (other than each drop). samples): The package
steel or aluminum), Steel must strike the target
Jerricans, Plywood drums, diagonally on the chime
Wooden barrels, Fiber drums, or, if the packaging
Plastic drums and Jerricans, has no chime, on a
Composite packagings which circumferential seam or
are in the shape of a drum. an edge. Second drop
(using the other three
samples): The package
must strike the target
on the weakest part not
tested by the first
drop, for example a
closure or, for some 7
cylindrical drums, the
welded longitudinal
seam of the drum body.
Boxes of natural wood, Five--(one for First drop: Flat on the
Plywood boxes, Reconstituted each drop). bottom (using the first
wood boxes, Fiberboard sample). Second drop:
boxes, Plastic boxes, Steel Flat on the top (using
or aluminum boxes, Composite the second sample).
packagings which are in the Third drop: Flat on the
shape of a box. long side (using the
third sample). Fourth
drop: Flat on the short
side (using the fourth
sample). Fifth drop: On
a corner (using the
fifth sample).
Bags--single-ply with a side Three--(three First drop: Flat on a
seam. drops per bag). wide face (using all
three samples). Second
drop: Flat on a narrow
face (using all three
samples). Third drop:
On an end of the bag
(using all three
samples).
Bags--single-ply without a Three--(two First drop: Flat on a
side seam, or multi-ply. drops per bag). wide face (using all
three samples). Second
drop: On an end of the
bag (using all three
samples).
------------------------------------------------------------------------
(b) Exceptions. For testing of single or composite packagings
constructed of stainless steel, nickel, or monel at periodic intervals
only (i.e., other than
[[Page 217]]
design qualification testing), the drop test may be conducted with two
samples, one sample each for the two drop orientations. These samples
may have been previously used for the hydrostatic pressure or stacking
test. Exceptions for the number of steel and aluminum packaging samples
used for conducting the drop test are subject to the approval of the
Associate Administrator.
(c) Special preparation of test samples for the drop test. (1)
Testing of plastic drums, plastic jerricans, plastic boxes other than
expanded polystyrene boxes, composite packagings (plastic material), and
combination packagings with plastic inner packagings other than plastic
bags intended to contain solids or articles must be carried out when the
temperature of the test sample and its contents has been reduced to -18
[deg]C (0 [deg]F) or lower. Test liquids must be kept in the liquid
state, if necessary, by the addition of anti-freeze. Water/anti-freeze
solutions with a minimum specific gravity of 0.95 for testing at -18
[deg]C (0 [deg]F) or lower are considered acceptable test liquids. Test
samples prepared in this way are not required to be conditioned in
accordance with Sec. 178.602(d).
(d) Target. The target must be a rigid, non-resilient, flat and
horizontal surface.
(e) Drop height. Drop heights, measured as the vertical distance
from the target to the lowest point on the package, must be equal to or
greater than the drop height determined as follows:
(1) For solids and liquids, if the test is performed with the solid
or liquid to be transported or with a non-hazardous material having
essentially the same physical characteristic, the drop height must be
determined according to packing group, as follows:
(i) Packing Group I: 1.8 m (5.9 feet).
(ii) Packing Group II: 1.2 m (3.9 feet).
(iii) Packing Group III: 0.8 m (2.6 feet).
(2) For liquids in single packagings and for inner packagings of
combination packagings, if the test is performed with water:
(i) Where the materials to be carried have a specific gravity not
exceeding 1.2, drop height must be determined according to packing
group, as follows:
(A) Packing Group I: 1.8 m (5.9 feet).
(B) Packing Group II: 1.2 m (3.9 feet).
(C) Packing Group III: 0.8 m (2.6 feet).
(ii) Where the materials to be transported have a specific gravity
exceeding 1.2, the drop height must be calculated on the basis of the
specific gravity (SG) of the material to be carried, rounded up to the
first decimal, as follows:
(A) Packing Group I: SG x 1.5 m (4.9 feet).
(B) Packing Group II: SG x 1.0 m (3.3 feet).
(C) Packing Group III: SG x 0.67 m (2.2 feet).
(f) Criteria for passing the test. A package is considered to
successfully pass the drop tests if for each sample tested--
(1) For packagings containing liquid, each packaging does not leak
when equilibrium has been reached between the internal and external
pressures, except for inner packagings of combination packagings when it
is not necessary that the pressures be equalized;
(2) For removable head drums for solids, the entire contents are
retained by an inner packaging (e.g., a plastic bag) even if the closure
on the top head of the drum is no longer sift-proof;
(3) For a bag, neither the outermost ply nor an outer packaging
exhibits any damage likely to adversely affect safety during transport;
(4) The packaging or outer packaging of a composite or combination
packaging must not exhibit any damage likely to affect safety during
transport. Inner receptacles, inner packagings, or articles must remain
completely within the outer packaging and there must be no leakage of
the filling substance from the inner receptacles or inner packagings;
(5) Any discharge from a closure is slight and ceases immediately
after impact with no further leakage; and
(6) No rupture is permitted in packagings for materials in Class 1
which
[[Page 218]]
would permit spillage of loose explosive substances or articles from the
outer packaging.
[Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286,
Dec. 20, 1991; 57 FR 45465, Oct. 1, 1992; Amdt. 178-99, 58 FR 51534,
Oct. 1, 1993; Amdt. 178-106, 59 FR 67522, Dec. 29, 1994; 65 FR 50462,
Aug. 18, 2000; 66 FR 45386, Aug. 28, 2001; 67 FR 61016, Sept. 27, 2002;
69 FR 76186, Dec. 20, 2004; 76 FR 3389, Jan. 19, 2011]
Sec. 178.604 Leakproofness test.
(a) General. The leakproofness test must be performed with
compressed air or other suitable gases on all packagings intended to
contain liquids, except that:
(1) The inner receptacle of a composite packaging may be tested
without the outer packaging provided the test results are not affected;
and
(2) This test is not required for inner packagings of combination
packagings.
(b) Number of packagings to be tested--(1) Production testing. All
packagings subject to the provisions of this section must be tested and
must pass the leakproofness test:
(i) Before they are first used in transportation; and
(ii) Prior to reuse, when authorized for reuse by Sec. 173.28 of
this subchapter.
(2) Design qualification and periodic testing. Three samples of each
different packaging must be tested and must pass the leakproofness test.
Exceptions for the number of samples used in conducting the
leakproofness test are subject to the approval of the Associate
Administrator.
(c) Special preparation--(1) For design qualification and periodic
testing, packagings must be tested with closures in place. For
production testing, packagings need not have their closures in place.
Removable heads need not be installed during production testing.
(2) For testing with closures in place, vented closures must either
be replaced by similar non-vented closures or the vent must be sealed.
(d) Test method. The packaging must be restrained under water while
an internal air pressure is applied; the method of restraint must not
affect the results of the test. The test must be conducted, for other
than production testing, for a minimum time of five minutes. Other
methods, at least equally effective, may be used in accordance with
appendix B of this part.
(e) Pressure applied. An internal air pressure (gauge) must be
applied to the packaging as indicated for the following packing groups:
(1) Packing Group I: Not less than 30 kPa (4 psi).
(2) Packing Group II: Not less than 20 kPa (3 psi).
(3) Packing Group III: Not less than 20 kPa (3 psi).
(f) Criteria for passing the test. A packaging passes the test if
there is no leakage of air from the packaging.
[Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286,
Dec. 20, 1991; Amdt. 178-106, 59 FR 67522, Dec. 29, 1994; 66 FR 45386,
Aug. 28, 2001]
Sec. 178.605 Hydrostatic pressure test.
(a) General. The hydrostatic pressure test must be conducted for the
qualification of all metal, plastic, and composite packaging design
types intended to contain liquids and be performed periodically as
specified in Sec. 178.601(e). This test is not required for inner
packagings of combination packagings. For internal pressure requirements
for inner packagings of combination packagings intended for
transportation by aircraft, see Sec. 173.27(c) of this subchapter.
(b) Number of test samples. Three test samples are required for each
different packaging. For packagings constructed of stainless steel,
monel, or nickel, only one sample is required for periodic retesting of
packagings. Exceptions for the number of aluminum and steel sample
packagings used in conducting the hydrostatic pressure test are subject
to the approval of the Associate Administrator.
(c) Special preparation of receptacles for testings. Vented closures
must either be replaced by similar non-vented closures or the vent must
be sealed.
(d) Test method and pressure to be applied. Metal packagings and
composite packagings other than plastic (e.g., glass, porcelain or
stoneware), including their closures, must be subjected to the test
pressure for 5 minutes. Plastic packagings and composite packagings
(plastic material), including their closures, must be subjected to the
test
[[Page 219]]
pressure for 30 minutes. This pressure is the one to be marked as
required in Sec. 178.503(a)(5). The receptacles must be supported in a
manner that does not invalidate the test. The test pressure must be
applied continuously and evenly, and it must be kept constant throughout
the test period. In addition, packagings intended to contain hazardous
materials of Packing Group I must be tested to a minimum test pressure
of 250 kPa (36 psig). The hydraulic pressure (gauge) applied, taken at
the top of the receptacle, and determined by any one of the following
methods must be:
(1) Not less than the total gauge pressure measured in the packaging
(i.e., the vapor pressure of the filling material and the partial
pressure of the air or other inert gas minus 100 kPa (15 psi)) at 55
[deg]C (131 [deg]F), multiplied by a safety factor of 1.5. This total
gauge pressure must be determined on the basis of a maximum degree of
filling in accordance with Sec. 173.24a(d) of this subchapter and a
filling temperature of 15 [deg]C (59 [deg]F);
(2) Not less than 1.75 times the vapor pressure at 50 [deg]C (122
[deg]F) of the material to be transported minus 100 kPa (15 psi) but
with a minimum test pressure of 100 kPa (15 psig); or
(3) Not less than 1.5 times the vapor pressure at 55 [deg]C (131
[deg]F) of the material to be transported minus 100 kPa (15 psi), but
with a minimum test pressure of 100 kPa (15 psig).
