DOT CFR 2018 Title49 Vol3

Title 49
Transportation
Parts 178 to 199
Revised as of October 1, 2018
Containing a codification of documents

of general applicability and future effect
As of October 1, 2018
Published by the Office of the Federal Register

National Archives and Records Administration
as a Special Edition of the Federal Register
Pmangrum on DSK3GMQ082PROD with CFR
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Table of Contents
Page
Explanation ................................................................................................ v
Title 49:
SUBTITLE B—OTHER REGULATIONS RELATING TO TRANSPORTATION

(CONTINUED)
Chapter I—Pipeline and Hazardous Materials Safety Administra-

tion, Department of Transportation (Continued) ........................ 5
Finding Aids:
Table of CFR Titles and Chapters ....................................................... 665
Alphabetical List of Agencies Appearing in the CFR ......................... 685
List of CFR Sections Affected ............................................................. 695

iii
Cite this Code: CFR
To cite the regulations in

this volume use title,
part and section num-
ber. Thus, 49 CFR 178.1
refers to title 49, part
178, section 1.
iv
Explanation
The Code of Federal Regulations is a codification of the general and permanent
rules published in the Federal Register by the Executive departments and agen-
cies of the Federal Government. The Code is divided into 50 titles which represent
broad areas subject to Federal regulation. Each title is divided into chapters
which usually bear the name of the issuing agency. Each chapter is further sub-
divided into parts covering specific regulatory areas.
Each volume of the Code is revised at least once each calendar year and issued
on a quarterly basis approximately as follows:
Title 1 through Title 16..............................................................as of January 1
Title 17 through Title 27 .................................................................as of April 1
Title 28 through Title 41 ..................................................................as of July 1
Title 42 through Title 50 .............................................................as of October 1
The appropriate revision date is printed on the cover of each volume.
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lishing in the CFR are also included in this volume.
vi
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OLIVER A. POTTS,
Director,
Office of the Federal Register
October 1, 2018
vii
THIS TITLE
Title 49—TRANSPORTATION is composed of nine volumes. The parts in these vol-

umes 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 regula-
tions issued under chapter I—Pipeline and Hazardous Materials Safety Adminis-
tration (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) con-
tains 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 V—National Highway Traffic Safety Administration (DOT), and the cur-
rent 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 some of the current regulations issued under chapter X—Surface Trans-
portation Board and the ninth volume (part 1200 to end) contains the rest of
the current regulations issued under chapter X—Surface Transportation Board,
chapter XI—Research and Innovative Technology Administration (DOT), and
chapter XII—Transportation Security Administration (DHS). The contents of
these volumes represent all current regulations codified under this title of the
CFR as of October 1, 2018.
In the volume containing parts 100–177, see § 172.101 for the Hazardous Materials
Table. The Federal Motor Vehicle Safety Standards appear in part 571.
For this volume, Cheryl E. Sirofchuck was Chief Editor. The Code of Federal
Regulations publication program is under the direction of John Hyrum Martinez,
assisted by Stephen J. Frattini.
ix
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 chap-
ters 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 Ad-

ministration, Department of Transportation, DOT ........... 178
Subtitle B—Other Regulations
Relating to Transportation
(Continued)
CHAPTER I—PIPELINE AND HAZARDOUS
MATERIALS SAFETY ADMINISTRATION,
DEPARTMENT OF TRANSPORTATION
(CONTINUED)
SUBCHAPTER C—HAZARDOUS MATERIALS REGULATIONS (CONTINUED)
Part Page
178 Specifications for packagings ................................. 7
179 Specifications for tank cars .................................... 258
180 Continuing qualification and maintenance of pack-
agings ................................................................... 320
181–185 [Reserved]
SUBCHAPTER D—PIPELINE SAFETY
186–189 [Reserved]
190 Pipeline safety enforcement and regulatory proce-
dures ..................................................................... 383
191 Transportation of natural and other gas by pipe-
line; annual reports, incident reports, and safety-
related condition reports ..................................... 412
192 Transportation of natural and other gas by pipe-
line: Minimum Federal safety standards ............. 419
193 Liquefied natural gas facilities: Federal safety
standards .............................................................. 537
194 Response plans for onshore oil pipelines ................. 557
195 Transportation of hazardous liquids by pipeline ..... 567
196 Protection of underground pipelines from exca-
vation activity ..................................................... 639
197 [Reserved]
198 Regulations for grants to aid State pipeline safety
programs .............................................................. 642
199 Drug and alcohol testing ......................................... 646
PART 178—SPECIFICATIONS FOR 178.39 Specification 3BN seamless nickel
cylinders.
PACKAGINGS 178.42 Specification 3E seamless steel cyl-
inders.
Sec. 178.44 Specification 3HT seamless steel cyl-
178.1 Purpose and scope. inders for aircraft use.
178.2 Applicability and responsibility. 178.45 Specification 3T seamless steel cyl-
178.3 Marking of packagings. inders.
178.46 Specification 3AL seamless alu-
Subpart A [Reserved] minum cylinders.
178.47 Specification 4DS welded stainless
Subpart B—Specifications for Inside steel cylinders for aircraft use.
Containers, and Linings 178.50 Specification 4B welded or brazed
steel cylinders.
178.33 Specification 2P; inner nonrefillable 178.51 Specification 4BA welded or brazed
metal receptacles. steel cylinders.
178.33–1 Compliance. 178.53 Specification 4D welded steel cyl-
178.33–2 Type and size. inders for aircraft use.
178.33–3 Inspection. 178.55 Specification 4B240ET welded or
178.33–4 Duties of inspector. brazed cylinders.
178.33–5 Material. 178.56 Specification 4AA480 welded steel cyl-
178.33–6 Manufacture. inders.
178.33–7 Wall thickness. 178.57 Specification 4L welded insulated cyl-
178.33–8 Tests. inders.
178.33–9 Marking. 178.58 Specification 4DA welded steel cyl-
178.33a Specification 2Q; inner nonrefillable inders for aircraft use.
metal receptacles. 178.59 Specification 8 steel cylinders with
178.33a–1 Compliance. porous fillings for acetylene.
178.33a–2 Type and size. 178.60 Specification 8AL steel cylinders
178.33a–3 Inspection. with porous fillings for acetylene.
178.33a–4 Duties of inspector. 178.61 Specification 4BW welded steel cyl-
178.33a–5 Material. inders with electric-arc welded longitu-
178.33a–6 Manufacture. dinal seam.
178.33a–7 Wall thickness. 178.65 Specification 39 non-reusable (non-re-
178.33a–8 Tests. fillable) cylinders.
178.33a–9 Marking. 178.68 Specification 4E welded aluminum
178.33b Specification 2S; inner nonrefillable cylinders.
plastic receptacles 178.69 Responsibilities and requirements for
178.33b–1 Compliance. manufacturers of UN pressure recep-
178.33b–2 Type and size. tacles.
178.33b–3 Inspection. 178.70 Approval of UN pressure receptacles.
178.33b–4 Duties of inspector. 178.71 Specifications for UN pressure recep-
178.33b–5 Material. tacles.
178.33b–6 Manufacture. 178.74 Approval of MEGCs.
178.33b–7 Design qualification test. 178.75 Specifications for MEGCs.
178.33b–8 Production tests. APPENDIX A TO SUBPART C OF PART 178—IL-
178.33b–9 Marking. LUSTRATIONS: CYLINDER TENSILE SAMPLE
178.33c Specification 2P; inner nonrefillable
metal receptacle variation. Subparts D–G [Reserved]
178.33c–1 Compliance.
178.33c–2 Variation. Subpart H—Specifications for Portable
178.33d Specification 2Q; inner nonrefillable Tanks
metal receptacle variations.
178.33d–1 Compliance. 178.251—178.253–5 [Reserved]
178.33d–2 Variation 1. 178.255 Specification 60; steel portable
178.33d–3 Variation 2. tanks.
178.255–1 General requirements.
Subpart C—Specifications for Cylinders 178.255–2 Material.
178.255–3 Expansion domes.
178.35 General requirements for specifica- 178.255–4 Closures for manholes and domes.
tion cylinders. 178.255–5 Bottom discharge outlets.
178.36 Specification 3A and 3AX seamless 178.255–6 Loading and unloading accessories.
steel cylinders. 178.255–7 Protection of valves and acces-
178.37 Specification 3AA and 3AAX seamless sories.

steel cylinders. 178.255–8 Safety devices.
178.38 Specification 3B seamless steel cyl- 178.255–9 Compartments.
inders. 178.255–10 Lining.
Pt. 178 49 CFR Ch. I (10–1–18 Edition)
178.255–11 Tank mountings. 178.338–8 Pressure relief devices, piping,
178.255–12 Pressure test. valves, and fittings.
178.255–13 Repair of tanks. 178.338–9 Holding time.
178.255–14 Marking. 178.338–10 Accident damage protection.
178.255–15 Report. 178.338–11 Discharge control devices.
178.273 Approval of Specification UN port- 178.338–12 Shear section.
able tanks. 178.338–13 Supporting and anchoring.
178.274 Specification for UN portable tanks. 178.338–14 Gauging devices.
178.275 Specification for UN Portable Tanks 178.338–15 Cleanliness.
intended for the transportation of liquid 178.338–16 Inspection and testing.
and solid hazardous materials. 178.338–17 Pumps and compressors.
178.276 Requirements for the design, con- 178.338–18 Marking.
struction, inspection and testing of port- 178.338–19 Certification.
able tanks intended for the transpor- 178.340–178.343 [Reserved]
tation of non-refrigerated liquefied com- 178.345 General design and construction re-
pressed gases. quirements applicable to Specification
178.277 Requirements for the design, con- DOT 406 (§ 178.346), DOT 407 (§ 178.347), and
struction, inspection and testing of port- DOT 412 (§ 178.348) cargo tank motor vehi-
able tanks intended for the transpor- cles.
tation of refrigerated liquefied gases. 178.345–1 General requirements.
178.345–2 Material and material thickness.
Subpart I [Reserved] 178.345–3 Structural integrity.
178.345–4 Joints.
Subpart J—Specifications for Containers for 178.345–5 Manhole assemblies.
Motor Vehicle Transportation 178.345–6 Supports and anchoring.
178.345–7 Circumferential reinforcements.
178.318 Specification MC 201; container for
178.345–8 Accident damage protection.
detonators and percussion caps.
178.318–1 Scope. 178.345–9 Pumps, piping, hoses and connec-
178.318–2 Container. tions.
178.318–3 Marking. 178.345–10 Pressure relief.
178.320 General requirements applicable to 178.345–11 Tank outlets.
all DOT specification cargo tank motor 178.345–12 Gauging devices.
vehicles. 178.345–13 Pressure and leakage tests.
178.337 Specification MC 331; cargo tank 178.345–14 Marking.
motor vehicle primarily for transpor- 178.345–15 Certification.
tation of compressed gases as defined in 178.346 Specification DOT 406; cargo tank
subpart G of part 173 of this subchapter. motor vehicle.
178.337–1 General requirements. 178.346–1 General requirements.
178.337–2 Material. 178.346–2 Material and thickness of mate-
178.337–3 Structural integrity. rial.
178.337–4 Joints. 178.346–3 Pressure relief.
178.337–5 Bulkheads, baffles and ring stiff- 178.346–4 Outlets.
eners. 178.346–5 Pressure and leakage tests.
178.337–6 Closure for manhole. 178.347 Specification DOT 407; cargo tank
178.337–7 Overturn protection. motor vehicle.
178.337–8 Openings, inlets and outlets. 178.347–1 General requirements.
178.337–9 Pressure relief devices, piping, 178.347–2 Material and thickness of mate-
valves, hoses, and fittings. rial.
178.337–10 Accident damage protection. 178.347–3 Manhole assemblies.
178.337–11 Emergency discharge control. 178.347–4 Pressure relief.
178.337–12 [Reserved] 178.347–5 Pressure and leakage test.
178.337–13 Supporting and anchoring. 178.348 Specification DOT 412; cargo tank
178.337–14 Gauging devices. motor vehicle.
178.337–15 Pumps and compressors. 178.348–1 General requirements.
178.337–16 Testing. 178.348–2 Material and thickness of mate-
178.337–17 Marking. rial.
178.337–18 Certification. 178.348–3 Pumps, piping, hoses and connec-
178.338 Specification MC–338; insulated tions.
cargo tank motor vehicle. 178.348–4 Pressure relief.
178.338–1 General requirements. 178.348–5 Pressure and leakage test.
178.338–2 Material.
178.338–3 Structural integrity. Subpart K—Specifications for Packagings
178.338–4 Joints. for Class 7 (Radioactive) Materials

178.338–5 Stiffening rings.
178.338–6 Manholes. 178.350 Specification 7A; general packaging,
178.338–7 Openings. Type A.
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178
Subpart L—Non-bulk Performance- Subpart O—Testing of IBCs

Oriented Packaging Standards
178.800 Purpose and scope.
178.500 Purpose, scope and definitions. 178.801 General requirements.
178.502 Identification codes for packagings. 178.802 Preparation of fiberboard IBCs for
178.503 Marking of packagings. testing.
178.504 Standards for steel drums. 178.803 Testing and certification of IBCs.
178.505 Standards for aluminum drums. 178.810 Drop test.
178.506 Standards for metal drums other 178.811 Bottom lift test.
than steel or aluminum. 178.812 Top lift test.
178.507 Standards for plywood drums. 178.813 Leakproofness test.
178.508 Standards for fiber drums. 178.814 Hydrostatic pressure test.
178.509 Standards for plastic drums and 178.815 Stacking test.
jerricans. 178.816 Topple test.
178.510 Standards for wooden barrels. 178.817 Righting test.
178.511 Standards for aluminum and steel 178.818 Tear test.
jerricans. 178.819 Vibration test.
178.512 Standards for steel, aluminum or
other metal boxes. Subpart P—Large Packagings Standards
178.513 Standards for boxes of natural wood.
178.514 Standards for plywood boxes. 178.900 Purpose and scope.
178.515 Standards for reconstituted wood 178.905 Large Packaging identification
boxes. codes.
178.516 Standards for fiberboard boxes. 178.910 Marking of Large Packagings.
178.517 Standards for plastic boxes. 178.915 General Large Packaging standards.
178.518 Standards for woven plastic bags. 178.920 Standards for metal Large Pack-
178.519 Standards for plastic film bags. agings.
178.520 Standards for textile bags. 178.925 Standards for rigid plastic Large
Packagings.
178.521 Standards for paper bags.
178.930 Standards for fiberboard Large
178.522 Standards for composite packagings
Packagings.
with inner plastic receptacles.
178.935 Standards for wooden Large Pack-
178.523 Standards for composite packagings
agings.
with inner glass, porcelain, or stoneware
178.940 Standards for flexible Large Pack-
receptacles.
agings.
Subpart M—Testing of Non-bulk
Subpart Q—Testing of Large Packagings
Packagings and Packages
178.600 Purpose and scope. 178.955 General requirements.
178.601 General requirements. 178.960 Preparation of Large Packagings for
178.602 Preparation of packagings and pack- testing.
ages for testing. 178.965 Drop test.
178.603 Drop test. 178.970 Bottom lift test.
178.604 Leakproofness test. 178.975 Top lift test.
178.605 Hydrostatic pressure test. 178.980 Stacking test.
178.606 Stacking test. 178.985 Vibration test.
178.607 Cooperage test for bung-type wooden
barrels. Subpart R—Flexible Bulk Container
178.608 Vibration standard. Standards
178.609 Test requirements for packagings for
infectious substances. 178.1000 Purpose and scope.
178.1005 Flexible Bulk Container identifica-
Subpart N—IBC Performance-Oriented tion code.
Standards 178.1010 Marking of Flexible Bulk Con-
tainers.
178.700 Purpose, scope and definitions. 178.1015 General Flexible Bulk Container
178.702 IBC codes. standards.
178.703 Marking of IBCs. 178.1020 Period of use for transportation of
178.704 General IBC standards. hazardous materials in Flexible Bulk
178.705 Standards for metal IBCs. Containers.
178.706 Standards for rigid plastic IBCs.
178.707 Standards for composite IBCs. Subpart S—Testing of Flexible Bulk
178.708 Standards for fiberboard IBCs. Containers

178.709 Standards for wooden IBCs.
178.710 Standards for flexible intermediate 178.1030 Purpose and scope.
bulk containers. 178.1035 General requirements.
§ 178.1 49 CFR Ch. I (10–1–18 Edition)
178.1040 Preparation of Flexible Bulk Con- (1) Except as otherwise provided in
tainers for testing. this section, all requirements of the
178.1045 Drop test. DOT specification or UN standard, in-
178.1050 Top lift test.
178.1055 Stacking test. cluding performance tests, are met;
178.1060 Topple test. and
178.1065 Righting test. (2) All functions performed by, or on
178.1070 Tear test. behalf of, the person whose name or
APPENDIX A TO PART 178—SPECIFICATIONS FOR symbol appears as part of the marking
STEEL conform to requirements specified in
APPENDIX B TO PART 178—ALTERNATIVE this part.
LEAKPROOFNESS TEST METHODS
APPENDIX C TO PART 178—NOMINAL AND MIN- (c) Notification. (1) Except as specifi-
IMUM THICKNESSES OF STEEL DRUMS AND cally provided in §§ 178.337–18, 178.338–19,
JERRICANS and 178.345–15 of this part, the manufac-
APPENDIX D TO PART 178—THERMAL RESIST- turer or other person certifying com-
ANCE TEST pliance with the requirements of this
APPENDIX E TO PART 178—FLAME PENETRA-
part, and each subsequent distributor
TION RESISTANCE TEST
of that packaging must:
AUTHORITY: 49 U.S.C. 5101–5128; 49 CFR 1.81 (i) Notify each person to whom that
and 1.97.
packaging is transferred—
§ 178.1 Purpose and scope. (A) Of all requirements in this part
not met at the time of transfer, and
This part prescribes the manufac-
turing and testing specifications for (B) With information specifying the
packaging and containers used for the type(s) and dimensions of the closures,
transportation of hazardous materials including gaskets and any other com-
in commerce. ponents needed to ensure that the
packaging is capable of successfully
[Amdt. 178–40, 42 FR 2689, Jan. 13, 1977. Redes- passing the applicable performance
ignated by Amdt. 178–97, 55 FR 52715, Dec. 21, tests. This information must include
1990]
any procedures to be followed, includ-
§ 178.2 Applicability and responsi- ing closure instructions for inner pack-
bility. agings and receptacles, to effectively
(a) Applicability. (1) The requirements assemble and close the packaging for
of this part apply to packagings manu- the purpose of preventing leakage in
factured— transportation. Closure instructions
(i) To a DOT specification, regardless must provide for a consistent and re-
of country of manufacture; or peatable means of closure that is suffi-
(ii) To a UN standard, for packagings cient to ensure the packaging is closed
manufactured within the United in the same manner as it was tested.
States. For UN standard packagings For packagings sold or represented as
manufactured outside the United being in conformance with the require-
States, see § 173.24(d)(2) of this sub- ments of this subchapter applicable to
chapter. For UN standard packagings transportation by aircraft, this infor-
for which standards are not prescribed mation must include relevant guidance
in this part, see § 178.3(b). to ensure that the packaging, as pre-
(2) A manufacturer of a packaging pared for transportation, will with-
subject to the requirements of this part stand the pressure differential require-
is primarily responsible for compliance ments in § 173.27 of this subchapter.
with the requirements of this part. (ii) Retain copies of each written no-
However, any person who performs a tification for at least one year from
function prescribed in this part shall date of issuance; and
perform that function in accordance (iii) Make copies of all written notifi-
with this part. cations available for inspection by a
(b) Specification markings. When this representative of the Department.
part requires that a packaging be (2) The notification required in ac-
marked with a DOT specification or UN cordance with this paragraph (c) may
standard marking, marking of the be in writing or by electronic means,
packaging with the appropriate DOT or including e-mailed transmission or
UN markings is the certification that— transmission on a CD or similar device.
10
Pipeline and Hazardous Materials Safety Admin., DOT § 178.3
If a manufacturer or subsequent dis- of the packaging manufacturer or the

tributor of the packaging utilizes elec- person certifying compliance with a
tronic means to make the required no- UN standard. Symbols, if used, must be
tifications, the notification must be registered with the Associate Adminis-
specific to the packaging in question trator. Unless authorized in writing by
and must be in a form that can be the holder of the symbol, symbols must
printed in hard copy by the person re- represent either the packaging manu-
ceiving the notification. facturer or the approval agency respon-
(d) Except as provided in paragraph sible for providing the most recent cer-
(c) of this section, a packaging not con- tification for the packaging through
forming to the applicable specifica- design certification testing or periodic
tions or standards in this part may not retesting, as applicable. Duplicative
be marked to indicate such conform- symbols are not authorized.
ance. (3) The markings must be stamped,
(e) Definitions. For the purpose of this embossed, burned, printed or otherwise
part— marked on the packaging to provide
Manufacturer means the person whose adequate accessibility, permanency,
name and address or symbol appears as contrast, and legibility so as to be
part of the specification markings re- readily apparent and understood.
quired by this part or, for a packaging (4) Unless otherwise specified, letters
marked with the symbol of an approval and numerals must be at least 12.0 mm
agency, the person on whose behalf the (0.47 inches) in height except that for
approval agency certifies the pack- packagings of less than or equal to 30 L
aging. (7.9 gallons) capacity for liquids or 30
Specification markings mean the pack- kg (66 pounds) capacity for solids the
aging identification markings required height must be at least 6.0 mm (0.2
by this part including, where applica- inches). For packagings having a ca-
ble, the name and address or symbol of pacity of 5 L (1 gallon) or 5 kg (11
the packaging manufacturer or ap- pounds) or less, letters and numerals
proval agency. must be of an appropriate size.
(f) No packaging may be manufac-
(5) For packages with a gross mass of
tured or marked to a packaging speci-
more than 30 kg (66 pounds), the mark-
fication that was in effect on Sep-
ings or a duplicate thereof must appear
tember 30, 1991, and that was removed
on the top or on a side of the pack-
from this part 178 by a rule published
in the FEDERAL REGISTER on December aging.
21, 1990 and effective October 1, 1991. (b) A UN standard packaging for
which the UN standard is set forth in
[Amdt. 178–97, 55 FR 52715, Dec. 21, 1990; 56 FR this part may be marked with the
66284, Dec. 20, 1991, as amended by Amdt. 178– United Nations symbol and other speci-
106, 59 FR 67519, Dec. 29, 1994; Amdt. 178–117,
62 FR 14338, Mar. 26, 1997; 68 FR 45041, July
fication markings only if it fully con-
31, 2003; 69 FR 34612, June 22, 2004; 75 FR 5395, forms to the requirements of this part.
Feb. 2, 2010; 75 FR 60339, Sept. 30, 2010; 78 FR A UN standard packaging for which the
1118, Jan. 7, 2013; 78 FR 15328, Mar. 11, 2013] UN standard is not set forth in this
part may be marked with the United
§ 178.3 Marking of packagings. Nations symbol and other specification
(a) Each packaging represented as markings for that standard as provided
manufactured to a DOT specification in the ICAO Technical Instructions or
or a UN standard must be marked on a the IMDG Code subject to the following
non-removable component of the pack- conditions:
aging with specification markings con- (1) The U.S. manufacturer must es-
forming to the applicable specification, tablish that the packaging conforms to
and with the following: the applicable provisions of the ICAO
(1) In an unobstructed area, with let- Technical Instructions (IBR, see § 171.7
ters, and numerals identifying the of this subchapter) or the IMDG Code
standards or specification (e.g. UN 1A1, (IBR, see § 171.7 of this subchapter), re-
DOT 4B240ET, etc.). spectively.
(2) Unless otherwise specified in this (2) If an indication of the name of the
part, the name and address or symbol manufacturer or other identification of
11
§ 178.33 49 CFR Ch. I (10–1–18 Edition)
the packaging as specified by the com- ed, soldered, brazed, double seamed, or
petent authority is required, the name swedged.
and address or symbol of the manufac- (b) The maximum capacity of con-
turer or the approval agency certifying tainers in this class shall not exceed
compliance with the UN standard must one liter (61.0 cubic inches). The max-
be entered. Symbols, if used, must be imum inside diameter shall not exceed
registered with the Associate Adminis- 3 inches.
trator.
(3) The letters ‘‘USA’’ must be used [29 FR 18813, Dec. 29, 1964, as amended by
Order 71, 31 FR 9074, July 1, 1966. Redesig-
to indicate the State authorizing the
nated at 32 FR 5606, Apr. 5, 1967, and amended
allocation of the specification marks if by Amdt. 178–101, 58 FR 50237, Sept. 24, 1993;
the packaging is manufactured in the 66 FR 45386, Aug. 28, 2001]
United States.
(c) Where a packaging conforms to § 178.33–3 Inspection.
more than one UN standard or DOT
(a) By competent inspector.
specification, the packaging may bear
more than one marking, provided the (b) [Reserved]
packaging meets all the requirements
§ 178.33–4 Duties of inspector.
of each standard or specification.
Where more than one marking appears (a) To inspect material and com-
on a packaging, each marking must ap- pleted containers and witness tests,
pear in its entirety. and to reject defective materials or
(d) No person may mark or otherwise containers.
certify a packaging or container as (b) [Reserved]
meeting the requirements of a manu-
facturing special permit unless that § 178.33–5 Material.
person is the holder of or a party to (a) Uniform quality steel plate such
that special permit, an agent of the as black plate, electro-tin plate, hot
holder or party for the purpose of dipped tin plate, tern plate or other
marking or certification, or a third commercially accepted can making
party tester. plate; or nonferrous metal of uniform
[Amdt. 178–97, 55 FR 52716, Dec. 21, 1990; 56 FR drawing quality.
66284, Dec. 20, 1991, as amended by Amdt. 178– (b) Material with seams, cracks, lam-
106, 59 FR 67519, Dec. 29, 1994; Amdt. 178–113, inations or other injurious defects not
61 FR 21102, May 9, 1996; 65 FR 50462, Aug. 18, authorized.
2000; 66 FR 45386, Aug. 28, 2001; 67 FR 61015,
Sept. 27, 2002; 68 FR 75748, Dec. 31, 2003; 70 FR
§ 178.33–6 Manufacture.
73166, Dec. 9, 2005; 78 FR 14714, Mar. 7, 2013]
(a) By appliances and methods that
Subpart A [Reserved] will assure uniformity of completed
containers; dirt and scale to be re-
moved as necessary; no defect accept-
Subpart B—Specifications for able that is likely to weaken the fin-
Inside Containers, and Linings ished container appreciably; reason-
ably smooth and uniform surface finish
SOURCE: 29 FR 18823, Dec. 29, 1964, unless required.
otherwise noted. Redesignated at 32 FR 5606, (b) Seams when used must be as fol-
Apr. 5, 1967.
lows:
§ 178.33 Specification 2P; inner non- (1) Circumferential seams: By weld-
refillable metal receptacles. ing, swedging, brazing, soldering, or
double seaming.
§ 178.33–1 Compliance. (2) Side seams: By welding, brazing,
(a) Required in all details. or soldering.
(b) [Reserved] (c) Ends: The ends shall be of pres-
sure design.
§ 178.33–2 Type and size.

[29 FR 18823, Dec. 29, 1964, as amended by
(a) Single-trip inside containers. Order 71, 31 FR 9074, July 1, 1966. Redesig-
Must be seamless, or with seams, weld- nated at 32 FR 5606, Apr. 5, 1967]
12
Pipeline and Hazardous Materials Safety Admin., DOT § 178.33a–6
§ 178.33–7 Wall thickness. § 178.33a–2 Type and size.

(a) The minimum wall thickness for (a) Single-trip inside containers.
any container shall be 0.007 inch. Must be seamless, or with seams weld-
(b) [Reserved] ed, soldered, brazed, double seamed, or
swedged.
[Order 71, 31 FR 9074, July 1, 1966. Redesig-
nated at 32 FR 5606, Apr. 5, 1967]
(b) The maximum capacity of con-
tainers in this class shall not exceed 1
§ 178.33–8 Tests. L (61.0 cubic inches). The maximum in-
side diameter shall not exceed 3 inches.
(a) One out of each lot of 25,000 con-
tainers or less, successively produced [Order 71, 31 FR 9074, July 1, 1966. Redesig-
per day shall be pressure tested to de- nated at 32 FR 5606, Apr. 5, 1967, and amended
struction and must not burst below 240 by Amdt. 178–43, 42 FR 42208, Aug. 22, 1977;
Amdt. 178–101, 58 FR 50237, Sept. 24, 1993; 66
psig gauge pressure. The container FR 45387, Aug. 28, 2001]
tested shall be complete with end as-
sembled. § 178.33a–3 Inspection.
(b) Each such 25,000 containers or
(a) By competent inspector.
less, successively produced per day,
(b) [Reserved]
shall constitute a lot and if the test
container shall fail, the lot shall be re- [Order 71, 31 FR 9074, July 1, 1966. Redesig-
jected or ten additional containers may nated at 32 FR 5606, Apr. 5, 1967]
be selected at random and subjected to
the test under which failure occurred. § 178.33a–4 Duties of inspector.
These containers shall be complete (a) To inspect material and com-
with ends assembled. Should any of the pleted containers and witness tests,
ten containers thus tested fail, the en- and to reject defective materials or
tire lot must be rejected. All con- containers.
tainers constituting a lot shall be of (b) [Reserved]
like material, size, design construc-
tion, finish, and quality. nated at 32 FR 5606, Apr. 5, 1967]
nated at 32 FR 5606, Apr. 5, 1967, as amended § 178.33a–5 Material.
by 66 FR 45387, Aug. 28, 2001] (a) Uniform quality steel plate such
as black plate, electrotin plate, hot
§ 178.33–9 Marking. dipped tinplate, ternplate or other
(a) By means of printing, commercially accepted can making
lithographing, embossing, or stamping, plate; or nonferrous metal of uniform
each container must be marked to drawing quality.
show: (b) Material with seams, cracks, lam-
(1) DOT-2P. inations or other injurious defects not
(2) Name or symbol of person making authorized.
the mark specified in paragraph (a)(1)
of this section. Symbol, if used, must nated at 32 FR 5606, Apr. 5, 1967]
be registered with the Associate Ad-
ministrator. § 178.33a–6 Manufacture.
(b) [Reserved]
(a) By appliances and methods that
[Amdt. 178–40, 41 FR 38181, Sept. 9, 1976, as will assure uniformity of completed
amended by Amdt. 178–97, 56 FR 66287, Dec. containers; dirt and scale to be re-
20, 1991; 66 FR 45386, Aug. 28, 2001] moved as necessary; no defect accept-
able that is likely to weaken the fin-
§ 178.33a Specification 2Q; inner non- ished container appreciably; reason-
refillable metal receptacles.
ably smooth and uniform surface finish
§ 178.33a–1 Compliance. required.
(b) Seams when used must be as fol-
(a) Required in all details.
lows:
(b) [Reserved] (1) Circumferential seams. By weld-
[Order 71, 31 FR 9074, July 1, 1966. Redesig- ing, swedging, brazing, soldering, or
nated at 32 FR 5606, Apr. 5, 1967] double seaming.
13
§ 178.33a–7 49 CFR Ch. I (10–1–18 Edition)
(2) Side seams. By welding, brazing or § 178.33b Specification 2S; inner non-
soldering. refillable plastic receptacles.
(c) Ends. The ends shall be of pres-
sure design. § 178.33b–1 Compliance.
(a) Required in all details.
[Order 71, 31 FR 9074, July 1, 1966. Redesig- (b) [Reserved]
nated at 32 FR 5606, Apr. 5, 1967]
[74 FR 2268, Jan. 14, 2009]
§ 178.33a–7 Wall thickness.
§ 178.33b–2 Type and size.
(a) The minimum wall thickness for
any container shall be 0.008 inch. (a) Single-trip inside containers.
(b) The maximum capacity of con-
(b) [Reserved]
tainers in this class shall not exceed
[Order 71, 31 FR 9074, July 1, 1966. Redesig- one liter (61.0 cubic inches). The max-
nated at 32 FR 5606, Apr. 5, 1967] imum inside diameter shall not exceed
3 inches.
§ 178.33a–8 Tests.
[74 FR 2268, Jan. 14, 2009]
(a) One out of each lot of 25,000 con-
tainers or less, successively produced § 178.33b–3 Inspection.
per day, shall be pressure tested to de- (a) By competent inspector.
struction and must not burst below 270 (b) [Reserved]
psig gauge pressure. The container
[74 FR 2268, Jan. 14, 2009]
tested shall be complete with end as-
sembled. § 178.33b–4 Duties of inspector.
(b) Each such 25,000 containers or
(a) To inspect material and com-
less, successively produced per day,
pleted containers and witness tests,
shall constitute a lot and if the test and to reject defective materials or
container shall fail, the lot shall be re- containers.
jected or ten additional containers may (b) [Reserved]
the test under which failure occurred. [74 FR 2268, Jan. 14, 2009]
These containers shall be complete
§ 178.33b–5 Material.
with ends assembled. Should any of the
ten containers thus tested fail, the en- (a) The receptacles must be con-
tire lot must be rejected. All constructed of polyethylene terephthalate
tainers constituting a lot shall be of (PET), polyethylene napthalate (PEN),
like material, size, design, construc- polyamide (Nylon) or a blend of PET,
tion, finish and quality. PEN, ethyl vinyl alcohol (EVOH) and/
or Nylon.
[Order 71, 31 FR 9074, July 1, 1966. Redesig- (b) Material with seams, cracks, lam-
nated at 32 FR 5606, Apr. 5, 1967, as amended inations or other injurious defects are
by 66 FR 45387, Aug. 28, 2001] forbidden.
§ 178.33a–9 Marking. [74 FR 2268, Jan. 14, 2009]
(a) By means of printing, § 178.33b–6 Manufacture.

lithographing, embossing, or stamping, (a) Each container must be manufac-
each container must be marked to tured by thermoplastic processes that
show: will assure uniformity of the com-
(1) DOT-2Q. pleted container. No used material
(2) Name or symbol of person making other than production residues or
the mark specified in paragraph (a)(1) regrind from the same manufacturing
of this section. Symbol, if used, must process may be used. The packaging
be registered with the Associate Ad- must be adequately resistant to aging
ministrator. and to degradation caused either by
(b) [Reserved] the substance contained or by ultra-
violet radiation.
[Amdt. 178–40, 41 FR 38181, Sept. 9, 1976, as (b) [Reserved]
amended by Amdt. 178–97, 56 FR 66287, Dec.
20, 1991; 66 FR 45386, Aug. 28, 2001] [74 FR 2268, Jan. 14, 2009]
14
Pipeline and Hazardous Materials Safety Admin., DOT § 178.33c–2
§ 178.33b–7 Design qualification test. (1) DOT–2S.

(a) Drop testing. (1) To ensure that (2) Name or symbol of person making
the mark specified in paragraph (a)(1)
creep does not affect the ability of the
of this section. Symbol, if used, must
container to retain the contents, each
be registered with the Associate Ad-
new design must be drop tested as fol-
ministrator.
lows: Three groups of twenty-five filled
(b) [Reserved]
containers must be dropped from 1.8 m
(5.9 ft) on to a rigid, non-resilient, flat [74 FR 2268, Jan. 14, 2009]
and horizontal surface. One group must
be conditioned at 38 °C (100 °F) for 26 § 178.33c Specification 2P; inner non-
weeks, the second group for 100 hours refillable metal receptacle vari-
ation.
at 50 °C (122 °F) and the third group for
18 hours at 55 °C (131 °F), prior to per- § 178.33c–1 Compliance.
forming the drop test. The closure, or
sealing component of the container, Required in all details.
must not be protected during the test. [81 FR 3685, Jan. 21, 2016]
The orientation of the test container
at drop must be statistically random, § 178.33c–2 Variation.
but direct impact on the valve or valve Notwithstanding the variation pro-
closure must be avoided. vided in this section, each container
(2) Criteria for passing the drop test: must otherwise conform to a DOT 2P
The containers must not break or leak. container in accordance with § 178.33.
(b) Design qualification testing must The following conditions also apply
be completed if the design is manufac- under Variation 1—
tured with a new mold or if there is (a) Manufacture. Side seams: not per-
any change in the properties of the ma- mitted. Ends: The ends shall be de-
terial of construction. signed to withstand pressure and be
[75 FR 73, Jan. 4, 2010] equipped with a pressure relief system
(e.g., rim-venting release or a dome ex-
§ 178.33b–8 Production tests. pansion device) designed to function
(a) Burst Testing. (1) One out of each prior to bursting of the container.
lot of 5,000 containers or less, succes- (b) Tests. (1) One out of each lot of
sively produced per day must be pres- 25,000 containers or less, successively
produced per day complete with ends
sure tested to destruction and must not
assembled (and without a pressure re-
burst below 240 psig. The container
lief system assembled) shall be pres-
tested must be complete as intended
sure tested to destruction at gauge
for transportation.
pressure and must not burst below 240
(2) Each such 5,000 containers or less,
psig. For containers with a pressure re-
successively produced per day, shall
lief system as described in paragraph
constitute a lot and if the test con-
(a) of this section and assembled, fail-
tainer shall fail, the lot shall be re-
ure at a location other than the pres-
jected or ten additional containers may
sure relief system will reject the lot.
For containers with an end expansion
the test under which failure occurred.
device, the lot must be rejected if the
These containers shall be complete as container bursts prior to buckling of
intended for transportation. Should the device.
any of the ten containers thus tested (2) Each such 25,000 containers or
fail, the entire lot must be rejected. All less, successively produced per day,
containers constituting a lot shall be shall constitute a lot and if the test
of like material, size, design construc- container(s) shall fail, the lot shall be
tion, finish, and quality. rejected. Otherwise, ten (10) additional
(b) [Reserved] containers of each container design
[74 FR 2268, Jan. 14, 2009, as amended at 75 produced may be selected at random
FR 74, Jan. 4, 2010] and subjected to the test. These con-
tainers shall be complete with ends as-

§ 178.33b–9 Marking. sembled. Should any of the containers
(a) Each container must be clearly thus tested fail, the entire lot must be
and permanently marked to show: rejected. All containers constituting a
15
§ 178.33d 49 CFR Ch. I (10–1–18 Edition)
lot shall be of like material, size, de- (2) Each such 25,000 containers or
sign construction, finish, and quality. less, successively produced per day,
(c) Marking. By means of printing, shall constitute a lot and if the test
lithographing, embossing, or stamping, container(s) shall fail, the lot shall be
each container must be marked: rejected. Otherwise, ten (10) additional
(1) DOT–2P1. pairs of containers may be selected at
(2) With the name or symbol of the random and subjected to the test under
person making the mark. A symbol, if which failure occurred. Should any of
used, must be registered with the Asso- the containers thus tested fail, the en-
ciate Administrator. tire lot must be rejected. All con-
tainers constituting a lot shall be of
[81 FR 3685, Jan. 21, 2016] like material, size, design construc-
tion, finish, and quality.
§ 178.33d Specification 2Q; inner non-
refillable metal receptacle vari- (e) Marking. By means of printing,
ations. lithographing, embossing, or stamping,
each container must be marked:
§ 178.33d–1 Compliance. (1) DOT–2Q1.
(2) With the name or symbol of the
Required in all details.
person making the mark. A symbol, if
[81 FR 3685, Jan. 21, 2016] used, must be registered with the Asso-
ciate Administrator.
§ 178.33d–2 Variation 1.
[81 FR 3685, Jan. 21, 2016]
Notwithstanding the variation pro-
vided in this paragraph, each container § 178.33d–3 Variation 2.
must otherwise conform to a DOT 2Q Notwithstanding the variation pro-
container in accordance with § 178.33a. vided in this paragraph, each container
The following conditions also apply must otherwise conform to a DOT 2Q
under Variation 1— container in accordance with § 178.33a.
(a) Type and size. The maximum ca- The following conditions also apply
pacity of containers in this class may under Variation 2—
not exceed 0.40 L (24.4 cubic inches). (a) Manufacture. Ends: The ends shall
The maximum inside diameter shall be designed to withstand pressure and
not exceed 2.1 inches. the container equipped with a pressure
(b) Manufacture. Ends: The top of the relief system (e.g., rim-venting release
container must be designed with a or a dome expansion device) designed
pressure relief system consisting of ra- to buckle prior to the burst of the con-
dial scores on the top seam(s). The bot- tainer.
tom of the container must be designed (b) Tests. (1) One out of each lot of
to buckle at a pressure greater than 25,000 containers or less, successively
the pressure at which the top buckles produced per day shall be pressure test-
and vents. ed to destruction at gauge pressure and
(c) Wall thickness. The minimum wall must not burst below 270 psig. For con-
thickness for any container shall be tainers with a pressure relief system as
0.0085 inches. described in paragraph (a) of this sec-
(d) Tests. (1) Two containers (one tion and assembled, failure at a loca-
without a pressure relief system and tion other than the pressure relief sys-
one with) out of each lot of 25,000 or tem will reject the lot.
less, successively produced per day (2) Each such 25,000 containers or
shall be pressure tested to destruction less, successively produced per day,
at gauge pressure. The container with- shall constitute a lot and if the test
out a pressure relief system must not container(s) shall fail, the lot shall be
burst below 320 psig. The container as- rejected. Otherwise, ten (10) additional
sembled with a pressure relief system containers of each container design
as described in paragraph (b) of this produced may be selected at random
section must be tested to destruction. and subjected to the test. These con-
The bottom of the container must tainers shall be complete with ends as-
buckle at a pressure greater than the sembled. Should any of the containers
pressure at which the top buckles and thus tested fail, the entire lot must be
vents. rejected. All containers constituting a
16
lot shall be of like material, size, de- (2) Verify the material of construc-
sign construction, finish, and quality. tion meets the requirements of the ap-
(c) Marking. By means of printing, plicable specification by—
lithographing, embossing, or stamping, (i) Making a chemical analysis of
each container must be marked: each heat of material;
(1) DOT–2Q2. (ii) Obtaining a certified chemical
(2) With the name or symbol of the analysis from the material manufac-
person making the mark. A symbol, if turer for each heat of material (a ladle
used, must be registered with the Asso- analysis is acceptable); or
ciate Administrator. (iii) If an analysis is not provided for
each heat of material by the material
[81 FR 3685, Jan. 21, 2016] manufacturer, by making a check anal-
ysis of a sample from each coil, sheet,
Subpart C—Specifications for or tube.
Cylinders (3) Verify compliance of cylinders
with the applicable specification by—
§ 178.35 General requirements for (i) Verifying identification of mate-
specification cylinders. rial is proper;
(a) Compliance. Compliance with the (ii) Inspecting the inside of the cyl-
requirements of this subpart is re- inder before closing in ends;
quired in all details. (iii) Verifying that the heat treat-
(b) Inspections and analyses. Chemical ment is proper;
analyses and tests required by this sub- (iv) Obtaining samples for all tests
chapter must be made within the and check chemical analyses (NOTE:
United States, unless otherwise ap- Recommended locations for test speci-
proved in writing by the Associate Ad- mens taken from welded cylinders are
ministrator, in accordance with sub- depicted in Figures 1 through 5 in Ap-
part I of part 107 of this chapter. In- pendix C to this subpart for the specific
construction design.);
spections and verification must be per-
formed by— (v) Witnessing all tests;
(vi) Verify threads by gauge;
(1) An independent inspection agency
approved in writing by the Associate (vii) Reporting volumetric capacity
and tare weight (see report form) and
Administrator, in accordance with sub-
minimum thickness of wall noted; and
part I of part 107 of this chapter; or
(viii) Verifying that each cylinder is
(2) For DOT Specifications 3B, 3BN,
marked in accordance with the applica-
3E, 4B, 4BA, 4D (water capacity less
ble specification.
than 1,100 cubic inches), 4B240ET,
(4) Inspector’s report. Prepare a report
4AA480, 4L, 8, 8AL, 4BW, 39 (marked
containing, at a minimum, the applica-
service pressure 900 p.s.i.g. or lower)
ble information listed in CGA C–11
and 4E manufactured in the United (IBR, see § 171.7 of this subchapter).
States, a competent inspector of the Any additional information or mark-
manufacturer. ings that are required by the applicable
(c) Duties of inspector. The inspector specification must be shown on the test
shall determine that each cylinder report. The signature of the inspector
made is in conformance with the appli- on the reports certifies that the proc-
cable specification. Except as other- esses of manufacture and heat treat-
wise specified in the applicable speci- ment of cylinders were observed and
fication, the inspector shall perform found satisfactory. The inspector must
the following: furnish the completed test reports re-
(1) Inspect all material and reject quired by this subpart to the maker of
any not meeting applicable require- the cylinder and, upon request, to the
ments. For cylinders made by the bil- purchaser. The test report must be re-
let-piercing process, billets must be in- tained by the inspector for fifteen
spected and shown to be free from pipe, years from the original test date of the
cracks, excessive segregation and other cylinder.
injurious defects after parting or, when (d) Defects and attachments. Cylinders
applicable, after nick and cold break. must conform to the following:
17
§ 178.36 49 CFR Ch. I (10–1–18 Edition)
(1) A cylinder may not be constructed 1234 = serial number

of material with seams, cracks or lam- XY = symbol of manufacturer
inations, or other injurious defects. AB = inspector’s mark
(2) Metal attachments to cylinders 5–95 = date of test
must have rounded or chamfered cor- (2) Additional required marking must
ners or must be protected in such a
be applied to the cylinder as follows:
manner as to prevent the likelihood of
(i) The word ‘‘spun’’ or ‘‘plug’’ must
causing puncture or damage to other
hazardous materials packages. This re- be placed near the DOT specification
quirement applies to anything tempo- marking when an end closure in the
rarily or permanently attached to the finished cylinder has been welded by
cylinder, such as metal skids. the spinning process, or effected by
(e) Safety devices. Pressure relief de- plugging.
vices and protection for valves, safety (ii) As prescribed in specification 3HT
devices, and other connections, if ap- (§ 178.44) or 3T (§ 178.45), if applicable.
plied, must be as required or author- (3) Marking exceptions. A DOT 3E cyl-
ized by the appropriate specification, inder is not required to be marked with
and as required in § 173.301 of this sub- an inspector’s mark or a serial number.
chapter. (4) Unless otherwise specified in the
(f) Markings. Markings on a DOT applicable specification, the markings
Specification cylinder must conform to on each cylinder must be stamped
applicable requirements. plainly and permanently on the shoul-
(1) Each cylinder must be marked der, top head, or neck.
with the following information: (5) The size of each marking must be
(i) The DOT specification marking at least 0.25 inch or as space permits.
must appear first, followed imme- (6) Other markings are authorized
diately by the service pressure. For ex- provided they are made in low stress
ample, DOT-3A1800. areas other than the side wall and are
(ii) The serial number must be placed not of a size and depth that will create
just below or immediately following harmful stress concentrations. Such
the DOT specification marking. marks may not conflict with any DOT
(iii) A symbol (letters) must be
required markings.
placed just below, immediately before
(g) Manufacturer’s reports. At or be-
or following the serial number. Other
fore the time of delivery to the pur-
variations in sequence of markings are
authorized only when necessitated by a chaser, the cylinder manufacturer
lack of space. The symbol and numbers must have all completed certification
must be those of the manufacturer. documents listed in CGA C–11. The
The symbol must be registered with manufacturer of the cylinders must re-
the Associate Administrator; duplica- tain the reports required by this sub-
tions are not authorized. part for 15 years from the original test
(iv) The inspector’s official mark and date of the cylinder.
date of test (such as 5–95 for May 1995) [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
must be placed near the serial number. amended at 66 FR 45185, Aug. 28, 2001; 67 FR
This information must be placed so 51652, Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003;
that dates of subsequent tests can be 76 FR 43531, July 20, 2011]
easily added. An example of the mark-
ings prescribed in this paragraph (f)(1) § 178.36 Specification 3A and 3AX
is as follows: seamless steel cylinders.
DOT-3A1800 (a) Type size and service pressure. In
1234 addition to the requirements of § 178.35,
XY cylinders must conform to the fol-
AB 5–95 lowing:
Or; (1) A DOT-3A cylinder is a seamless
DOT-3A1800–1234–XY steel cylinder with a water capacity
AB 5–95 (nominal) not over 1,000 pounds and a

Where: service pressure of at least 150 psig.
DOT-3A = specification number (2) A DOT–3AX is a seamless steel
1800 = service pressure cylinder with a water capacity not less
18
than 1,000 pounds and a service pres- or other defect is permitted that is
sure of at least 500 psig, conforming to likely to weaken the finished cylinder
the following requirements: appreciably. A reasonably smooth and
(i) Assuming the cylinder is to be uniform surface finish is required. If
supported horizontally at its two ends not originally free from such defects,
only and to be uniformly loaded over the surface may be machined or other-
its entire length consisting of the wise treated to eliminate these defects.
weight per unit of length of the The thickness of the bottoms of cyl-
straight cylindrical portion filled with inders welded or formed by spinning is,
water and compressed to the specified under no condition, to be less than two
test pressure; the sum of two times the times the minimum wall thickness of
maximum tensile stress in the bottom the cylindrical shell; such bottom
fibers due to bending, plus that in the thicknesses must be measured within
same fibers (longitudinal stress), due to an area bounded by a line representing
hydrostatic test may not exceed 80 per- the points of contact between the cyl-
cent of the minimum yield strength of inder and floor when the cylinder is in
the steel at such maximum stress. Wall a vertical position.
thickness must be increased when nec- (e) Welding or brazing. Welding or
essary to meet the requirement. brazing for any purpose whatsoever is
(ii) To calculate the maximum longi- prohibited except as follows:
tudinal tensile stress due to bending, (1) Welding or brazing is authorized
the following formula must be used: for the attachment of neckrings and
S = Mc/I footrings which are non-pressure parts
and only to the tops and bottoms of
(iii) To calculate the maximum lon- cylinders having a service pressure of
gitudinal tensile stress due to hydro- 500 psig or less. Cylinders, neckrings,
static test pressure, the following for-
and footrings must be made of weldable
mula must be used:
steel, the carbon content of which may
S = A1 P/A2 not exceed 0.25 percent except in the
where: case of 4130X steel which may be used
with proper welding procedures.
S = tensile stress—p.s.i.;
M = bending moment-inch pounds—(wl2)/8; (2) As permitted in paragraph (d) of
w = weight per inch of cylinder filled with this section.
water; (3) Cylinders used solely in anhy-
l = length of cylinder-inches; drous ammonia service may have a 1⁄2
c = radius (D)/(2) of cylinder-inches; inch diameter bar welded within their
I = moment of inertia—0.04909 (D4¥d4) inches concave bottoms.
fourth;
D = outside diameter-inches;
(f) Wall thickness. For cylinders with
d = inside diameter-inches; service pressure less than 900 psig, the
A1 = internal area in cross section of cyl- wall stress may not exceed 24,000 psig.
inder-square inches; A minimum wall thickness of 0.100 inch
A2 = area of metal in cross section of cyl- is required for any cylinder over 5
inder-square inches; inches outside diameter. Wall stress
P = hydrostatic test pressure-psig. calculation must be made by using the
(b) Steel. Open-hearth or electric steel following formula:
of uniform quality must be used. Con- S = [P(1.3D2 + 0.4d2)]/(D2¥d2)
tent percent may not exceed the fol-
lowing: Carbon, 0.55; phosphorous, 0.045; Where:
sulphur, 0.050. S = wall stress in psi;
(c) Identification of material. Material P = minimum test pressure prescribed for
must be identified by any suitable water jacket test or 450 psig whichever is
method, except that plates and billets the greater;
for hot-drawn cylinders must be D = outside diameter in inches;
d = inside diameter in inches.
marked with the heat number.
(d) Manufacture. Cylinders must be (g) Heat treatment. The completed cyl-
manufactured using equipment and inder must be uniformly and properly

processes adequate to ensure that each heat-treated prior to tests.
cylinder produced conforms to the re- (h) Openings in cylinders and connec-
quirements of this subpart. No fissure tions (valves, fuse plugs, etc.) for those
19
§ 178.36 49 CFR Ch. I (10–1–18 Edition)
openings. Threads are required on open- and reduction of area of material as

ings. follows:
(1) Threads must be clean cut, even, (1) The test is required on 2 speci-
without checks, and to gauge. mens cut from 1 cylinder taken at ran-
(2) Taper threads, when used, must be dom out of each lot of 200 or less. For
of length not less than as specified for lots of 30 or less, physical tests are au-
American Standard taper pipe threads. thorized to be made on a ring at least
(3) Straight threads having at least 6 8 inches long cut from each cylinder
engaged threads are authorized. and subjected to same heat treatment
Straight threads must have a tight fit as the finished cylinder.
and calculated shear strength of at (2) Specimens must conform to the
least 10 times the test pressure of the following:
cylinder. Gaskets, adequate to prevent (i) Gauge length of 8 inches with a
leakage, are required. width of not over 11⁄2 inches, a gauge
(i) Hydrostatic test. Each cylinder length of 2 inches with a width of not
must successfully withstand a hydro- over 11⁄2 inches, or a gauge length of at
static test, as follows: least 24 times thickness with width not
(1) The test must be by water-jacket, over 6 times thickness is authorized
or other suitable methods, operated so when cylinder wall is not over 3⁄16 inch
as to obtain accurate data. The pres- thick.
sure gauge must permit reading to an (ii) The specimen, exclusive of grip
accuracy of 1 percent. The expansion ends, may not be flattened. Grip ends
gauge must permit reading of total ex- may be flattened to within 1 inch of
pansion to an accuracy of either 1 per- each end of the reduced section.
cent or 0.1 cubic centimeter. (iii) When size of cylinder does not
(2) Pressure must be maintained for permit securing straight specimens,
at least 30 seconds and sufficiently the specimens may be taken in any lo-
longer to ensure complete expansion. cation or direction and may be
Any internal pressure applied after straightened or flattened cold, by pres-
heat-treatment and previous to the of- sure only, not by blows. When speci-
ficial test may not exceed 90 percent of mens are so taken and prepared, the in-
the test pressure. If, due to failure of spector’s report must show in connec-
the test apparatus the test pressure tion with record of physical tests de-
cannot be maintained the test may be tailed information in regard to such
repeated at a pressure increased by 10 specimens.
percent or 100 psig, whichever is the (iv) Heating of a specimen for any
lower. purpose is not authorized.
(3) Permanent, volumetric expansion (3) The yield strength in tension
may not exceed 10 percent of the total must be the stress corresponding to a
volumetric expansion at test pressure. permanent strain of 0.2 percent of the
(4) Each cylinder must be tested to at gauge length. The following conditions
least 5⁄3 times service pressure. apply:
(j) Flattening test. A flattening test (i) The yield strength must be deter-
must be performed on one cylinder mined by either the ‘‘offset’’ method or
taken at random out of each lot of 200 the ‘‘extension under load’’ method as
or less, by placing the cylinder between prescribed in ASTM E 8 (IBR, see § 171.7
wedge shaped knife edges having a 60° of this subchapter).
included angle, rounded to 1⁄2-inch ra- (ii) In using the ‘‘extension under
dius. The longitudinal axis of the cyl- load’’ method, the total strain (or ‘‘ex-
inder must be at a 90-degree angle to tension under load’’) corresponding to
knife edges during the test. For lots of the stress at which the 0.2-percent per-
30 or less, flattening tests are author- manent strain occurs may be deter-
ized to be made on a ring at least 8 mined with sufficient accuracy by cal-
inches long cut from each cylinder and culating the elastic extension of the
subjected to same heat treatment as gauge length under appropriate load
the finished cylinder. and adding thereto 0.2 percent of the

(k) Physical test. A physical test must gauge length. Elastic extension cal-
be conducted to determine yield culations must be based on an elastic
strength, tensile strength, elongation, modulus of 30,000,000. In the event of
20
controversy the entire stress-strain before the hydrostatic test, the manu-
diagram must be plotted and the yield facturer should design the test appa-
strength determined from the 0.2 per- ratus so that the pressure is applied to
cent offset. the smallest area practicable, around
(iii) For the purpose of strain meas- the point of closure, and so as to use
urement, the initial strain must be set the smallest possible volume of air or
while the specimen is under a stress of gas.
12,000 psig and the strain indicator (n) Rejected cylinders. Reheat treat-
reading must be set at the calculated ment is authorized for rejected cyl-
corresponding strain. inders. Subsequent thereto, cylinders
(iv) Cross-head speed of the testing must pass all prescribed tests to be ac-
machine may not exceed 1⁄8 inch per ceptable. Repair by welding or spinning
minute during yield strength deter-
is not authorized. Spun cylinders re-
mination.
jected under the provisions of para-
(l) Acceptable results for physical and
graph (m) of this section may be re-
flattening tests. Either of the following
is an acceptable result: moved from the spun cylinder category
(1) An elongation at least 40 percent by drilling to remove defective mate-
for a 2-inch gauge length or at least 20 rial, tapping and plugging.
percent in other cases and yield [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
strength not over 73 percent of tensile amended at 62 FR 51561, Oct. 1, 1997; 66 FR
strength. In this instance, the flat- 45185, 45386, Aug. 28, 2001; 67 FR 51652, Aug. 8,
tening test is not required. 2002; 68 FR 75748, Dec. 31, 2003; 73 FR 57006,
(2) An elongation at least 20 percent Oct. 1, 2008]
for a 2-inch gauge length or 10 percent
in other cases and a yield strength not § 178.37 Specification 3AA and 3AAX
over 73 percent of tensile strength. In seamless steel cylinders.
this instance, the flattening test is re- (a) Type, size and service pressure. In
quired, without cracking, to 6 times addition to the requirements of § 178.35,
the wall thickness. cylinders must conform to the fol-
(m) Leakage test. All spun cylinders lowing:
and plugged cylinders must be tested (1) A DOT-3AA cylinder is a seamless
for leakage by gas or air pressure after steel cylinder with a water capacity
the bottom has been cleaned and is free (nominal) of not over 1,000 pounds and
from all moisture subject to the fol- a service pressure of at least 150 psig.
lowing conditions and limitations: (2) A DOT-3AAX cylinder is a seam-
(1) Pressure, approximately the same
less steel cylinder with a water capac-
as but no less than service pressure,
ity of not less than 1,000 pounds and a
must be applied to one side of the fin-
service pressure of at least 500 psig,
ished bottom over an area of at least
1⁄16 of the total area of the bottom but conforming to the following require-
ments:
not less than 3⁄4 inch in diameter, in-
cluding the closure, for at least 1 (i) Assuming the cylinder is to be
minute, during which time the other supported horizontally at its two ends
side of the bottom exposed to pressure only and to be uniformly loaded over
must be covered with water and closely its entire length consisting of the
examined for indications of leakage. weight per unit of length of the
Except as provided in paragraph (n) of straight cylindrical portion filled with
this section, a cylinder that is leaking water and compressed to the specified
must be rejected. test pressure; the sum of two times the
(2) A spun cylinder is one in which an maximum tensile stress in the bottom
end closure in the finished cylinder has fibers due to bending, plus that in the
been welded by the spinning process. same fibers (longitudinal stress), due to
(3) A plugged cylinder is one in which hydrostatic test pressure may not ex-
a permanent closure in the bottom of a ceed 80 percent of the minimum yield
finished cylinder has been effected by a strength of the steel at such maximum
plug. stress. Wall thickness must be in-
(4) As a safety precaution, if the creased when necessary to meet the re-
manufacturer elects to make this test quirement.
21
§ 178.37 49 CFR Ch. I (10–1–18 Edition)
(ii) To calculate the maximum ten- P = hydrostatic test pressure-psig.

sile stress due to bending, the following (b) Authorized steel. Open-hearth,
formula must be used: basic oxygen, or electric steel of uni-
S = Mc/I form quality must be used. A heat of
steel made under the specifications in
(iii) To calculate the maximum lon-
table 1 of this paragraph (b), check
gitudinal tensile stress due to hydro-
chemical analysis of which is slightly
static test pressure, the following for-
out of the specified range, is accept-
mula must be used:
able, if satisfactory in all other re-
S = A1P/A2 spects, provided the tolerances shown
Where: in table 2 of this paragraph (b) are not
exceeded. When a carbon-boron steel is
S = tensile stress-p.s.i.;
M = bending moment-inch pounds (wl2)/8; used, a hardenability test must be per-
w = weight per inch of cylinder filled with formed on the first and last ingot of
water; each heat of steel. The results of this
l = length of cylinder-inches; test must be recorded on the Record of
c = radius (D)/(2) of cylinder-inches; Chemical Analysis of Material for Cyl-
I = moment of inertia-0.04909 (D4¥d4) inches inders required by § 178.35. This hard-
fourth; ness test must be made 5⁄16-inch from
D = outside diameter-inches;
the quenched end of the Jominy quench
d = inside diameter-inches;
A1 = internal area in cross section of cyl- bar and the hardness must be at least
inder-square inches; Rc 33 and no more than Rc 53. The fol-
A2 = area of metal in cross section of cyl- lowing chemical analyses are author-
inder-square inches; ized:
TABLE 1—AUTHORIZED MATERIALS
4130X (per- NE–8630 (per- Inter- mediate
9115 (percent) 9125 (percent) Carbon-boron
Designation cent) (see Note cent) (see Note manganese
(see Note 1) (see Note 1) (percent)
1) 1) (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.
TABLE 2—CHECK ANALYSIS TOLERANCES

Tolerance (percent) over
the maximum limit or
Limit or maximum specified under the minimum limit
Element (percent)
Under min- Over max-
imum limit imum 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
Phosphorus1 ............................................. 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.
22
(c) Identification of material. Material quired in paragraphs (k) and (l) of this
must be identified by any suitable section and must be not over 70,000 psi.
method except that plates and billets (3) Calculation must be made by the
for hot-drawn cylinders must be formula:
S = [P(1.3D2 + 0.4d2)]/(D2¥d2)
(d) Manufacture. Cylinders must be
manufactured using equipment and Where:
processes adequate to ensure that each S = wall stress in psi;
cylinder produced conforms to the re- P = minimum test pressure prescribed for
quirements of this subpart. No fissure water jacket test or 450 psig whichever is
or other defects is permitted that is the greater;
likely to weaken the finished cylinder D = outside diameter in inches;
appreciably. A reasonably smooth and
uniform surface finish is required. If (g) Heat treatment. The completed cyl-
not originally free from such defects, inders must be uniformly and properly
the surface may be machined or other- heat treated prior to tests. Heat treat-
wise treated to eliminate these defects. ment of cylinders of the authorized
The thickness of the bottoms of cyl- analyses must be as follows:
inders welded or formed by spinning is, (1) All cylinders must be quenched by
under no condition, to be less than two oil, or other suitable medium except as
times the minimum wall thickness of provided in paragraph (g)(5) of this sec-
the cylindrical shell; such bottom tion.
thicknesses must be measured within (2) The steel temperature on quench-
an area bounded by a line representing ing must be that recommended for the
the points of contact between the cyl- steel analysis, but may not exceed 1750
inder and floor when the cylinder is in °F.
a vertical position. (3) All steels must be tempered at a
(e) Welding or brazing. Welding or temperature most suitable for that
brazing for any purpose whatsoever is steel.
prohibited except as follows: (4) The minimum tempering tempera-
(1) Welding or brazing is authorized ture may not be less than 1000 °F ex-
for the attachment of neckrings and cept as noted in paragraph (g)(6) of this
footrings which are non-pressure parts, section.
and only to the tops and bottoms of (5) Steel 4130X may be normalized at
cylinders having a service pressure of a temperature of 1650 °F instead of
500 psig or less. Cylinders, neckrings, being quenched and cylinders so nor-
and footrings must be made of weldable malized need not be tempered.
steel, the carbon content of which may (6) Intermediate manganese steels
not exceed 0.25 percent except in the may be tempered at temperatures not
case of 4130X steel which may be used less than 1150 °F., and after heat treat-
with proper welding procedure. ing each cylinder must be submitted to
(2) As permitted in paragraph (d) of a magnetic test to detect the presence
this section. of quenching cracks. Cracked cylinders
(f) Wall thickness. The thickness of must be rejected and destroyed.
each cylinder must conform to the fol- (7) Except as otherwise provided in
lowing: paragraph (g)(6) of this section, all cyl-
(1) For cylinders with a service pres- inders, if water quenched or quenched
sure of less than 900 psig, the wall with a liquid producing a cooling rate
stress may not exceed 24,000 psi. A min- in excess of 80 percent of the cooling
imum wall thickness of 0.100 inch is re- rate of water, must be inspected by the
quired for any cylinder with an outside magnetic particle, dye penetrant or ul-
diameter of over 5 inches. trasonic method to detect the presence
(2) For cylinders with service pres- of quenching cracks. Any cylinder de-
sure of 900 psig or more the minimum signed to the requirements for speci-
wall must be such that the wall stress fication 3AA and found to have a
at the minimum specified test pressure quenching crack must be rejected and
may not exceed 67 percent of the min- may not be requalified. Cylinders de-
imum tensile strength of the steel as signed to the requirements for speci-
determined from the physical tests re- fication 3AAX and found to have
23
§ 178.37 49 CFR Ch. I (10–1–18 Edition)
cracks must have cracks removed to inder must be at a 90-degree angle to

sound metal by mechanical means. knife edges during the test. For lots of
Such specification 3AAX cylinders will 30 or less, flattening tests are author-
be acceptable if the repaired area is ized to be made on a ring at least 8
subsequently examined to assure no de- inches long cut from each cylinder and
fect, and it is determined that design subjected to the same heat treatment
thickness requirements are met. as the finished cylinder. Cylinders may
(h) Openings in cylinders and connec- be subjected to a bend test in lieu of
tions (valves, fuse plugs, etc.) for those the flattening test. Two bend test
openings. Threads are required on open- specimens must be taken in accordance
ings. with ISO 9809–1 or ASTM E 290 (IBR, see
(1) Threads must be clean cut, even, § 171.7 of this subchapter), and must be
without checks, and to gauge. subjected to the bend test specified
(2) Taper threads, when used, must be therein.
of a length not less than as specified (k) Physical test. A physical test must
for American Standard taper pipe be conducted to determine yield
threads. strength, tensile strength, elongation,
(3) Straight threads having at least 6 and reduction of area of material as
engaged threads are authorized. follows:
Straight threads must have a tight fit (1) The test is required on 2 speci-
and a calculated shear strength of at mens cut from 1 cylinder taken at ran-
least 10 times the test pressure of the dom out of each lot of 200 or less. For
cylinder. Gaskets, adequate to prevent lots of 30 or less, physical tests are au-
leakage, are required. thorized to be made on a ring at least
(i) Hydrostatic test. Each cylinder 8 inches long cut from each cylinder
must successfully withstand a hydro- and subjected to the same heat treat-
static test as follows: ment as the finished cylinder.
(1) The test must be by water-jacket, (2) Specimens must conform to the
or other suitable method, operated so following:
as to obtain accurate data. The pres- (i) Gauge length of 8 inches with a
sure gauge must permit reading to an width of not over 11⁄2 inches, a gauge
accuracy of 1 percent. The expansion length of 2 inches with a width of not
gauge must permit reading of total ex- over 11⁄2 inches, or a gauge length of at
pansion to an accuracy of either 1 per- least 24 times the thickness with width
cent or 0.1 cubic centimeter. not over 6 times thickness when the
(2) Pressure must be maintained for thickness of the cylinder wall is not
at least 30 seconds and sufficiently over 3⁄16 inch.
longer to ensure complete expansion. (ii) The specimen, exclusive of grip
Any internal pressure applied after ends, may not be flattened. Grip ends
heat-treatment and previous to the of- may be flattened to within 1 inch of
ficial test may not exceed 90 percent of each end of the reduced section.
the test pressure. If, due to failure of (iii) When size of cylinder does not
the test apparatus, the test pressure permit securing straight specimens,
cannot be maintained, the test may be the specimens may be taken in any lo-
repeated at a pressure increased by 10 cation or direction and may be
percent or 100 psig, whichever is the straightened or flattened cold, by pres-
lower. sure only, not by blows. When speci-
(3) Permanent volumetric expansion mens are so taken and prepared, the in-
may not exceed 10 percent of total vol- spector’s report must show in connec-
umetric expansion at test pressure. tion with record of physical tests de-
(4) Each cylinder must be tested to at tailed information in regard to such
least 5⁄3 times the service pressure. specimens.
(j) Flattening test. A flattening test (iv) Heating of a specimen for any
must be performed on one cylinder purpose is not authorized.
taken at random out of each lot of 200 (3) The yield strength in tension
or less, by placing the cylinder between must be the stress corresponding to a

wedge shaped knife edges having a 60° permanent strain of 0.2 percent of the
included angle, rounded to 1⁄2-inch ra- gauge length. The following conditions
dius. The longitudinal axis of the cyl- apply:
24
(i) The yield strength must be deter- and closely examined for indications of
mined by either the ‘‘offset’’ method or leakage. Except as provided in para-
the ‘‘extension under load’’ method as graph (n) of this section, a cylinder
prescribed in ASTM E 8 (IBR, see § 171.7 must be rejected if there is any leak-
of this subchapter). ing.
(ii) In using the ‘‘extension under (1) A spun cylinder is one in which an
load’’ method, the total strain (or ‘‘ex- end closure in the finished cylinder has
tension under load’’) corresponding to been welded by the spinning process.
the stress at which the 0.2 percent per- (2) A plugged cylinder is one in which
manent strain occurs may be deter- a permanent closure in the bottom of a
mined with sufficient accuracy by cal- finished cylinder has been effected by a
culating the elastic extension of the plug.
gauge length under appropriate load (3) As a safety precaution, if the
and adding thereto 0.2 percent of the manufacturer elects to make this test
gauge length. Elastic extension cal- before the hydrostatic test, the manu-
culations must be based on an elastic facturer should design the test appa-
modulus of 30,000,000. In the event of ratus so that the pressure is applied to
controversy, the entire stress-strain the smallest area practicable, around
diagram must be plotted and the yield the point of closure, and so as to use
strength determined from the 0.2 per- the smallest possible volume of air or
cent offset. gas.
(iii) For the purpose of strain meas- (n) Rejected cylinders. Reheat treat-
urement, the initial strain must be set ment is authorized for rejected cyl-
while the specimen is under a stress of inders. Subsequent thereto, cylinders
12,000 psi, the strain indicator reading must pass all prescribed tests to be ac-
being set at the calculated cor- ceptable. Repair by welding or spinning
responding strain. is not authorized. Spun cylinders re-
(iv) Cross-head speed of the testing jected under the provision of paragraph
machine may not exceed 1⁄8 inch per (m) of this section may be removed
minute during yield strength deter- from the spun cylinder category by
mination. drilling to remove defective material,
(l) Acceptable results for physical, flat- tapping and plugging.
tening and bend tests. An acceptable re- [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
sult for physical and flattening tests is amended at 65 FR 58631, Sept. 29, 2000; 66 FR
elongation of at least 20 percent for 2 45386, Aug. 28, 2001; 67 FR 51652, Aug. 8, 2002;
inches of gauge length or at least 10 68 FR 75748, Dec. 31, 2003; 76 FR 43531, July 20,
percent in other cases. Flattening is re- 2011]
quired, without cracking, to 6 times
the wall thickness of the cylinder. An § 178.38 Specification 3B seamless
acceptable result for the alternative steel cylinders.
bend test is no crack when the cylinder (a) Type, size, and service pressure. A
is bent inward around the mandrel DOT 3B cylinder is seamless steel cyl-
until the interior edges are not further inder with a water capacity (nominal)
apart than the diameter of the man- of not over 1,000 pounds and a service
drel. pressure of at least 150 to not over 500
(m) Leakage test. All spun cylinders psig.
and plugged cylinders must be tested (b) Steel. Open-hearth or electric steel
for leakage by gas or air pressure after of uniform quality must be used. Con-
the bottom has been cleaned and is free tent percent may not exceed the fol-
from all moisture. Pressure, approxi- lowing: carbon, 0.55; phosphorus, 0.045;
mately the same as but no less than sulphur, 0.050.
the service pressure, must be applied to (c) Identification of material. Material
one side of the finished bottom over an must be identified by any suitable
area of at least 1⁄16 of the total area of method except that plates and billets
the bottom but not less than 3⁄4 inch in for hot-drawn cylinders must be
diameter, including the closure, for at marked with the heat number.
least one minute, during which time (d) Manufacture. Cylinders must be
the other side of the bottom exposed to manufactured using equipment and
pressure must be covered with water processes adequate to ensure that each
25
§ 178.38 49 CFR Ch. I (10–1–18 Edition)
cylinder produced conforms to the re- (2) Taper threads when used, must be
quirements of this subpart. No fissure of a length not less than as specified
or other defect is permitted that is for American Standard taper pipe
likely to weaken the finished cylinder threads.
appreciably. A reasonably smooth and (3) Straight threads having at least 4
uniform surface finish is required. If engaged threads are authorized.
not originally free from such defects, Straight threads must have a tight fit,
the surface may be machined or other- and calculated shear strength at least
wise treated to eliminate these defects. 10 times the test pressure of the cyl-
The thickness of the bottoms of cylinder. Gaskets, adequate to prevent
inders welded or formed by spinning is, leakage, are required.
under no condition, to be less than two (i) Hydrostatic test. Cylinders must
times the minimum wall thickness of successfully withstand a hydrostatic
the cylindrical shell; such bottom test, as follows:
thicknesses to be measured within an (1) The test must be by water-jacket,
area bounded by a line representing the or other suitable method, operated so
points of contact between the cylinder as to obtain accurate data. The pres-
and floor when the cylinder is in a sure gauge must permit reading to an
vertical position. accuracy of 1 percent. The expansion
(e) Welding or brazing. Welding or gauge must permit reading of total ex-
brazing for any purpose whatsoever is pansion to an accuracy either of 1 per-
prohibited except as follows: cent or 0.1 cubic centimeter.
(1) Welding or brazing is authorized (2) Pressure must be maintained for
for the attachment of neckrings and at least 30 seconds and sufficiently
footrings which are non-pressure parts, longer to insure complete expansion.
and only to the tops and bottoms of Any internal pressure applied after
cylinders having a service pressure of heat-treatment and previous to the of-
500 psig or less. Cylinders, neckrings, ficial test may not exceed 90 percent of
and footrings must be made of weldable the test pressure. If, due to failure of
steel, carbon content of which may not the test apparatus, the test pressure
exceed 0.25 percent except in the case cannot be maintained, the test may be
of 4130X steel which may be used with repeated at a pressure increased by 10
proper welding procedure. percent or 100 psig, whichever is the
(2) As permitted in paragraph (d) of lower.
this section. (3) Permanent volumetric expansion
(f) Wall thickness. The wall stress may may not exceed 10 percent of total vol-
not exceed 24,000 psi. The minimum umetric expansion at test pressure.
wall thickness is 0.090 inch for any cyl- (4) Cylinders must be tested as fol-
inder with an outside diameter of 6 lows:
inches. Calculation must be made by
(i) Each cylinder; to at least 2 times
the following formula:
service pressure; or
S = [P(1.3D2 + 0.4d2)]/(D2¥d2) (ii) 1 cylinder out of each lot of 200 or
Where:
less; to at least 3 times service pres-
sure. Others must be examined under
S = wall stress in psi; pressure of 2 times service pressure and
P = at least two times service pressure or 450
show no defect.
psig, whichever is the greater;
D = outside diameter in inches; (j) Flattening test. A flattening test
d = inside diameter in inches. must be performed on one cylinder
taken at random out of each lot of 200
(g) Heat treatment. The completed cyl- or less, by placing the cylinder between
inders must be uniformly and properly wedge shaped knife edges having a 60°
heat-treated prior to tests. included angle, rounded to 1⁄2-inch ra-
(h) Openings in cylinders and connec- dius. The longitudinal axis of the cyl-
tions (valves, fuse plugs, etc.) for those inder must be at a 90-degree angle to
openings. Threads, conforming to the knife edges during the test. For lots of
following, are required on all openings: 30 or less, flattening tests are author-
(1) Threads must be clean cut, even, ized to be made on a ring at least 8
without checks, and to gauge. inches long cut from each cylinder and
26

and reduction of area of material, as controversy, the entire stress-strain
follows: diagram must be plotted and the yield
(1) The test is required on 2 speci- strength determined from the 0.2 per-
mens cut from 1 cylinder taken at ran- cent offset.
dom out of each lot of 200 or less. For (iii) For the purpose of strain meas-
lots of 30 or less, physical tests are au- urement, the initial strain must be set
thorized to be made on a ring at least while the specimen is under a stress of
8 inches long cut from each cylinder 12,000 psi, and the strain indicator
and subjected to same heat treatment reading being set at the calculated cor-
as the finished cylinder. responding strain.
(2) Specimens must conform to the (iv) Cross-head speed of the testing
following: machine may not exceed 1⁄8 inch per
(i) Gauge length of 8 inches with a minute during yield strength deter-
width of not over 11⁄2 inches; or a gauge mination.
length of 2 inches with a width of not (l) Acceptable results for physical and
over 11⁄2 inches; or a gauge length at flattening tests. Either of the following
least 24 times the thickness with a is an acceptable result:
width not over 6 times thickness is au- (1) An elongation of at least 40 per-
thorized when a cylinder wall is not cent for a 2-inch gauge length or at
over 3⁄16 inch thick. least 20 percent in other cases and
(ii) The specimen, exclusive of grip yield strength not over 73 percent of
ends, may not be flattened. Grip ends tensile strength. In this instance, the
may be flattened to within one inch of flattening test is not required.
each end of the reduced section. (2) An elongation of at least 20 per-
(iii) When size of cylinder does not cent for a 2-inch gauge length or 10 per-
permit securing straight specimens, cent in other cases and yield strength
the specimens may be taken in any lo- not over 73 percent of tensile strength.
cation or direction and may be Flattening is required, without crack-
straightened or flattened cold, by pres- ing, to 6 times the wall thickness.
sure only, not by blows. When speci- (m) Leakage test. All spun cylinders
mens are so taken and prepared, the in- and plugged cylinders must be tested
spector’s report must show in connec- for leakage by gas or air pressure after
tion with record of physical tests de- the bottom has been cleaned and is free
tailed information in regard to such from all moisture, subject to the fol-
specimens. lowing conditions and limitations:
(iv) Heating of a specimen for any (1) Pressure, approximately the same
purpose is not authorized. as but no less than service pressure,
(3) The yield strength in tension must be applied to one side of the fin-
must be the stress corresponding to a ished bottom over an area of at least
permanent strain of 0.2 percent of the 1⁄16 of the total area of the bottom but
gauge length. The following conditions not less than 3⁄4 inch in diameter, in-
apply: cluding the closure, for at least one
(i) The yield strength must be deter- minute, during which time the other
mined by either the ‘‘offset’’ method or side of the bottom exposed to pressure
the ‘‘extension under load’’ method as must be covered with water and closely
prescribed in ASTM E 8 (IBR, see § 171.7 examined for indications of leakage.
of this subchapter). Except as provided in paragraph (n) of
(ii) In using the ‘‘extension under this section, a cylinder must be re-
load’’ method, the total strain (or ‘‘ex- jected if there is any leaking.
tension under load’’) corresponding to (2) A spun cylinder is one in which an
the stress at which the 0.2 percent per- end closure in the finished cylinder has
manent strain occurs may be deter- been welded by the spinning process.
mined with sufficient accuracy by cal- (3) A plugged cylinder is one in which
culating the elastic extension of the a permanent closure in the bottom of a
27
§ 178.39 49 CFR Ch. I (10–1–18 Edition)
finished cylinder has been effected by a (c) Identification of material. The ma-
plug. terial must be identified by any suit-
(4) As a safety precaution, if the able method except that plates and bil-
manufacturer elects to make this test lets for hot-drawn cylinders must be
before the hydrostatic test, he should marked with the heat number.
design his apparatus so that the pres- (d) Manufacture. Cylinders must be
sure is applied to the smallest area manufactured using equipment and
practicable, around the point of clo- processes adequate to ensure that each
sure, and so as to use the smallest pos- cylinder produced conforms to the re-
sible volume of air or gas. quirements of this subpart. No defect is
(n) Rejected cylinders. Reheat treat- permitted that is likely to weaken the
ment of rejected cylinders is author- finished cylinder appreciably. A rea-
ized. Subsequent thereto, cylinders sonably smooth and uniform surface
must pass all prescribed tests to be ac- finish is required. Cylinders closed in
ceptable. Repair by welding or spinning by spinning process are not authorized.
is not authorized. Spun cylinders re- (e) Welding or brazing. Welding or
jected under the provisions of para- brazing for any purpose whatsoever is
graph (m) of this section may be re- prohibited except that welding is au-
moved from the spun cylinder category thorized for the attachment of
by drilling to remove defective mate- neckrings and footrings which are non-
rial, tapping and plugging. pressure parts, and only to the tops and
(o) Marking. Markings may be bottoms of cylinders. Neckrings and
stamped into the sidewalls of cylinders footrings must be of weldable material,
having a service pressure of 150 psig if the carbon content of which may not
all of the following conditions are met: exceed 0.25 percent. Nickel welding rod
(1) Wall stress at test pressure may must be used.
not exceed 24,000 psi. (f) Wall thickness. The wall stress may
(2) Minimum wall thickness must be not exceed 15,000 psi. A minimum wall
not less than 0.090 inch. thickness of 0.100 inch is required for
(3) Depth of stamping must be no any cylinder over 5 inches in outside
greater than 15 percent of the min- diameter. Wall stress calculation must
imum wall thickness, but may not ex- be made by using the following for-
ceed 0.015 inch. mula:
(4) Maximum outside diameter of cyl- S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
inder may not exceed 5 inches.
Where:
(5) Carbon content of cylinder may
S = wall stress in psi;
not exceed 0.25 percent. If the carbon P = minimum test pressure prescribed for
content exceeds 0.25 percent, the com- water jacket test or 450 psig whichever is
plete cylinder must be normalized after the greater;
stamping. D = outside diameter in inches;
(6) Stamping must be adjacent to the d = inside diameter in inches.
top head. (g) Heat treatment. The completed cyl-
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as inders must be uniformly and properly
amended by 66 FR 45185, 45386, Aug. 28, 2001; heat-treated prior to tests.
67 FR 51652, Aug. 8, 2002; 68 FR 75748, Dec. 31, (h) Openings in cylinders and connec-
2003] tions (valves, fuse plugs, etc.) for those
openings. Threads conforming to the
§ 178.39 Specification 3BN seamless following are required on openings:
nickel cylinders.
(1) Threads must be clean cut, even,
(a) Type, size and service pressure. A without checks, and to gauge.
DOT 3BN cylinder is a seamless nickel (2) Taper threads, when used, to be of
cylinder with a water capacity (nomi- length not less than as specified for
nal) not over 125 pounds water capacity American Standard taper pipe threads.
(nominal) and a service pressure at (3) Straight threads having at least 6
least 150 to not over 500 psig. engaged threads are authorized.
(b) Nickel. The percentage of nickel Straight threads must have a tight fit
plus cobalt must be at least 99.0 per- and a calculated shear strength of at
cent. least 10 times the test pressure of the
28
cylinder. Gaskets, adequate to prevent (i) A gauge length of 8 inches with a