Packagings intended to contain hazardous materials of Packing Group I
must be tested to a minimum test pressure of 250 kPa (36 psig).
(e) Criteria for passing the test. A package passes the hydrostatic
test if, for each test sample, there is no leakage of liquid from the
package.
[Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286,
Dec. 20, 1991; Amdt. 178-99, 58 FR 51534, Oct. 1, 1993; Amdt. 178-102,
59 FR 28494, June 2, 1994; 65 FR 50462, Aug. 18, 2000; 66 FR 45386,
45390, Aug. 28, 2001; 73 FR 57007, Oct. 1, 2008]
Sec. 178.606 Stacking test.
(a) General. All packaging design types other than bags must be
subjected to a stacking test.
(b) Number of test samples. Three test samples are required for each
different packaging. For periodic retesting of packagings constructed of
stainless steel, monel, or nickel, only one test sample is required.
Exceptions for the number of aluminum and steel sample packagings used
in conducting the stacking test are subject to the approval of the
Associate Administrator. Notwithstanding the provisions of Sec.
178.602(a) of this subpart, combination packagings may be subjected to
the stacking test without their inner packagings, except where this
would invalidate the results of the test.
(c) Test method--(1) Design qualification testing. The test sample
must be subjected to a force applied to the top surface of the test
sample equivalent to the total weight of identical packages which might
be stacked on it during transport; where the contents of the test sample
are non-hazardous liquids with specific gravities different from that of
the liquid to be transported, the force must be calculated based on the
specific gravity that will be marked on the packaging. The minimum
height of the stack, including the test sample, must be 3.0 m (10 feet).
The duration of the test must be 24 hours, except that plastic drums,
jerricans, and composite packagings 6HH intended for liquids shall be
subjected to the stacking test for a period of 28 days at a temperature
of not less than 40[deg]C (104[deg]F). Alternative test methods which
yield equivalent results may be used if approved by the Associate
Administrator. In guided load tests, stacking stability must be assessed
after completion of the test by placing two filled packagings of the
same type on the test sample. The stacked packages must maintain their
position for one hour. Plastic packagings must be cooled to ambient
temperature before this stacking stability assessment.
(2) Periodic retesting. The test sample must be tested in accordance
with:
(i) Section 178.606(c)(1) of this subpart; or
(ii) The packaging may be tested using a dynamic compression testing
machine. The test must be conducted at room temperature on an empty,
unsealed packaging. The test sample must be centered on the bottom
platen of the testing machine. The top platen
[[Page 220]]
must be lowered until it comes in contact with the test sample.
Compression must be applied end to end. The speed of the compression
tester must be one-half inch plus or minus one-fourth inch per minute.
An initial preload of 50 pounds must be applied to ensure a definite
contact between the test sample and the platens. The distance between
the platens at this time must be recorded as zero deformation. The force
A to then be applied must be calculated using the formula:
Liquids: A = (n-1) [w + (s x v x 8.3 x .98)] x 1.5;
Solids: A = (n-1) (m x 2.2 x 1.5)
Where:
A = applied load in pounds
m = the certified maximum gross mass for the container in kilograms.
n = minimum number of containers that, when stacked, reach a height of 3
meters.
s = specific gravity of lading.
w = maximum weight of one empty container in pounds.
v = actual capacity of container (rated capacity + outage) in gallons.
And:
8.3 corresponds to the weight in pounds of 1.0 gallon of water.
.98 corresponds to the minimum filling percentage of the maximum
capacity for liquids.
1.5 is a compensation factor that converts the static load of the
stacking test into a load suitable for dynamic compression testing.
2.2 is the conversion factor for kilograms to pounds.
(d) Criteria for passing the test. No test sample may leak. In
composite packagings or combination packagings, there must be no leakage
of the filling substance from the inner receptacle, or inner packaging.
No test sample may show any deterioration which could adversely affect
transportation safety or any distortion likely to reduce its strength,
cause instability in stacks of packages, or cause damage to inner
packagings likely to reduce safety in transportation. For the dynamic
compression test, a container passes the test if, after application of
the required load, there is no buckling of the sidewalls sufficient to
cause damage to its expected contents; in no case may the maximum
deflection exceed one inch.
[Amdt. 178-97, 55 FR 52723, Dec. 21, 1990, as amended at 56 FR 66286,
Dec. 20, 1991; 57 FR 45465, Oct. 1, 1992; Amdt. 178-102, 59 FR 28494,
June 2, 1994; Amdt. 178-106, 59 FR 67522, Dec. 29, 1994; 65 FR 58632,
Sept. 29, 2000; 66 FR 45386, Aug. 28, 2001; 70 FR 34076, June 13, 2005;
72 FR 55696, Oct. 1, 2007]
Sec. 178.607 Cooperage test for bung-type wooden barrels.
(a) Number of samples. One barrel is required for each different
packaging.
(b) Method of testing. Remove all hoops above the bilge of an empty
barrel at least two days old.
(c) Criteria for passing the test. A packaging passes the cooperage
test only if the diameter of the cross-section of the upper part of the
barrel does not increase by more than 10 percent.