leakage, are required. width of not over 11⁄2 inches, a gauge
(i) Hydrostatic test. Each cylinder length of 2 inches with a width of not
must successfully withstand a hydro- over 11⁄2 inches, or a gauge length of at
static test, as follows: least 24 times the thickness with a
(1) The test must be by water-jacket, width not over 6 times thickness is au-
or other suitable method, operated so thorized when a cylinder wall is not
as to obtain accurate data. The pres- over 3⁄16 inch thick.
sure gauge must permit reading to an (ii) The specimen, exclusive of grip
accuracy of 1 percent. The expansion ends, may not be flattened. Grip ends
gauge must permit reading of total ex- may be flattened to within one inch of
pansion to an accuracy either of 1 per- each end of the reduced section.
cent or 0.1 cubic centimeter. (iii) When size of cylinder does not
(2) Pressure must be maintained for permit securing straight specimens,
at least 30 seconds and sufficiently the specimens may be taken in any lo-
longer to ensure complete expansion. cation or direction and may be
Any internal pressure applied after straightened or flattened cold, by pres-
heat-treatment and previous to the of- sure only, not by blows. When speci-
ficial test may not exceed 90 percent of mens are so taken and prepared, the in-
the test pressure. If, due to failure of spector’s report must show in connec-
the test apparatus, the test pressure tion with record of physical tests de-
cannot be maintained, the test may be tailed information in regard to such
repeated at a pressure increased by 10 specimens.
percent or 100 psig, whichever is the (iv) Heating of a specimen for any
lower. purpose is not authorized.
(3) Permanent volumetric expansion (3) The yield strength in tension
may not exceed 10 percent of total vol- must be the stress corresponding to a
umetric expansion at test pressure. permanent strain of 0.2 percent of the
(4) Each cylinder must be tested to at gauge length. The following conditions
least 2 times service pressure. apply:
(j) Flattening test. A flattening test (i) The yield strength must be deter-
must be performed on one cylinder mined by either the ‘‘offset’’ method or
taken at random out of each lot of 200 the ‘‘extension under load’’ method as
or less, by placing the cylinder between prescribed in ASTM E 8 (IBR, see § 171.7
wedge shaped knife edges having a 60° of this subchapter).
included angle, rounded to 1⁄2-inch ra- (ii) In using the ‘‘extension under
dius. The longitudinal axis of the cyl- load’’ method, the total strain (or ‘‘ex-
inder must be at a 90-degree angle to tension under load’’) corresponding to
knife edges during the test. For lots of the stress at which the 0.2 percent per-
30 or less, flattening tests are author- manent strain occurs may be deter-
ized to be made on a ring at least 8 mined with sufficient accuracy by cal-
inches long cut from each cylinder and culating the elastic extension of the
and reduction of area of material, as controversy, the entire stress-strain
follows: diagram must be plotted and the yield
(1) The test is required on 2 speci- strength determined from the 0.2 per-
mens cut from 1 cylinder taken at ran- cent offset.
dom out of each lot of 200 or less. For (iii) For the purpose of strain meas-
lots of 30 or less, physical tests are au- urement, the initial strain must be set
thorized to be made on a ring at least while the specimen is under a stress of
8 inches long cut from each cylinder 12,000 psi, and the strain indicator
and subjected to same heat treatment reading must be set at the calculated
as the finished cylinder. corresponding strain.
29
§ 178.42 49 CFR Ch. I (10–1–18 Edition)
minute during yield strength deter- (e) Openings in cylinders and connec-
mination. tions (valves, fuse plugs, etc.) for those
(l) Acceptable results for physical and openings. Threads conforming to the
flattening tests. Either of the following following are required on openings.
is an acceptable result: (1) Threads must be clean cut, even,
(1) An elongation of at least 40 per- without checks, and to gauge.
cent for a 2 inch gauge length or at (2) Taper threads, when used, must be
least 20 percent in other cases and of length not less than as specified for
yield point not over 50 percent of ten- American Standard taper pipe threads.
sile strength. In this instance, the flat- (3) Straight threads having at least 4
tening test is not required. engaged threads are authorized.
(2) An elongation of at least 20 per- Straight threads must have a tight fit
cent for a 2 inch gauge length or 10 per- and a calculated shear strength of at
cent in other cases and a yield point least 10 times the test pressure of the
not over 50 percent of tensile strength. cylinder. Gaskets, adequate to prevent
Flattening is required, without crack- leakage, are required.
ing, to 6 times the wall thickness. (f) Hydrostatic test. Cylinders must be
(m) Rejected cylinders. Reheat treat- tested as follows:
ment is authorized for rejected cyl- (1) One cylinder out of each lot of 500
inders. Subsequent thereto, cylinders or less must be subjected to a hydro-
must pass all prescribed tests to be ac- static pressure of 6,000 psig or higher.
ceptable. Repair by welding is not au- (2) The cylinder referred to in para-
thorized. graph (f)(1) of this section must burst
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as at a pressure higher than 6,000 psig
amended by 66 FR 45185, 45386, 45388, Aug. 28, without fragmenting or otherwise
2001; 67 FR 51652, Aug. 8, 2002; 68 FR 75748, showing lack of ductility, or must hold
Dec. 31, 2003] a pressure of 12,000 psig for 30 seconds
without bursting. In which case, it
§ 178.42 Specification 3E seamless steel must be subjected to a flattening test
cylinders. without cracking to six times wall
(a) Type, size, and service pressure. A thickness between knife edges, wedge
DOT 3E cylinder is a seamless steel shaped 60 degree angle, rounded out to
cylinder with an outside diameter not a 1⁄2 inch radius. The inspector’s report
greater than 2 inches nominal, a length must be suitably changed to show re-
less than 2 feet and a service pressure sults of latter alternate and flattening
of 1,800 psig. test.
(b) Steel. Open-hearth or electric steel (3) Other cylinders must be examined
of uniform quality must be used. Con- under pressure of at least 3,000 psig and
tent percent may not exceed the fol- not to exceed 4,500 psig and show no de-
lowing: Carbon, 0.55; phosphorus, 0.045; fect. Cylinders tested at a pressure in
sulphur, 0.050. excess of 3,600 psig must burst at a
(c) Identification of steel. Materials pressure higher than 7,500 psig when
must be identified by any suitable tested as specified in paragraph (f)(2) of
method. this section. The pressure must be
(d) Manufacture. Cylinders must be maintained for at least 30 seconds and
manufactured by best appliances and sufficiently longer to ensure complete
methods. No defect is permitted that is examination.
likely to weaken the finished cylinder (g) Leakage test. All spun cylinders
appreciably. A reasonably smooth and and plugged cylinders must be tested
uniform surface finish is required. The for leakage by gas or air pressure after
thickness of the spun bottom is, under the bottom has been cleaned and is free
no condition, to be less than two times from all moisture subject to the fol-
the minimum wall thickness of the cy- lowing conditions and limitations:
lindrical shell; such bottom thickness (1) A pressure, approximately the
must be measured within an area same as but not less than the service
bounded by a line representing the pressure, must be applied to one side of

points of contact between the cylinder the finished bottom over an area of at
and floor when the cylinder is in a least 1⁄16 of the total area of the bottom
vertical position. but not less than 3⁄4 inch in diameter,
30
including the closure, for at least one The grain size must be determined in
minute, during which time the other accordance with ASTM E 112–88 (IBR,
side of the bottom exposed to pressure see § 171.7 of this subchapter). Steel of
must be covered with water and closely the following chemical analysis is au-
examined for indications of leakage. thorized:
Accept as provided in paragraph (h) of
this section, a cylinder must be re- TABLE 1—AUTHORIZED MATERIALS
jected if there is any leakage. AISI 4130
(2) A spun cylinder is one in which an Designation (percent)
end closure in the finished cylinder has
Carbon ............................................... 0.28/0.33
been welded by the spinning process. Manganese ........................................ 0.40/0.60
(3) A plugged cylinder is one in which Phosphorus ........................................ 0.040 maximum
a permanent closure in the bottom of a Sulfur ................................................. 0.040 maximum
finished cylinder has been effected by a Silicon ................................................ 0.15/0.35
Chromium .......................................... 0.80/1.10
plug. Molybdenum ...................................... 0.15/0.25
(4) As a safety precaution, if the
manufacturer elects to make this test
before the hydrostatic test, the manu- TABLE 2—CHECK ANALYSIS TOLERANCES
facturer shall design the test apparatus Tolerance
so that the pressure is applied to the (percent) over the
maximum limit or
smallest area practicable, around the under the
point of closure, and so as to use the Element Limit or maximum minimum limit
specified (percent)
smallest possible volume of air or gas. Under Over
(h) Rejected cylinders. Reheat treat- min- max-
imum imum
ment is authorized for rejected cyl- limit limit
inders. Subsequent thereto, cylinders
must pass all prescribed tests to be ac- Carbon ........... Over 0.15 to 0.40 incl .03 .04
Manganese .... To 0.60 incl ................ .03 .03
ceptable. Repair by welding or spinning Phosphorus1 .. All ranges .................. .............. .01
is not authorized. Spun cylinders re- Sulphur .......... All ranges .................. .............. .01
jected under the provisions of para- Silicon ............ To 0.30 incl ................ .02 .03
graph (g) of this section may be re- Over 0.30 to 1.00 incl .05 .05
Chromium ...... To 0.90 incl ................ .03 .03
moved from the spun cylinder category Over 0.90 to 2.10 incl .05 .05
by drilling to remove defective mate- Molybdenum .. To 0.20 incl ................ .01 .01
rial, tapping and plugging. Over 0.20 to 0.40 incl .02 .02
(i) Marking. Markings required by 1 Rephosphorized steels not subject to check analysis for
§ 178.35 must be stamped plainly and phosphorus.

permanently on the shoulder, top head, (c) Identification of material. Material
neck or sidewall of each cylinder. must be identified by any suitable
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as method. Steel stamping of heat identi-
amended by 66 FR 45386, Aug. 28, 2001] fications may not be made in any area
which will eventually become the side
§ 178.44 Specification 3HT seamless wall of the cylinder. Depth of stamping
steel cylinders for aircraft use. may not encroach upon the minimum
(a) Type, size and service pressure. A prescribed wall thickness of the cyl-
DOT 3HT cylinder is a seamless steel inder.
cylinder with a water capacity (nomi- (d) Manufacture. Cylinders must be
nal) of not over 150 pounds and a serv- manufactured using equipment and
ice pressure of at least 900 psig. processes adequate to ensure that each
(b) Authorized steel. Open hearth or cylinder produced conforms to the re-
electric furnace steel of uniform qual- quirements of this subpart. No fissure
ity must be used. A heat of steel made or other defect is permitted that is
under the specifications listed in Table likely to weaken the finished container
1 in this paragraph (b), a check chem- appreciably. The general surface finish
ical analysis that is slightly out of the may not exceed a roughness of 250
specified range is acceptable, if satis- RMS. Individual irregularities such as
factory in all other respects, provided draw marks, scratches, pits, etc.,
the tolerances shown in Table 2 in this should be held to a minimum con-
paragraph (b) are not exceeded. The sistent with good high stress pressure
maximum grain size shall be 6 or finer. vessel manufacturing practices. If the
31
§ 178.44 49 CFR Ch. I (10–1–18 Edition)
cylinder is not originally free of such ticular steel analysis but not less than
defects or does not meet the finish re- 850 °F.
quirements, the surface may be ma- (4) All cylinders must be inspected by
chined or otherwise treated to elimi- the magnetic particle or dye penetrant
nate these defects. The point of closure method to detect the presence of
of cylinders closed by spinning may not quenching cracks. Any cylinder found
be less than two times the prescribed to have a quenching crack must be re-
wall thickness of the cylindrical shell. jected and may not be requalified.
The cylinder end contour must be hem- (h) Openings in cylinders and connec-
ispherical or ellipsoidal with a ratio of tions (valves, fuse plugs, etc.) for those
major-to-minor axis not exceeding two openings. Threads conforming to the
to one and with the concave side to following are required on openings:
pressure. (1) Threads must be clean cut, even,
(e) Welding or brazing. Welding or without cracks, and to gauge.
brazing for any purpose whatsoever is (2) Taper threads, when used, must be
prohibited, except that welding by of length not less than as specified for
spinning is permitted to close the bot- National Gas Tapered Thread (NGT) as
tom of spun cylinders. Machining or required by American Standard Com-
grinding to produce proper surface fin- pressed Gas Cylinder Valve Outlet and
ish at point of closure is required. Inlet Connections.
(f) Wall thickness. (1) Minimum wall (3) Straight threads having at least 6
thickness for any cylinder must be engaged threads are authorized.
0.050 inch. The minimum wall thick- Straight threads must have a tight fit
ness must be such that the wall stress and a calculated shear stress of at least
at the minimum specified test pressure 10 times the test pressure of the cyl-
may not exceed 75 percent of the min- inder. Gaskets, adequate to prevent
imum tensile strength of the steel as leakage, are required.
determined from the physical tests re- (i) Hydrostatic test. Each cylinder
quired in paragraph (m) of this section must withstand a hydrostatic test, as
and may not be over 105,000 psi. follows:
(2) Calculations must be made by the (1) The test must be by water-jacket,
formula: or other suitable method, operated so
as to obtain accurate data. Pressure
S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
gauge must permit reading to an accu-
Where: racy of 1 percent. The expansion gauge
S = Wall stress in psi; must permit reading of total expansion
P = Minimum test pressure prescribed for to an accuracy either of 1 percent of 0.1
water jacket test; cubic centimeter.
D = Outside diameter in inches; (2) Pressure must be maintained for
d = Inside diameter in inches.
at least 30 seconds and sufficiently
(3) Wall thickness of hemispherical longer to ensure complete expansion.
bottoms only permitted to 90 percent Any internal pressure applied after
of minimum wall thickness of cylinder heat treatment and previous to the of-
sidewall but may not be less than 0.050 ficial test may not exceed 90 percent of
inch. In all other cases, thickness to be the test pressure. If, due to failure of
no less than prescribed minimum wall. the test apparatus, the test pressure
(g) Heat treatment. The completed cyl- cannot be maintained, the test may be
inders must be uniformly and properly repeated at a pressure increased by 10
heated prior to tests. Heat treatment percent or 100 psig, which ever is the
of the cylinders of the authorized anal- lower.
ysis must be as follows: (3) Permanent volumetric expansion
(1) All cylinders must be quenched by may not exceed 10 percent of total vol-
oil, or other suitable medium. umetric expansion at test pressure.
(2) The steel temperature on quench- (4) Each cylinder must be tested to at
ing must be that recommended for the least 5⁄3 times service pressure.
steel analysis, but may not exceed 1750 (j) Cycling tests. Prior to the initial
°F. shipment of any specific cylinder de-
(3) The steel must be tempered at a sign, cyclic pressurization tests must
temperature most suitable for the par- have been performed on at least three
32
representative samples without failure duced section. When size of cylinder

as follows: does not permit securing straight
(1) Pressurization must be performed specimens, the specimens may be
hydrostatically between approximately taken in any location or direction and
zero psig and the service pressure at a may be straightened or flattened cold
rate not in excess of 10 cycles per by pressure only, not by blows. When
minute. Adequate recording instrumen- specimens are so taken and prepared,
tation must be provided if equipment is the inspector’s report must show in
to be left unattended for periods of connection with the record of physical
time. tests detailed information in regard to
(2) Tests prescribed in paragraph such specimens.
(j)(1) of this section must be repeated (ii) Heating of a specimen for any
on one random sample out of each lot purpose is not authorized.
of cylinders. The cylinder may then be (3) The yield strength in tension
subjected to a burst test. must be the stress corresponding to a
(3) A lot is defined as a group of cyl- permanent strain of 0.2 percent of the
inders fabricated from the same heat of gauge length.
steel, manufactured by the same proc- (i) The yield strength must be deter-
ess and heat treated in the same equip- mined by either the ‘‘offset’’ method or
ment under the same conditions of
the ‘‘extension under load’’ method as
time, temperature, and atmosphere,
prescribed in ASTM E 8 (IBR, see § 171.7
and may not exceed a quantity of 200
of this subchapter).
cylinders.
(4) All cylinders used in cycling tests (ii) In using the ‘‘extension under
must be destroyed. load’’ method, the total strain (or ‘‘ex-
(k) Burst test. One cylinder taken at tension under load’’) corresponding to
random out of each lot of cylinders the stress at which the 0.2 percent per-
must be hydrostatically tested to de- manent strain occurs may be deter-
struction. mined with sufficient accuracy by cal-
(l) Flattening test. A flattening test culating the elastic extension of the
must be performed on one cylinder gauge length under appropriate load
taken at random out of each lot of 200 and adding thereto 0.2 percent of the
or less, by placing the cylinder between gauge length. Elastic extension cal-
wedge shaped knife edges having a 60° culations must be based on an elastic
included angle, rounded to 1⁄2-inch ra- modulus of 30,000,000. In the event of
dius. The longitudinal axis of the cyl- controversy, the entire stress-strain
inder must be at a 90-degree angle to diagram must be plotted and the yield
knife edges during the test. For lots of strength determined from the 0.2 per-
30 or less, flattening tests are author- cent offset.
ized to be made on a ring at least 8 (iii) For the purpose of strain meas-
inches long cut from each cylinder and urement, the initial strain must be set
subjected to same heat treatment as while the specimen is under a stress of
the finished cylinder. 12,000 psi, the strain indicator reading
(m) Physical tests. A physical test being set at the calculated cor-
must be conducted to determine yield responding strain.
strength, tensile strength, elongation, (iv) Cross-head speed of the testing
and reduction of area of material, as machine may not exceed 1⁄8 inch per
follows: minute during yield strength deter-
(1) Test is required on 2 specimens mination.
cut from 1 cylinder taken at random (n) Magnetic particle inspection. In-
out of each lot of cylinders. spection must be performed on the in-
(2) Specimens must conform to the side of each container before closing
following: and externally on each finished con-
(i) A gauge length of at least 24 times tainer after heat treatment. Evidence
the thickness with a width not over six of discontinuities, which in the opinion
times the thickness. The specimen, ex- of a qualified inspector may appre-
clusive of grip ends, may not be flat- ciably weaken or decrease the dura-
tened. Grip ends may be flattened to bility of the cylinder, must be cause for
within one inch of each end of the re- rejection.
33
§ 178.45 49 CFR Ch. I (10–1–18 Edition)
(o) Leakage test. All spun cylinders is not authorized. For each cylinder
and plugged cylinders must be tested subjected to reheat treatment during
for leakage by dry gas or dry air pres- original manufacture, sidewall meas-
sure after the bottom has been cleaned urements must be made to verify that
and is free from all moisture, subject the minimum sidewall thickness meets
to the following conditions and limita- specification requirements after the
tions: final heat treatment.
(1) Pressure, approximately the same (r) Marking. (1) Cylinders must be
as but not less than service pressure, marked by low stress type steel stamp-
must be applied to one side of the fin- ing in an area and to a depth which
ished bottom over an area of at least
1⁄16 of the total area of the bottom but will insure that the wall thickness
measured from the root of the stamp-
not less than 3⁄4 inch in diameter, in-
cluding the closure, for at least one ing to the interior surface is equal to
minute, during which time the other or greater than the minimum pre-
side of the bottom exposed to pressure scribed wall thickness. Stamping must
must be covered with water and closely be permanent and legible. Stamping on
examined for indications of leakage. side wall not authorized.
Except as provided in paragraph (q) of (2) The rejection elastic expansion
this section, a cylinder must be re- (REE), in cubic cm (cc), must be
jected if there is leakage. marked on the cylinder near the date
(2) A spun cylinder is one in which an of test. The REE for a cylinder is 1.05
end closure in the finished cylinder has times its original elastic expansion.
been welded by the spinning process. (3) Name plates are authorized, pro-
(3) A plugged cylinder is one in which vided that they can be permanently
a permanent closure in the bottom of a and securely attached to the cylinder.
finished cylinder has been effected by a Attachment by either brazing or weld-
plug. ing is not permitted. Attachment by
(4) As a safety precaution, if the soldering is permitted provided steel
manufacturer elects to make this test temperature does not exceed 500 °F.
before the hydrostatic test, the manu-
(s) Inspector’s report. In addition to
facturer should design the test appa-
the requirements of § 178.35, the inspec-
ratus so that the pressure is applied to
tor’s report must indicate the rejection
the smallest area practicable, around
the point of closure, and so as to use elastic expansion (REE), in cubic cm
the smallest possible volume of air or (cc).
gas. [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
(p) Acceptable results of tests. Results amended at 62 FR 51561, Oct. 1, 1997; 65 FR
of the flattening test, physical tests, 58631, Sept. 29, 2000; 66 FR 45385, Aug. 28, 2001;
burst test, and cycling test must con- 67 FR 51652, Aug. 8, 2002; 68 FR 75748, 75749,
form to the following: Dec. 31, 2003]
(1) Flattening required without
cracking to ten times the wall thick- § 178.45 Specification 3T seamless steel
ness of the cylinder. cylinder.
(2) Physical tests: (a) Type, size, and service pressure. A
(i) An elongation of at least 6 percent DOT 3T cylinder is a seamless steel
for a gauge length of 24 times the wall cylinder with a minimum water capac-
thickness. ity of 1,000 pounds and a minimum
(ii) The tensile strength may not ex- service pressure of 1,800 psig. Each cyl-
ceed 165,000 p.s.i. inder must have integrally formed
(3) The burst pressure must be at heads concave to pressure at both ends.
least 4⁄3 times the test pressure. The inside head shape must be hemi-
(4) Cycling-at least 10,000 pressuriza-
spherical, ellipsoidal in which the
tions.
major axis is two times the minor axis,
(q) Rejected cylinders. Reheat treat-
or a dished shape falling within these
ment is authorized for rejected cyl-

inders. Subsequent thereto, cylinders two limits. Permanent closures formed
must pass all prescribed tests to be ac- by spinning are prohibited.
ceptable. Repair by welding or spinning
34
(b) Material, steel. Only open hearth, (1) Calculation of the stress for cyl-
basic oxygen, or electric furnace proc- inders must be made by the following
ess steel of uniform quality is author- formula:
ized. The steel analysis must conform S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
to the following:
Where:
ANALYSIS TOLERANCES S = Wall stress in psi;
P = Minimum test pressure, at least 5⁄3 serv-
Check Analysis ice pressure;
Element Ladle analysis
Under Over D = Outside diameter in inches;
Carbon ........................ 0.35 to 0.50 ...... 0.03 0.04
Manganese ................. 0.75 to 1.05 ...... 0.04 0.04 (2) Each cylinder must meet the fol-
Phosphorus (max) ...... 0.035 ................. ............ 0.01 lowing additional requirement which
Sulphur (max) ............. 0.04 ................... ............ 0.01 assumes a cylinder horizontally sup-
Silicon ......................... 0.15 to 0.35 ...... 0.02 0.03
Chromium ................... 0.80 to 1.15 ...... 0.05 0.05 ported at its two ends and uniformly
Molybdenum ............... 0.15 to 0.25 ...... 0.02 0.02 loaded over its entire length. This load
consists of the weight per inch of
(1) A heat of steel made under the length of the straight cylindrical por-
specifications in the table in this para- tion filled with water compressed to
graph (b), the ladle analysis of which is the specified test pressure. The wall
slightly out of the specified range, is thickness must be increased when nec-
acceptable if satisfactory in all other essary to meet this additional require-
aspects. However, the check analysis ment:
tolerances shown in the table in this (i) The sum of two times the max-
paragraph (b) may not be exceeded ex- imum tensile stress in the bottom fi-
cept as approved by the Department. bers due to bending (see paragraph
(2) Material with seams, cracks, lam- (d)(2)(ii) of this section), plus the max-
inations, or other injurious defects is imum tensile stress in the same fibers
not permitted. due to hydrostatic testing (see para-
(3) Material used must be identified graph (d)(2)(iii) of this section) may
by any suitable method. not exceed 80 percent of the minimum
(c) Manufacture. General manufac- yield strength of the steel at this max-
turing requirements are as follows: imum stress.
(1) Surface finish must be uniform (ii) The following formula must be
and reasonably smooth. used to calculate the maximum tensile
(2) Inside surfaces must be clean, dry, stress due to bending:
and free of loose particles. S = Mc / I
(3) No defect of any kind is permitted
if it is likely to weaken a finished cyl- Where:
inder. S = Tensile stress in psi;
(4) If the cylinder surface is not origi- M = Bending moment in inch-pounds (wl2/8);
nally free from the defects, the surface I = Moment of inertia—0.04909 (D4¥d4) in
inches fourth;
may be machined or otherwise treated c = Radius (D/2) of cylinder in inches;
to eliminate these defects provided the w = Weight per inch of cylinder filled with
minimum wall thickness is main- water;
tained. l = Length of cylinder in inches;
(5) Welding or brazing on a cylinder D = Outside diameter in inches;
is not permitted. d = Inside diameter in inches.
(d) Wall thickness. The minimum wall (iii) The following formula must be
thickness must be such that the wall used to calculate the maximum longi-
stress at the minimum specified test tudinal tensile stress due to hydro-
pressure does not exceed 67 percent of static test pressure:
the minimum tensile strength of the
steel as determined by the physical S = A1 P / A2
tests required in paragraphs (j) and (k) Where:
of this section. A wall stress of more S = Tensile stress in psi;

than 90,500 p.s.i. is not permitted. The A1 = Internal area in cross section of cyl-
minimum wall thickness for any cylinder in square inches;
inder may not be less than 0.225 inch. P = Hydrostatic test pressure-psig;
35
§ 178.45 49 CFR Ch. I (10–1–18 Edition)
A2 = Area of metal in cross section of cyl- threads must be in compliance with the
inder in square inches. requirements of NBS Handbook H–28.
(e) Heat treatment. Each completed (g) Hydrostatic test. Each cylinder
cylinder must be uniformly and prop- must be tested at an internal pressure
erly heat treated prior to testing, as by the water jacket method or other
follows: suitable method, conforming to the fol-
(1) Each cylinder must be heated and lowing requirements:
held at the proper temperature for at (1) The testing apparatus must be op-
least one hour per inch of thickness erated in a manner that will obtain ac-
based on the maximum thickness of curate data. Any pressure gauge used
the cylinder and then quenched in a must permit reading to an accuracy of
suitable liquid medium having a cool- one percent. Any expansion gauge used
ing rate not in excess of 80 percent of must permit reading of the total ex-
water. The steel temperature on pansion to an accuracy of one percent.
quenching must be that recommended (2) Any internal pressure applied to
for the steel analysis, but it must the cylinder after heat treatment and
never exceed 1750 °F. before the official test may not exceed
(2) After quenching, each cylinder 90 percent of the test pressure.
must be reheated to a temperature (3) The pressure must be maintained
below the transformation range but sufficiently long to assure complete ex-
not less than 1050 °F., and must be held pansion of the cylinder. In no case may
at this temperature for at least one the pressure be held less than 30 sec-
hour per inch of thickness based on the onds.
maximum thickness of the cylinder. (4) If, due to failure of the test appa-
Each cylinder must then be cooled ratus, the required test pressure can-
under conditions recommended for the not be maintained, the test must be re-
steel. peated at a pressure increased by 10
(f) Openings. Openings in cylinders percent or 100 psig, whichever is lower
must comply with the following: or, the cylinder must be reheat treated.
(1) Openings are permitted on heads (5) Permanent volumetric expansion
only. of the cylinder may not exceed 10 per-
(2) The size of any centered opening cent of its total volumetric expansion
in a head may not exceed one half the at the required test pressure.
outside diameter of the cylinder. (6) Each cylinder must be tested to at
(3) Openings in a head must have lig- least 5⁄3 times its service pressure.
aments between openings of at least (h) Ultrasonic examination. After the
three times the average of their hole hydrostatic test, the cylindrical sec-
diameter. No off-center opening may tion of each vessel must be examined in
exceed 2.625 inches in diameter. accordance with ASTM E 213 for shear
(4) All openings must be circular. wave and E 114 for straight beam (IBR,
(5) All openings must be threaded. Standard see § 171.7 of this subchapter).
Threads must be in compliance with The equipment used must be calibrated
the following: to detect a notch equal to five percent
(i) Each thread must be clean cut, of the design minimum wall thickness.
even, without any checks, and to Any discontinuity indication greater
gauge. than that produced by the five percent
(ii) Taper threads, when used, must notch must be cause for rejection of
be the American Standard Pipe thread the cylinder, unless the discontinuity
(NPT) type and must be in compliance is repaired within the requirements of
with the requirements of NBS Hand- this specification.
book H–28 (IBR, see § 171.7 of this sub- (i) Basic requirements for tension and
chapter). Charpy impact tests. Cylinders must be
(iii) Taper threads conforming to Na- subjected to a tension and Charpy im-
tional Gas Taper thread (NGT) stand- pact as follows:
ards must be in compliance with the (1) When the cylinders are heat treat-
requirements of NBS Handbook H–28. ed in a batch furnace, two tension

(iv) Straight threads conforming specimens and three Charpy impact
with National Gas Straight thread specimens must be tested from one of
(NGS) standards are authorized. These the cylinders or a test ring from each
36
batch. The lot size represented by these (3) The yield strength in tension
tests may not exceed 200 cylinders. must be the stress corresponding to a
(2) When the cylinders are heat treat- permanent strain of 0.2 percent of the
ed in a continuous furnace, two tension gage length.
specimens and three Charpy impact (i) This yield strength must be deter-
specimens must be tested from one of mined by the ‘‘offset’’ method or the
the cylinders or a test ring from each ‘‘extension under load’’ method de-
four hours or less of production. How- scribed in ASTM E 8 (IBR, see § 171.7 of
ever, in no case may a test lot based on this subchapter).
this production period exceed 200 cyl- (ii) For the ‘‘extension under load’’
inders. method, the total strain (or extension
(3) Each specimen for the tension and under load) corresponding to the stress
Charpy impact tests must be taken at which the 0.2 percent permanent
from the side wall of a cylinder or from strain occurs may be determined with
a ring which has been heat treated sufficient accuracy by calculating the
with the finished cylinders of which elastic extension of the gage length
the specimens must be representative. under appropriate load and adding
The axis of the specimens must be par- thereto 0.2 percent of the gage length.
allel to the axis of the cylinder. Each Elastic extension calculations must be
cylinder or ring specimen for test must based on an elastic modulus of
be of the same diameter, thickness, and 30,000,000. However, when the degree of
metal as the finished cylinders they accuracy of this method is question-
represent. A test ring must be at least able the entire stress-strain diagram
must be plotted and the yield strength
24 inches long with ends covered during
determined from the 0.2 percent offset.
the heat treatment process so as to
(iii) For the purpose of strain meas-
simulate the heat treatment process of
urement, the initial strain must be set
the finished cylinders it represents.
with the specimen under a stress of
(4) A test cylinder or test ring need 12,000 p.s.i. and the strain indicator
represent only one of the heats in a reading set at the calculated cor-
furnace batch provided the other heats responding strain.
in the batch have previously been test- (iv) The cross-head speed of the test-
ed and have passed the tests and that ing machine may not exceed 1⁄8 inch per
such tests do not represent more than minute during the determination of
200 cylinders from any one heat. yield strength.
(5) The test results must conform to (4) Each impact specimen must be
the requirements specified in para- Charpy V-notch type size 10 mm × 10
graphs (j) and (k) of this section. mm taken in accordance with para-
(6) When the test results do not con- graph 11 of ASTM A 333 (IBR, see § 171.7
form to the requirements specified, the of this subchapter). When a reduced
cylinders represented by the tests may size specimen is used, it must be the
be reheat treated and the tests re- largest size obtainable.
peated. Paragraph (i)(5) of this section (k) Acceptable physical test results. Re-
applies to any retesting. sults of physical tests must conform to
(j) Basic conditions for acceptable phys- the following:
ical testing. The following criteria must (1) The tensile strength may not ex-
be followed to obtain acceptable phys- ceed 155,000 p.s.i.
ical test results: (2) The elongation must be at least 16
(1) Each tension specimen must have percent for a two-inch gage length.
a gauge length of two inches with a (3) The Charpy V-notch impact prop-
width not exceeding one and one-half erties for the three impact specimens
inches. Except for the grip ends, the which must be tested at 0 °F may not
specimen may not be flattened. The be less than the values shown as fol-
grip ends may be flattened to within lows:
one inch of each end of the reduced sec-
Average value Minimum value
tion. Size of specimen for acceptance (1 specimen only

(mm)
(2) A specimen may not be heated (3 specimens) of the 3)
after heat treatment specified in para- 10.0 × 10.0 ............ 25.0 ft. lbs. ........... 20.0 ft. lbs.
graph (d) of this section. 10.0 × 7.5 .............. 21.0 ft. lbs. ........... 17.0 ft. lbs.
37
§ 178.46 49 CFR Ch. I (10–1–18 Edition)
Size of specimen Average value Minimum value value for one specimen for each lot
for acceptance (1 specimen only number.
(mm) (3 specimens) of the 3)
10.0 × 5.0 .............. 17.0 ft. lbs. ........... 14.0 ft. lbs.
[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,
(4) After the final heat treatment, 2003; 68 FR 75748, 75749, Dec. 31, 2003]
each vessel must be hardness tested on
the cylindrical section. The tensile § 178.46 Specification 3AL seamless
strength equivalent of the hardness aluminum cylinders.
number obtained may not be more than (a) Size and service pressure. A DOT
165,000 p.s.i. (Rc 36). When the result of 3AL cylinder is a seamless aluminum
a hardness test exceeds the maximum cylinder with a maximum water capac-
permitted, two or more retests may be ity of 1000 pounds and minimum service
made; however, the hardness number pressure of 150 psig.
obtained in each retest may not exceed (b) Authorized material and identifica-
the maximum permitted. tion of material. The material of con-
(l) Rejected cylinders. Reheat treat- struction must meet the following con-
ment is authorized for rejected cyl- ditions:
inders. However, each reheat treated (1) Starting stock must be cast stock
cylinder must subsequently pass all the or traceable to cast stock.
prescribed tests. Repair by welding is (2) Material with seams, cracks, lam-
inations, or other defects likely to
not authorized.
weaken the finished cylinder may not
(m) Markings. Marking must be done be used.
by stamping into the metal of the cyl- (3) Material must be identified by a
inder. All markings must be legible and suitable method that will identify the
located on a shoulder. alloy, the aluminum producer’s cast
(n) Inspector’s report. In addition to number, the solution heat treat batch
the requirements of § 178.35, the inspec- number and the lot number.
tor’s report for the physical test re- (4) The material must be of uniform
port, must indicate the average value quality. Only the following heat treat-
for three specimens and the minimum able aluminum alloys in table 1 and 2
are permitted as follows:
TABLE 1—HEAT OR CAST ANALYSIS FOR ALUMINUM; SIMILAR TO ‘‘ALUMINUM ASSOCIATION’’1 ALLOY
6061
[CHEMICAL ANALYSIS IN WEIGHT PERCENT2]
Other
Si Mg
Fe Cu Mn Cr Zn Ti Pb Bi
min/ min/ A1
max min/max max min/max max max max max each total
max max max max
0.4/0.8 0.7 0.15/0.4 0.15 0.8/1.2 0.04/0.35 0.25 0.15 0.005 0.005 0.05 0.15 Bal.
1 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 § 171.7 of this
subchapter) for Aluminum Association alloy 6061.
TABLE 2—MECHANICAL PROPERTY LIMITS

Tensile strength—PSI Elongation—percent
Alloy and temper minimum for 2″ or
Ultimate—minimum Yield—minimum 4D 1 size specimen
6061–T6 .................................................................................. 38,000 35,000 214
1 ‘‘D’’
represents specimen diameters. When the cylinder wall is greater than ⁄ inch thick, a retest without reheat treatment
3 16
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 24t × 6t size test specimen.
(5) All starting stock must be 100 per- one another. The equipment and con-
cent ultrasonically inspected, along tinuous scanning procedure must be ca-
the length at right angles to the cen- pable of detecting and rejecting inter-
tral axis from two positions at 90° to nal defects such as cracks which have
38
an ultrasonic response greater than (5) Each new design and any signifi-
that of a calibration block with a 5⁄64- cant change to any acceptable design
inch diameter flat bottomed hole. must be qualified for production by
(6) Cast stock must have uniform testing prototype samples as follows:
equiaxed grain structure not to exceed (i) Three samples must be subjected
500 microns maximum. to 100,000 pressure reversal cycles be-
(7) Any starting stock not complying tween zero and service pressure or
with the provisions of paragraphs (b)(1) 10,000 pressure reversal cycles between
through (b)(6) of this section must be zero and test pressure, at a rate not in
rejected. excess of 10 cycles per minute without
(c) Manufacture. Cylinders must be failure.
manufactured in accordance with the (ii) Three samples must be pressur-
following requirements: ized to destruction and failure may not
(1) Cylinder shells must be manufac- occur at less than 2.5 times the marked
tured by the backward extrusion meth- cylinder service pressure. Each cyl-
od and have a cleanliness level ade- inder must remain in one piece. Fail-
quate to ensure proper inspection. No ure must initiate in the cylinder side-
fissure or other defect is acceptable wall in a longitudinal direction. Rate
that is likely to weaken the finished of pressurization may not exceed 200
cylinder below the design strength re- psig per second.
quirements. A reasonably smooth and (6) In this specification ‘‘significant
uniform surface finish is required. If change’’ means a 10 percent or greater
not originally free from such defects, change in cylinder wall thickness, serv-
the surface may be machined or other- ice pressure, or diameter; a 30 percent
wise conditioned to eliminate these de- or greater change in water capacity or
fects. base thickness; any change in material;
(2) Thickness of the cylinder base over 100 percent increase in size of
may not be less than the prescribed openings; or any change in the number
minimum wall thickness of the cylin- of openings.
drical shell. The cylinder base must (d) Wall thickness. The minimum wall
have a basic torispherical, hemi- thickness must be such that the wall
spherical, or ellipsoidal interior base stress at the minimum specified test
configuration where the dish radius is pressure will not exceed 80 percent of
no greater than 1.2 times the inside di- the minimum yield strength nor exceed
ameter of the shell. The knuckle radius 67 percent of the minimum ultimate
may not be less than 12 percent of the tensile strength as verified by physical
inside diameter of the shell. The inte- tests in paragraph (i) of this section.
rior base contour may deviate from the The minimum wall thickness for any
true torispherical, hemispherical or el- cylinder with an outside diameter
lipsoidal configuration provided that— greater than 5 inches must be 0.125
(i) Any areas of deviation are accom- inch. Calculations must be made by the
panied by an increase in base thick- following formula:
ness; S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
(ii) All radii of merging surfaces are
equal to or greater than the knuckle Where:
radius; S = Wall stress in psi;
(iii) Each design has been qualified P = Prescribed minimum test pressure in
by successfully passing the cycling psig (see paragraph (g) of this section);
tests in this paragraph (c); and D = Outside diameter in inches; and
(iv) Detailed specifications of the
base design are available to the inspec- (e) Openings. Openings must comply
tor. with the following requirements:
(3) For free standing cylinders, the (1) Openings are permitted in heads
base thickness must be at least two only.
times the minimum wall thickness (2) The size of any centered opening
along the line of contact between the in a head may not exceed one-half the
cylinder base and the floor when the outside diameter of the cylinder.
cylinders are in the vertical position. (3) Other openings are permitted in
(4) Welding or brazing is prohibited. the head of a cylinder if:
39
§ 178.46 49 CFR Ch. I (10–1–18 Edition)
(i) Each opening does not exceed 2.625 (g) Hydrostatic test. Each cylinder
inches in diameter, or one-half the out- must be subjected to an internal test
side diameter of the cylinder; which- pressure using the water jacket equip-
ever is less; ment and method or other suitable
(ii) Each opening is separated from equipment and method and comply
each other by a ligament; and with the following requirements:
(iii) Each ligament which separates (1) The testing apparatus must be op-
two openings must be at least three erated in a manner so as to obtain ac-
times the average of the diameters of curate data. The pressure gauge used
the two openings. must permit reading to an accuracy of
(4) All openings must be circular. one percent. The expansion gauge must
(5) All openings must be threaded. permit reading the total expansion to
Threads must comply with the fol- an accuracy of either one percent or 0.1
lowing: cubic centimeter.
(i) Each thread must be clean cut, (2) The test pressure must be main-
even, without checks, and to gauge. tained for a sufficient period of time to
(ii) Taper threads, when used, must assure complete expansion of the cyl-
conform to one of the following: inder. In no case may the pressure be
(A) American Standard Pipe Thread held less than 30 seconds. If, due to fail-
(NPT) type, conforming to the require-
ure of the test apparatus, the required
ments of NBS Handbook H–28 (IBR, see
test pressure cannot be maintained,
§ 171.7 of this subchapter);
the test may be repeated at a pressure
(B) National Gas Taper Thread (NGT)
increased by 10 percent or 100 psig,
type, conforming to the requirements
of NBS Handbook H–28; or whichever is lower. If the test appa-
(C) Other taper threads conforming ratus again fails to maintain the test
to other standards may be used pro- pressure, the cylinder being tested
vided the length is not less than that must be rejected. Any internal pressure
specified for NPT threads. applied to the cylinder before any offi-
(iii) Straight threads, when used, cial test may not exceed 90 percent of
must conform to one of the following: the test pressure.
(A) National Gas Straight Thread (3) The minimum test pressure is the
(NGS) type, conforming to the require- greatest of the following:
ments of NBS Handbook H–28; (i) 450 psig regardless of service pres-
(B) Unified Thread (UN) type, con- sure;
forming to the requirements of NBS (ii) Two times the service pressure
Handbook H–28; for cylinders having service pressure
(C) Controlled Radius Root Thread less than 500 psig; or
(UN) type, conforming to the require- (iii) Five-thirds times the service
ments of NBS Handbook H–28; or pressure for cylinders having a service
(D) Other straight threads con- pressure of at least 500 psig.
forming to other recognized standards (4) Permanent volumetric expansion
may be used provided that the require- may not exceed 10 percent of total vol-
ments in paragraph (e)(5)(iv) of this umetric expansion at test pressure.
section are met. (h) Flattening test. One cylinder taken
(iv) All straight threads must have at at random out of each lot must be sub-
least 6 engaged threads, a tight fit, and jected to a flattening test as follows:
a factor of safety in shear of at least 10
(1) The test must be between knife
at the test pressure of the cylinder.
edges, wedge shaped, having a 60° in-
Shear stress must be calculated by
using the appropriate thread shear area cluded angle, and rounded in accord-
in accordance with NBS Handbook H– ance with the following table. The lon-
28. gitudinal axis of the cylinder must be
(f) Heat treatment. Prior to any test, at an angle 90° to the knife edges dur-
ing the test. The flattening test table
all cylinders must be subjected to a so-

lution heat treatment and aging treat- is as follows:
ment appropriate for the aluminum
alloy used.
40
TABLE 3—FLATTENING TEST TABLE the inspector’s report must show that
the specimens were so taken and pre-
Radius
Cylinder wall thickness in inches in pared. Heating of specimens for any
inches purpose is forbidden.
Under .150 ............................................................... .500 (3) The yield strength in tension
.150 to .249 ............................................................. .875 must be the stress corresponding to a
.250 to .349 ............................................................. 1.500 permanent strain of 0.2 percent of the
.350 to .449 ............................................................. 2.125
.450 to .549 ............................................................. 2.750 gauge length.
.550 to .649 ............................................................. 3.500 (i) The yield strength must be deter-
.650 to .749 ............................................................. 4.125 mined by either the ‘‘offset’’ method or
(2) An alternate bend test in accord- prescribed in ASTM B 557 (IBR, see
ance with ASTM E 290 using a mandrel § 171.7 of this subchapter).
diameter not more than 6 times the (ii) In using the ‘‘extension under
wall thickness is authorized to qualify load’’ method, the total strain (or ‘‘ex-
lots that fail the flattening test of this tension under load’’) corresponding to
section without reheat treatment. If the stress at which the 0.2 percent per-
used, this test must be performed on manent strain occurs may be deter-
two samples from one cylinder taken mined with sufficient accuracy by cal-
at random out of each lot of 200 cyl- culating the elastic extension of the
inders or less. gauge length under appropriate load
(3) Each test cylinder must withstand and adding thereto 0.2 percent of the
flattening to nine times the wall thick- gauge length. Elastic extension cal-
ness without cracking. When the alter- culations must be based on an elastic
nate bend test is used, the test speci- modulus of 10,000,000 psi. In the event
mens must remain uncracked when of controversy, the entire stress-strain
bent inward around a mandrel in the diagram must be plotted and the yield
direction of curvature of the cylinder strength determined from the 0.2 per-
wall until the interior edges are at a cent offset.
distance apart not greater than the di-
(iii) For the purpose of strain meas-
ameter of the mandrel.
urement, the initial strain must be set
(i) Mechanical properties test. Two test
while the specimen is under a stress of
specimens cut from one cylinder rep-
6,000 psi, the strain indicator reading
resenting each lot of 200 cylinders or
being set at the calculated cor-
less must be subjected to the mechan-
responding strain.
ical properties test, as follows:
(1) The results of the test must con- (iv) Cross-head speed of the testing
form to at least the minimum accept- machine may not exceed 1⁄8 inch per
able mechanical property limits for minute during yield strength deter-
aluminum alloys as specified in para- mination.
graph (b) of this section. (j) Rejected cylinder. Reheat treat-
(2) Specimens must be 4D bar or ment of rejected cylinders is author-
gauge length 2 inches with width not ized one time. Subsequent thereto, cyl-
over 11⁄2 inch taken in the direction of inders must pass all prescribed tests to
extrusion approximately 180° from each be acceptable.
other; provided that gauge length at (k) Duties of inspector. In addition to
least 24 times thickness with width not the requirements of § 178.35, the inspec-
over 6 times thickness is authorized, tor shall:
when cylinder wall is not over 3⁄16 inch (1) Verify compliance with the provi-
thick. The specimen, exclusive of grip sions of paragraph (b) of this section
ends, may not be flattened. Grip ends by:
may be flattened to within one inch of (i) Performing or witnessing the per-
each end of the reduced section. When formance of the chemical analyses on
the size of the cylinder does not permit each melt or cast lot or other unit of
securing straight specimens, the speci- starting material; or
mens may be taken in any location or (ii) Obtaining a certified chemical

direction and may be straightened or analysis from the material or cylinder
flattened cold by pressure only, not by manufacturer for each melt, or cast of
blows. When such specimens are used, material; or
41
§ 178.47 49 CFR Ch. I (10–1–18 Edition)
(iii) Obtaining a certified check anal- (v) Conditions of time, temperature

ysis on one cylinder out of each lot of and atmosphere during heat treatment.
200 cylinders or less, if a certificate (2) In no case may the lot size exceed
containing data to indicate compliance 200 cylinders, but any cylinder proc-
with the material specification is ob- essed for use in the required destruc-
tained. tive physical testing need not be count-
(2) The inspector must verify ultra- ed as being one of the 200.
sonic inspection of all material by in- (m) Inspector’s report. In addition to
spection or by obtaining the material the information required by § 178.35, the
producer’s certificate of ultrasonic in- record of chemical analyses must also
spection. Ultrasonic inspection must be include the alloy designation, and ap-
performed or verified as having been plicable information on iron, titanium,
performed in accordance with para- zinc, magnesium and any other appli-
graph (b)(5) of this section. cable element used in the construction
(3) The inspector must also deter- of the cylinder.
mine that each cylinder complies with [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
this specification by: amended at 66 FR 45386, Aug. 28, 2001; 67 FR
(i) Selecting the samples for check 51652, Aug. 8, 2002; 68 FR 75749, Dec. 31, 2003;
analyses performed by other than the 77 FR 60943, Oct. 5, 2012]
material producer;
§ 178.47 Specification 4DS welded
(ii) Verifying that the prescribed stainless steel cylinders for aircraft
minimum thickness was met by meas- use.
uring or witnessing the measurement
of the wall thickness; and (a) Type, size, and service pressure. A
DOT 4DS cylinder is either a welded
(iii) Verifying that the identification
stainless steel sphere (two seamless
of material is proper.
hemispheres) or circumferentially
(4) Prior to initial production of any welded cylinder both with a water ca-
design or design change, verify that the pacity of not over 100 pounds and a
design qualification tests prescribed in service pressure of at least 500 but not
paragraph (c)(6) of this section have over 900 psig.
been performed with acceptable re- (b) Steel. Types 304, 321 and 347 stain-
sults. less steel are authorized with proper
(l) Definitions. (1) In this specifica- welding procedure. A heat of steel
tion, a ‘‘lot’’ means a group of cyl- made under the specifications in table
inders successively produced having 1 in this paragraph (b), check chemical
the same: analysis of which is slightly out of the
(i) Size and configuration; specified range, is acceptable, if satis-
(ii) Specified material of construc- factory in all other respects, provided
tion; the tolerances shown in table 2 in this
(iii) Process of manufacture and heat paragraph (b) are not exceeded, except
treatment; as approved by Associate Adminis-
(iv) Equipment of manufacture and trator. The following chemical anal-
heat treatment; and yses 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 Titaniummay 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%.
42

under the minimum limit
Element Limit or maximum specified (percent)
Carbon ..................................................... To 0.15 incl ...................................................................... 0.01 0.01

Manganese .............................................. Over 1.15 to 2.50 incl ..................................................... 0.05 0.05
Phosphorus1 ............................................ 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
1Rephosphorized steels not subject to check analysis for phosphorus.
(c) Identification of material. Materials P = Test pressure prescribed for water jacket
must be identified by any suitable test, i.e., at least two times service pres-
method. sure, in psig;
D = Outside diameter in inches;
(d) Manufacture. Cylinders must be t = Minimum wall thickness in inches;
manufactured using equipment and E = 0.85 (provides 85 percent weld efficiency
processes adequate to ensure that each factor which must be applied in the girth
cylinder produced conforms to the re- weld area and heat zones which zone
quirements of this subpart. No defect is must extend a distance of 6 times wall
permitted that is likely to weaken the thickness from center of weld);
finished cylinder appreciably, a reason- E = 1.0 (for all other areas).
ably smooth and uniform surface finish (2) Calculation for a cylinder must be
is required. No abrupt change in wall made by the formula:
thickness is permitted. Welding proce-
dures and operators must be qualified S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
in accordance with CGA Pamphlet C–3 Where:
(IBR, see § 171.7 of this subchapter). All S = Wall stress in psi;
seams of the sphere or cylinder must be P = Test pressure prescribed for water jacket
fusion welded. Seams must be of the test, i.e., at least two times service pres-
butt type and means must be provided sure, in psig;
for accomplishing complete penetra- D = Outside diameter in inches;
tion of the joint. d = Inside diameter in inches.
(e) Attachments. Attachments to the (g) Heat treatment. The seamless
container are authorized by fusion hemispheres and cylinders may be
welding provided that such attach- stress relieved or annealed for forming.
ments are made of weldable stainless Welded container must be stress re-
steel in accordance with paragraph (b) lieved at a temperature of 775 °F ±25°
of this section. after process treatment and before hy-
(f) Wall thickness. The minimum wall drostatic test.
thickness must be such that the wall (h) Openings in container. Openings
stress at the minimum specified test must comply with the following:
pressure may not be over 60,000 psig. A (1) Each opening in the container
minimum wall thickness of 0.040 inch is must be provided with a fitting, boss or
required for any diameter container. pad of weldable stainless steel securely
Calculations must be made by the fol- attached to the container by fusion
lowing formulas: welding.
(1) Calculation for sphere must be (2) Attachments to a fitting, boss, or
made by the formula: pad must be adequate to prevent leak-
age. Threads must comply with the fol-

S = PD / 4tE
lowing:
Where: (i) Threads must be clean cut, even,
S = Wall stress in psi; without checks, and tapped to gauge.
43
§ 178.50 49 CFR Ch. I (10–1–18 Edition)
(ii) Taper threads to be of length not jection. Radiographic inspection must

less than as specified for American be performed subsequent to the hydro-
Standard taper pipe threads. static test.
(iii) Straight threads having at least (l) Burst test. One container taken at
4 engaged threads, to have tight fit and random out of 200 or less must be
calculated shear strength at least 10 hydrostatically tested to destruction.
times the test pressure of the con- Rupture pressure must be included as
tainer; gaskets required, adequate to part of the inspector’s report.
prevent leakage. (m) Flattening test. A flattening test
(i) Process treatment. Each container must be performed as follows:
must be hydraulically pressurized in a (1) For spheres the test must be at
water jacket to at least 100 percent, the weld between parallel steel plates
but not more than 110 percent, of the on a press with welded seam at right
test pressure and maintained at this angles to the plates. Test one sphere
pressure for a minimum of 3 minutes. taken at random out of each lot of 200
Total and permanent expansion must or less after the hydrostatic test. Any
be recorded and included in the inspec- projecting appurtenances may be cut
tor’s report. off (by mechanical means only) prior to
(j) Hydrostatic test. Each cylinder crushing.
must successfully withstand a hydro- (2) For cylinders the test must be be-
static test as follows: tween knife edges, wedge shaped, 60°
(1) The test must be by water-jacket, angle, rounded to 1⁄2-inch radius. Test
operated so as to obtain accurate data. one cylinder taken at random out of
The pressure gauge must permit read- each lot of 200 or less, after the hydro-
ing to an accuracy of 1 percent. The ex- static test.
pansion gauge must permit reading of (n) Acceptable results for flattening and
total expansion to an accuracy either burst tests. Acceptable results for flat-
of 1 percent or 0.1 cubic centimeter. tening and burst tests are as follows:
(2) Pressure must be maintained for (1) Flattening required to 50 percent
at least 30 seconds and sufficiently of the original outside diameter with-
longer to ensure complete expansion. out cracking.
If, due to failure of the test apparatus, (2) Burst pressure must be at least 3
the test pressure cannot be main- times the service pressure.
tained, the test may be repeated at a (o) Rejected containers. Repair of weld-
pressure increased by 10 percent or 100 ed seams by welding prior to process
psig, whichever is the lower. treatment is authorized. Subsequent
(3) Permanent volumetric expansion thereto, containers must be heat treat-
may not exceed 10 percent of total vol- ed and pass all prescribed tests.
umetric expansion at test pressure. (p) Duties of inspector. In addition to
(4) Each container must be tested to the requirements of § 178.35, the inspec-
at least 2 times service pressure. tor must verify that all tests are con-
(5) Container must then be inspected. ducted at temperatures between 60 °F
Any wall thickness lower than that re- and 90 °F.
quired by paragraph (f) of this section (q) Marking. Markings must be
must be cause for rejection. Bulges and stamped plainly and permanently on a
cracks must be cause for rejection. permanent attachment or on a metal
Welded joint defects exceeding require- nameplate permanently secured to the
ments of paragraph (k) of this section container by means other than soft sol-
must be cause for rejection. der.
(k) Radiographic inspection. Radio- [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
graphic inspection is required on all amended at 66 FR 45386, 45388, Aug. 28, 2001;
welded joints which are subjected to in- 67 FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31,
ternal pressure, except that at the dis- 2003]
cretion of the disinterested inspector,
openings less than 25 percent of the § 178.50 Specification 4B welded or
brazed steel cylinders.
container diameter need not be sub-

jected to radiographic inspection. Evi- (a) Type, size, and service pressure. A
dence of any defects likely to seriously DOT 4B is a welded or brazed steel cyl-
weaken the container is cause for re- inder with longitudinal seams that are
44
forged lap-welded or brazed and with placing brazing material on one side of
water capacity (nominal) not over 1,000 seam and applying heat until this ma-
pounds and a service pressure of at terial shows uniformly along the seam
least 150 but not over 500 psig. Cyl- of the other side.
inders closed in by spinning process are (e) Welding or brazing. Only the at-
not authorized. tachment of neckrings, footrings, han-
(b) Steel. Open-hearth, electric or dles, bosses, pads, and valve protection
basic oxygen process steel of uniform rings to the tops and bottoms of cyl-
quality must be used. Content percent inders by welding or brazing is author-
may not exceed the following: Carbon, ized. Such attachments and the portion
0.25; phosphorus, 0.045; sulphur, 0.050. of the container to which they are at-
(c) Identification of material. Material tached must be made of weldable steel,
must be identified by any suitable the carbon content of which may not
method except that plates and billets exceed 0.25 percent except in the case
for hotdrawn cylinders must be marked of 4130X steel which may be used with
with the heat number. proper welding procedure.
(d) Manufacture. Cylinders must be (f) Wall thickness. The wall thickness
manufactured using equipment and of the cylinder must comply with the
processes adequate to ensure that each following requirements:
cylinder produced conforms to the re- (1) For cylinders with outside diame-
quirements of this subpart. No defect is ters over 6 inches the minimum wall
permitted that is likely to weaken the thickness must be 0.090 inch. In any
finished cylinder appreciably. A rea- case, the minimum wall thickness
sonably smooth and uniform surface must be such that calculated wall
finish is required. Exposed bottom stress at minimum test pressure (para-
welds on cylinders over 18 inches long graph (i)(4) of this section) may not ex-
must be protected by footrings. Weld- ceed the following values:
ing procedures and operators must be (i) 24,000 psi for cylinders without
qualified in accordance with CGA Pam- longitudinal seam.
phlet C–3 (IBR, see § 171.7 of this sub- (ii) 22,800 psig for cylinders having
chapter). Seams must be made as fol- copper brazed or silver alloy brazed
lows: longitudinal seam.
(1) Welded or brazed circumferential (iii) 18,000 psi for cylinders having
seams. Heads attached by brazing must forged lapped welded longitudinal
have a driving fit with the shell, unless seam.
the shell is crimped, swedged, or curled (2) Calculation must be made by the
over the skirt or flange of the head, formula:
and be thoroughly brazed until com-
S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
plete penetration by the brazing mate-
rial of the brazed joint is secured. Where:
Depth of brazing from end of shell must S = wall stress in psi;
be at least four times the thickness of P = minimum test pressure prescribed for
shell metal. water jacket test or 450 psig whichever is
(2) Longitudinal seams in shells. Longi- the greater;
tudinal seams must be forged lap weld- D = outside diameter in inches;
ed, by copper brazing, by copper alloy
brazing, or by silver alloy brazing. Cop- (g) Heat treatment. Cylinder body and
per alloy composition must be: Copper, heads, formed by drawing or pressing,
95 percent minimum; Silicon, 1.5 per- must be uniformly and properly heat
cent to 3.85 percent; Manganese, 0.25 treated prior to tests.
percent to 1.10 percent. The melting (h) Opening in cylinders. Openings in
point of the silver alloy brazing mate- cylinders must conform to the fol-
rial must be in excess of 1000 °F. When lowing:
brazed, the plate edge must be lapped (1) Each opening in cylinders, except
at least eight times the thickness of those for safety devices, must be pro-
plate, laps being held in position, sub- vided with a fitting, boss, or pad, se-
stantially metal to metal, by riveting curely attached to cylinder by brazing
or electric spot-welding; brazing must or by welding or by threads. Fitting,
be done by using a suitable flux and by boss, or pad must be of steel suitable
45
§ 178.50 49 CFR Ch. I (10–1–18 Edition)
for the method of attachment em- (ii) All cylinders not tested as out-
ployed, and which need not be identi- lined in paragraph (i)(4)(i) of this sec-
fied or verified as to analysis except tion must be examined under pressure
that if attachment is by welding, car- of at least two times service pressure
bon content may not exceed 0.25 per- and show no defect.
cent. If threads are used, they must (j) Flattening test. After the hydro-
comply with the following: static test, a flattening test must be
(i) Threads must be clean cut, even performed on one cylinder taken at
without checks, and tapped to gauge. random out or each lot of 200 or less, by
(ii) Taper threads to be of length not placing the cylinder between wedge
less than as specified for American shaped knife edges having a 60° in-
Standard taper pipe threads. cluded angle, rounded to 1⁄2-inch radius.
(iii) Straight threads, having at least The longitudinal axis of the cylinder
4 engaged threads, to have tight fit and must be at a 90-degree angle to knife
calculated shear strength at least 10 edges during the test. For lots of 30 or
times the test pressure of the cylinder; less, flattening tests are authorized to
gaskets required, adequate to prevent be made on a ring at least 8 inches long
leakage. cut from each cylinder and subjected to
(iv) A brass fitting may be brazed to same heat treatment as the finished
the steel boss or flange on cylinders cylinder.
used as component parts of hand fire (k) Physical test. A physical test must
extinguishers. be conducted to determine yield
strength, tensile strength, elongation,
(2) The closure of a fitting, boss, or
and reduction of area of material as
pad must be adequate to prevent leak-
follows:
age.
(1) The test is required on 2 speci-
(i) Hydrostatic test. Cylinders must mens cut from 1 cylinder, or part
withstand a hydrostatic test as follows: thereof heat-treated as required, taken
(1) The test must be by water-jacket, at random out of each lot of 200 or less.
or other suitable method, operated so For lots of 30 or less, physical tests are
as to obtain accurate data. The pres- authorized to be made on a ring at
sure gauge must permit reading to an least 8 inches long cut from each cyl-
accuracy of 1 percent. The expansion inder and subjected to same heat treat-
gauge must permit reading of total ex- ment as the finished cylinder.
pansion to an accuracy either of 1 per- (2) Specimens must conform to the
cent or 0.1 cubic centimeter. following:
(2) Pressure must be maintained for (i) A gauge length of 8 inches with a
at least 30 seconds and sufficiently width of not over 11⁄2 inches, a gauge
longer to ensure complete expansion. length of 2 inches with a width of not
Any internal pressure applied after over 11⁄2 inches, or a gauge length at
heat-treatment and previous to the of- least 24 times the thickness with a
ficial test may not exceed 90 percent of width not over 6 times the thickness is
the test pressure. If, due to failure of authorized when a cylinder wall is not
the test apparatus, the test pressure over 3⁄16 inch thick.
cannot be maintained, the test may be (ii) The specimen, exclusive of grip
repeated at a pressure increased by 10 ends, may not be flattened. Grip ends
percent or 100 psig, whichever is the may be flattened to within one inch of
lower. each end of the reduced section.
(3) Permanent volumetric expansion (iii) When size of cylinder does not
may not exceed 10 percent of total vol- permit securing straight specimens,
umetric expansion at test pressure. the specimens may be taken in any lo-
(4) Cylinders must be tested as fol- cation or direction and may be
lows: straightened or flattened cold, by pres-
(i) At least one cylinder selected at sure only, not by blows. When speci-
random out of each lot of 200 or less mens are so taken and prepared, the in-
must be tested as outlined in para- spector’s report must show in connec-

graphs (i)(1), (i)(2), and (i)(3) of this section with record of physical tests de-
tion to at least two times service pres- tailed information in regard to such
sure. specimens.
46
(iv) Heating of a specimen for any must pass all prescribed tests to be ac-
purpose is not authorized. ceptable. Repair of brazed seams by
(3) The yield strength in tension brazing and welded seams by welding is
must be the stress corresponding to a authorized.
permanent strain of 0.2 percent of the (n) Markings. Markings must be
gauge length. The following conditions stamped plainly and permanently in
apply: any of the following locations on the
(i) The yield strength must be deter- cylinder:
mined by either the ‘‘offset’’ method or (1) On shoulders and top heads when
the ‘‘extension under load’’ method as they are not less than 0.087-inch thick.
prescribed in ASTM E 8 (IBR, see § 171.7 (2) On side wall adjacent to top head
of this subchapter). for side walls which are not less than
(ii) In using the ‘‘extension under 0.090 inch thick.
load’’ method, the total strain (or ‘‘ex- (3) On a cylindrical portion of the
tension under load’’) corresponding to shell which extends beyond the re-
the stress at which the 0.2 percent per- cessed bottom of the cylinder, consti-
manent strain occurs may be deter- tuting an integral and non-pressure
mined with sufficient accuracy by cal- part of the cylinder.
culating the elastic extension of the (4) On a metal plate attached to the
gauge length under appropriate load top of the cylinder or permanent part
and adding thereto 0.2 percent of the thereof; sufficient space must be left on
gauge length. Elastic extension cal- the plate to provide for stamping at
culations must be based on an elastic least six retest dates; the plate must be
modulus of 30,000,000. In the event of at least 1⁄16-inch thick and must be at-
controversy, the entire stress-strain tached by welding, or by brazing. The
diagram must be plotted and the yield brazing rod must melt at a tempera-
strength determined from the 0.2 per- ture of 1100 °F. Welding or brazing
cent offset. must be along all the edges of the
(iii) For the purpose of strain meas- plate.
urement, the initial strain must be set (5) On the neck, neckring, valve boss,
while the specimen is under a stress of valve protection sleeve, or similar part
12,000 psi, and strain indicator reading permanently attached to the top of the
must be set at the calculated cor- cylinder.
responding strain. (6) On the footring permanently at-
(iv) Cross-head speed of the testing tached to the cylinder, provided the
machine may not exceed 1⁄8 inch per water capacity of the cylinder does not
minute during yield strength deter- exceed 25 pounds.
mination. [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
(l) Acceptable results for physical and amended at 62 FR 51561, Oct. 1, 1997; 66 FR
flattening tests. Either of the following 45385, 45388, Aug. 28, 2001; 67 FR 51653, Aug. 8,
is an acceptable result: 2002; 68 FR 75748, Dec. 31, 2003]
(1) An elongation of at least 40 per-
cent for a 2-inch gauge length or at § 178.51 Specification 4BA welded or
least 20 percent in other cases and brazed steel cylinders.
yield strength not over 73 percent of (a) Type, size, and service pressure. A
tensile strength. In this instance, a DOT 4BA cylinder is a cylinder, either
flattening test is not required. spherical or cylindrical in shape, with
(2) When cylinders are constructed of a water capacity of 1,000 pounds or less
lap welded pipe, flattening test is re- and a service pressure of at least 225
quired, without cracking, to 6 times and not over 500 psig. Closures made by
the wall thickness. In such case, the the spinning process are not author-
rings (crop ends) cut from each end of ized.
pipe, must be tested with the weld 45° (1) Spherical type cylinders must be
or less from the point of greatest made from two seamless hemispheres
stress. If a ring fails, another from the joined by the welding of one circum-
same end of pipe may be tested. ferential seam.

(m) Rejected cylinders. Reheat treat- (2) Cylindrical type cylinders must be
ment is authorized for rejected cyl- of circumferentially welded or brazed
inder. Subsequent thereto, cylinders construction.
47
§ 178.51 49 CFR Ch. I (10–1–18 Edition)
(b) Steel. The steel used in the con- least 3⁄2 times the strength of the steel
struction of the cylinder must be as wall.
specified in table 1 of appendix A to (2) Welding procedures and operators
this part. must be qualified in accordance with
(c) Identification of material. Material CGA Pamphlet C–3 (IBR, see § 171.7 of
must be identified by any suitable this subchapter).
method except that plates and billets (e) Welding and brazing. Only the
for hotdrawn cylinders must be marked welding or brazing of neckrings,
with the heat number. footrings, handles, bosses, pads, and
(d) Manufacture. Cylinders must be valve protection rings to the tops and
manufactured using equipment and bottoms of cylinders is authorized.
processes adequate to ensure that each Provided that such attachments and
cylinder produced conforms to the re- the portion of the container to which
quirements of this subpart. No defect is they are attached are made of weldable
permitted that is likely to weaken the steel, the carbon content of which may
finished cylinder appreciably. A rea- not exceed 0.25 percent except in the
sonably smooth and uniform surface case of 4130 × steel which may be used
with proper welding procedure.
finish is required. Exposed bottom
(f) Wall thickness. The minimum wall
welds on cylinders over 18 inches long
thickness of the cylinder must meet
must be protected by footrings.
the following conditions:
(1) Seams must be made as follows: (1) For any cylinder with an outside
(i) Minimum thickness of heads and diameter of greater than 6 inches, the
bottoms must be not less than 90 per- minimum wall thickness is 0.078 inch.
cent of the required thickness of the In any case the minimum wall thick-
side wall. ness must be such that the calculated
(ii) Circumferential seams must be wall stress at the minimum test pres-
made by welding or by brazing. Heads sure may not exceed the lesser value of
must be attached by brazing and must any of the following:
have a driving fit with the shell, unless (i) The value shown in table 1 of ap-
the shell is crimped, swedged or curled pendix A to this part, for the particular
over the skirt or flange of the head and material under consideration;
must be thoroughly brazed until com- (ii) One-half of the minimum tensile
plete penetration by the brazing mate- strength of the material determined as
rial of the brazed joint is secured. required in paragraph (j) of this sec-
Depth of brazing from end of the shell tion;
must be at least four times the thick- (iii) 35,000 psi; or
ness of shell metal. (iv) Further provided that wall stress
(iii) Longitudinal seams in shells for cylinders having copper brazed lon-
must be made by copper brazing, cop- gitudinal seams may not exceed 95 per-
per alloy brazing, or by silver alloy cent of any of the above values. Meas-
brazing. Copper alloy composition ured wall thickness may not include
must be: Copper 95 percent minimum, galvanizing or other protective coat-
Silicon 1.5 percent to 3.85 percent, Man- ing.
ganese 0.25 percent to 1.10 percent. The (2) Cylinders that are cylindrical in
melting point of the silver alloy braz- shape must have the wall stress cal-
ing material must be in excess of 1,000 culated by the formula:
°F. The plate edge must be lapped at S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
least eight times the thickness of
Where:
plate, laps being held in position, sub-
stantially metal to metal, by riveting S = wall stress in psi;
P = minimum test pressure prescribed for
or by electric spot-welding. Brazing water jacket test;
must be done by using a suitable flux D = outside diameter in inches;
and by placing brazing material on one d = inside diameter in inches.
side of seam and applying heat until
(3) Cylinders that are spherical in
this material shows uniformly along

the seam of the other side. Strength of shape must have the wall stress cal-
longitudinal seam: Copper brazed lon- culated by the formula:
gitudinal seam must have strength at S = PD / 4tE
48
Where: (ii) Taper threads must be of a length
S = wall stress in psi; not less than that specified for Amer-
P = minimum test pressure prescribed for ican Standard taper pipe threads.
water jacket test; (iii) Straight threads, having at least
D = outside diameter in inches; 4 engaged threads, must have a tight
t = minimum wall thickness in inches; fit and a calculated shear strength of
E = 0.85 (provides 85 percent weld efficiency at least 10 times the test pressure of
factor which must be applied in the girth the cylinder. Gaskets, adequate to pre-
weld area and heat affected zones which vent leakage, are required.
zone must extend a distance of 6 times
(i) Hydrostatic test. Each cylinder
wall thickness from center line of weld);
must successfully withstand a hydro-
E = 1.0 (for all other areas).
static test, as follows:
(4) For a cylinder with a wall thick- (1) The test must be by water jacket,
ness less than 0.100 inch, the ratio of or other suitable method, operated so
tangential length to outside diameter as to obtain accurate data. A pressure
may not exceed 4.1. gauge must permit reading to an accu-
(g) Heat treatment. Cylinders must be racy of 1 percent. An expansion gauge
heat treated in accordance with the must permit reading of total expansion
following requirements: to an accuracy of either 1 percent or 0.1
(1) Each cylinder must be uniformly cubic centimeter.
and properly heat treated prior to test (2) Pressure must be maintained for
by the applicable method shown in at least 30 seconds and sufficiently
table 1 of appendix A to this part. Heat longer to ensure complete expansion.
treatment must be accomplished after Any internal pressure applied after
all forming and welding operations, ex- heat treatment and previous to the of-
cept that when brazed joints are used, ficial test may not exceed 90 percent of
heat treatment must follow any form- the test pressure.
ing and welding operations, but may be (3) Permanent volumetric expansion
done before, during or after the brazing may not exceed 10 percent of the total
operations. volumetric expansion at test pressure.
(4) Cylinders must be tested as fol-
(2) Heat treatment is not required
lows:
after the welding or brazing of weldable
(i) At least one cylinder selected at
low carbon parts to attachments of
random out of each lot of 200 or less
similar material which have been pre-
must be tested as outlined in para-
viously welded or brazed to the top or
graphs (i)(1), (i)(2), and (i)(3) of this sec-
bottom of cylinders and properly heat
tion to at least two times service pres-
treated, provided such subsequent
sure.
welding or brazing does not produce a
(ii) All cylinders not tested as out-
temperature in excess of 400 °F in any
lined in paragraph (i)(4)(i) of this sec-
part of the top or bottom material.
tion must be examined under pressure
(h) Openings in cylinders. Openings in of at least two times service pressure
cylinders must comply with the fol- and show no defect.
lowing requirements: (j) Physical test. A physical test must
(1) Any opening must be placed on be conducted to determine yield
other than a cylindrical surface. strength, tensile strength, elongation,
(2) Each opening in a spherical type and reduction of area of material, as
cylinder must be provided with a fit- follows:
ting, boss, or pad of weldable steel se- (1) The test is required on 2 speci-
curely attached to the container by fu- mens cut from one cylinder or part
sion welding. thereof having passed the hydrostatic
(3) Each opening in a cylindrical type test and heat-treated as required,
cylinder must be provided with a fit- taken at random out of each lot of 200
ting, boss, or pad, securely attached to or less. Physical tests for spheres are
container by brazing or by welding. required on 2 specimens cut from flat
(4) If threads are used, they must representative sample plates of the
comply with the following: same heat taken at random from the
(i) Threads must be clean-cut, even, steel used to produce the spheres. This
without checks and tapped to gauge. flat steel from which 2 specimens are
49
§ 178.51 49 CFR Ch. I (10–1–18 Edition)
to be cut must receive the same heat must be set while the specimen is
treatment as the spheres themselves. under a stress of 12,000 psi, and the
Sample plates must be taken from each strain indicator reading must be set at
lot of 200 or less spheres. the calculated corresponding strain.
(i) A gauge length of 8 inches with a minute during yield strength deter-
width not over 11⁄2 inches, or a gauge mination.
length of 2 inches with a width not (k) Elongation. Physical test speci-
over 11⁄2 inches, or a gauge length at
mens must show at least a 40 percent
least 24 times the thickness with a
elongation for a 2-inch gauge length or
width not over 6 times the thickness is
authorized when a cylinder wall is not at least 20 percent in other cases. Ex-
over 3⁄16 inch thick. cept that these elongation percentages
(ii) The specimen, exclusive of grip may be reduced numerically by 2 for 2-
ends, may not be flattened. Grip ends inch specimens, and by 1 in other cases,
may be flattened to within one inch of for each 7,500 psi increment of tensile
each end of the reduced section. strength above 50,000 psi to a maximum
(iii) When size of the cylinder does of four such increments.
not permit securing straight speci- (l) Tests of welds. Except for brazed
mens, the specimens may be taken in seams, welds must be tested as follows:
any location or direction and may be (1) Tensile test. A specimen must be
straightened or flattened cold, by pres- cut from one cylinder of each lot of 200
sure only, not by blows. When speci- or less, or welded test plate. The weld-
mens are so taken and prepared, the ined test plate must be of one of the
spector’s report must show in connec- heats in the lot of 200 or less which it
tion with record of physical tests de- represents, in the same condition and
tailed information in regard to such approximately the same thickness as
specimens. the cylinder wall except that in no case
(iv) Heating of a specimen for any must it be of a lesser thickness than
purpose is not authorized.
that required for a quarter size Charpy
(3) The yield strength in tension
impact specimen. The weld must be
must be the stress corresponding to a
permanent strain of 0.2 percent of the made by the same procedures and sub-
gauge length. The following conditions jected to the same heat treatment as
apply: the major weld on the cylinder. The
(i) The yield strength must be deter- specimen must be taken from across
mined by either the ‘‘offset’’ method or the major seam and must be prepared
the ‘‘extension under load’’ method as and tested in accordance with and
prescribed in ASTM E 8 (IBR, see § 171.7 must meet the requirements of CGA
of this subchapter). Pamphlet C–3 (IBR, see § 171.7 of this
(ii) In using the ‘‘extension under subchapter). Should this specimen fail
load’’ method, the total strain (or ‘‘ex- to meet the requirements, specimens
tension under load’’), corresponding to may be taken from two additional cyl-
the stress at which the 0.2 percent per- inders or welded test plates from the
manent strain occurs may be deter- same lot and tested. If either of the lat-
mined with sufficient accuracy by cal- ter specimens fail to meet the require-
culating the elastic extension of the ments, the entire lot represented must
gauge length under appropriate load be rejected.
and adding thereto 0.2 percent of the (2) Guided bend test. A root bend test
gauge length. Elastic extension cal- specimen must be cut from the cyl-
culations must be based on an elastic inder or welded test plate, used for the
modulus of 30,000,000. In the event of tensile test specified in paragraph (l)(1)
controversy, the entire stress-strain
of this section. Specimens must be
diagram must be plotted and the yield
taken from across the major seam and
strength determined from the 0.2 per-

cent offset. must be prepared and tested in accord-
(iii) For the purpose of strain meas- ance with and must meet the require-
urement, the initial strain reference ments of CGA Pamphlet C–3.
50
(3) Alternate guided-bend test. This water capacity of the cylinder does not
test may be used and must be as re- exceed 25 pounds.
quired by CGA Pamphlet C–3. The spec-
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as
imen must be bent until the elongation amended at 66 FR 4535, Aug. 28, 2001; 67 FR
at the outer surface, adjacent to the 16015, Sept. 27, 2002; 67 FR 51653, Aug. 8, 2002;
root of the weld, between the lightly 68 FR 75748, Dec. 31, 2003]
scribed gage lines a to b, must be at
least 20 percent, except that this per- § 178.53 Specification 4D welded steel
centage may be reduced for steels hav- cylinders for aircraft use.
ing a tensile strength in excess of 50,000 (a) Type, size, and service pressure. A
psig, as provided in paragraph (k) of DOT 4D cylinder is a welded steel
this section. sphere (two seamless hemispheres) or
(m) Rejected cylinders. Reheat treat- circumferentially welded cylinder (two
ment is authorized for rejected cyl- seamless drawn shells) with a water ca-
inders. Subsequent thereto, cylinders pacity not over 100 pounds and a serv-
must pass all prescribed tests to be ac- ice pressure of at least 300 but not over
ceptable. Repair of brazed seams by 500 psig. Cylinders closed in by spin-
brazing and welded seams by welding is ning process are not authorized.
authorized. (b) Steel. Open-hearth or electric steel
(n) Markings. Markings must be of uniform and weldable quality must
stamped plainly and permanently in be used. Content may not exceed the
one of the following locations on the following: Carbon, 0.25; phosphorus,
cylinder: 0.045; sulphur, 0.050, except that the fol-
(1) On shoulders and top heads not lowing steels commercially known as
less than 0.087 inch thick. 4130X and Type 304, 316, 321, and 347
(2) On side wall adjacent to top head stainless steels may be used with prop-
for side walls not less than 0.090 inch er welding procedure. A heat of steel
thick. made under table 1 in this paragraph
(3) On a cylindrical portion of the (b), check chemical analysis of which is
shell which extends beyond the re- slightly out of the specified range, is
cessed bottom of the cylinder consti- acceptable, if satisfactory in all other
tuting an integral and non-pressure respects, provided the tolerances shown
part of the cylinder. in table 2 in this paragraph (b) are not
(4) On a plate attached to the top of exceeded, except as approved by the As-
the cylinder or permanent part thereof; sociate Administrator. The following
sufficient space must be left on the chemical analyses are authorized:
plate to provide for stamping at least
six retest dates; the plate must be at TABLE 1—4130X STEEL
least 1⁄16 inch thick and must be at-
tached by welding, or by brazing at a 4130X Percent
temperature of at least 1100 °F., Carbon ........................................................... 0.25/0.35.
throughout all edges of the plate. Manganese .................................................... 0.40/0.60.
(5) On the neck, neckring, valve boss, Phosphorus .................................................... 0.04 max.
Sulphur .......................................................... 0.05 max
valve protection sleeve, or similar part Silicon ............................................................ 0.15/0.35.
permanently attached to the top of the Chromium ...................................................... 0.80/1.10.
cylinder. Molybdenum .................................................. 0.15/0.25.
(6) On the footring permanently at- Zirconium ....................................................... None.
Nickel ............................................................. None.
tached to the cylinder, provided the
TABLE 2—AUTHORIZED STAINLESS STEELS
Stainless steels
304 316 321 347

(percent) (percent) (percent) (percent)
Carbon (max) ........................................................................ 0.08 0.08 0.08 0.08

Manganese (max) ................................................................. 2.00 2.00 2.00 2.00
Phosphorus (max) ................................................................. .030 .045 .030 .030

Sulphur (max) ........................................................................ .030 .030 .030 .030
Silicon (max) ......................................................................... .75 1.00 .75 .75
Nickel ..................................................................................... 8.0/11.0 10.0/14.0 9.0/13.0 9.0/13.0
Chromium .............................................................................. 18.0/20.0 16.0/18.0 17.0/20.0 17.0/20.0
51
§ 178.53 49 CFR Ch. I (10–1–18 Edition)
TABLE 2—AUTHORIZED STAINLESS STEELS—Continued

Stainless steels
304 316 321 347

(percent) (percent) (percent) (percent)
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%.

Limit or maximum specified under the minimum limit
Element (percent)
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
(c) Identification of material. Material ing a capacity of 1,100 cubic inches or

must be identified by any suitable less is 0.04 inch. The minimum wall
method except that plates and billets thickness for any container having a
for hotdrawn cylinders must be marked capacity in excess of 1,100 cubic inches
with the heat number. is 0.095 inch. Calculations must be done
(d) Manufacture. Cylinders must be by the following:
manufactured using equipment and (1) Calculation for a ‘‘sphere’’ must
processes adequate to ensure that each be made by the formula:
cylinder produced conforms to the re-
quirements of this subpart. No defect is S = PD / 4tE
permitted that is likely to weaken the Where:
finished container appreciably. A rea- S = wall stress in psi;
sonably smooth and uniform surface P = test pressure prescribed for water jacket
finish is required. Welding procedures test, i.e., at least two times service pres-
and operators must be qualified in ac- sure, in psig;
cordance with CGA Pamphlet C–3 (IBR, D = outside diameter in inches;
see § 171.7 of this subchapter). t = minimum wall thickness in inches;
(e) Wall thickness. The wall stress at E = 0.85 (provides 85 percent weld efficiency
the minimum test pressure may not ex- factor which must be applied in the girth
ceed 24,000 psi, except where steels weld area and heat affected zones which
commercially known as 4130X, types zone must extend a distance of 6 times
304, 316, 321, and 347 stainless steels are

used, stress at the test pressures may
not exceed 37,000 psi. The minimum (2) Calculation for a cylinder must be
wall thickness for any container hav- made by the formula:
52
S = [P(1.3D2 + 0.4d2)] / (D2 ¥ dT12) (3) Permanent volumetric expansion

may not exceed 10 percent of the total
Where:
volumetric expansion at test pressure.
S = wall stress in psi; (4) Containers must be tested as fol-
P = test pressure prescribed for water jacket lows:
test, i.e., at least two times service pres-
(i) Each container to at least 2 times
sure, in psig;
service pressure; or
D = outside diameter in inches;
(ii) One container out of each lot of
200 or less to at least 3 times service
(f) Heat treatment. The completed cyl- pressure. Others must be examined
inders must be uniformly and properly under pressure of 2 times service pres-
heat-treated prior to tests. sure and show no defects.
(g) Openings in container. Openings in (i) Flattening test for spheres and cyl-
cylinders must comply with the fol- inders. Spheres and cylinders must be
lowing: subjected to a flattening test as fol-
(1) Each opening in the container, ex- lows:
cept those for safety devices, must be (1) One sphere taken at random out
provided with a fitting, boss, or pad, se- of each lot of 200 or less must be sub-
curely attached to the container by jected to a flattening test as follows:
brazing or by welding or by threads. If (i) The test must be performed after
threads are used, they must comply the hydrostatic test.
with the following: (ii) The test must be between parallel
(i) Threads must be clean cut, even, steel plates on a press with a welded
without checks, and tapped to gauge. seam at right angles to the plates. Any
(ii) Taper threads must be of a length projecting appurtenances may be cut
not less than that specified for Amer- off (by mechanical means only) prior to
ican Standard taper pipe threads. crushing.
(iii) Straight threads, having at least (2) One cylinder taken at random out
4 engaged threads, must have a tight of each lot of 200 or less must be sub-
fit and calculated shear strength of at jected to a flattening test, as follows:
least 10 times the test pressure of the (i) The test must be performed after
container. Gaskets, adequate to pre- the hydrostatic test.
vent leakage, are required. (ii) The test must be between knife
edges, wedge shaped, 60° angle, rounded
(2) Closure of a fitting, boss, or pad
to 1⁄2 inch radius. For lots of 30 or less,
must be adequate to prevent leakage.
physical tests are authorized to be
(h) Hydrostatic test. Each cylinder made on a ring at least 8 inches long
must successfully withstand a hydro- cut from each cylinder and subjected to
static test, as follows: the same heat treatment as the fin-
(1) The test must be by water-jacket, ished cylinder.
or other suitable method, operated so (j) Physical test and specimens for
as to obtain accurate data. A pressure spheres and cylinders. Spheres and cyl-
gauge must permit a reading to an ac- inders must be subjected to a physical
curacy of 1 percent. An expansion test as follows:
gauge must permit reading of total ex- (1) Physical test for spheres are re-
pansion to an accuracy of either 1 per- quired on 2 specimens cut from a flat
cent or 0.1 cubic centimeter. representative sample plate of the
(2) Pressure must be maintained for same heat taken at random from the
at least 30 seconds and sufficiently steel used to produce the sphere. This
longer to ensure complete expansion. flat steel from which the 2 specimens
Any internal pressure applied after are to be cut must receive the same
heat-treatment and previous to the of- heat-treatment as the spheres them-
ficial test may not exceed 90 percent of selves. Sample plates must be taken for
the test pressure. If, due to failure of each lot of 200 or less spheres.
the test apparatus, the test pressure (2) Specimens for spheres must have
cannot be maintained, the test may be a gauge length 2 inches with a width
repeated at a pressure increased by 10 not over 11⁄2 inches, or a gauge length
percent or 100 psig, whichever is the at least 24 times the thickness with a
lower. width not over 6 times the thickness is
53
§ 178.55 49 CFR Ch. I (10–1–18 Edition)
authorized when a wall is not over 3⁄16 (iv) Cross-head speed of the testing
inch thick. machine may not exceed 1⁄8 inch per
(3) Physical test for cylinders is re- minute during yield strength deter-
quired on 2 specimens cut from 1 cyl- mination.
inder taken at random out of each lot (k) Acceptable results for physical and
of 200 or less. For lots of 30 or less, flattening tests. Either of the following
physical tests are authorized to be is an acceptable result:
made on a ring at least 8 inches long (1) An elongation of at least 40 per-
cut from each cylinder and subjected to cent for a 2 inch gauge length or at
the same heat treatment as the fin- least 20 percent in other cases and
ished cylinder. yield strength not over 73 percent of
(4) Specimens for cylinders must con- tensile strength. In this instance, the
form to the following: flattening test is not required.
(i) A gauge length of 8 inches with a (2) An elongation of at least 20 per-
width not over 11⁄2 inches, or a gauge cent for a 2 inch gauge length or 10 per-
length of 2 inches with a width not cent in other cases. Flattening is re-
over 11⁄2 inches, or a gauge length at quired to 50 percent of the original out-
least 24 times the thickness with a side diameter without cracking.
width not over 6 times the thickness is (l) Rejected cylinders. Reheat-treat-
authorized when a cylinder wall is not ment is authorized for rejected cyl-
over 3⁄16 inch thick. inders. Subsequent thereto, containers
(ii) The specimen, exclusive of grip must pass all prescribed tests to be ac-
ends, may not be flattened. Grip ends ceptable. Repair of welded seams by
may be flattened to within 1 inch of welding prior to reheat-treatment is
each end of the reduced section. Heat- authorized.
ing of the specimen for any purpose is (m) Marking. Marking on each con-
not authorized. tainer by stamping plainly and perma-
(5) The yield strength in tension nently are only authorized where the
must be the stress corresponding to a metal is at least 0.09 inch thick, or on
permanent strain of 0.2 percent of the a metal nameplate permanently se-
gauge length. The following conditions cured to the container by means other
apply: than soft solder, or by means that
(i) The yield strength must be deter- would not reduce the wall thickness.
mined by either the ‘‘offset’’ method or [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
the ‘‘extension under load’’ method as amended at 66 FR 45386, 45388, Aug. 28, 2001;
prescribed in ASTM E 8 (IBR, see § 171.7 67 FR 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31,
of this subchapter). 2003]
(ii) In using the ‘‘extension under
load’’ method, the total strain (or ‘‘ex- § 178.55 Specification 4B240ET welded
tension under load’’) corresponding to or brazed cylinders.
the stress at which the 0.2 percent per- (a) Type, spinning process, size and
manent strain occurs may be deter- service pressure. A DOT 4B240ET cyl-
mined with sufficient accuracy by cal- inder is a brazed type cylinder made
culating the elastic extension of the from electric resistance welded tubing.
gauge length under appropriate load The maximum water capacity of this
and adding thereto 0.2 percent of the cylinder is 12 pounds or 333 cubic
gauge length. Elastic extension cal- inches and the service must be 240 psig.
culations must be based on an elastic The maximum outside diameter of the
modulus of 30,000,000. In the event of shell must be five inches and maximum
controversy, the entire stress-strain length of the shell is 21 inches. Cyl-
diagram must be plotted and the yield inders closed in by a spinning process
strength determined from the 0.2 per- are authorized.
cent offset. (b) Steel. Open-hearth, basic oxygen,
(iii) For the purpose of strain meas- or electric steel of uniform quality
urement, the initial strain must be set must be used. Plain carbon steel con-
while the specimen is under a stress of tent may not exceed the following: Car-
12,000 psi and the strain indicator read- bon, 0.25; phosphorus, 0.045; sulfur,
ing being set at the calculated cor- 0.050. The addition of other elements
responding strain. for alloying effect is prohibited.
54
(c) Identification of material. Material pressure and may not exceed 18,000 psi.
must be identified by any suitable The minimum wall thickness is 0.044
method. inch. Calculation must be made by the
(d) Manufacture. Cylinders must be following formula:
manufactured using equipment and
S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
processes adequate to ensure that each
cylinder produced conforms to the re- Where:
quirements of this subpart. No defect is S = wall stress in psig;
permitted that is likely to weaken the P = 2 times service pressure;
finished cylinder appreciably. A rea- D = outside diameter in inches;
sonably smooth and uniform surface d = inside diameter in inches.
finish is required. Heads may be at- (g) Heat treatment. Heads formed by
tached to shells by lap brazing or may drawing or pressing must be uniformly
be formed integrally. The thickness of and properly heat treated prior to
the bottom of cylinders welded or tests. Cylinders with integral formed
formed by spinning is, under no condi- heads or bases must be subjected to a
tion, to be less than two times the min- normalizing operation. Normalizing
imum wall thickness of the cylindrical and brazing operations may be com-
shell. Such bottom thicknesses must be bined, provided the operation is carried
measured within an area bounded by a out at a temperature in excess of the
line representing the points of contact upper critical temperature of the steel.
between the cylinder and the floor
(h) Openings in cylinders. Openings in
when the cylinder is in a vertical posi-
cylinders must comply with the fol-
tion. Seams must conform to the fol-
lowing:
lowing:
(1) Circumferential seams must be by (1) Each opening in cylinders, except
brazing only. Heads must be attached those for safety devices, must be pro-
to shells by the lap brazing method and vided with a fitting, boss, or pad, se-
must overlap not less than four times curely attached to the cylinder by
the wall thickness. Brazing material brazing or by welding or by threads. A
must have a melting point of not less fitting, boss, or pad must be of steel
than 1000 °F. Heads must have a driving suitable for the method of attachment
fit with the shell unless the shell is employed, and which need not be iden-
crimped, swedged, or curled over the tified or verified as to analysis, except
skirt or flange of the head and be thor- that if attachment is by welding, car-
oughly brazed until complete penetra- bon content may not exceed 0.25 per-
tion of the joint by the brazing mate- cent. If threads are used, they must
rial is secured. Brazed joints may be re- comply with the following:
paired by brazing. (i) Threads must be clean cut, even
(2) Longitudinal seams in shell must without checks, and tapped to gauge.
be by electric resistance welded joints (ii) Taper threads to be of length not
only. No repairs to longitudinal joints less than as specified for American
is permitted. Standard taper pipe threads.
(3) Welding procedures and operators (iii) Straight threads, having at least
must be qualified in accordance with 4 engaged threads, to have tight fit and
CGA C–3 (IBR, see § 171.7 of this sub- calculated shear strength at least 10
chapter). times the test pressure of the cylinder;
(e) Welding or brazing. Only the at- gaskets required, adequate to prevent
tachment, by welding or brazing, to the leakage.
tops and bottoms of cylinders of (2) Closure of a fitting, boss, or pad
neckrings, footrings, handles, bosses, must be adequate to prevent leakage.
pads, and valve protection rings is au- (i) Hydrostatic test. Each cylinder
thorized. Provided that such attach- must successfully withstand a hydro-
ments and the portion of the container static test as follows:
to which they are attached are made of (1) The test must be by water-jacket,
weldable steel, the carbon content of or other suitable method, operated so

which may not exceed 0.25 percent. as to obtain accurate data. The pres-
(f) Wall thickness. The wall stress sure gauge must permit reading to an
must be at least two times the service accuracy of 1 percent. The expansion
55
§ 178.55 49 CFR Ch. I (10–1–18 Edition)
gauge must permit reading of total ex- (1) The test is required on 2 speci-
pansion to an accuracy of either 1 per- mens cut from 1 cylinder, or part
cent or 0.1 cubic centimeter. thereof heat-treated as required, taken
(2) Pressure must be maintained for at random out of each lot of 200 or less
at least 30 seconds and sufficiently in the case of cylinders of capacity
longer to ensure complete expansion. greater than 86 cubic inches and out of
Any internal pressure applied after each lot of 500 or less for cylinders hav-
heat-treatment and previous to the of- ing a capacity of 86 cubic inches or
ficial test may not exceed 90 percent of less.
the test pressure. If, due to failure of (2) Specimens must conform to the
the test apparatus, the test pressure following:
cannot be maintained, the test may be (i) A gauge length of 8 inches with a
repeated at a pressure increased by 10 width not over 11⁄2 inches, a gauge
percent or 100 psig, whichever is the length of 2 inches with a width not
lower. over 11⁄2 inches, or a gauge length at
(3) Permanent volumetric expansion least 24 times the thickness with a
may not exceed 10 percent of total vol- width not over 6 times the thickness is
umetric expansion at test pressure. authorized when a cylinder wall is not
(4) Cylinders must be tested as fol- over 3⁄16 inch thick.
(ii) The specimen, exclusive of grip
lows:
ends, may not be flattened. Grip ends
may be flattened to within one inch of
random out of each lot of 200 or less
each end of the reduced section.
must be tested as outlined in para- (iii) When size of cylinder does not
graphs (i)(1), (i)(2), and (i)(3) of this sec- permit securing straight specimens,
tion to at least two times service pres- the specimens may be taken in any lo-
sure. cation or direction and may be
(ii) All cylinders not tested as out- straightened or flattened cold by pres-
lined in paragraph (i)(4)(i) of this sec- sure only, not by blows. When speci-
tion must be examined under pressure mens are so taken and prepared, the in-
of at least two times service pressure spector’s report must show in connec-
and show no defect. tion with record of physical tests de-
(5) Each 1000 cylinders or less succes- tailed information in regard to such
sively produced each day must con- specimens.
stitute a lot. One cylinder must be se- (iv) Heating of a specimen for any
lected from each lot and purpose is not authorized.
hydrostatically tested to destruction. (3) The yield strength in tension
If this cylinder bursts below five times must be the stress corresponding to a
the service pressure, then two addi- permanent strain of 0.2 percent of the
tional cylinders must be selected and gauge length. The following conditions
subjected to this test. If either of these apply:
cylinders fails by bursting below five (i) The yield strength must be deter-
times the service pressure then the en- mined by either the ‘‘offset’’ method or
tire lot must be rejected. All cylinders the ‘‘extension under load’’ method as
constituting a lot must be of identical prescribed in ASTM E 8 (IBR, see § 171.7
size, construction heat-treatment, fin- of this subchapter).
ish, and quality. (ii) In using the ‘‘extension under
(j) Flattening test. Following the hy- load’’ method, the total strain (or ‘‘ex-
drostatic test, one cylinder taken at tension under load’’) corresponding to
random out of each lot of 200 or less, the stress at which the 0.2 percent per-
must be subjected to a flattening test manent strain occurs may be deter-
that is between knife edges, wedge mined with sufficient accuracy by cal-
shaped, 60° angle, rounded to 1⁄2 inch ra- culating the elastic extension of the
dius. gauge length under appropriate load
(k) Physical test. A physical test must and adding thereto 0.2 percent of the
be conducted to determine yield gauge length. Elastic extension cal-

strength, tensile strength, elongation, culations must be based on an elastic
and reduction of area of material, as modulus of 30,000,000. In the event of
follows: controversy, the entire stress-strain
56
diagram must be plotted and the yield (4) As a safety precaution, if the
strength determined from the 0.2 per- manufacturer elects to make this test
cent offset. before the hydrostatic test, he should
(iii) For the purpose of strain meas- design his apparatus so that the pres-
urement, the initial strain must be set sure is applied to the smallest area
while the specimen is under a stress of practicable, around the point of clo-
12,000 psi and the strain indicator read- sure, and so as to use the smallest pos-
ing being set at the calculated cor- sible volume of air or gas.
responding strain. (n) Rejected cylinders. Repairs of re-
(iv) Cross-head speed of the testing jected cylinders is authorized. Cyl-
machine may not exceed 1⁄8 inch per inders that are leaking must be re-
minute during yield strength deter- jected, except that:
mination. (1) Spun cylinders rejected under the
(l) Acceptable results for physical and provisions of paragraph (m) of this sec-
flattening tests. Acceptable results for tion may be removed from the spun
the physical and flattening tests are an cylinder category by drilling to remove
elongation of at least 40 percent for a 2 defective material, tapping, and plug-
ging.
inch gauge length or at least 20 percent
(2) Brazed joints may be rebrazed.
in other cases and a yield strength not
(3) Subsequent to the operations
over 73 percent of tensile strength. In
noted in paragraphs (n)(1) and (n)(2) of
this instance the flattening test is re-
this section, acceptable cylinders must
quired, without cracking, to six times
pass all prescribed tests.
the wall thickness with a weld 90° from
(o) Marking. Markings on each cyl-
the direction of the applied load. Two
inder must be by stamping plainly and
rings cut from the ends of length of permanently on shoulder, top head,
pipe used in production of a lot may be neck or valve protection collar which
used for the flattening test provided is permanently attached to the cyl-
the rings accompany the lot which inders and forming an integral part
they represent in all thermal proc- thereof, provided that cylinders not
essing operations. At least one of the less than 0.090 inch thick may be
rings must pass the flattening test. stamped on the side wall adjacent to
(m) Leakage test. All spun cylinders top head.
and plugged cylinders must be tested
for leakage by gas or air pressure after [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
amended at 66 FR 45386, Aug. 28, 2001; 67 FR
the bottom has been cleaned and is free
51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31,
from all moisture, subject to the fol- 2003]
lowing conditions:
(1) Pressure, approximately the same § 178.56 Specification 4AA480 welded
as but no less than service pressure, steel cylinders.
must be applied to one side of the fin- (a) Type, size, and service pressure. A
ished bottom over an area of at least DOT 4AA480 cylinder is a welded steel
1⁄16 of the total area of the bottom but
cylinder having a water capacity
not less than 3⁄4 inch in diameter, in- (nominal) not over 1,000 pounds water
cluding the closure, for at least 1 capacity and a service pressure of 480
minute, during which time the other psig. Closures welded by spinning proc-
side of the bottom exposed to pressure ess not permitted.
must be covered with water and closely (b) Steel. The limiting chemical com-
examined for indications of leakage. position of steel authorized by this
Except as provided in paragraph (n) of specification must be as shown in table
this section, cylinders which are leak- I of appendix A to this part.
ing must be rejected. (c) Identification of material. Material
(2) A spun cylinder is one in which an must be identified by any suitable
end closure in the finished cylinder has method except that plates and billets
been welded by the spinning process. for hotdrawn cylinders must be marked
(3) A plugged cylinder is one in which with the heat number.

a permanent closure in the bottom of a (d) Manufacture. Cylinders must be
finished cylinder has been effected by a manufactured using equipment and
plug. processes adequate to ensure that each
57
§ 178.56 49 CFR Ch. I (10–1–18 Edition)
cylinder produced conforms to the re- (g) Heat treatment. Each cylinder
quirements of this subpart. No defect is must be uniformly and properly heat
permitted that is likely to weaken the treated prior to tests. Any suitable
finished cylinder appreciably. A rea- heat treatment in excess of 1100 °F is
sonably smooth and uniform surface authorized except that liquid quench-
finish is required. Exposed bottom ing is not permitted. Heat treatment
welds on cylinders over 18 inches long must be accomplished after all forming
must be protected by footrings. Min- and welding operations. Heat treat-
imum thickness of heads and bottoms ment is not required after welding
may not be less than 90 percent of the weldable low carbon parts to attach-
required thickness of the side wall. ments of similar material which have
Seams must be made as follows: been previously welded to the top or
(1) Circumferential seams must be bottom of cylinders and properly heat
welded. Brazing is not authorized. treated, provided such subsequent
(2) Longitudinal seams are not per- welding does not produce a tempera-
mitted. ture in excess of 400 °F., in any part of
(3) Welding procedures and operators the top or bottom material.
must be qualified in accordance with (h) Openings in cylinders. Openings in
CGA C–3 (IBR, see § 171.7 of this sub- cylinders must conform to the fol-
chapter). lowing:
(e) Welding. Only the welding of (1) All openings must be in the heads
neckrings, footrings, bosses, pads, and or bases.
valve protection rings to the tops and (2) Each opening in the cylinder, ex-
bottoms of cylinders is authorized. cept those for safety devices, must be
Provided that such attachments are provided with a fitting boss, or pad, se-
made of weldable steel, the carbon con- curely attached to the cylinder by
tent of which does not exceed 0.25 per- welding or by threads. If threads are
cent. used they must comply with the fol-
(f) Wall thickness. The wall thickness lowing:
of the cylinder must conform to the (i) Threads must be clean-cut, even
following: without checks and cut to gauge.
(1) For cylinders with an outside di- (ii) Taper threads to be of length not
ameter over 5 inches, the minimum less than as specified for American
wall thickness is 0.078 inch. In any Standard taper pipe threads.
case, the minimum wall thickness (iii) Straight threads having at least
must be such that the calculated wall 6 engaged threads, must have a tight
stress at the minimum test pressure (in fit and a calculated shear strength at
paragraph (i) of this section) may not least 10 times the test pressure of the
exceed the lesser value of either of the cylinder. Gaskets, adequate to prevent
following: leakage, are required.
(i) One-half of the minimum tensile (3) Closure of a fitting, boss or pad
strength of the material determined as must be adequate to prevent leakage.
required in paragraph (j) of this sec- (i) Hydrostatic test. Each cylinder
tion; or must successfully withstand a hydro-
(ii) 35,000 psi. static test as follows:
(2) Calculation must be made by the (1) The test must be by water jacket,
formula: or other suitable method, operated so
S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2) as to obtain accurate data. The pres-
sure gauge must permit reading to an
Where: accuracy of 1 percent. The expansion
S = wall stress in psi; gauge must permit reading of total ex-
P = minimum test pressure prescribed for pansion to an accuracy of either 1 per-
water jacket test; cent or 0.1 cubic centimeter.
D = outside diameter in inches; (2) Pressure must be maintained for
at least 30 seconds or sufficiently
(3) The ratio of tangential length to longer to assure complete expansion.

outside diameter may not exceed 4.0 for Any internal pressure applied after
cylinders with a wall thickness less heat-treatment and before the official
than 0.100 inch. test may not exceed 90 percent of the
58
test pressure. If, due to failure of test sure only, not by blows. When speci-
apparatus, the test pressure cannot be mens are so taken and prepared, the in-
maintained, the test may be repeated spector’s report must show in connec-
at a pressure increased by 10 percent or tion with record of physical tests de-
100 psig, whichever is lower. tailed information in regard to such
(3) Permanent volumetric expansion specimens.
may not exceed 10 percent of the total (iv) Heating of a specimen for any
volumetric expansion at test pressure. purpose is not authorized.
(4) Cylinders must be tested as fol- (3) The yield strength in tension
lows: must be the stress corresponding to a
(i) At least one cylinder selected at permanent strain of 0.2 percent of the
random out of each lot of 200 or less gauge length. The following conditions
must be tested as described in para- apply:
graphs (i)(1), (i)(2), and (i)(3) of this sec- (i) The yield strength must be deter-
tion, to at least two times service pres- mined by either the ‘‘offset’’ method or
sure. If a selected cylinder fails, then the ‘‘extension under load’’ method as
two additional specimens must be se- prescribed in ASTM E 8 (IBR, see § 171.7
lected at random from the same lot and of this subchapter).
subjected to the prescribed test. If ei- (ii) In using the ‘‘extension under
ther of these fails the test, then each load’’ method, the total strain (or ‘‘ex-
cylinder in that lot must be so tested; tension under load’’), corresponding to
and the stress at which the 0.2 percent per-
(ii) Each cylinder not tested as pre- manent strain occurs may be deter-
scribed in paragraph (i)(4)(i) of this sec- mined with sufficient accuracy by cal-
tion must be examined under pressure culating the elastic extension of the
of at least two times service pressure gauge length under appropriate load
and must show no defect. A cylinder and adding thereto 0.2 percent of the
showing a defect must be rejected un- gauge length. Elastic extension cal-
less it may be requalified under para- culations must be based on an elastic
graph (m) of this section. modulus of 30,000,000. In the event of
(j) Physical test. A physical test must controversy, the entire stress-strain
be conducted to determine yield diagram must be plotted and the yield
strength, tensile strength, elongation, strength determined from the 0.2 per-
and reduction of area of material, as cent offset.
follows: (iii) For the purpose of strain meas-
(1) The test is required on 2 speci- urement, the initial strain reference
mens cut from one cylinder having must be set while the specimen is
passed the hydrostatic test, or part under a stress of 12,000 psi and the
thereof heat-treated as required, taken strain indicator reading being set at
at random out of each lot of 200 or less. the calculated corresponding strain.
(i) A gauge length of 8 inches with a minute during yield strength deter-
width not over 11⁄2 inches, a gauge mination.
length of 2 inches with a width not (k) Elongation. Physical test speci-
over 11⁄2 inches, or a gauge length at mens must show at least a 40 percent
least 24 times the thickness with a elongation for 2-inch gauge lengths or
width not over 6 times thickness is au- at least a 20 percent elongation in
thorized when the cylinder wall is not other cases. Except that these elon-
over 3⁄16 inch thick. gation percentages may be reduced nu-
(ii) The specimen, exclusive of grip merically by 2 for 2-inch specimens and
ends, may not be flattened. Grip ends by 1 in other cases for each 7,500 psi in-
may be flattened to within one inch of crement of tensile strength above 50,000
each end of the reduced section. psi to a maximum of four such incre-
(iii) When size of cylinder does not ments.
permit securing straight specimens, (l) Tests of welds. Welds must be test-
the specimens may be taken in any lo- ed as follows:
cation or direction and may be (1) Tensile test. A specimen must be
straightened or flattened cold, by pres- cut from one cylinder of each lot of 200
59
§ 178.57 49 CFR Ch. I (10–1–18 Edition)
or less, or a welded test plate. The (3) On a plate attached to the top of
welded test plate must be of one of the the cylinder or permanent part thereof:
heats in the lot of 200 or less which it sufficient space must be left on the
represents, in the same condition and plate to provide for stamping at least
approximately the same thickness as six retest dates: the plate must be at
the cylinder wall except that it may least 1⁄16 inch thick and must be at-
not be of a lesser thickness than that tached by welding or by brazing at a
required for a quarter size Charpy im- temperature of at least 1100 °F,
pact specimen. The weld must be made throughout all edges of the plate.
by the same procedures and subjected (4) Variations in location of mark-
to the same heat treatment as the ings authorized only when necessitated
major weld on the cylinder. The speci- by lack of space.
mens must be taken across the major [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
seam and must be prepared and tested amended at 66 FR 45386, Aug. 28, 2001; 67 FR
in accordance with and must meet the 51653, Aug. 8, 2002; 68 FR 75748, 75749, Dec. 31,
requirements of CGA Pamphlet C–3. 2003]
Should this specimen fail to meet the
requirements, specimens may be taken § 178.57 Specification 4L welded insu-
from two additional cylinders or weld- lated cylinders.
ed test plates from the same lot and (a) Type, size, service pressure, and de-
tested. If either of the latter specimens sign service temperature. A DOT 4L cyl-
fail to meet the requirements, the en- inder is a fusion welded insulated cyl-
tire lot represented must be rejected. inder with a water capacity (nominal)
(2) Guided bend test. A root bend test not over 1,000 pounds water capacity
specimen must be cut from the cyl- and a service pressure of at least 40 but
inder or a welded test plate, used for not greater than 500 psig conforming to
the tensile test specified in paragraph the following requirements:
(l)(1) of this section. Specimens must (1) For liquefied hydrogen service,
be taken from across the major seam the cylinders must be designed to stand
and must be prepared and tested in ac- on end, with the axis of the cylindrical
cordance with and must meet the re- portion vertical.
quirements of CGA Pamphlet C–3. (2) The design service temperature is
(3) Alternate guided-bend test. This the coldest temperature for which a
test may be used and must be as re- cylinder is suitable. The required de-
quired by CGA Pamphlet C–3. The spec- sign service temperatures for each
imen must be bent until the elongation cryogenic liquid is as follows:
at the outer surface, adjacent to the
root of the weld, between the lightly Cryogenic liquid Design service temperature
scribed gage lines-a to b, is at least 20 Argon ...................... Minus 320 °F or colder.
percent, except that this percentage Helium .................... Minus 452 °F or colder.
may be reduced for steels having a ten- Hydrogen ................ Minus 42 3 °F or colder.
Neon ....................... Minus 411 °F or colder.
sile strength in excess of 50,000 psi, as Nitrogen .................. Minus 320 °F or colder.
provided in paragraph (k) of this sec- Oxygen ................... Minus 320 °F or colder.
tion.
(m) Rejected cylinders. Reheat treat- (b) Material. Material use in the con-
ment of rejected cylinders is author- struction of this specification must
ized. Subsequent thereto, cylinders conform to the following:
must pass all prescribed tests to be ac- (1) Inner containment vessel (cylinder).
ceptable. Repair of welded seams by Designations and limiting chemical
welding is authorized. compositions of steel authorized by
(n) Markings. Markings must be this specification must be as shown in
stamped plainly and permanently in table 1 in paragraph (o) of this section.
one of the following locations on the (2) Outer jacket. Steel or aluminum
cylinder: may be used subject to the require-
(1) On shoulders and top heads not ments of paragraph (o)(2) of this sec-
less than 0.087 inch thick. tion.

(2) On neck, valve boss, valve protec- (c) Identification of material. Material
tion sleeve, or similar part perma- must be identified by any suitable
nently attached to top end of cylinder. method.
60
(d) Manufacture. Cylinders must be an impact test of the weld must be per-
manufactured using equipment and formed in accordance with paragraph
processes adequate to ensure that each (l) of this section as part of the quali-
cylinder produced conforms to the re- fication of each welding procedure and
quirements of this subpart and to the operator.
following requirements: (e) Welding. Welding of the cylinder
(1) No defect is permitted that is must be as follows:
likely to weaken the finished cylinder (1) All seams of the cylinder must be
appreciably. A reasonably smooth and fusion welded. A means must be pro-
uniform surface finish is required. The vided for accomplishing complete pene-
shell portion must be a reasonably true tration of the joint. Only butt or joggle
cylinder. butt joints for the cylinder seams are
(2) The heads must be seamless, con- authorized. All joints in the cylinder
cave side to the pressure, hemi- must have reasonably true alignment.
spherical or ellipsoidal in shape with (2) All attachments to the sidewalls
the major diameter not more than and heads of the cylinder must be by
twice the minor diameter. Minimum fusion welding and must be of a
thickness of heads may not be less weldable material complying with the
than 90 percent of the required thick- impact requirements of paragraph (l) of
ness of the sidewall. The heads must be this section.
reasonably true to shape, have no ab- (3) For welding the cylinder, each
rupt shape changes, and the skirts procedure and operator must be quali-
must be reasonably true to round. fied in accordance with the sections of
(3) The surface of the cylinder must CGA Pamphlet C–3 that apply. In addi-
be insulated. The insulating material tion, impact tests of the weld must be
must be fire resistant. The insulation performed in accordance with para-
on non-evacuated jackets must be cov- graph (l) of this section as part of the
ered with a steel jacket not less than qualification of each welding procedure
0.060-inch thick or an aluminum jacket and operator.
not less than 0.070 inch thick, so con- (4) Brazing, soldering and threading
structed that moisture cannot come in are permitted only for joints not made
contact with the insulating material. If directly to the cylinder body. Threads
a vacuum is maintained in the insula- must comply with the requirements of
tion space, the evacuated jacket must paragraph (h) of this section.
be designed for a minimum collapsing (f) Wall thickness. The minimum wall
pressure of 30 psig differential whether thickness of the cylinder must be such
made of steel or aluminum. The con- that the calculated wall stress at the
struction must be such that the total minimum required test pressure may
heat transfer, from the atmosphere at not exceed the least value of the fol-
ambient temperature to the contents lowing:
of the cylinder, will not exceed 0.0005 (1) 45,000 psi.
Btu per hour, per Fahrenheit degree (2) One-half of the minimum tensile
differential in temperature, per pound strength across the welded seam deter-
of water capacity of the cylinder. For mined in paragraph (l) of this section.
hydrogen, cryogenic liquid service, the (3) One-half of the minimum tensile
total heat transfer, with a temperature strength of the base metal determined
differential of 520 Fahrenheit degrees, as required in paragraph (j) of this sec-
may not exceed that required to vent tion.
30 SCF of hydrogen gas per hour. (4) The yield strength of the base
(4) For a cylinder having a design metal determined as required in para-
service temperature colder than minus graph (l) of this section.
320 °F, a calculation of the maximum
(5) Further provided that wall stress
weight of contents must be made and
for cylinders having longitudinal
that weight must be marked on the
seams may not exceed 85 percent of the
cylinder as prescribed in § 178.35.
above value, whichever applies.
(5) Welding procedures and oper-

(6) Calculation must be made by the
ations must be qualified in accordance
following formula:
with CGA Pamphlet C–3 (IBR, see
§ 171.7 of this subchapter). In addition, S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
61
§ 178.57 49 CFR Ch. I (10–1–18 Edition)
where: 6 times thickness (authorized when cyl-
S = wall stress in pounds psi; inder wall is not over 1⁄16 inch thick).
P = minimum test pressure prescribed for (ii) The specimen, exclusive of grip
pressure test in psig; ends, may not be flattened. Grip ends
D = outside diameter in inches; may be flattened to within one inch of
d = inside diameter in inches. each end of the reduced section.
(g) Heat treatment. Heat treatment is (iii) When size of the cylinder does
not permitted. not permit securing straight speci-
(h) Openings in cylinder. Openings in mens, the specimens may be taken in
cylinders must conform to the fol- any location or direction and may be
lowing: straightened or flattened cold by pres-
(1) Openings are permitted in heads sure only, not by blows. When speci-
only. They must be circular and may mens are so taken and prepared, the in-
not exceed 3 inches in diameter or one spector’s report must show in connec-
third of the cylinder diameter, which- tion with record of physical tests de-
ever is less. Each opening in the cyl- tailed information in regard to such
inder must be provided with a fitting, specimens.
boss or pad, either integral with, or se- (iv) Heating of a specimen for any
curely attached to, the cylinder body purpose is not authorized.
by fusion welding. Attachments to a (3) The yield strength in tension
fitting, boss or pad may be made by must be the stress corresponding to a
welding, brazing, mechanical attach- permanent strain of 0.2 percent of the
ment, or threading. gauge length. The following conditions
(2) Threads must comply with the fol- apply:
lowing: (i) The yield strength must be deter-
(i) Threads must be clean-cut, even, mined by either the ‘‘offset’’ method or
without checks and cut to gauge. the ‘‘extension under load’’ method as
(ii) Taper threads to be of a length prescribed in ASTM E 8 (IBR, see § 171.7
not less than that specified for NPT. of this subchapter).
(iii) Straight threads must have at (ii) In using the ‘‘extension under
least 4 engaged threads, tight fit and load’’ method, the total strain (or ‘‘ex-
calculated shear strength at least 10 tension under load’’), corresponding to
times the test pressure of the cylinder. the stress at which the 0.2 percent per-
Gaskets, which prevent leakage and manent strain occurs may be deter-
are inert to the hazardous material, mined with sufficient accuracy by cal-
are required. culating the elastic expansion of the
(i) Pressure test. Each cylinder, before gauge length under appropriate load
insulating and jacketing, must be ex- and adding thereto 0.2 percent of the
amined under a pressure of at least 2 gauge length. Elastic extension cal-
times the service pressure maintained culations must be based on the elastic
for at least 30 seconds without evidence modulus of the material used. In the
of leakage, visible distortion or other event of controversy, the entire stress-
defect. The pressure gauge must permit strain diagram must be plotted and the
reading to an accuracy of 1 percent. yield strength determined from the 0.2
(j) Physical test. A physical test must percent offset.
be conducted to determine yield (iii) For the purpose of strain meas-
strength, tensile strength, and elon- urement, the initial strain reference
gation as follows: must be set while the specimen is
(1) The test is required on 2 speci- under a stress of 12,000 psi and the
mens selected from material of each strain indicator reading being set at
heat and in the same condition as that the calculated corresponding strain.
in the completed cylinder. (iv) Cross-head speed of the testing
(2) Specimens must conform to the machine may not exceed 1⁄8 inch per
following: minute during yield strength deter-
(i) A gauge length of 8 inches with a mination.
width not over 11⁄2 inches, a gauge (k) Acceptable results for physical tests.
length of 2 inches with width not over Physical properties must meet the lim-
11⁄2 inches, or a gauge length at least 24 its specified in paragraph (o)(1), table 1,
times thickness with a width not over of this section, for the particular steel
62
in the annealed condition. The speci- may be reduced for steels having a ten-
mens must show at least a 20 percent sile strength in excess of 100,000 psig, as
elongation for a 2-inch gage length. Ex- provided in paragraph (c) of this sec-
cept that the percentage may be re- tion.
duced numerically by 2 for each 7,500 (4) Impact tests. One set of three im-
psi increment of tensile strength above pact test specimens (for each test)
100,000 psi to a maximum of 5 such in- must be prepared and tested for deter-
crements. Yield strength and tensile mining the impact properties of the de-
strength must meet the requirements posited weld metal—
of paragraph (o)(1), table 1, of this sec- (i) As part of the qualification of the
tion. welding procedure.
(l) Tests of welds. Welds must be test- (ii) As part of the qualification of the
ed as follows: operators.
(1) Tensile test. A specimen must be (iii) For each ‘‘heat’’ of welding rodor
cut from one cylinder of each lot of 200 wire used.
or less, or welded test plate. The weld- (iv) For each 1,000 feet of weld made
ed test plate must be of one of the with the same heat of welding rod or
heats in the lot of 200 or less which it wire.
represents, in the same condition and (v) All impact test specimens must be
approximately the same thickness as of the charpy type, keyhole or milled
the cylinder wall except that it may U-notch, and must conform in all re-
not be of a lesser thickness than that spects to ASTM E 23 (IBR, see § 171.7 of
required for a quarter size Charpy im- this subchapter). Each set of impact
pact specimen. The weld must be made specimens must be taken across the
by the same procedures and subjected weld and have the notch located in the
to the same heat treatment as the weld metal. When the cylinder mate-
major weld on the cylinder. The speci- rial thickness is 2.5 mm or thicker, im-
men must be taken across the major pact specimens must be cut from a cyl-
seam and must be prepared in accord- inder or welded test plate used for the
ance with and must meet the require- tensile or bend test specimens. The di-
ments of CGA Pamphlet C–3. Should mension along the axis of the notch
this specimen fail to meet the require- must be reduced to the largest possible
ments, specimens may be taken from of 10 mm, 7.5 mm, 5 mm or 2.5 mm, de-
two additional cylinders or welded test pending upon cylinder thickness. When
plates from the same lot and tested. If the material in the cylinder or welded
either of the latter specimens fails to test plate is not of sufficient thickness
meet the requirements, the entire lot to prepare 2.5 mm impact test speci-
represented must be rejected. mens, 2.5 mm specimens must be pre-
(2) Guided bend test. A ‘‘root’’ bend pared from a welded test plate made
test specimen must be cut from the from 1⁄8 inch thick material meeting
cylinder or welded test plate, used for the requirements specified in para-
the tensile test specified in paragraph graph (o)(1), table 1, of this section and
(l)(1) of this section and from any other having a carbon analysis of .05 min-
seam or equivalent welded test plate if imum, but not necessarily from one of
the seam is welded by a procedure dif- the heats used in the lot of cylinders.
ferent from that used for the major The test piece must be welded by the
seam. Specimens must be taken across same welding procedure as used on the
the particular seam being tested and particular cylinder seam being quali-
must be prepared and tested in accord- fied and must be subjected to the same
ance with and must meet the require- heat treatment.
ments of CGA Pamphlet C–3. (vi) Impact test specimens must be
(3) Alternate guided-bend test. This cooled to the design service tempera-
test may be used and must be as speci- ture. The apparatus for testing the
fied in CGA Pamphlet C–3. The speci- specimens must conform to require-
men must be bent until the elongation ments of ASTM Standard E 23. The test
at the outer surface, adjacent to the piece, as well as the handling tongs,
root of the weld, between the lightly must be cooled for a length of time suf-
scribed gage lines a to b, is at least 20 ficient to reach the service tempera-
percent, except that this percentage ture. The temperature of the cooling
63
§ 178.57 49 CFR Ch. I (10–1–18 Edition)
device must be maintained within a must pass all prescribed tests to be ac-
range of plus or minus 3 °F. The speci- ceptable. Welds may be repaired by
men must be quickly transferred from suitable methods of fusion welding.
the cooling device to the anvil of the (o) Authorized materials of construc-
testing machine and broken within a tion. Authorized materials of construc-
time lapse of not more than six section are as follows:
onds. (1) Inner containment vessel (cylinder).
(vii) The impact properties of each Electric furnace steel of uniform qual-
set of impact specimens may not be ity must be used. Chemical analysis
less than the values in the following must conform to ASTM A 240/A 240M
table: (IBR, see § 171.7 of this subchapter),
Type 304 stainless steel. Chemical anal-
Minimum Minimum ysis must conform to ASTM A240, Type
impact value impact value
required for 304 Stainless Steel. A heat of steel
permitted on
Size of specimen avg. of each one only of a made under table 1 and table 2 in this
set of three set of three
specimens paragraph (o)(1) is acceptable, even
(ft.-lb.)
(ft.-lb.)
though its check chemical analysis is
10 mm × 10 mm .................... 15 10 slightly out of the specified range, if it
10 mm × 7.5 mm ................... 12.5 8.5 is satisfactory in all other respects,
10 mm × 5 mm ...................... 10 7.0
10 mm × 2.5 mm ................... 5 3.5 provided the tolerances shown in table
3 in this paragraph (o)(1) are not ex-
(viii) When the average value of the ceeded. The following chemical anal-
three specimens equals or exceeds the yses and physical properties are au-
minimum value permitted for a single thorized:
specimen and the value for more than
one specimen is below the required av- TABLE 1—AUTHORIZED MATERIALS
erage value, or when the value for one Chemical analysis,
Designation
specimen is below the minimum value limits in percent
permitted for a single specimen, a Carbon 1 ............................................. 0.08 max.
retest of three additional specimens Manganese ........................................ 2.00 max.
must be made. The value of each of Phosphorus ........................................ 0.045 max.
Sulphur .............................................. 0.030 max.
these retest specimens must equal or Silicon ................................................ 1.00 max.
exceed the required average value. Nickel ................................................. 8.00–10.50.
When an erratic result is caused by a Chromium .......................................... 18.00–20.00.
Molybdenum ...................................... None.
defective specimen, or there is uncer- Titanium ............................................. None.
tainty in test procedure, a retest is au- Columbium ......................................... None.
thorized. 1 The carbon analysis must be reported to the nearest hun-
(m) Radiographic examination. Cyl- dredth of one percent.
inders must be subject to a radio-
graphic examination as follows: TABLE 2—PHYSICAL PROPERTIES
(1) The techniques and acceptability Physical
of radiographic inspection must con- properties
form to the standards set forth in CGA (annealed)
Pamphlet C–3. Tensile strength, p.s.i. (minimum) ....................... 75,000
(2) One finished longitudinal seam Yield strength, p.s.i. (minimum) ........................... 30,000
must be selected at random from each Elongation in 2 inches (minimum) percent .......... 30.0
Elongation other permissible gauge lengths
lot of 100 or less successively produced (minimum) percent ........................................... 15.0
and be radiographed throughout its en-
tire length. Should the radiographic
examination fail to meet the require-
ments of paragraph (m)(1) of this sec- Tolerance
tion, two additional seams of the same over the
Limit or specified range maximum
lot must be examined, and if either of Elements (percent) limit or under
these fail to meet the requirements of the minimum
limit
(m)(1) of this section, only those pass-
ing are acceptable. Carbon ............... To 0.030, incl ................... 0.005

Over 0.30 to 0.20, incl ..... 0.01
(n) Rejected cylinders. Reheat treat- Manganese ........ To 1.00 incl ...................... .03
ment of rejected cylinders is author- Over 1.00 to 3.00, incl ..... 0.04
ized. Subsequent thereto, cylinders Phosphorus 1 ..... To 0.040, incl ................... 0.005
64
TABLE 3—CHECK ANALYSIS TOLERANCES— (q) Inspector’s report. In addition to

Continued the information required by § 178.35, the
inspector’s reports must contain infor-
Tolerance
over the mation on:
Elements Limit or specified range maximum (1) The jacket material and insula-
(percent) limit or under
the minimum tion type;
limit (2) The design service temperature
Over 0.040 to 0.020 incl .. 0.010 (°F); and
Sulphur .............. To .40 incl ........................ 0.005 (3) The impact test results, on a lot
Silicon ................ To 1.00, incl ..................... 0.05 basis.
Nickel ................. Over 5.00 to 10.00, incl ... 0.10
Over 10.00 to 20.00, incl 0.15 [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
Chromium .......... Over 15.00 to 20.00, incl 0.20 amended at 66 FR 45386, Aug. 28, 2001; 67 FR
1 Rephosphorized steels not subject to check analysis for 51653, Aug. 8, 2002; 68 FR 75748, Dec. 31, 2003]
phosphorus.
(2) Outer jacket. (i) Nonflammable § 178.58 Specification 4DA welded steel
cylinders for aircraft use.
cryogenic liquids. Cylinders intended
for use in the transportation of non- (a) Type, size, and service pressure. A
flammable cryogenic liquid must have DOT 4DA is a welded steel sphere (two
an outer jacket made of steel or alu- seamless hemispheres) or a circum-
minum. ferentially welded cylinder (two seam-
(ii) Flammable cryogenic liquids. less drawn shells) with a water capac-
Cylinders intended for use in the trans- ity not over 100 pounds and a service
portation of flammable cryogenic liq- pressure of at least 500 but not over 900
uid must have an outer jacket made of psig.
steel. (b) Steel. Open-hearth or electric steel
(p) Markings. (1) Markings must be of uniform quality must be used. A
stamped plainly and permanently on heat of steel made under table 1 in this
shoulder or top head of jacket or on a paragraph (b), check chemical analysis
permanently attached plate or head of which is slightly out of the specified
protective ring. range, is acceptable, if satisfactory in
(2) The letters ‘‘ST’’, followed by the all other respects, provided the toler-
design service temperature (for exam- ances shown in table 2 in this para-
ple, ST–423F), must be marked on cyl- graph (b) are not exceeded except as ap-
inders having a design service tempera- proved by the Associate Administrator.
ture of colder than minus 320 °F only. The following chemical analyses are
Location to be just below the DOT authorized:
mark.
(3) The maximum weight of contents, TABLE 1—AUTHORIZED MATERIALS
in pounds (for example, ‘‘Max. Content 4130 Percent
51 #’’), must be marked on cylinders
having a design service temperature Carbon ........................................................ 0.28/0.33.
Manganese ................................................. 0.40/0.60.
colder than minus 320 °F only. Loca- Phosphorus ................................................ 0.040 max.
tion to be near symbol. Sulfur .......................................................... 0.040 max.
(4) Special orientation instructions Silicon ......................................................... 0.15/0.35.
Chromium ................................................... 0.80/1.10.
must be marked on the cylinder (for Molybdenum ............................................... 0.15/0.25.
example, THIS END UP), if the cyl-
inder is used in an orientation other
than vertical with openings at the top TABLE 2—CHECK ANALYSIS TOLERANCES
of the cylinder. Tolerance (per-
(5) If the jacket of the cylinder is cent) over the
maximum limit or
constructed of aluminum, the letters under the min-
‘‘AL’’ must be marked after the service Element Limit or maximum imum limit
specified (percent)
pressure marking. Example: DOT-4L150 Under Over
AL. min- max-
imum imum
(6) Except for serial number and jack- limit limit
et material designation, each marking

prescribed in this paragraph (p) must Carbon ............ Over 0.15 to 0.40 incl .03 ....... .04
Manganese ..... To 0.60 incl ................. .03 ....... .03
be duplicated on each cylinder by any Phosphorus1 ... All ranges .................... .............. .01
suitable means. Sulphur ........... All ranges .................... .............. .01
65
§ 178.58 49 CFR Ch. I (10–1–18 Edition)
TABLE 2—CHECK ANALYSIS TOLERANCES— (1) Calculation for a sphere must be

Continued made by the following formula:
Tolerance (per- S = PD / 4tE
cent) over the
maximum limit or Where:
under the min-
Limit or maximum imum limit S = wall stress in pounds psi;
Element specified (percent) P = test pressure prescribed for water jacket
Under Over
min- max- test, i.e., at least 2 times service pres-
imum imum sure, in psig;
limit limit D = outside diameter in inches;
Silicon ............. To 0.30 incl ................. .02 ....... .03 t = minimum wall thickness in inches;
Over 0.30 to 1.00 incl .05 ....... .05 E = 0.85 (provides 85 percent weld efficiency
Chromium ....... To 0.90 incl ................. .03 ....... .03 factor which must be applied in the girth
Over 0.90 to 2.10 incl .05 ....... .05 weld area and heat affected zones which
Molybdenum ... To 0.20 incl ................. .01 ....... .01 zone must extend a distance of 6 times
Over 0.20 to 0.40, incl .02 ....... .02
1 Rephosphorized steels not subject to check analysis for
phosphorus.
(2) Calculation for a cylinder must be
(c) Identification of material. Materials
made by the following formula:
must be identified by any suitable
method except that plates and billets S = [P(1.3D 2 + 0.4d 2)] / (D 2 ¥ d 2)
for hot-drawn containers must be
Where:
(d) Manufacture. Cylinders must be S = wall stress in pounds psi;
manufactured in accordance with the P = test pressure prescribed for water jacket
test, i.e., at least 2 times service pres-
following requirements: sure, in psig;
(1) By best appliances and methods. D = outside diameter in inches;
No defect is acceptable that is likely to d = inside diameter in inches.
weaken the finished container appre-
ciably. A reasonably smooth and uni- (g) Heat treatment. The completed
form surface finish is required. No ab- containers must be uniformly and
rupt change in wall thickness is per- properly heat-treated prior to tests.
mitted. Welding procedures and opera- Heat-treatment of containers of the au-
tors must be qualified in accordance thorized analysis must be as follows:
with CGA Pamphlet C–3 (IBR, see (1) All containers must be quenched
§ 171.7 of this subchapter). by oil, or other suitable medium except
(2) All seams of the sphere or cyl- as provided in paragraph (g)(4) of this
inders must be fusion welded. Seams section.
must be of the butt or joggle butt type (2) The steel temperature on quench-
and means must be provided for accom- ing must be that recommended for the
plishing complete penetration of the steel analysis, but may not exceed 1,750
joint. °F.
(e) Welding. Attachments to the con- (3) The steel must be tempered at the
tainer are authorized by fusion welding temperature most suitable for the
provided that such attachments are analysis except that in no case shall
made of weldable steel, the carbon con- the tempering temperature be less than
tent of which may not exceed 0.25 per- 1,000 °F.
cent except in the case of 4130 steel. (4) The steel may be normalized at a
(f) Wall thickness. The minimum wall temperature of 1,650 °F instead of being
thickness must be such that the wall quenched, and containers so normal-
stress at the minimum specified test ized need not be tempered.
pressure may not exceed 67 percent of (5) All cylinders, if water quenched or
the minimum tensile strength of the quenched with a liquid producing a
steel as determined from the physical cooling rate in excess of 80 percent of
and burst tests required and may not the cooling rate of water, must be in-
be over 70,000 p.s.i. For any diameter spected by the magnetic particle or dye
container, the minimum wall thickness penetrant method to detect the pres-
is 0.040 inch. Calculations must be ence of quenching cracks. Any cylinder
made by the formulas in (f)(1) or (f)(2) found to have a quench crack must be
of this section: rejected and may not be requalified.
66
(h) Openings in container. Openings in (1) Flattening test for spheres. One
the container must comply with the sphere taken at random out of each lot
following requirements: of 200 or less must be subjected to a
(1) Each opening in the container flattening test as follows:
must be provided with a fitting, boss, (i) The test must be performed after
or pad of weldable steel securely at- the hydrostatic test.
tached to the container by fusion weld- (ii) The test must be at the weld be-
ing. tween the parallel steel plates on a
(2) Attachments to a fitting, boss, or press with a welded seam, at right an-
pad must be adequate to prevent leak- gles to the plates. Any projecting ap-
age. Threads must comply with the fol- purtenances may be cut off (by me-
lowing: chanical means only) prior to crushing.
(i) Threads must be clean cut, even, (2) Flattening test for cylinders. One
without checks, and tapped to gauge. cylinder taken at random out of each
(ii) Taper threads to be of length not lot of 200 or less, must be subjected to
less than as specified for American a flattening test as follows:
Standard taper pipe threads.
(i) The test must be performed after
(iii) Straight threads, having at least
the hydrostatic test.
4 engaged threads, to have tight fit and
(ii) The test cylinder must be placed
calculated shear strength at least 10
between wedge-shaped knife edges hav-
times the test pressure of the con-
ing a 60° angle, rounded to a 1⁄2-inch ra-
tainer; gaskets required, adequate to
dius.
prevent leakage.
(i) Hydrostatic test. Each cylinder (l) Radiographic inspection. Radio-
must successfully withstand a hydro- graphic examinations is required on all
static test as follows: welded joints which are subjected to in-
(1) The test must be by water-jacket, ternal pressure, except that at the dis-
or other suitable method, operated so cretion of the disinterested inspector,
as to obtain accurate data. The pres- openings less than 25 percent of the
sure gauge must permit reading to an sphere diameter need not be subjected
accuracy of 1 percent. The expansion to radiographic inspection. Evidence of
gauge must permit reading of total ex- any defects likely to seriously weaken
pansion to accuracy either of 1 percent the container must be cause for rejec-
or 0.1 cubic centimeter. tion.
(2) Pressure must be maintained for (m) Physical test and specimens for
at least 30 seconds and sufficiently spheres and cylinders. Spheres and cyl-
longer to ensure complete expansion. inders must be subjected to a physical
Any internal pressure applied after test as follows:
heat-treatment and previous to the of- (1) A physical test for a sphere is re-
ficial test may not exceed 90 percent of quired on 2 specimens cut from a flat
the test pressure. If, due to failure of representative sample plate of the
the test apparatus, the test pressure same heat taken at random from the
cannot be maintained, the test may be steel used to produce the sphere. This
repeated at a pressure increased by 10 flat steel from which the 2 specimens
percent or 100 psig, whichever is the are to be cut must receive the same
lower. heat-treatment as the spheres them-
(3) Permanent volumetric expansion selves. Sample plates to be taken for
may not exceed 10 percent of total vol- each lot of 200 or less spheres.
umetric expansion at test pressure. (2) Specimens for spheres have a
(4) Each container must be tested to gauge length of 2 inches with a width
at least 2 times service pressure. not over 11⁄2 inches, or a gauge length
(j) Burst test. One container taken at at least 24 times thickness with a
random out of 200 or less must be width not over 6 times thickness is au-
hydrostatically tested to destruction. thorized when wall of sphere is not
The rupture pressure must be included over 3⁄16 inch thick.
as part of the inspector’s report. (3) A physical test for cylinders is re-
(k) Flattening test. Spheres and cyl- quired on 2 specimens cut from 1 cyl-
inders must be subjected to a flat- inder taken at random out of each lot
tening test as follows: of 200 or less.
67
§ 178.59 49 CFR Ch. I (10–1–18 Edition)
(4) Specimens for cylinder must con- (2) Flattening is required to 50 per-
form to the following: cent of the original outside diameter
(i) A gauge length of 8 inches with a without cracking.
width not over 11⁄2 inches, a gauge (3) Burst pressure must be at least 3
length of 2 inches with a width not times service pressure.
over 11⁄2 inches, a gauge length at least (o) Rejected containers. Reheat-treat-
24 times thickness with a width not ment of rejected cylinders is author-
over 6 times thickness is authorized ized. Subsequent thereto, containers
when a cylinder wall is not over 3⁄16 must pass all prescribed tests to be ac-
inch thick. ceptable. Repair of welded seams by
(ii) The specimen, exclusive of grip welding prior to reheat-treatment is
ends, may not be flattened. Grip ends authorized.
may be flattened to within 1 inch of (p) Marking. Markings on each con-
each end of the reduced section. tainer must be stamped plainly and
(iii) Heating of a specimen for any permanently on a permanent attach-
purpose is not authorized. ment or on a metal nameplate perma-
(5) The yield strength in tension nently secured to the container by
must be the stress corresponding to a means other than soft solder.
permanent strain of 0.2 percent of the
gauge length. The following conditions [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
apply: amended at 66 FR 45386, 45388, Aug. 28, 2001;
67 FR 51654, Aug. 8, 2002; 67 FR 61015, Sept. 27,
(i) The yield strength must be deter- 2002; 68 FR 75748, Dec. 31, 2003]
mined by either the ‘‘offset’’ method or
the ‘‘extension under load’’ method as § 178.59 Specification 8 steel cylinders
prescribed in ASTM E 8 (IBR, see § 171.7 with porous fillings for acetylene.
(ii) In using the ‘‘extension under (a) Type and service pressure. A DOT 8
load’’ method, the total strain (or ‘‘ex- cylinder is a seamless cylinder with a
tension under load’’) corresponding to service pressure of 250 psig. The fol-
the stress at which the 0.2 percent per- lowing steel is authorized:
manent strain occurs may be deter- (1) A longitudinal seam if forge lap
mined with sufficient accuracy by cal- welded;
culating the elastic extension of the (2) Attachment of heads by welding
gauge length under appropriate load or by brazing by dipping process; or
and adding thereto 0.2 percent of the (3) A welded circumferential body
gauge length. Elastic extension cal- seam if the cylinder has no longitu-
culations must be based on an elastic dinal seam.
modulus of 30,000,000. In the event of (b) Steel. Open-hearth, electric or
controversy, the entire stress-strain basic oxygen process steel of uniform
diagram must be plotted and the yield quality must be used. Content percent
strength determined from the 0.2 per- may not exceed the following: Carbon,
cent offset. 0.25; phosphorus, 0.045; sulphur, 0.050.
(iii) For the purpose of strain meas- (c) Identification of steel. Materials
urement, the initial strain must be set must be identified by any suitable
while the specimen is under a stress of method except that plates and billets
12,000 psi and the strain indicator read- for hot-drawn cylinders must be
ing being set at the calculated cor- marked with the heat number.
responding strain. (d) Manufacture. Cylinders must be
(iv) Cross-head speed of the testing manufactured using equipment and
machine may not exceed 1⁄8 inch per processes adequate to ensure that each
minute during yield strength deter- cylinder produced conforms to the re-
mination. quirements of this subpart. No defect is
(n) Acceptable results for physical, flat- acceptable that is likely to weaken the
tening, and burst tests. The following are finished cylinder appreciably. A rea-
acceptable results of the physical, flat- sonably smooth and uniform surface
tening and burst test: finish is required. Welding procedures

(1) Elongation must be at least 20 and operators must be qualified in ac-
percent for a 2-inch gauge length or 10 cordance with CGA Pamphlet C–3 (IBR,
percent in other cases. see § 171.7 of this subchapter).
68
(e) Exposed bottom welds. Exposed bot- (2) Specimens must conform to a
tom welds on cylinders over 18 inches gauge length of 8 inches with a width
long must be protected by footrings. not over 11⁄2 inches, a gauge length of 2
(f) Heat treatment. Body and heads inches with width not over 11⁄2, or a
formed by drawing or pressing must be gauge length at least 24 times thick-
uniformly and properly heat treated ness with a width not over 6 times
prior to tests. thickness is authorized when a cylinder
(g) Openings. Openings in the cyl- wall is not over 3⁄16 inch thick.
inders must comply with the following: (3) The yield strength in tension
(1) Standard taper pipe threads are must be the stress corresponding to a
required; permanent strain of 0.2 percent of the
(2) Length may not be less than as gauge length. The following conditions
specified for American Standard pipe apply:
threads; tapped to gauge; clean cut, (i) The yield strength must be deter-
even, and without checks. mined by either the ‘‘offset’’ method or
(h) Hydrostatic test. Each cylinder
prescribed in ASTM E 8 (IBR, see § 171.7
must successfully withstand a hydro-
static test as follows:
(ii) In using the ‘‘extension under
(1) The test must be by water-jacket,
load’’ method, the total strain (or ‘‘ex-
or other suitable method, operated so
tension under load’’) corresponding to
as to obtain accurate data. The pres-
the stress at which the 0.2 percent per-
sure gauge must permit reading to an
manent strain occurs may be deter-
accuracy of 1 percent. The expansion
mined with sufficient accuracy by cal-
gauge must permit reading of total ex-
culating the elastic extension of the
pansion to an accuracy of either 1 per-
gauge length under appropriate load
cent or 0.1 cubic centimeter.
and adding thereto 0.2 percent of the
(2) Pressure must be maintained for gauge length. Elastic extension cal-
at least 30 seconds and sufficiently culations must be based on an elastic
longer to ensure complete expansion. modulus of 30,000,000. In the event of
Any internal pressure applied after controversy, the entire stress-strain
heat-treatment and previous to the of- diagram must be plotted and the yield
ficial test may not exceed 90 percent of strength determined from the 0.2 off-
the test pressure. set.
(3) Permanent volumetric expansion (iii) For the purpose of strain meas-
may not exceed 10 percent of total vol- urement, the initial strain must be set
umetric expansion at test pressure. while the specimen is under a stress of
(4) One cylinder out of each lot of 200 12,000 psi and the strain indicator read-
or less must be hydrostatically tested ing being set at the calculated cor-
to at least 750 psig. Cylinders not so responding strain.
tested must be examined under pres- (iv) Cross-head speed of the testing
sure of between 500 and 600 psig and machine may not exceed 1⁄8 inch per
show no defect. If hydrostatically test- minute during yield strength deter-
ed cylinder fails, each cylinder in the mination.
lot may be hydrostatically tested and (4) Yield strength may not exceed 73
those passing are acceptable. percent of tensile strength. Elongation
(i) Leakage test. Cylinders with bot- must be at least 40 percent in 2 inch or
toms closed in by spinning must be 20 percent in other cases.
subjected to a leakage test by setting (k) Rejected cylinders. Reheat treat-
the interior air or gas pressure to not ment of rejected cylinder is authorized.
less than the service pressure. Cyl- Subsequent thereto, cylinders must
inders which leak must be rejected. pass all prescribed tests to be accept-
(j) Physical test. A physical test must able. Repair by welding is authorized.
be conducted as follows: (l) Porous filling. (1) Cylinders must
(1) The test is required on 2 speci- be filled with a porous material in ac-
mens cut longitudinally from 1 cyl- cordance with the following:

inder or part thereof taken at random (i) The porous material may not dis-
out of each lot of 200 or less, after heat integrate or sag when wet with solvent
treatment. or when subjected to normal service;
69
§ 178.59 49 CFR Ch. I (10–1–18 Edition)
(ii) The porous filling material must (ii) Having volumetric capacity of 20
be uniform in quality and free of voids, pounds or less water capacity (nomi-
except that a well drilled into the fill- nal), may not exceed the following:
ing material beneath the valve is au-
Maximum
thorized if the well is filled with a ma- acetone sol-
terial of such type that the functions Percent porosity of filler vent percent
shell capac-
of the filling material are not imity by vol-
paired; ume
(iii) Overall shrinkage of the filling
90 to 92 ............................................................. 41.8
material is authorized if the total 83 to 90 ............................................................. 38.5
clearance between the cylinder shell 80 to 83 ............................................................. 37.1
and filling material, after solvent has 75 to 80 ............................................................. 34.8
been added, does not exceed 1⁄2 of 1 per- 70 to 75 ............................................................. 32.5
65 to 70 ............................................................. 30.2
cent of the respective diameter or
length, but not to exceed 1⁄8 inch, meas-
ured diametrically and longitudinally; (m) Tare weight. The tare weight is
(iv) The clearance may not impair the combined weight of the cylinder
the functions of the filling material; proper, porous filling, valve, and sol-
vent, without removable cap.
(v) The installed filling material
must meet the requirements of CGA C– (n) Duties of inspector. In addition to
12 (IBR, see § 171.7 of this subchapter); the requirements of § 178.35, the inspec-
and tor is required to—
(vi) Porosity of filling material may (1) Certify chemical analyses of steel
not exceed 80 percent except that fill- used, signed by manufacturer thereof;
ing material with a porosity of up to 92 also verify by, check analyses of sam-
percent may be used when tested with ples taken from each heat or from 1 out
satisfactory results in accordance with of each lot of 200 or less, plates, shells,
CGA Pamphlet C–12. or tubes used.
(2) When the porosity of each cyl- (2) Verify compliance of cylinder
inder is not known, a cylinder taken at shells with all shell requirements; in-
random from a lot of 200 or less must spect inside before closing in both ends;
be tested for porosity. If the test cyl- verify heat treatment as proper; obtain
inder fails, each cylinder in the lot all samples for all tests and for check
may be tested individually and those analyses; witness all tests; verify
cylinders that pass the test are accept- threads by gauge; report volumetric ca-
able. pacity and minimum thickness of wall
(3) For filling that is molded and noted.
dried before insertion in cylinders, po- (3) Prepare report on manufacture of
rosity test may be made on a sample steel shells in form prescribed in
block taken at random from material § 178.35. Furnish one copy to manufac-
to be used. turer and three copies to the company
(4) The porosity of the filling mate- that is to complete the cylinders.
rial must be determined. The amount (4) Determine porosity of filling and
of solvent at 70 °F for a cylinder: tare weights; verify compliance of
(i) Having shell volumetric capacity marking with prescribed requirements;
above 20 pounds water capacity (nomi- obtain necessary copies of steel shell
nal) may not exceed the following: reports; and furnish complete reports
required by this specification to the
Maximum person who has completed the manu-
acetone sol-
vent percent facture of the cylinders and, upon re-
Percent porosity of filler shell capac- quest, to the purchaser. The test re-
ity by vol-
ume ports must be retained by the inspector
for fifteen years from the original test
90 to 92 ............................................................. 43.4 date of the cylinder.
87 to 90 ............................................................. 42.0
83 to 87 ............................................................. 40.0 (o) Marking. (1) Marking on each cyl-
80 to 83 ............................................................. 38.6 inder must be stamped plainly and per-

75 to 80 ............................................................. 36.2 manently on or near the shoulder, top
70 to 75 ............................................................. 33.8 head, neck or valve protection collar
65 to 70 ............................................................. 31.4
which is permanently attached to the
70
cylinder and forming integral part (2) Heat treatment is not required
thereof. after welding or brazing weldable low
(2) Tare weight of cylinder, in pounds carbon parts to attachments, specified
and ounces, must be marked on the in paragraph (f)(1) of this section, of
cylinder. similar material which have been pre-
(3) Cylinders, not completed, when viously welded or brazed to the top or
delivered must each be marked for bottom of cylinders and properly heat
identification of each lot of 200 or less. treated, provided such subsequent
welding or brazing does not produce a
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as
amended at 66 FR 45386, Aug. 28, 2001; 67 FR temperature in excess of 400 °F in any
61016, Sept. 27, 2002; 67 FR 51654, Aug. 8, 2002; part of the top or bottom material.
68 FR 75748, 75749, Dec. 31, 2003] (g) Wall thickness; wall stress. The wall
thickness/wall stress of the cylinder
§ 178.60 Specification 8AL steel cyl- must conform to the following:
inders with porous fillings for acet- (1) The calculated wall stress at 750
ylene. psi may not exceed 35,000 psi, or one-
(a) Type and service pressure. A DOT half of the minimum ultimate strength
8AL cylinder is a seamless steel cyl- of the steel as determined in paragraph
inder with a service pressure of 250 (l) of this section, whichever value is
psig. However, the attachment of heads the smaller. The measured wall thick-
by welding or by brazing by dipping ness may not include galvanizing or
process and a welded circumferential other protective coating.
body seam is authorized. Longitudinal (i) Calculation of wall stress must be
seams are not authorized. made by the formula:
(b) Authorized steel. The authorized S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
steel is as specified in table I of appen-
dix A to this part. Where:
(c) Identification of steel. Material S = wall stress in pounds psi;
must be identified by any suitable P = 750 psig (minimum test pressure);
method except that plates and billets D = outside diameter in inches;
for hot-drawn cylinders must be
marked with heat number. (ii) Either D or d must be calculated
(d) Manufacture. Cylinders must be from the relation D = d + 2t, where t =
manufactured using equipment and minimum wall thickness.
processes adequate to ensure that each (2) Cylinders with a wall thickness
cylinder produced conforms to the re- less than 0.100 inch, the ratio of
quirements of this subpart. No defect is straight side wall length to outside di-
permitted that is likely to weaken the ameter may not exceed 3.5.
finished cylinder appreciably. A rea- (3) For cylinders having outside di-
sonably smooth and uniform surface ameter over 5 inches, the minimum
finish is required. Welding procedures wall thickness must be 0.087 inch.
and operators must be qualified in ac- (h) Heat treatment. Each cylinder
cordance with CGA Pamphlet C–3 (IBR, must be uniformly and properly heat
see § 171.7 of this subchapter). treated, prior to tests, by any suitable
(e) Footrings. Exposed bottom welds method in excess of 1100 °F. Heat treat-
on cylinders over 18 inches long must ment must be accomplished after all
be protected by footrings. forming and welding operations, except
(f) Welding or brazing. Welding or that when brazed joints are used, heat
brazing for any purpose whatsoever is treatment must follow any forming
prohibited except as follows: and welding operations but may be
(1) The attachment to the tops or done before, during, or after the braz-
bottoms of cylinders of neckrings, ing operations. Liquid quenching is not
footrings, handlers, bosses, pads, and authorized.
valve protecting rings is authorized (i) Openings. Standard taper pipe
provided that such attachments and threads required in all openings. The
the portion of the container to which length of the opening may not be less
they are attached are made of weldable than as specified for American Stand-
steel, the carbon content of which may ard pipe threads; tapped to gauge;
not exceed 0.25 percent. clean cut, even, and without checks.
71
§ 178.60 49 CFR Ch. I (10–1–18 Edition)
(j) Hydrostatic test. Each cylinder prescribed in ASTM E 8 (IBR, see § 171.7
must successfully withstand a hydro- of this subchapter).
static test as follows: (ii) In using the ‘‘extension under
(1) The test must be by water-jacket, load’’ method, the total strain (or ‘‘ex-
or other suitable method, operated so tension under load’’) corresponding to
as to obtain accurate data. The pres- the stress at which the 0.2 percent per-
sure gauge must permit reading to an manent strain occurs may be deter-
accuracy of 1 percent. The expansion mined with sufficient accuracy by cal-
gauge must permit reading of total ex- culating the elastic extension of the
pansion to an accuracy of either 1 per- gauge length under appropriate load
cent or 0.1 cubic centimeter. and adding thereto 0.2 percent of the
(2) Pressure must be maintained for gauge length. Elastic extension cal-
at least 30 seconds and sufficiently culations must be based on an elastic
longer to ensure complete expansion. modulus of 30,000,000. In the event of
Any internal pressure applied after controversy, the entire stress-strain
heat-treatment and previous to the of- diagram must be plotted and the yield
ficial test may not exceed 90 percent of strength determined from the 0.2 off-
the test pressure. set.
(3) Permanent volumetric expansion (iii) For the purpose of strain meas-
may not exceed 10 percent of total vol- urement, the initial strain must be set
umetric expansion at test pressure. while the specimen is under a stress of
(4) One cylinder out of each lot of 200 12,000 psi, the strain indicator reading
or less must be hydrostatically tested being set at the calculated cor-
to at least 750 psig. Cylinders not so responding strain.
tested must be examined under pres- (iv) Cross-head speed of the testing
sure of between 500 and 600 psig and machine may not exceed 1⁄8 inch per
show no defect. If a hydrostatically minute during yield strength deter-
tested cylinder fails, each cylinder in mination.
the lot may be hydrostatically tested (m) Elongation. Physical test speci-
and those passing are acceptable. mens must show at least a 40 percent
(k) Leakage test. Cylinders with bot- elongation for a 2 inch gauge length or
toms closed in by spinning must be at least a 20 percent elongation in
leakage tested by setting the interior other cases. Except that these elon-
air or gas pressure at not less than the gation percentages may be reduced nu-
service pressure. Any cylinder that merically by 2 for 2 inch specimens and
leaks must be rejected. 1 in other cases for each 7,500 psi incre-
(l) Physical test. A physical test must ment of tensile strength above 50,000
be conducted as follows; psi to a maximum of four such incre-
(1) The test is required on 2 speci- ments.
mens cut longitudinally from 1 cyl- (n) Weld tests. Specimens taken
inder or part thereof taken at random across the circumferentially welded
out of each lot of 200 or less, after heat seam must be cut from one cylinder
treatment. taken at random from each lot of 200 or
(2) Specimens must conform to a less cylinders after heat treatment and
gauge length of 8 inches with a width must pass satisfactorily the following
not over 11⁄2 inches, a gauge length 2 tests:
inches with a width not over 11⁄2 inches, (1) Tensile test. A specimen must be
or a gauge length at least 24 times cut from one cylinder of each lot of 200
thickness with a width not over 6 times or less, or welded test plate. The speci-
thickness is authorized when a cylinder men must be taken from across the
wall is not over 3⁄16 inch thick. major seam and must be prepared and
(3) The yield strength in tension tested in accordance with and must
must be the stress corresponding to a meet the requirements of CGA Pam-
permanent strain of 0.2 percent of the phlet C–3. Should this specimen fail to
gauge length. The following conditions meet the requirements, specimens may
apply: be taken from two additional cylinders

(i) The yield strength must be deter- or welded test plates from the same lot
mined by either the ‘‘offset’’ method or and tested. If either of the latter speci-
the ‘‘extension under load’’ method as mens fail to meet the requirements,
72
the entire lot represented must be re- satisfactory results in accordance with
jected. CGA Pamphlet C–12.
(2) Guided bend test. A root bend test (2) When the porosity of each cyl-
specimen must be cut from the cylinder is not known, a cylinder taken at
inder or welded test plate, used for the random from a lot of 200 or less must
tensile test specified in paragraph be tested for porosity. If the test cyl-
(n)(1) of this section. Specimens must inder fails, each cylinder in the lot
be prepared and tested in accordance may be tested individually and those
with and must meet the requirements cylinders that pass the test are accept-
of CGA Pamphlet C–3. able.
(3) Alternate guided-bend test. This (3) For filling that is molded and
test may be used and must be as re- dried before insertion in cylinders, po-
quired by CGA Pamphlet C–3. The spec- rosity test may be made on sample
imen must be bent until the elongation block taken at random from material
at the outer surface, adjacent to the to be used.
root of the weld, between the lightly (4) The porosity of the filling mate-
scribed gage lines-a to b, must be at rial must be determined; the amount of
least 20 percent, except that this per- solvent at 70 °F for a cylinder:
centage may be reduced for steels hav- (i) Having shell volumetric capacity
ing a tensile strength in excess of 50,000 above 20 pounds water capacity (nomi-
psi, as provided in paragraph (m) of nal) may not exceed the following:
this section.
Maximum acetone
(o) Rejected cylinders. Reheat treat- Percent porosity of filler solvent percent shell
ment of rejected cylinders is author- capacity by volume
ized. Subsequent thereto, cylinders 90 to 92 ......................................... 43.4
must pass all prescribed tests to be ac- 87 to 90 ......................................... 42.0
ceptable. Repair by welding is author- 83 to 87 ......................................... 40.0
80 to 83 ......................................... 38.6
ized. 75 to 80 ......................................... 36.2
(p) Porous filling. (1) Cylinders must 70 to 75 ......................................... 33.8
be filled with a porous material in ac- 65 to 70 ......................................... 31.4
cordance with the following:
(i) The porous material may not dis- (ii) Having volumetric capacity of 20
integrate or sag when wet with solvent pounds or less water capacity (nomi-
or when subjected to normal service; nal), may not exceed the following:
(ii) The filling material must be uni- Maximum acetone
form in quality and free of voids, ex- Percent porosity of filler solvent percent shell
cept that a well drilled into the filling capacity by volume
material beneath the valve is author- 90 to 92 ......................................... 41.8
ized if the well is filled with a material 83 to 90 ......................................... 38.5
of such type that the functions of the 80 to 83 ......................................... 37.1
75 to 80 ......................................... 34.8
filling material are not impaired; 70 to 75 ......................................... 32.5
(iii) Overall shrinkage of the filling 65 to 70 ......................................... 30.2
material is authorized if the total
clearance between the cylinder shell (q) Tare weight. The tare weight is
and filling material, after solvent has the combined weight of the cylinder
been added, does not exceed 1⁄2 of 1 per- proper, porous filling, valve, and sol-
cent of the respective diameter or vent, but without removable cap.
length but not to exceed 1⁄8 inch, meas- (r) Duties of inspector. In addition to
ured diametrically and longitudinally; the requirements of § 178.35, the inspec-
(iv) The clearance may not impair tor shall—
the functions of the filling material; (1) Certify chemical analyses of steel
(v) The installed filling material used, signed by manufacturer thereof;
must meet the requirements of CGA C– also verify by check analyses, of sam-
12 (IBR, see § 171.7 of this subchapter); ples taken from each heat or from 1 out
and of each lot of 200 or less plates, shells,
(vi) Porosity of filling material may or tubes used.

not exceed 80 percent except that fill- (2) Verify compliance of cylinder
ing material with a porosity of up to 92 shells with all shell requirements, in-
percent may be used when tested with spect inside before closing in both ends,
73
§ 178.61 49 CFR Ch. I (10–1–18 Edition)
verify heat treatment as proper; obtain § 178.61 Specification 4BW welded

all samples for all tests and for check steel cylinders with electric-arc
analyses, witness all tests; verify welded longitudinal seam.
threads by gauge, report volumetric ca- (a) Type, size and service pressure. A
pacity and minimum thickness of wall DOT 4BW cylinder is a welded type
noted. steel cylinder with a longitudinal elec-
(3) Report percentage of each speci- tric-arc welded seam, a water capacity
fied alloying element in the steel. Pre- (nominal) not over 1,000 pounds and a
pare report on manufacture of steel service pressure at least 225 and not
shells in form prescribed in § 178.35. over 500 psig gauge. Cylinders closed in
Furnish one copy to manufacturer and by spinning process are not authorized.
three copies to the company that is to (b) Authorized steel. Steel used in the
complete the cylinders. construction of the cylinder must con-
(4) Determine porosity of filling and form to the following:
tare weights; verify compliance of (1) The body of the cylinder must be
marking with prescribed requirements; constructed of steel conforming to the
obtain necessary copies of steel shell limits specified in table 1 of appendix A
reports prescribed in paragraph (b) of to this part.
this section; and furnish complete test (2) Material for heads must meet the
reports required by this specification requirements of paragraph (b)(1) of this
to the person who has completed the section or be open hearth, electric or
manufacturer of the cylinders and, basic oxygen carbon steel of uniform
upon request, to the purchaser. The quality. Content percent may not ex-
ceed the following: Carbon 0.25, Man-
test reports must be retained by the in-
ganese 0.60, Phosphorus 0.045, Sulfur
spector for fifteen years from the origi-
0.050. Heads must be hemispherical or
nal test date of the cylinder. ellipsoidal in shape with a maximum
(s) Marking. (1) Tare weight of cyl- ratio of 2.1. If low carbon steel is used,
inder, in pounds and ounces, must be the thickness of such heads must be de-
marked on the cylinder. termined by using a maximum wall
(2) Cylinders, not completed, when stress of 24,000 p.s.i. in the formula de-
delivered must each be marked for scribed in paragraph (f)(4) of this sec-
identification of each lot of 200 or less. tion.
(3) Markings must be stamped plainly (c) Identification of material. Material
and permanently in locations in ac- must be identified by any suitable
cordance with the following: method.
(i) On shoulders and top heads not (d) Manufacture. Cylinders must be
less than 0.087 inch thick; or manufactured using equipment and
(ii) On neck, valve boss, valve protec- processes adequate to ensure that each
tion sleeve, or similar part perma- cylinder produced conforms to the re-
nently attached to the top end of cyl- quirements of this subpart and the fol-
inder; or lowing:
(iii) On a plate of ferrous material at- (1) No defect is permitted that is
tached to the top of the cylinder or likely to weaken the finished cylinder
permanent part thereof; the plate must appreciably. A reasonably smooth and
be at least 1⁄16 inch thick, and must be uniform surface is required. Exposed
attached by welding, or by brazing at a bottom welds on cylinders over 18
inches long must be protected by
temperature of at least 1,100 °F
footrings. Minimum thickness of heads
throughout all edges of the plate. Suffi-
may not be less than 90 percent of the
cient space must be left on the plate to required thickness of the sidewall.
provide for stamping at least four (4) Heads must be concave to pressure.
retest dates. (2) Circumferential seams must be by
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as electric-arc welding. Joints must be
amended at 66 FR 45386, 45388, Aug. 28, 2001; butt with one member offset (joggle
67 FR 51654, Aug. 8, 2002; 68 FR 75748, 75749, butt) or lap with minimum overlap of
Dec. 31, 2003] at least four times nominal sheet
thickness.
74
(3) Longitudinal seams in shells must thickness must be 0.078 inch. For a cyl-
conform to the following: inder with a wall thickness less than
(i) Longitudinal electric-arc welded 0.100 inch, the ratio of tangential
seams must be of the butt welded type. length to outside diameter may not ex-
Welds must be made by a machine ceed 4 to1 (4:1). In any case the min-
process including automatic feed and imum wall thickness must be such that
welding guidance mechanisms. Longi- the wall stress calculated by the for-
tudinal seams must have complete mula listed in paragraph (f)(4) of this
joint penetration, and must be free section may not exceed the lesser value
from undercuts, overlaps or abrupt of any of the following:
ridges or valleys. Misalignment of mat- (1) The value referenced in paragraph
ing butt edges may not exceed 1⁄6 of (b) of this section for the particular
nominal sheet thickness or 1⁄32 inch material under consideration.
whichever is less. All joints with nomi- (2) One-half of the minimum tensile
nal sheet thickness up to and including strength of the material determined as
1⁄8 inch must be tightly butted. When
required in paragraph (j) of this sec-
nominal sheet thickness is greater tion.
than 1⁄8 inch, the joint must be gapped (3) 35,000 psi.
with maximum distance equal to one- (4) Stress must be calculated by the
half the nominal sheet thickness or 1⁄32 following formula:
inch whichever is less. Joint design,
preparation and fit-up must be such S = [2P(1.3D2 + 0.4d2)] / [E(D2 ¥ d2)]
that requirements of this paragraph (d) where:
are satisfied.
S = wall stress, psi;
(ii) Maximum joint efficiency must P = service pressure, psig;
be 1.0 when each seam is radiographed D = outside diameter, inches;
completely. Maximum joint efficiency d = inside diameter, inches;
must be 0.90 when one cylinder from E = joint efficiency of the longitudinal seam
each lot of 50 consecutively welded cyl- (from paragraph (d) of this section).
inders is spot radiographed. In addi-
tion, one out of the first five cylinders (g) Heat treatment. Each cylinder
welded following a shut down of weld- must be uniformly and properly heat
ing operations exceeding four hours treated prior to test by the applicable
must be spot radiographed. Spot method referenced in Table 1 of appen-
radiographs, when required, must be dix A to this part. Heat treatment
made of a finished welded cylinder and must be accomplished after all forming
must include the girth weld for 2 and welding operations. Heat treat-
inches in both directions from the ment is not required after welding or
intersection of the longitudinal and brazing of weldable low carbon parts to
girth welds and include at least 6 attachments of similar material which
inches of the longitudinal weld. Max- have been previously welded to the top
imum joint efficacy of 0.75 must be per- or bottom of cylinders and properly
missible without radiography. heat treated, provided such subsequent
(4) Welding procedures and operators welding or brazing does not produce a
must be qualified in accordance with temperature in excess of 400 °F in any
CGA Pamphlet C–3 (IBR, see § 171.7 of part of the top or bottom material.
this subchapter). (h) Openings in cylinders. Openings in
(e) Welding of attachments. The at- the cylinder must conform to the fol-
tachment to the tops and bottoms only lowing:
of cylinders by welding of neckrings, (1) All openings must be in the heads
footrings, handles, bosses, pads and or bases.
valve protection rings is authorized (2) Openings in cylinders must be pro-
provided that such attachments and vided with adequate fittings, bosses, or
the portion of the container to which pads, integral with or securely at-
they are attached are made of weldable tached to the cylinder by welding.
steel, the carbon content of which may (3) Threads must comply with the fol-
not exceed 0.25 percent. lowing:
(f) Wall thickness. For outside diame- (i) Threads must be clean cut and to
ters over 6 inches the minimum wall gauge.
75
§ 178.61 49 CFR Ch. I (10–1–18 Edition)
(ii) Taper threads must be of length body section at least 90 degrees away
not less than as specified for American from the weld.
Standard Taper Pipe threads. (ii) Head specimen. One specimen
(iii) Straight threads, having at least must be taken from either head on a
4 engaged threads, to have tight fit and cylinder when both heads are made of
calculated shear strength at least 10 the same material. However, if the two
times the test pressure of the cylinder; heads are made of differing materials,
gaskets required, adequate to prevent a specimen must be taken from each
leakage. head.
(4) Closure of fittings, boss or pads (iii) If due to welded attachments on
must be adequate to prevent leakage. the top head there is insufficient sur-
(i) Hydrostatic test. Cylinders must face from which to take a specimen, it
withstand a hydrostatic test, as fol- may be taken from a representative
lows: head of the same heat treatment as the
(1) The test must be by water-jacket, test cylinder.
or other suitable method, operated so (2) Specimens must conform to the
as to obtain accurate data. The pres- following:
sure gauge must permit readings to an (i) A gauge length of 8 inches with a
accuracy of 1 percent. The expansion width not over 11⁄2 inches, a gauge
gauge must permit readings of total length of 2 inches with a width not
volumetric expansion to an accuracy over 11⁄2 inches, or a gauge length at
either of 1 percent or 0.1 cubic centi- least 24 times thickness with a width
meter. not over 6 times thickness is author-
(2) Pressure must be maintained for ized when a cylinder wall is not over 3⁄16
at least 30 seconds and sufficiently inch thick.
longer to ensure complete expansion. (ii) The specimen, exclusive of grip
Any internal pressure applied after ends, may not be flattened. Grip ends
heat treatment and previous to the of- may be flattened to within 1 inch of
ficial test may not exceed 90 percent of each end of the reduced section.
the test pressure. (iii) When size of the cylinder does
not permit securing straight speci-
(3) Permanent volumetric expansion
mens, the specimens may be taken in
may not exceed 10 percent of the total
any location or direction and may be
volumetric expansion at test pressure.
straightened or flattened cold, by pres-
(4) Cylinders must be tested as fol-
sure only, not by blows when speci-
lows:
mens are so taken and prepared, the in-
(i) At least 1 cylinder selected at ran- spector’s report must show in connec-
dom out of each lot of 200 or less must tion with record of physical tests de-
be tested as outlined in paragraphs tailed information in regard to such
(i)(1), (i)(2), and (i)(3) of this section to specimens.
at least two times service pressure. (iv) Heating of a specimen for any
(ii) All cylinders not tested as out- purpose is not authorized.
lined in paragraph (i)(4)(i) of this sec- (3) The yield strength in tension
tion must be examined under pressure must be the stress corresponding to a
of at least two times service pressure permanent strain of 0.2 percent of the
and show no defect. gauge length. The following conditions
(5) One finished cylinder selected at apply:
random out of each lot of 500 or less (i) The yield strength must be deter-
successively produced must be mined by either the ‘‘off-set’’ method
hydrostatically tested to 4 times serv- or the ‘‘extension under load’’ method
ice pressure without bursting. as prescribed in ASTM E 8 (IBR, see
(j) Physical tests. Cylinders must be § 171.7 of this subchapter).
subjected to a physical test as follows: (ii) In using the ‘‘extension under
(1) Specimens must be taken from load’’ method, the total strain (or ‘‘ex-
one cylinder after heat treatment and tension under load’’), corresponding to
chosen at random from each lot of 200 the stress at which the 0.2-percent per-
or less, as follows: manent strain occurs may be deter-
(i) Body specimen. One specimen mined with sufficient accuracy by cal-
must be taken longitudinally from the culating the elastic extension of the
76
gauge length under appropriate load (m) Radiographic examination. Welds

and adding thereto 0.2 percent of the of the cylinders must be subjected to a
gauge length. Elastic extension cal- radiographic examination as follows:
culations must be based on an elastic (1) Radiographic inspection must
modulus of 30,000,000. In the event of conform to the techniques and accept-
controversy, the entire stress-strain ability criteria set forth in CGA Pam-
diagram must be plotted and the yield phlet C–3. When fluoroscopic inspection
strength determined from the 0.2-per- is used, permanent film records need
cent offset. not be retained.
(iii) For the purpose of strain meas- (2) Should spot radiographic exam-
urement, the initial strain reference ination fail to meet the requirements
must be set while the specimen is of paragraph (m)(1) of this section, two
under a stress of 12,000 psi and the additional welds from the same lot of
strain indicator reading being set at 50 cylinders or less must be examined,
the calculated corresponding strain. and if either of these fail to meet the
(iv) Cross-head speed of the testing requirements, each cylinder must be
machine may not exceed 1⁄8 inch per examined as previously outlined; only
minute during yield strength deter- those passing are acceptable.
mination. (n) Rejected cylinders. (1) Unless oth-
(k) Elongation. Physical test speci- erwise stated, if a sample cylinder or
mens must show at least a 40 percent specimen taken from a lot of cylinders
elongation for a 2-inch gauge length or fails the prescribed test, then two addi-
at least a 20 percent elongation in tional specimens must be selected from
other cases. Except that these elon- the same lot and subjected to the pre-
gation percentages may be reduced nu- scribed test. If either of these fails the
merically by 2 for 2-inch specimens and test, then the entire lot must be re-
by 1 in other cases for each 7,500 psi in- jected.
crement of tensile strength above 50,000 (2) Reheat treatment of rejected cyl-
psi to a maximum of four increments. inders is authorized. Subsequent there-
(l) Tests of welds. Welds must be sub- to, cylinders must pass all prescribed
jected to the following tests: tests to be acceptable. Repair of welded
(1) Tensile test. A specimen must be seams by welding is authorized pro-
cut from one cylinder of each lot of 200 vided that all defective metal is cut
or less. The specimen must be taken away and the joint is rewelded as pre-
from across the longitudinal seam and scribed for original welded joints.
must be prepared and tested in accord- (o) Markings. Markings must be
ance with and must meet the require- stamped plainly and permanently in
ments of CGA Pamphlet C–3. any of the following locations on the
(2) Guided bend test. A root test speci- cylinder:
men must be cut from the cylinder (1) On shoulders and top heads when
used for the tensile test specified in they are not less than 0.087-inch thick.
paragraph (l)(1) of this section. Speci- (2) On a metal plate attached to the
mens must be taken from across the top of the cylinder or permanent part
longitudinal seam and must be pre- thereof; sufficient space must be left on
pared and tested in accordance with the plate to provide for stamping at
and must meet the requirements of least six retest dates; the plate must be
CGA Pamphlet C–3. at least 1⁄16-inch thick and must be at-
(3) Alternate guided bend test. This tached by welding, or by brazing. The
test may be used and must be as re- brazing rod is to melt at a temperature
quired by CGA Pamphlet C–3. The spec- of 1100 °F Welding or brazing must be
imen must be bent until the elongation along all the edges of the plate.
at the outer surface, adjacent to the (3) On the neck, valve boss, valve pro-
root of the weld, between the lightly tection sleeve, or similar part perma-
scribed gauge lines a to b, must be at nently attached to the top of the cyl-
least 20 percent, except that this per- inder.
centage may be reduced for steels hav- (4) On the footring permanently at-
ing a tensile strength in excess of 50,000 tached to the cylinder, provided the
psi, as provided in paragraph (k) of this water capacity of the cylinder does not
section. exceed 25 pounds.
77
§ 178.65 49 CFR Ch. I (10–1–18 Edition)
(p) Inspector’s report. In addition to (iv) Longitudinal or helical welded

the information required by § 178.35, the cylinders are not authorized for service
inspector’s report must indicate the pressures in excess of 500 p.s.i.g.
type and amount of radiography. (2) Aluminum. Aluminum is not au-
thorized for service pressures in excess
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as
of 500 psig. The analysis of the alu-
amended at 64 FR 51919, Sept. 27, 1999; 66 FR
45386, 45388, Aug. 28, 2001; 67 FR 51654, Aug. 6, minum must conform to the Aluminum
2002; 67 FR 61016, Sept. 27, 2002; 68 FR 57633, Association standard for alloys 1060,
Oct. 6, 2003; 68 FR 75748, Dec. 31, 2003; 78 FR 1100, 1170, 3003, 5052, 5086, 5154, 6061, and
60754, Oct. 2, 2013] 6063, as specified in its publication en-
titled ‘‘Aluminum Standards and
§ 178.65 Specification 39 non-reusable Data’’ (IBR, see § 171.7 of this sub-
(non-refillable) cylinders. chapter).
(a) Type, size, service pressure, and test (3) Material with seams, cracks, lam-
pressure. A DOT 39 cylinder is a seam- inations, or other injurious defects not
less, welded, or brazed cylinder with a permitted.
service pressure not to exceed 80 per- (4) Material used must be identified
cent of the test pressure. Spherical by any suitable method.
pressure vessels are authorized and (c) Manufacture. (1) General manufac-
covered by references to cylinders in turing requirements are as follows:
this specification. (i) The surface finish must be uni-
(1) Size limitation. Maximum water ca- form and reasonably smooth.
pacity may not exceed: (i) 55 pounds (ii) Inside surfaces must be clean,
(1,526 cubic inches) for a service pres- dry, and free of loose particles.
sure of 500 p.s.i.g. or less, and (ii) 10 (iii) No defect of any kind is per-
pounds (277 cubic inches) for a service mitted if it is likely to weaken a fin-
pressure in excess of 500 p.s.i.g. ished cylinder.
(2) Test pressure. The minimum test (2) Requirements for seams:
pressure is the maximum pressure of (i) Brazing is not authorized on alu-
contents at 130 °F or 180 p.s.i.g. which- minum cylinders.
ever is greater. (ii) Brazing material must have a
(3) Pressure of contents. The term melting point of not lower than 1,000
‘‘pressure of contents’’ as used in this °F.
specification means the total pressure (iii) Brazed seams must be assembled
of all the materials to be shipped in the with proper fit to ensure complete pen-
cylinder. etration of the brazing material
(b) Material; steel or aluminum. The throughout the brazed joint.
cylinder must be constructed of either (iv) Minimum width of brazed joints
steel or aluminum conforming to the must be at least four times the thick-
following requirements: ness of the shell wall.
(1) Steel. (i) The steel analysis must (v) Brazed seams must have design
conform to the following: strength equal to or greater than 1.5
times the minimum strength of the
Ladle Check shell wall.
analysis analysis
(vi) Welded seams must be properly
Carbon, maximum percent .................... 0.12 0.15 aligned and welded by a method that
Phosphorus, maximum percent ............. .04 .05 provides clean, uniform joints with
Sulfur, maximum percent ...................... .05 .06 adequate penetration.
(vii) Welded joints must have a
(ii) For a cylinder made of seamless strength equal to or greater than the
steel tubing with integrally formed minimum strength of the shell mate-
ends, hot drawn, and finished, content rial in the finished cylinder.
percent for the following may not ex- (3) Attachments to the cylinder are
ceed: Carbon, 0.55; phosphorous, 0.045; permitted by any means which will not
sulfur, 0.050. be detrimental to the integrity of the

(iii) For non-heat treated welded cylinder. Welding or brazing of attach-
steel cylinders, adequately killed deep ments to the cylinder must be com-
drawing quality steel is required. pleted prior to all pressure tests.
78
(4) Welding procedures and operators (i) The leakage test must be con-
must be qualified in accordance with ducted by submersion under water or
CGA Pamphlet C–3 (IBR, see § 171.7 of by some other method that will be
this subchapter). equally sensitive.
(d) Wall thickness. The minimum wall (ii) If the cylinder leaks, evidences
thickness must be such that the wall visible distortion, or any other defect,
stress at test pressure does not exceed while under test, it must be rejected
the yield strength of the material of (see paragraph (h) of this section).
the finished cylinder wall. Calculations (2) One cylinder taken from the be-
must be made by the following for- ginning of each lot, and one from each
mulas: 1,000 or less successively produced
(1) Calculation of the stress for cyl- within the lot thereafter, must be
inders must be made by the following hydrostatically tested to destruction.
formula: The entire lot must be rejected (see
S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2) paragraph (h) of this section) if:
(i) A failure occurs at a gage pressure
Where: less than 2.0 times the test pressure;
S = Wall stress, in psi; (ii) A failure initiates in a braze or a
P = Test pressure in psig; weld or the heat affected zone thereof;
D = Outside diameter, in inches; (iii) A failure is other than in the
d = Inside diameter, in inches.
sidewall of a cylinder longitudinal with
(2) Calculation of the stress for its long axis; or
spheres must be made by the following (iv) In a sphere, a failure occurs in
formula: any opening, reinforcement, or at a
S = PD / 4t point of attachment.
(3) A ‘‘lot’’ is defined as the quantity
Where: of cylinders successively produced per
S = Wall stress, in psi; production shift (not exceeding 10
P = Test pressure i psig; hours) having identical size, design,
D = Outside diameter, in inches; construction, material, heat treat-
t = Minimum wall thickness, in inches. ment, finish, and quality.
(e) Openings and attachments. Open- (g) Flattening test. One cylinder must
ings and attachments must conform to be taken from the beginning of produc-
the following: tion of each lot (as defined in para-
(1) Openings and attachments are graph (f)(3) of this section) and sub-
permitted on heads only. jected to a flattening test as follows:
(2) All openings and their reinforce- (1) The flattening test must be made
ments must be within an imaginary on a cylinder that has been tested at
circle, concentric to the axis of the cyl- test pressure.
inder. The diameter of the circle may (2) A ring taken from a cylinder may
not exceed 80 percent of the outside di- be flattened as an alternative to a test
ameter of the cylinder. The plane of on a complete cylinder. The test ring
the circle must be parallel to the plane may not include the heat affected zone
of a circumferential weld and normal or any weld. However, for a sphere, the
to the long axis of the cylinder. test ring may include the circumferen-
(3) Unless a head has adequate thick- tial weld if it is located at a 45 degree
ness, each opening must be reinforced angle to the ring, ±5 degrees.
by a securely attached fitting, boss, (3) The flattening must be between 60
pad, collar, or other suitable means. degrees included-angle, wedge shaped
(4) Material used for welded openings knife edges, rounded to a 0.5 inch ra-
and attachments must be of weldable dius.
quality and compatible with the mate- (4) Cylinders and test rings may not
rial of the cylinder. crack when flattened so that their
(f) Pressure tests. (1) Each cylinder outer surfaces are not more than six
must be tested at an internal pressure times wall thickness apart when made
of at least the test pressure and must of steel or not more than ten times
be held at that pressure for at least 30 wall thickness apart when made of alu-
seconds. minum.
79
§ 178.68 49 CFR Ch. I (10–1–18 Edition)
(5) If any cylinder or ring cracks at least 1⁄8 inch high and displayed se-
when subjected to the specified flat- quentially. For example:
tening test, the lot of cylinders rep-
DOT-39 NRC 250/500 M1001.
resented by the test must be rejected
(see paragraph (h) of this section). (4) No person may mark any cylinder
(h) Rejected cylinders. Rejected cyl- with the specification identification
inders must conform to the following ‘‘DOT-39’’ unless it was manufactured
requirements: in compliance with the requirements of
(1) If the cause for rejection of a lot this section and its manufacturer has a
is determinable, and if by test or in- registration number (M****) from the
spection defective cylinders are elimi- Associate Administrator.
nated from the lot, the remaining cyl- [Amdt. 178–114, 61 FR 25942, May 23, 1996, as
inders must be qualified as a new lot amended at 65 FR 58631, Sept. 29, 2000; 66 FR
under paragraphs (f) and (g) of this sec- 45389, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002;
tion. 68 FR 75748, 75749, Dec. 31, 2003]
(2) Repairs to welds are permitted.
Following repair, a cylinder must pass § 178.68 Specification 4E welded alu-
the pressure test specified in paragraph minum cylinders.
(f) of this section. (a) Type, size and service pressure. A
(3) If a cylinder made from seamless DOT 4E cylinder is a welded aluminum
steel tubing fails the flattening test de- cylinder with a water capacity (nomi-
scribed in paragraph (g) of this section, nal) of not over 1,000 pounds and a serv-
suitable uniform heat treatment must ice pressure of at least 225 to not over
be used on each cylinder in the lot. All 500 psig. The cylinder must be con-
prescribed tests must be performed structed of not more than two seamless
subsequent to this heat treatment. drawn shells with no more than one
(i) Markings. (1) The markings re- circumferential weld. The circumferen-
quired by this section must be durable tial weld may not be closer to the point
and waterproof. The requirements of of tangency of the cylindrical portion
§ 178.35(h) do not apply to this section. with the shoulder than 20 times the
(2) Required markings are as follows: cylinder wall thickness. Cylinders or
(i) DOT-39. shells closed in by spinning process and
(ii) NRC. cylinders with longitudinal seams are
(iii) The service pressure. not authorized.
(iv) The test pressure. (b) Authorized material. The cylinder
(v) The registration number (M****) must be constructed of aluminum of
of the manufacturer. uniform quality. The following chem-
(vi) The lot number. ical analyses are authorized:
(vii) The date of manufacture if the
lot number does not establish the date TABLE 1—AUTHORIZED MATERIALS
of manufacture. Chemical analysis—limits in
(viii) With one of the following state- Designation percent 5154 1
ments:
Iron plus silicon .................... 0.45 maximum.
(A) For cylinders manufactured prior Copper .................................. 0.10 maximum.
to October 1, 1996: ‘‘Federal law forbids Manganese ........................... 0.10 maximum.
transportation if refilled-penalty up to Magnesium ........................... 3.10/3.90.
$25,000 fine and 5 years imprisonment Chromium ............................. 0.15/0.35.
Zinc ....................................... 0.20 maximum.
(49 U.S.C. 1809)’’ or ‘‘Federal law for- Titanium ................................ 0.20 maximum.
bids transportation if refilled-penalty Others, each ......................... 0.05 maximum.
up to $500,000 fine and 5 years imprison- Others, total .......................... 0.15 maximum.
Aluminum .............................. remainder.
ment (49 U.S.C. 5124).’’
(B) For cylinders manufactured on or 1 Analysis must regularly be made only for the elements
specifically mentioned in this table. If, however, the presence
after October 1, 1996: ‘‘Federal law for- of other elements is indicated in the course of routine anal-
bids transportation if refilled-penalty ysis, further analysis should be made to determine conform-
ance with the limits specified for other elements.
up to $500,000 fine and 5 years imprison-
ment (49 U.S.C. 5124).’’ (c) Identification. Material must be

(3) The markings required by para- identified by any suitable method that
graphs (i)(2)(i) through (i)(2)(v) of this will identify the alloy and manufactur-
section must be in numbers and letters er’s lot number.
80
(d) Manufacture. Cylinders must be (i) Threads must be clean-cut, even,

manufactured using equipment and without checks and cut to gauge.
processes adequate to ensure that each (ii) Taper threads to be of length not
cylinder produced conforms to the re- less than as specified for American
quirements of this subpart. No defect is Standard taper pipe threads.
permitted that is likely to weaken the (iii) Straight threads, having at least
finished cylinder appreciably. A rea- 4 engaged threads, to have tight fit and
sonably smooth and uniform surface calculated shear strength at least 10
finish is required. All welding must be times the test pressure of the cylinder;
by the gas shielded arc process. gaskets required, adequate to prevent
(e) Welding. The attachment to the leakage.
tops and bottoms only of cylinders by (3) Closure of a fitting, boss, or pad
welding of neckrings or flanges, must be adequate to prevent leakage.
footrings, handles, bosses and pads and (h) Hydrostatic test. Each cylinder
valve protection rings is authorized. must successfully withstand a hydro-
However, such attachments and the static test, as follows:
portion of the cylinder to which it is (1) The test must be by water jacket,
attached must be made of weldable alu- or other suitable method, operated so
minum alloys. as to obtain accurate data. The pres-
(f) Wall thickness. The wall thickness sure gauge must permit reading to an
of the cylinder must conform to the accuracy of 1 percent. The expansion
following: gauge must permit a reading of the
(1) The minimum wall thickness of total expansion to an accuracy either
the cylinder must be 0.140 inch. In any of 1 percent or 0.1 cubic centimeter.
case, the minimum wall thickness (2) Pressure of 2 times service pres-
must be such that calculated wall sure must be maintained for at least 30
stress at twice service pressure may seconds and sufficiently longer to in-
not exceed the lesser value of either of sure complete expansion. Any internal
the following: pressure applied previous to the official
(i) 20,000 psi. test may not exceed 90 percent of the
(ii) One-half of the minimum tensile test pressure. If, due to failure of the
strength of the material as required in test apparatus, the test pressure can-
paragraph (j) of this section. not be maintained, the test may be re-
(2) Calculation must be made by the peated at a pressure increased by 10
following formula: percent over the pressure otherwise
specified.
S = [P(1.3D2 + 0.4d2)] / (D2 ¥ d2)
(3) Permanent volumetric expansion
Where: may not exceed 12 percent of total vol-
S = wall stress in psi; umetric expansion at test pressure.
P = minimum test pressure prescribed for (4) Cylinders having a calculated wall
water jacket test; stress of 18,000 psi or less at test pres-
D = outside diameter in inches; sure may be tested as follows:
(3) Minimum thickness of heads and random out of each lot of 200 or less
bottoms may not be less than the min- must be tested in accordance with
imum required thickness of the side paragraphs (h)(1), (h)(2), and (h)(3) of
wall. this section.
(g) Opening in cylinder. Openings in (ii) All cylinders not tested as pro-
cylinders must conform to the fol- vided in paragraph (h)(4)(i) of this sec-
lowing: tion must be examined under pressure
(1) All openings must be in the heads of at least 2 times service pressure and
or bases. show no defect.
(2) Each opening in cylinders, except (5) One finished cylinder selected at
those for safety devices, must be pro- random out of each lot of 1,000 or less
vided with a fitting, boss, or pad, se- must be hydrostatically tested to 4
curely attached to cylinder by welding times the service pressure without

by inert gas shielded arc process or by bursting. Inability to meet this re-
threads. If threads are used, they must quirement must result in rejection of
comply with the following: the lot.
81
§ 178.68 49 CFR Ch. I (10–1–18 Edition)
(i) Flattening test. After hydrostatic (3) The yield strength in tension
testing, a flattening test is required on must be the stress corresponding to a
one section of a cylinder, taken at ran- permanent strain of 0.2 percent of the
dom out of each lot of 200 or less as fol- gauge length. The following conditions
lows: apply:
(1) If the weld is not at midlength of (i) The yield strength must be deter-
the cylinder, the test section must be mined by the ‘‘offset’’ method as pre-
no less in width than 30 times the cyl- scribed in ASTM E 8 (IBR, see § 171.7 of
inder wall thickness. The weld must be this subchapter).
in the center of the section. Weld rein- (ii) Cross-head speed of the testing
forcement must be removed by machin- machine may not exceed 1⁄8 inch per
ing or grinding so that the weld is flush minute during yield strength deter-
with the exterior of the parent metal. mination.
There must be no evidence of cracking (k) Acceptable results for physical tests.
in the sample when it is flattened be- An acceptable result of the physical
tween flat plates to no more than 6 test requires an elongation to at least
times the wall thickness. 7 percent and yield strength not over 80
(2) If the weld is at midlength of the percent of tensile strength.
cylinder, the test may be made as spec- (l) Weld tests. Welds of the cylinder
ified in paragraph (i)(1) of this section are required to successfully pass the
or must be made between wedge shaped following tests:
knife edges (60° angle) rounded to a 1⁄2 (1) Reduced section tensile test. A speci-
inch radius. There must be no evidence men must be cut from the cylinder
of cracking in the sample when it is used for the physical tests specified in
flattened to no more than 6 times the paragraph (j) of this section. The speci-
wall thickness. men must be taken from across the
seam, edges must be parallel for a dis-
(j) Physical test. A physical test must
tance of approximately 2 inches on ei-
be conducted to determine yield
ther side of the weld. The specimen
strength, tensile strength, elongation,
must be fractured in tension. The ap-
and reduction of area of material as
parent breaking stress calculated on
follows:
the minimum wall thickness must be
(1) The test is required on 2 speci- at least equal to 2 times the stress cal-
mens cut from one cylinder or part culated under paragraph (f)(2) of this
thereof taken at random out of each section, and in addition must have an
lot of 200 or less. actual breaking stress of at least 30,000
(2) Specimens must conform to the psi. Should this specimen fail to meet
following: the requirements, specimens may be
(i) A gauge length of 8 inches with a taken from 2 additional cylinders from
width not over 11⁄2 inches, a gauge the same lot and tested. If either of the
length of 2 inches with a width not latter specimens fails to meet require-
over 11⁄2 inches. ments, the entire lot represented must
(ii) The specimen, exclusive of grip be rejected.
ends, may not be flattened. Grip ends (2) Guided bend test. A bend test speci-
may be flattened to within 1 inch of men must be cut from the cylinder
each end of the reduced section. used for the physical test specified in
(iii) When size of cylinder does not paragraph (j) of this section. Specimen
permit securing straight specimens, must be taken across the seam, must
the specimens may be taken in any lo- be a minimum of 11⁄2 inches wide, edges
cation or direction and may be must be parallel and rounded with a
straightened or flattened cold, by pres- file, and back-up strip, if used, must be
sure only, not by blows; when speci- removed by machining. The specimen
mens are so taken and prepared, the in- shall be tested as follows:
spector’s report must show in connec- (i) The specimen must be bent to re-
tion with record of physical test de- fusal in the guided bend test jig as il-
tailed information in regard to such lustrated in paragraph 6.10 of CGA C–3

specimens. (IBR, see § 171.7 of this subchapter). The
(iv) Heating of a specimen for any root of the weld (inside surface of the
purpose is not authorized. cylinder) must be located away from
82
the ram of the jig. The specimen must its quality system approved by the As-
not show a crack or other open defect sociate Administrator. The quality sys-
exceeding 1⁄8 inch in any direction upon tem will initially be assessed through
completion of the test. Should this an audit by the Associate Adminis-
specimen fail to meet the require- trator or his or her representative to
ments, specimens may be taken from determine whether it meets the re-
each of 2 additional cylinders from the quirements of this section. The Asso-
same lot and tested. If either of the lat- ciate Administrator will notify the
ter specimens fails to meet require- manufacturer in writing of the results
ments, the entire lot represented must of the audit. The notification will con-
be rejected. tain the conclusions of the audit and
(ii) Alternatively, the specimen may any corrective action required. The As-
be tested in a guided bend test jig as il- sociate Administrator may perform
lustrated in Figure 12.1 of The Alu- periodic audits to ensure that the man-
minum Association’s 2002 publication, ufacturer operates in accordance with
‘‘Welding Aluminum: Theory and Prac- the quality system. Reports of periodic
tice.’’ The root of the weld (inside sur- audits will be provided to the manufac-
face of the cylinder) must be located turer. The manufacturer must bear the
away from the mandrel of the jig. No
cost of audits.
specimen must show a crack or other
(2) Quality system documentation. The
open defect exceeding 1⁄8 inch in any di-
rection upon completion of the test. manufacturer must be able to dem-
Should this specimen fail to meet the onstrate a documented quality system.
requirements, specimens may be taken Management must review the adequacy
from each of 2 additional cylinders of the quality system to assure that it
from the same lot and tested. If either is effective and conforms to the re-
of the latter specimens fails to meet quirements in § 178.70. The quality sys-
requirements, the entire lot rep- tem records must be in English and
resented must be rejected. must include detailed descriptions of
(m) Rejected cylinders. Repair of weld- the following:
ed seams is authorized. Acceptable cyl- (i) The organizational structure and
inders must pass all prescribed tests. responsibilities of personnel with re-
(n) Inspector’s report. In addition to gard to design and product quality;
the information required by § 178.35, the (ii) The design control and design
record of chemical analyses must also verification techniques, processes, and
include applicable information on iron, procedures used when designing the
titanium, zinc, and magnesium used in pressure receptacles;
the construction of the cylinder. (iii) The relevant procedures for pres-
[Amdt. 178–114, 61 FR 25942, May 23, 1996, as sure receptacle manufacturing, quality
amended at 62 FR 51561, Oct. 1, 1997; 66 FR control, quality assurance, and process
45386, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002; operation instructions;
68 FR 75748, Dec. 31, 2003; 69 FR 54046, Sept. (iv) Inspection and testing meth-
7, 2004; 74 FR 16143, Apr. 9, 2009] odologies, measuring and testing equip-
ment, and calibration data;
§ 178.69 Responsibilities and require-
ments for manufacturers of UN (v) The process for meeting customer
pressure receptacles. requirements;
(a) Each manufacturer of a UN pres- (vi) The process for document control
sure receptacle marked with ‘‘USA’’ as and document revision;
a country of approval must comply (vii) The system for controlling non-
with the requirements in this section. conforming material and records, in-
The manufacturer must maintain a cluding procedures for identification,
quality system, obtain an approval for segregation, and disposition;
each initial pressure receptacle design (viii) Production, processing and fab-
type, and ensure that all production of rication, including purchased compo-
UN pressure receptacles meets the ap- nents, in-process and final materials;
plicable requirements. and
(1) Quality system. The manufacturer (ix) Training programs for relevant
of a UN pressure receptacle must have personnel.
83
§ 178.70 49 CFR Ch. I (10–1–18 Edition)
(3) Maintenance of quality system. The mentation, including drawings and cal-
manufacturer must maintain the qual- culations, to verify that the design
ity system as approved by the Asso- meets all requirements of the applica-
ciate Administrator. The manufacturer ble UN pressure receptacle standard
shall notify the Associate Adminis- and specification requirements. If the
trator of any intended changes to the technical documentation shows that
approved quality system prior to mak- the pressure receptacle prototype de-
ing the change. The Associate Adminis- sign conforms to the applicable stand-
trator will evaluate the proposed ards and requirements in § 178.70, the
change to determine whether the manufacturer will fabricate a proto-
amended quality system will satisfy type lot of pressure receptacles in con-
the requirements. The Associate Ad- formance with the technical docu-
ministrator will notify the manufac- mentation representative of the design.
turer of the findings. The IIA will verify that the prototype
(b) Design type approvals. The manu- lot conforms to the applicable require-
facturer must have each pressure re- ments by selecting pressure receptacles
ceptacle design type reviewed by an IIA and witnessing their testing. After pro-
and approved by the Associate Admin- totype testing has been satisfactorily
istrator in accordance with § 178.70. A completed, showing the pressure recep-
cylinder is considered to be of a new tacles fully conform to all applicable
design, compared with an existing ap- specification requirements, the certi-
proved design, as stated in the applica- fying IIA must prepare a letter of rec-
ble ISO design, construction and test- ommendation and a design type ap-
ing standard. proval certificate. The design type ap-
(c) Production inspection and certifi- proval certificate must contain the
cation. The manufacturer must ensure name and address of the manufacturer
that each UN pressure receptacle is in- and the IIA certifying the design type,
spected and certified in accordance the test results, chemical analyses, lot
with § 178.71. identification, and all other supporting
[71 FR 33885, June 12, 2006] data specified in the applicable ISO de-
sign, construction and testing stand-
§ 178.70 Approval of UN pressure re- ard. The IIA must provide the certifi-
ceptacles. cate and documentation to the manu-
(a) Initial design-type approval. The facturer.
manufacturer of a UN pressure recep- (c) Application for initial design type
tacle must obtain an initial design approval. If the pre-audit is found satis-
type approval from the Associate Ad- factory by the IIA, the manufacturer
ministrator. The initial design type ap- will submit the letter of recommenda-
proval must be of the pressure recep- tion from the IIA and an application
tacle design as it is intended to be pro- for design type approval to the Asso-
duced. The manufacturer must arrange ciate Administrator. An application for
for an IIA, approved by the Associate initial design type approval must be
Administrator in accordance with sub- submitted for each manufacturing fa-
part I of part 107 of this chapter, to cility. The application must be in
perform a pre-audit of its pressure re- English and, at a minimum, contain
ceptacle manufacturing operation prior the following information:
to having an audit conducted by the (1) The name and address of the man-
Associate Administrator or his des- ufacturing facility. If the application is
ignee. submitted by an authorized representa-
(b) IIA pre-audit. The manufacturer tive on behalf of the manufacturer, the
must submit an application for initial application must include the represent-
design type approval to the IIA for re- ative’s name and address.
view. The IIA will examine the manu- (2) The name and title of the indi-
facturer’s application for initial design vidual responsible for the manufactur-
type approval for completeness. An in- er’s quality system, as required by
complete application will be returned § 178.69.

to the manufacturer with an expla- (3) The designation of the pressure
nation. If an application is complete, receptacle and the relevant pressure re-
the IIA will review all technical docu- ceptacle standard.
84
(4) Details of any refusal of approval (3) Select UN pressure receptacles

of a similar application by a designated from a prototype production lot and
approval agency of another country. witness testing as required for the de-
(5) The name and address of the pro- sign type approval;
duction IIA that will perform the func- (4) Ensure that the various design
tions prescribed in paragraph (e) of this type approval examinations and tests
section. The IIA must be approved in are performed accurately;
writing by the Associate Administrator (5) Verify that each pressure recep-
in accordance with subpart I of part 107 tacle is marked in accordance with the
of this chapter. applicable requirements in § 178.71; and
(6) Documentation on the manufac- (6) Furnish complete test reports to
turing facility as specified in § 178.69. the manufacturer and upon request to
(7) Design specifications and manu- the purchaser. The test reports and
facturing drawings, showing compo- certificate of compliance must be re-
nents and subassemblies if relevant, de- tained by the IIA for at least 20 years
sign calculations, and material speci- from the original test date of the pres-
fications necessary to verify compli- sure receptacles.
ance with the applicable pressure re- (f) Production inspection audit and cer-
ceptacle design standard. tification. (1) If the application, design
(8) Manufacturing procedures and drawing and quality control documents
any applicable standards that describe are found satisfactory, PHMSA will
in detail the manufacturing processes schedule an on-site audit of the pres-
and control. sure receptacle manufacturer’s quality
(9) Design type approval test reports system, manufacturing processes, in-
detailing the results of examinations spections, and test procedures.
and tests conducted in accordance with (2) During the audit, the manufac-
the relevant pressure receptacle stand- turer will be required to produce pres-
ard, to include any additional data, sure receptacles to the technical stand-
such as suitability for underwater ap- ards for which approval is sought.
plications or compatibility with hydro- (3) The production IIA must witness
gen embrittlement gases. the required inspections and
(d) Modification of approved pressure verifications on the pressure recep-
receptacle design type. Modification of tacles during the production run. The
an approved UN pressure receptacle de- IIA selected by the manufacturer for
sign type is not authorized without the production inspection and testing may
approval of the Associate Adminis- be different from the IIA who per-
trator. A manufacturer seeking modi- formed the design type approval
fication of an approved UN pressure re- verifications.
ceptacle design type may be required (4) If the procedures and controls are
to submit design qualification test deemed acceptable, test sample pres-
data to the Associate Administrator sure receptacles will be selected at ran-
before production. An audit may be re- dom from the production lot and sent
quired as part of the process to modify to a laboratory designated by the Asso-
an approval. ciate Administrator for verification
(e) Responsibilities of the production testing.
IIA. The production IIA is responsible (5) If the pressure receptacle test
for ensuring that each pressure recep- samples are found to conform to all the
tacle conforms to the design type ap- applicable requirements, the Associate
proval. The production IIA must per- Administrator will issue approvals to
form the following functions: the manufacturer and the production
(1) Witness all inspections and tests IIA to authorize the manufacture of
specified in the UN pressure receptacle the pressure receptacles. The approved
standard to ensure compliance with the design type approval certificate will be
standard and that the procedures returned to the manufacturer.
adopted by the manufacturer meet the (6) Upon the receipt of the approved
requirements of the standard; design type approval certificate from

(2) Verify that the production inspec- the Associate Administrator, the pres-
tions were performed in accordance sure receptacle manufacturer must
with this section; sign the certificate.
85
§ 178.71 49 CFR Ch. I (10–1–18 Edition)
(g) Recordkeeping. The production IIA (i) Written notice of the facts or con-
and the manufacturer must retain a duct believed to warrant the with-
copy of the design type approval cer- drawal;
tificate and certificate of compliance (ii) Opportunity to submit oral and
records for at least 20 years. written evidence, and
(h) Denial of design type application. If (iii) Opportunity to demonstrate or
the design type application is denied, achieve compliance with the applica-
the Associate Administrator will no- tion requirement.
tify the applicant in writing and pro- (3) If the Associate Administrator de-
vide the reason for the denial. The termines that a certificate of approval
manufacturer may request that the As- must be withdrawn to preclude a sig-
sociate Administrator reconsider the nificant and imminent adverse affect
decision. The application request on public safety, the procedures in
must— paragraph (j)(2)(ii) and (iii) of this sec-
(1) Be written in English and filed tion need not be provided prior to with-
within 60 days of receipt of the deci- drawal of the approval, but shall be
sion; provided as soon as practicable there-
(2) State in detail any alleged errors after.
of fact and law; and [71 FR 33886, June 12, 2006, as amended at 71
(3) Enclose any additional informa- FR 54397, Sept. 14, 2006; 77 FR 60943, Oct. 5,
tion needed to support the request to 2012]
reconsider.
§ 178.71 Specifications for UN pressure
(i) Appeal. (1) A manufacturer whose receptacles.
reconsideration request is denied may
appeal to the PHMSA Administrator. (a) General. Each UN pressure recep-
The appeal must— tacle must meet the requirements of
this section. UN pressure receptacles
(i) Be written in English and filed
and service equipment constructed ac-
within 60 days of receipt of the Asso-
cording to the standards applicable at
ciate Administrator’s decision on re-
the date of manufacture may continue
consideration;
in use subject to the continuing quali-
(ii) State in detail any alleged errors
fication and maintenance provisions of
of fact and law;
part 180 of this subchapter. Require-
(iii) Enclose any additional informa- ments for approval, qualification,
tion needed to support the appeal; and maintenance, and testing are contained
(iv) State in detail the modification in § 178.70, and subpart C of part 180 of
of the final decision sought. this subchapter.
(2) The PHMSA Administrator will (b) Definitions. The following defini-
grant or deny the relief and inform the tions apply for the purposes of design
appellant in writing of the decision. and construction of UN pressure recep-
PHMSA Administrator’s decision is the tacles under this subpart:
final administrative action. Alternative arrangement means an ap-
(j) Termination of a design type approval granted by the Associate Ad-
proval certificate. (1) The Associate Ad- ministrator for a MEGC that has been
ministrator may terminate an approval designed, constructed or tested to the
certificate issue under this section if it technical requirements or testing
is determined that, because of a change methods other than those specified for
in circumstances, the approval no UN pressure receptacles in part 178 or
longer is needed or no longer would be part 180 of this subchapter.
granted if applied for; information Bundle of cylinders. See § 171.8 of this
upon which the approval was based is subchapter.
fraudulent or substantially erroneous; Design type means a pressure recep-
or termination of the approval is nec- tacle design as specified by a particular
essary to adequately protect against pressure receptacle standard.
risks to life and property. Design type approval means an overall
(2) Before an approval is terminated, approval of the manufacturer’s quality

the Associate Administrator will pro- system and design type of each pres-
vide the manufacturer and the ap- sure receptacle to be produced within
proval agency— the manufacturer’s facility.
86
UN tube. See § 171.8 of this subchapter. stresses. The frame design must ensure
(c) Following the final heat treat- stability under normal operating con-
ment, all cylinders, except those se- ditions.
lected for batch testing must be sub- (1) The frame must securely retain
jected to a proof pressure or a hydrau- all the components of the bundle and
lic volumetric expansion test. must protect them from damage during
(d) Service equipment. (1) Except for conditions normally incident to trans-
pressure relief devices, UN pressure re- portation. The method of cylinder re-
ceptacle equipment, including valves, straint must prevent any vertical or
piping, fittings, and other equipment horizontal movement or rotation of the
subjected to pressure must be designed cylinder that could cause undue strain
and constructed to withstand at least on the manifold. The total assembly
1.5 times the test pressure of the pres-
must be able to withstand rough han-
sure receptacle.
dling, including being dropped or over-
(2) Service equipment must be config-
turned.
ured or designed to prevent damage
that could result in the release of the (2) The frame must include features
pressure receptacle contents during designed for the handling and transpor-
normal conditions of handling and tation of the bundle. The lifting rings
transport. Manifold piping leading to must be designed to withstand a design
shut-off valves must be sufficiently load of 2 times the maximum gross
flexible to protect the valves and the weight. Bundles with more than one
piping from shearing or releasing the lifting ring must be designed such that
pressure receptacle contents. The fill- a minimum sling angle of 45 degrees to
ing and discharge valves and any pro- the horizontal can be achieved during
tective caps must be secured against lifting using the lifting rings. If four
unintended opening. The valves must lifting rings are used, their design
conform to ISO 10297:2014(E) or ISO must be strong enough to allow the
13340:2001(E) (IBR, see § 171.7 of this sub- bundle to be lifted by two rings. Where
chapter) for non-refillable pressure re- two or four lifting rings are used, dia-
ceptacles, and be protected as specified metrically opposite lifting rings must
in § 173.301b(f) of this subchapter. Until be aligned with each other to allow for
December 31, 2020, the manufacture of a correct lifting using shackle pins. If
valve conforming to the requirements the bundle is filled with forklift pock-
in ISO 10297:2006(E) (IBR, see § 171.7 of ets, it must contain two forklift pock-
this subchapter) is authorized. Until ets on each side from which it is to be
December 31, 2008, the manufacture of a lifted. The forklift pockets must be po-
valve conforming to the requirements sitioned symmetrically consistent with
in ISO 10297:1999(E) (IBR, see § 171.7 of the bundle center of gravity.
this subchapter) is authorized. (3) The frame structural members
(3) UN pressure receptacles that can- must be designed for a vertical load of
not be handled manually or rolled,
2 times the maximum gross weight of
must be equipped with devices (e.g.,
the bundle. Design stress levels may
skids, rings, straps) ensuring that they
not exceed 0.9 times the yield strength
can be safely handled by mechanical
of the material.
means and so arranged as not to impair
the strength of, nor cause undue (4) The frame must not contain any
stresses, in the pressure receptacle. protrusions from the exterior frame
(4) Pressure receptacles filled by vol- structure that could cause a hazardous
ume must be equipped with a level in- condition.
dicator. (5) The frame design must prevent
(e) Bundles of cylinders. UN pressure collection of water or other debris that
receptacles assembled in bundles must would increase the tare weight of bun-
be structurally supported and held to- dles filled by weight.
gether as a unit and secured in a man- (6) The floor of the bundle frame
ner that prevents movement in rela- must not buckle during normal oper-
tion to the structural assembly and ating conditions and must allow for the
movement that would result in the drainage of water and debris from
concentration of harmful local around the base of the cylinders.
87
§ 178.71 49 CFR Ch. I (10–1–18 Edition)
(7) If the frame design includes mov- 9809–2:2000 (IBR, see § 171.7 of this sub-
able doors or covers, they must be ca- chapter) is authorized.
pable of being secured with latches or (3) ISO 9809–3: Gas cylinders—Refill-
other means that will not become dis- able seamless steel gas cylinders—De-
lodged by operational impact loads. sign, construction and testing—Part 3:
Valves that need to be operated in nor- Normalized steel cylinders. (IBR, see
mal service or in an emergency must § 171.7 of this subchapter). Until Decem-
be accessible. ber 31, 2018, the manufacture of a cyl-
(8) For bundles of cylinders, pressure inder conforming to the requirements
receptacle marking requirements only in ISO 9809–3:2000 (IBR, see § 171.7 of
apply to the individual cylinders of a this subchapter) is authorized.
bundle and not to any assembly struc- (4) ISO 9809–4:2014(E) (IBR, see § 171.7
ture. of this subchapter).
(f) Design and construction require- (h) Design and construction require-
ments for UN refillable welded cylinders. ments for UN refillable seamless aluminum
In addition to the general requirements alloy cylinders. In addition to the gen-
of this section, UN refillable welded eral requirements of this section, UN
cylinders must conform to the fol- refillable seamless aluminum cylinders
lowing ISO standards, as applicable: must conform to ISO 7866:2012(E) as
modified by ISO 7866:2012/Cor.1:2014(E)
(1) ISO 4706: Gas cylinders—Refillable
(IBR, see § 171.7 of this subchapter).
welded steel cylinders—Test pressure
Until December 31, 2020, the manufac-
60 bar and below (IBR, see § 171.7 of this
ture of a cylinder conforming to the re-
subchapter).
quirements in ISO 7866(E) (IBR, see
(2) ISO 18172–1: Gas cylinders—Refill- § 171.7 of this subchapter) is authorized.
able welded stainless steel cylinders— The use of Aluminum alloy 6351–T6 or
Part 1: Test pressure 6 MPa and below equivalent is prohibited.
(IBR, see § 171.7 of this subchapter). (i) Design and construction require-
(3) ISO 20703: Gas cylinders—Refill- ments for UN non-refillable metal cyl-
able welded aluminum-alloy cylinders. In addition to the general re-
inders—Design, construction and test- quirements of this section, UN non-re-
ing (IBR, see § 171.7 of this subchapter). fillable metal cylinders must conform
(g) Design and construction require- to ISO 11118: Gas cylinders—Non-refill-
ments for UN refillable seamless steel cyl- able metallic gas cylinders—Specifica-
inders. In addition to the general re- tion and test methods. (IBR, see § 171.7
quirements of this section, UN refill- of this subchapter.)
able seamless steel cylinders must con- (j) Design and construction require-
form to the following ISO standards, as ments for UN refillable seamless steel
applicable: tubes. In addition to the general re-
(1) ISO 9809–1:2010 Gas cylinders—Re- quirements of this section, UN refill-
fillable seamless steel gas cylinders— able seamless steel tubes must conform
Design, construction and testing—Part to ISO 11120: Gas cylinders—Refillable
1: Quenched and tempered steel cyl- seamless steel tubes of water capacity
inders with tensile strength less than between 150 L and 3000 L—Design, con-
1100 MPa. (IBR, see § 171.7 of this sub- struction and testing. (IBR, see § 171.7
chapter). Until December 31, 2018, the of this subchapter).
manufacture of a cylinder conforming (k) Design and construction require-
to the requirements in ISO 9809–1:1999 ments for UN acetylene cylinders. In ad-
(IBR, see § 171.7 of this subchapter) is dition to the general requirements of
authorized. this section, UN acetylene cylinders
(2) ISO 9809–2: Gas cylinders—Refill- must conform to the following ISO
able seamless steel gas cylinders—De- standards, as applicable:
sign, construction and testing—Part 2: (1) For the cylinder shell:
Quenched and tempered steel cylinders (i) ISO 9809–1:2010 Gas cylinders—Re-
with tensile strength greater than or fillable seamless steel gas cylinders—
equal to 1100 MPa. (IBR, see § 171.7 of Design, construction and testing—Part
this subchapter). Until December 31, 1: Quenched and tempered steel cyl-
2018, the manufacture of a cylinder inders with tensile strength less than
conforming to the requirements in ISO 1100 MPa. Until December 31, 2018, the
88
manufacture of a cylinder conforming § 171.7 of this subchapter) are author-

to the requirements in ISO 9809–1:1999 ized.
(IBR, see § 171.7 of this subchapter) is (iii) ISO 11119–3:2013(E) (IBR, see
authorized. § 171.7 of this subchapter). Until Decem-
(ii) ISO 9809–3: Gas cylinders—Refill- ber 31, 2020, cylinders conforming to
able seamless steel gas cylinders—De- the requirements in ISO 11119–3(E)
sign, construction and testing—Part 3: (IBR, see § 171.7 of this subchapter) are
Normalized steel cylinders. Until De- authorized.
cember 31, 2018, the manufacture of a (2) ISO 11119–2 and ISO 11119–3 gas
cylinder conforming to the require- cylinders of composite construction
ments in ISO 9809–3:2000 (IBR, see § 171.7 manufactured in accordance with the
of this subchapter) is authorized. requirements for underwater use must
(2) The porous mass in an acetylene bear the ‘‘UW’’ mark.
cylinder must conform to ISO (m) Design and construction require-
3807:2013(E) (IBR, see § 171.7 of this sub- ments for UN metal hydride storage sys-
chapter). Until December 31, 2020, the tems. In addition to the general require-
manufacture of a cylinder conforming ments of this section, metal hydride
to the requirements in ISO 3807–2(E) storage systems must conform to the
(IBR, see § 171.7 of this subchapter) is following ISO standards, as applicable:
authorized. ISO 16111: Transportable gas storage
(l) Design and construction require-
devices—Hydrogen absorbed in revers-
ments for UN composite cylinders and
ible metal hydride (IBR, see § 171.7 of
tubes. (1) In addition to the general re-
this subchapter).
quirements of this section, UN com-
posite cylinders and tubes must be de- (n) Design and construction require-
signed for a design life of not less than ments for UN cylinders for the transpor-
15 years. Composite cylinders and tubes tation of adsorbed gases. In addition to
with a design life longer than 15 years the general requirements of this sec-
must not be filled after 15 years from tion, UN cylinders for the transpor-
the date of manufacture, unless the de- tation of adsorbed gases must conform
sign has successfully passed a service to the following ISO standards, as ap-
life test program. The service life test plicable: ISO 11513:2011, Gas cylinders—
program must be part of the initial de- Refillable welded steel cylinders con-
sign type approval and must specify in- taining materials for sub-atmospheric
spections and tests to demonstrate gas packaging (excluding acetylene)—
that cylinders manufactured accord- Design, construction, testing, use and
ingly remain safe to the end of their periodic inspection, or ISO 9809–1:2010:
design life. The service life test pro- Gas cylinders—Refillable seamless
gram and the results must be approved steel gas cylinders—Design, construc-
by the competent authority of the tion and testing—Part 1: Quenched and
country of approval that is responsible tempered steel cylinders with tensile
for the initial approval of the cylinder strength less than 1100 MPa. (IBR, see
design. The service life of a composite § 171.7 of this subchapter.)
cylinder or tube must not be extended (o) Material compatibility. In addition
beyond its initial approved design life. to the material requirements specified
Additionally, composite cylinders and in the UN pressure receptacle design
tubes must conform to the following and construction ISO standards, and
ISO standards, as applicable: any restrictions specified in part 173
(i) ISO 11119–1:2012(E) (IBR, see § 171.7 for the gases to be transported, the re-
of this subchapter). Until December 31, quirements of the following standards
2020, cylinders conforming to the re- must be applied with respect to mate-
quirements in ISO 11119–1(E), (IBR, see rial compatibility:
§ 171.7 of this subchapter) are author- (1) ISO 11114–1:2012: Gas cylinders—
ized. Compatibility of cylinder and valve
(ii) ISO 11119–2:2012(E) (ISO 11119– materials with gas contents—Part 1:
2:2012/Amd.1:2014(E)) (IBR, see § 171.7 of Metallic materials. (IBR, see § 171.7 of

this subchapter). Until December 31, this subchapter).
2020, cylinders conforming to the re- (2) ISO 11114–2:2013(E) (IBR, see § 171.7
quirements in ISO 11119–2(E) (IBR, see of this subchapter).
89
§ 178.71 49 CFR Ch. I (10–1–18 Edition)
(p) Protection of closures. Closures and mm for pressure receptacles with a di-
their protection must conform to the ameter greater than or equal to 140
requirements in § 173.301(f) of this sub- mm, and 2.5 mm for pressure recep-
chapter. tacles with a diameter less than 140
(q) Marking of UN refillable pressure re- mm. The minimum size of the ‘‘UN’’
ceptacles. UN refillable pressure recep- mark must be 5 mm for pressure recep-
tacles must be marked clearly and leg- tacles with a diameter less than 140
ibly. The required markings must be mm, and 10 mm for pressure recep-
permanently affixed by stamping, en-
tacles with a diameter of greater than
graving, or other equivalent method,
or equal to 140 mm. The depth of the
on the shoulder, top end or neck of the
markings must not create harmful
pressure receptacle or on a perma-
nently affixed component of the pres- stress concentrations. A refillable pres-
sure receptacle, such as a welded col- sure receptacle conforming to the UN
lar. Except for the ‘‘UN’’ mark, the standard must be marked as follows:
minimum size of the marks must be 5 (1) The UN packaging symbol.
(2) The ISO standard, for example (7) The rated charging pressure of the
ISO 9809–1, used for design, construc- metal hydride storage system in bar,
tion and testing. Acetylene cylinders preceded by the letters ‘‘RCP’’ and fol-
must be marked to indicate the porous lowed by the letters ‘‘BAR.’’
mass and the steel shell, for example: (8) The empty or tare weight. Except
‘‘ISO 3807–2/ISO 9809–1.’’ for acetylene cylinders, empty weight
(3) The mark of the country where is the mass of the pressure receptacle
the approval is granted. The letters in kilograms, including all integral
‘‘USA’’ must be marked on UN pressure parts (e.g., collar, neck ring, foot ring,
receptacles approved by the United etc.), followed by the letters ‘‘KG’’. The
States. The manufacturer must obtain empty weight does not include the
an approval number from the Associate mass of the valve, valve cap or valve
Administrator. The manufacturer ap- guard or any coating. The empty
proval number must follow the country weight must be expressed to three sig-
of approval mark, separated by a slash nificant figures rounded up to the last
(for example, USA/MXXXX). Pressure digit. For cylinders of less than 1 kg,
receptacles approved by more than one the empty weight must be expressed to
national authority may contain the two significant figures rounded down
mark of each country of approval, sep- to the last digit. For acetylene cyl-
arated by a comma. inders, the tare weight must be marked
(4) The identity mark or stamp of the on the cylinders in kilograms. The tare
IIA. weight is the sum of the empty weight,
(5) The date of the initial inspection, mass of the valve, any coating and all
the year (four digits) followed by the permanently attached parts (e.g., fit-
month (two digits) separated by a tings and accessories) that are not re-
slash, for example ‘‘2006/04’’. moved during filling. The tare weight
(6) The test pressure in bar, preceded must be expressed to two significant
by the letters ‘‘PH’’ and followed by figures rounded down to the last digit.
the letters ‘‘BAR’’. The tare weight does not include the
90
ER19JA11.035</GPH>
cylinder cap or any outlet cap or plug (19) For metal hydride storage sys-
not permanently attached to the cyl- tems having a limited life, the date of
inder. expiration indicated by the word
(9) The minimum wall thickness of ‘‘FINAL,’’ followed by the year (four
the pressure receptacle in millimeters digits), the month (two digits) and sep-
followed by the letters ‘‘MM’’. This arated by a slash.
mark is not required for pressure re- (20) For composite cylinders and
ceptacles with a water capacity less tubes having a limited design life, the
than or equal to 1.0 L or for composite letters ‘‘FINAL’’ followed by the design
cylinders. life shown as the year (four digits) fol-
(10) For pressure receptacles intended lowed by the month (two digits) sepa-
for the transport of compressed gases rated by a slash (i.e. ‘‘/’’).
and UN 1001 acetylene, dissolved, the (21) For composite cylinders and
working pressure in bar, proceeded by tubes having a limited design life
the letters ‘‘PW’’. greater than 15 years and for composite
(11) For liquefied gases, the water ca- cylinders and tubes having non-limited
pacity in liters expressed to three sig- design life, the letters ‘‘SERVICE’’ fol-
nificant digits rounded down to the lowed by the date 15 years from the
last digit, followed by the letter ‘‘L’’. If date of manufacture (initial inspec-
the value of the minimum or nominal tion) shown as the year (four digits)
water capacity is an integer, the digits followed by the month (two digits) sep-
after the decimal point may be omit- arated by a slash (i.e. ‘‘/’’).
ted. (r) Marking sequence. The marking re-
(12) Identification of the cylinder quired by paragraph (q) of this section
thread type (e.g., 25E). must be placed in three groups as
(13) The country of manufacture. The shown in the example below:
letters ‘‘USA’’ must be marked on cyl- (1) The top grouping contains manu-
inders manufactured in the United facturing marks and must appear con-
States. secutively in the sequence given in
(14) The serial number assigned by paragraphs (q)(13) through (19) of this
the manufacturer. section.
(15) For steel pressure receptacles, (2) The middle grouping contains
the letter ‘‘H’’ showing compatibility operational marks described in para-
of the steel, as specified in ISO 11114–1. graphs (q)(6) through (11) of this sec-
(16) Identification of aluminum alloy, tion.
if applicable. (3) The bottom grouping contains
(17) Stamp for nondestructive test- certification marks and must appear
ing, if applicable. consecutively in the sequence given in
(18) Stamp for underwater use of paragraphs (q)(1) through (5) of this
composite cylinders, if applicable. section.
91
§ 178.71 49 CFR Ch. I (10–1–18 Edition)
(s) Other markings. Other markings stitute the marking required by this
are allowed in areas other than the side paragraph with a label. Reduction in
wall, provided they are made in low marking size is authorized only as pre-
stress areas and are not of a size and scribed in ISO 7225, Gas cylinders—Pre-
depth that will create harmful stress cautionary labels. (IBR, see § 171.7 of
concentrations. Such marks must not this subchapter).
conflict with required marks. (4) Each non-refillable pressure re-
(t) Marking of UN non-refillable pres- ceptacle must also be legibly marked
sure receptacles. Unless otherwise speci- by stenciling the following statement:
fied in this paragraph, each UN non-re- ‘‘Federal law forbids transportation if
fillable pressure receptacle must be refilled-penalty up to $500,000 fine and 5
clearly and legibly marked as pre- years in imprisonment (49 U.S.C.
scribed in paragraph (q) of this section. 5124).’’
In addition, permanent stenciling is (u) Marking of bundles of cylinders. (1)
authorized. Except when stenciled, the Individual cylinders in a bundle of cyl-
marks must be on the shoulder, top end inders must be marked in accordance
or neck of the pressure receptacle or on with paragraphs (q), (r), (s) and (t) of
a permanently affixed component of this section as appropriate.
the pressure receptacle (e.g., a welded (2) Refillable UN bundles of cylinders
collar). must be marked clearly and legibly
(1) The marking requirements and se- with certification, operational, and
quence listed in paragraphs (q)(1) manufacturing marks. These marks
through (19) of this section are re- must be permanently affixed (e.g.,
quired, except the markings in para- stamped, engraved, or etched) on a
graphs (q)(8), (9), (12) and (18) are not plate permanently attached to the
applicable. The required serial number frame of the bundle of cylinders. Ex-
marking in paragraph (q)(14) may be cept for the ‘‘UN’’ mark, the minimum
replaced by the batch number. size of the marks must be 5 mm. The
(2) Each receptacle must be marked minimum size of the ‘‘UN’’ mark must
with the words ‘‘DO NOT REFILL’’ in be 10 mm. A refillable UN bundle of
letters of at least 5 mm in height. cylinders must be marked with the fol-

(3) A non-refillable pressure recep- lowing:
tacle, because of its size, may sub- (i) The UN packaging symbol;
92
ER30MR17.035</GPH>
(ii) The ISO standard, for example (x) The country of manufacture. The
ISO 9809–1, used for design, construc- letters ‘‘USA’’ must be marked on cyl-
tion and testing. Acetylene cylinders inders manufactured in the United
must be marked to indicate the porous States;
mass and the steel shell, for example: (xi) The serial number assigned by
‘‘ISO 3807–2/ISO 9809–1’’; the manufacturer; and
(iii) The mark of the country where (xii) For steel pressure receptacles,
the approval is granted. The letters the letter ‘‘H’’ showing compatibility
‘‘USA’’ must be marked on UN pressure of the steel, as specified in 1SO 11114–1.
receptacles approved by the United (v) Marking sequence. The marking re-
States. The manufacturer must obtain quired by paragraph (u) of this section
an approval number from the Associate must be placed in three groups as fol-
Administrator. The manufacturer ap- lows:
proval number must follow the country (1) The top grouping contains manu-
of approval mark, separated by a slash facturing marks and must appear con-
(for example, USA/MXXXX). Pressure secutively in the sequence given in
receptacles approved by more than one paragraphs (u)(2)(x) through (u)(2)(xii)
national authority may contain the of this section as applicable.
mark of each country of approval, sep- (2) The middle grouping contains
arated by a comma; operational marks described in para-
(iv) The identity mark or stamp of graphs (u)(2)(vi) through (u)(2)(ix) of
the IIA; this section as applicable. When the
(v) The date of the initial inspection, operational mark specified in para-
the year in four digits followed by the graph (u)(2)(vii) is required, it must im-
two digit month separated by a slash, mediately precede the operational
for example ‘‘2006/04’’; mark specified in paragraph (u)(2)(vi).
(vi) The test pressure in bar, preceded (3) The bottom grouping contains
by the letters ‘‘PH’’ and followed by certification marks and must appear
the letters ‘‘BAR’’; consecutively in the sequence given in
(vii) For pressure receptacles in- paragraphs (u)(2)(i) through (u)(2)(v) of
tended for the transport of compressed this section as applicable.
gases and UN 1001 acetylene, dissolved, [76 FR 3385, Jan. 19, 2011, as amended at 76
the working pressure in bar, proceeded FR 43532, July 20, 2011; 77 FR 60943, Oct. 5,
by the letters ‘‘PW’’; 2012; 78 FR 1096, Jan. 7, 2013; 80 FR 1166, Jan.
(viii) For liquefied gases, the water 8, 2015; 80 FR 72929, Nov. 23, 2015; 82 FR 15895,
capacity in liters expressed to three Mar. 30, 2017]
significant digits rounded down to the
last digit, followed by the letter ‘‘L’’. If § 178.74 Approval of MEGCs.
the value of the minimum or nominal (a) Application for design type ap-
water capacity is an integer, the digits proval. (1) Each new MEGC design type
after the decimal point may be omit- must have a design approval certifi-
ted; cate. An owner or manufacturer must
(ix) The total mass of the frame of apply to an approval agency that is ap-
the bundle and all permanently at- proved by the Associate Administrator
tached parts (cylinders, manifolds, fit- in accordance with subpart E of part
tings and valves). Bundles intended for 107 of this chapter + to obtain approval
the carriage of UN 1001 acetylene, dis- of a new design. When a series of
solved must bear the tare mass as spec- MEGCs is manufactured without
ified in clause N.4.2 of ISO 10961:2010; change in the design, the certificate is
93
ER08JA15.002</GPH>
§ 178.74 49 CFR Ch. I (10–1–18 Edition)
valid for the entire series. The design Design Type Approval Certificate ap-
approval certificate must refer to the plication, the approval agency and the
prototype test report, the materials of manufacturer must each maintain a
construction of the manifold, the copy of the approved drawings, calcula-
standards to which the pressure recep- tions, and test data for at least 20
tacles are made and an approval num- years.
ber. The compliance requirements or (c) Approval agency’s responsibilities.
test methods applicable to MEGCs as The approval agency is responsible for
specified in this subpart may be varied ensuring that the MEGC conforms to
when the level of safety is determined the design type approval. The approval
to be equivalent to or exceed the re- agency must:
quirements of this subchapter and is (1) Witness all tests required for the
approved in writing by the Associate approval of the MEGC specified in this
Administrator. A design approval may section and § 178.75.
serve for the approval of smaller
(2) Ensure, through appropriate in-
MEGCs made of materials of the same
spection, that each MEGC is fabricated
type and thickness, by the same fab-
rication techniques and with identical in all respects in conformance with the
supports, equivalent closures and other approved drawings, calculations, and
appurtenances. test data.
(2) Each application for design ap- (3) Determine and ensure that the
proval must be in English and contain MEGC is suitable for its intended use
the following information: and that it conforms to the require-
(i) Two complete copies of all engi- ments of this subchapter.
neering drawings, calculations, and (4) Apply its name, identifying mark
test data necessary to ensure that the or identifying number, and the date the
design meets the relevant specifica- approval was issued, to the metal iden-
tion. tification marking plate attached to
(ii) The manufacturer’s serial number the MEGC upon successful completion
that will be assigned to each MEGC. of all requirements of this subpart.
(iii) A statement as to whether the Any approvals by the Associate Admin-
design type has been examined by any istrator authorizing design or con-
approval agency previously and judged struction alternatives (Alternate Ar-
unacceptable. Affirmative statements rangements) of the MEGC (see para-
must be documented with the name of graph (a) of this section) must be indi-
the approval agency, reason for non-ac- cated on the metal identification plate
ceptance, and the nature of modifica- as specified in § 178.75(j).
tions made to the design type. (5) Prepare an approval certificate
(b) Actions by the approval agency. The for each MEGC or, in the case of a se-
approval agency must review the appli- ries of identical MEGCs manufactured
cation for design type approval, includ- to a single design type, for each series
ing all drawings and calculations, to of MEGCs. The approval certificate
ensure that the design of the MEGC must include all of the following infor-
meets all requirements of the relevant mation:
specification and to determine whether (i) The information displayed on the
it is complete and conforms to the re-
metal identification plate required by
quirements of this section. An incom-
§ 178.75(j);
plete application will be returned to
the applicant with the reasons why the (ii) The results of the applicable
application was returned. If the appli- framework test specified in ISO 1496–3
cation is complete and all applicable (IBR, see § 171.7 of this subchapter);
requirements of this section are met, (iii) The results of the initial inspec-
the approval agency must prepare a tion and test specified in paragraph (h)
MEGC design approval certificate con- of this section;
taining the manufacturer’s name and (iv) The results of the impact test
address, results and conclusions of the specified in § 178.75(i)(4);

examination and necessary data for (v) Certification documents verifying
identification of the design type. If the that the cylinders and tubes conform
Associate Administrator approves the to the applicable standards; and
94
(vi) A statement that the approval (3) Enclose any additional informa-
agency certifies the MEGC in accord- tion needed to support the request to
ance with the procedures in this sec- reconsider.
tion and that the MEGC is suitable for (f) Appeal. (1) A manufacturer whose
its intended purpose and meets the re- reconsideration request is denied may
quirements of this subchapter. When a appeal to the PHMSA Administrator.
series of MEGCs is manufactured with- The appeal must—
out change in the design type, the cer- (i) Be in writing and filed within 90
tificate may be valid for the entire se- days of receipt of the Associate Admin-
ries of MEGCs representing a single de- istrator s decision on reconsideration;
sign type. The approval number must
(ii) State in detail any alleged errors
consist of the distinguishing sign or
of fact and law;
mark of the country (‘‘USA’’ for the
United States of America) where the (iii) Enclose any additional informa-
approval was granted and a registration needed to support the appeal; and
tion number. (iv) State in detail the modification
(6) Retain on file a copy of each ap- of the final decision sought.
proval certificate for at least 20 years. (2) The Administrator will grant or
(d) Manufacturers’ responsibilities. The deny the relief and inform the appel-
manufacturer is responsible for compli- lant in writing of the decision. The Ad-
ance with the applicable specifications ministrator’s decision is the final ad-
for the design and construction of ministrative action.
MEGCs. The manufacturer of a MEGC (g) Modifications to approved MEGCs.
must: (1) Prior to modification of any ap-
(1) Comply with all the requirements proved MEGC that may affect conform-
of the applicable ISO standard specified ance and safe use, and that may in-
in § 178.71; volve a change to the design type or af-
(2) Obtain and use an approval agen- fect its ability to retain the hazardous
cy to review the design, construction material in transportation, the
and certification of the MEGC; MEGC’s owner must inform the ap-
(3) Provide a statement in the manu- proval agency that prepared the initial
facturers’ data report certifying that approval certificate for the MEGC or, if
each MEGC manufactured complies the initial approval agency is unavail-
with the relevant specification and all able, another approval agency, of the
the applicable requirements of this nature of the modification and request
subchapter; and certification of the modification. The
(4) Retain records for the MEGCs for owner must supply the approval agency
at least 20 years. When required by the with all revised drawings, calculations,
specification, the manufacturer must and test data relative to the intended
provide copies of the records to the ap- modification. The MEGC’s owner must
proval agency, the owner or lessee of also provide a statement as to whether
the MEGC, and to a representative of the intended modification has been ex-
DOT, upon request. amined and determined to be unaccept-
(e) Denial of application for approval. able by any approval agency. The writ-
If the Associate Administrator finds ten statement must include the name
that the MEGC will not be approved for of the approval agency, the reason for
any reason, the Associate Adminis-
non-acceptance, and the nature of
trator will notify the applicant in writ-
changes made to the modification since
ing and provide the reason for the de-
nial. The manufacturer may request its original rejection.
that the Associate Administrator re- (2) The approval agency must review
consider the decision. The application the request for modification. If the ap-
request must— proval agency determines that the pro-
(1) Be written in English and filed posed modification does not conform to
the relevant specification, the approval
within 90 days of receipt of the deci-

sion; agency must reject the request in ac-
(2) State in detail any alleged errors cordance with paragraph (d) of this sec-
of fact and law; and tion. If the approval agency determines
95
§ 178.75 49 CFR Ch. I (10–1–18 Edition)
that the proposed modification con- (3) An opportunity to demonstrate or

forms fully with the relevant specifica- achieve compliance with the applicable
tion, the request is accepted. If modi- requirements.
fication to an approved MEGC alters (i) Imminent Danger. If the Associate
any information on the approval cer- Administrator determines that a cer-
tificate, the approval agency must pre- tificate of approval must be terminated
pare a new approval certificate for the to preclude a significant and imminent
modified MEGC and submit the certifi- adverse effect on public safety, the As-
cate to the Associate Administrator for sociate Administrator may terminate
approval. After receiving approval the certificate immediately. In such
from the Associate Administrator, the circumstances, the opportunities of
approval agency must ensure that any paragraphs (h)(2) and (3) of this section
necessary changes are made to the need not be provided prior to termi-
metal identification plate. A copy of nation of the approval, but must be
each newly issued approval certificate provided as soon as practicable there-
must be retained by the approval agen- after.
cy and the MEGC’s owner for at least
[71 FR 33890, June 12, 2006]
20 years. The approval agency must
perform the following activities: § 178.75 Specifications for MEGCs.
(i) Retain a set of the approved re-
vised drawings, calculations, and data (a) General. Each MEGC must meet
as specified in § 178.69(b)(4) for at least the requirements of this section. In a
20 years; MEGC that meets the definition of a
‘‘container’’ within the terms of the
(ii) Ensure through appropriate in-
International Convention for Safe Con-
spection that all modifications con-
tainers (CSC) must meet the require-
form to the revised drawings, calcula-
ments of the CSC as amended and 49
tions, and test data; and
CFR parts 450 through 453, and must
(iii) Determine the extent to which have a CSC approval plate.
retesting of the modified MEGC is nec-
(b) Alternate Arrangements. The tech-
essary based on the nature of the pro-
nical requirements applicable to
posed modification, and ensure that all
MEGCs may be varied when the level of
required retests are satisfactorily per-
safety is determined to be equivalent
formed.
to or exceed the requirements of this
(h) Termination of Approval Certificate. subchapter. Such an alternate arrange-
(1) The Associate Administrator may ment must be approved in writing by
terminate an approval issued under the Associate Administrator. MEGCs
this section if he or she determines approved to an Alternate Arrangement
that— must be marked as required by para-
(i) Because of a change in cir- graph (j) of this section.
cumstances, the approval no longer is (c) Definitions. The following defini-
needed or no longer would be granted if tions apply:
applied for; Leakproofness test means a test using
(ii) Information upon which the ap- gas subjecting the pressure receptacles
proval was based is fraudulent or sub- and the service equipment of the MEGC
stantially erroneous; to an effective internal pressure of not
(iii) Termination of the approval is less than 20% of the test pressure.
necessary to adequately protect Manifold means an assembly of piping
against risks to life and property; or and valves connecting the filling and/or
(iv) The MEGC does not meet the discharge openings of the pressure re-
specification. ceptacles.
(2) Before an approval is terminated, Maximum permissible gross mass or
the Associate Administrator will pro- MPGM means the heaviest load author-
vide the person— ized for transport (sum of the tare
(i) Written notice of the facts or con- mass of the MEGC, service equipment
duct believed to warrant the termi- and pressure receptacle).

nation; Service equipment means manifold sys-
(ii) An opportunity to submit oral tem (measuring instruments, piping
and written evidence; and and safety devices).
96
Shut-off valve means a valve that (iii) ISO 9809–3: Gas cylinders—Refill-
stops the flow of gas. able seamless steel gas cylinders—De-
Structural equipment means the rein- sign, construction and testing—Part 3:
forcing, fastening, protective and stabi- Normalized steel cylinders. (IBR, see
lizing members external to the pres- § 171.7 of this subchapter). Until Decem-
sure receptacles. ber 31, 2018, the manufacture of a cyl-
(d) General design and construction re- inder conforming to the requirements
quirements. (1) The MEGC must be capa- in ISO 9809–3:2000 (IBR, see § 171.7 of
ble of being loaded and discharged this subchapter) is authorized; or
without the removal of its structural (iv) ISO 9809–4:2014(E) Gas cylinders—
equipment. It must possess stabilizing Refillable seamless steel gas cyl-
members external to the pressure re- inders—Design, construction and test-
ceptacles to provide structural integ- ing—Part 4: Stainless steel cylinders
rity for handling and transport. MEGCs with an Rm value of less than 1 100
must be designed and constructed with MPa (IBR, see § 171.7 of this sub-
supports to provide a secure base dur- chapter).
ing transport and with lifting and tie- (v) ISO 11120: Gas cylinders—Refill-
down attachments that are adequate able seamless steel tubes of water ca-
for lifting the MEGC including when pacity between 150 L and 3000 L—De-
loaded to its maximum permissible sign, construction and testing. (IBR,
gross mass. The MEGC must be de- see § 171.7 of this subchapter).
signed to be loaded onto a transport ve- (4) Pressure receptacles of MEGCs,
hicle or vessel and equipped with skids, fittings, and pipework must be con-
mountings or accessories to facilitate structed of a material that is compat-
mechanical handling. ible with the hazardous materials in-
(2) MEGCs must be designed, manu- tended to be transported, as specified
factured and equipped to withstand, in this subchapter.
without loss of contents, all normal (5) Contact between dissimilar met-
handling and transportation condi- als that could result in damage by gal-
tions. The design must take into ac- vanic action must be prevented by ap-
count the effects of dynamic loading propriate means.
and fatigue. (6) The materials of the MEGC, in-
(3) Each pressure receptacle of a cluding any devices, gaskets, and ac-
MEGC must be of the same design type, cessories, must have no adverse effect
seamless steel, and constructed and on the gases intended for transport in
tested according to one of the following the MEGC.
ISO standards: (7) MEGCs must be designed to with-
(i) ISO 9809–1: Gas cylinders—Refill- stand, without loss of contents, at
able seamless steel gas cylinders—De- least the internal pressure due to the
sign, construction and testing—Part 1: contents, and the static, dynamic and
Quenched and tempered steel cylinders thermal loads during normal condi-
with tensile strength less than 1100 tions of handling and transport. The
MPa. (IBR, see § 171.7 of this sub- design must take into account the ef-
chapter). Until December 31, 2018, the fects of fatigue, caused by repeated ap-
manufacture of a cylinder conforming plication of these loads through the ex-
to the requirements in ISO 9809–1:1999 pected life of the MEGC.
(IBR, see § 171.7 of this subchapter) is (8) MEGCs and their fastenings must,
authorized; under the maximum permissible load,
(ii) ISO 9809–2: Gas cylinders—Refill- be capable of withstanding the fol-
able seamless steel gas cylinders—De- lowing separately applied static forces
sign, construction and testing—Part 2: (for calculation purposes, acceleration
Quenched and tempered steel cylinders due to gravity (g) = 9.81 m/s2):
with tensile strength greater than or (i) In the direction of travel: 2g
equal to 1100 MPa. (IBR, see § 171.7 of (twice the MPGM multiplied by the ac-
this subchapter). Until December 31, celeration due to gravity);
2018, the manufacture of a cylinder (ii) Horizontally at right angles to

conforming to the requirements in ISO the direction of travel: 1g (the MPGM
9809–2:2000 (IBR, see § 171.7 of this sub- multiplied by the acceleration due to
chapter) is authorized; gravity. When the direction of travel is
97
§ 178.75 49 CFR Ch. I (10–1–18 Edition)
not clearly determined, the forces must threaded plugs, and any protective caps
be equal to twice the MPGM); must be capable of being secured
(iii) Vertically upwards: 1g (the against unintended opening.
MPGM multiplied by the acceleration (2) Each pressure receptacle intended
due to gravity); and for the transport of Division 2.3 gases
(iv) Vertically downwards: 2g (twice must be equipped with an individual
the MPGM (total loading including the shut-off valve. The manifold for Divi-
effect of gravity) multiplied by the ac- sion 2.3 liquefied gases must be de-
celeration due to gravity. signed so that each pressure receptacle
(9) Under each of the forces specified can be filled separately and be kept
in paragraph (d)(8) of this section, the isolated by a valve capable of being
stress at the most severely stressed closed during transit. For Division 2.1
point of the pressure receptacles must gases, the pressure receptacles must be
not exceed the values given in the ap- isolated by an individual shut-off valve
plicable design specifications (e.g., ISO into assemblies of not more than 3,000
11120). L.
(10) Under each of the forces specified (3) For MEGC filling and discharge
in paragraph (d)(8) of this section, the openings:
safety factor for the framework and (i) Two valves in series must be
fastenings must be as follows: placed in an accessible position on each
(i) For steels having a clearly defined discharge and filling pipe. One of the
yield point, a safety factor of 1.5 in re- valves may be a backflow prevention
lation to the guaranteed yield valve. (ii) The filling and discharge de-
strength; or vices may be equipped to a manifold.
(ii) For steels with no clearly defined (iii) For sections of piping which can
yield point, a safety factor of 1.5 in re- be closed at both ends and where a liq-
lation to the guaranteed 0.2 percent uid product can be trapped, a pressure-
proof strength and, for austenitic relief valve must be provided to pre-
steels, the 1 percent proof strength. vent excessive pressure build-up.
(11) MEGCs must be capable of being (iv) The main isolation valves on a
electrically grounded to prevent elec- MEGC must be clearly marked to indi-
trostatic discharge when intended for cate their directions of closure. All
flammable gases. shutoff valves must close by a clock-
(12) The pressure receptacles of a wise motion of the handwheel.
MEGC must be secured in a manner to (v) Each shut-off valve or other
prevent movement that could result in means of closure must be designed and
damage to the structure and con- constructed to withstand a pressure
centration of harmful localized equal to or greater than 1.5 times the
stresses. test pressure of the MEGC.
(e) Service equipment. (1) Service (vi) All shut-off valves with screwed
equipment must be arranged so that it spindles must close by a clockwise mo-
is protected from mechanical damage tion of the handwheel. For other shut-
by external forces during handling and off valves, the open and closed posi-
transportation. When the connections tions and the direction of closure must
between the frame and the pressure re- be clearly shown.
ceptacles allow relative movement be- (vii) All shut-off valves must be de-
tween the subassemblies, the equip- signed and positioned to prevent unin-
ment must be fastened to allow move- tentional opening.
ment to prevent damage to any work- (viii) Ductile metals must be used in
ing part. The manifolds, discharge fit- the construction of valves or acces-
tings (pipe sockets, shut-off devices), sories.
and shut-off valves must be protected (4) The piping must be designed, con-
from damage by external forces. Mani- structed and installed to avoid damage
fold piping leading to shut-off valves due to expansion and contraction, me-
must be sufficiently flexible to protect chanical shock and vibration. Joints in
the valves and the piping from shear- tubing must be brazed or have an
ing, or releasing the pressure recep- equally strong metal union. The melt-
tacle contents. The filling and dis- ing point of brazing materials must be
charge devices, including flanges or no lower than 525 °C (977 °F). The rated
98
pressure of the service equipment and installed, must be arranged to ensure

of the manifold must be not less than the escaping vapor is discharged up-
two-thirds of the test pressure of the wards and unrestrictedly to prevent
pressure receptacles. impingement of escaping gas or liquid
(f) Pressure relief devices. Each pres- upon the MEGC, its pressure recep-
sure receptacle must be equipped with tacles or personnel. For flammable,
one or more pressure relief devices as pyrophoric and oxidizing gases, the es-
specified in § 173.301(f) of this sub- caping gas must be directed away from
chapter. When pressure relief devices the pressure receptacle in such a man-
are installed, each pressure receptacle ner that it cannot impinge upon the
or group of pressure receptacles of a other pressure receptacles. Heat resist-
MEGC that can be isolated must be ant protective devices that deflect the
equipped with one or more pressure re- flow of gas are permissible provided the
lief devices. Pressure relief devices required pressure relief device capacity
must be of a type that will resist dy- is not reduced. Arrangements must be
namic forces including liquid surge and made to prevent access to the pressure
must be designed to prevent the entry relief devices by unauthorized persons
of foreign matter, the leakage of gas and to protect the devices from damage
and the development of any dangerous caused by rollover.
excess pressure. (g) Gauging devices. When a MEGC is
(1) The size of the pressure relief de- intended to be filled by mass, it must
vices: CGA S–1.1 (IBR, see § 171.7 of this be equipped with one or more gauging
subchapter) must be used to determine devices. Glass level-gauges and gauges
the relief capacity of individual pres- made of other fragile material are pro-
sure receptacles. hibited.
(2) Connections to pressure-relief de- (h) MEGC supports, frameworks, lifting
vices: Connections to pressure relief and tie-down attachments. (1) MEGCs
devices must be of sufficient size to en- must be designed and constructed with
able the required discharge to pass un- a support structure to provide a secure
restricted to the pressure relief device. base during transport. MEGCs must be
A shut-off valve installed between the protected against damage to the pres-
pressure receptacle and the pressure re- sure receptacles and service equipment
lief device is prohibited, except where resulting from lateral and longitudinal
duplicate devices are provided for impact and overturning. The forces
maintenance or other reasons, and the specified in paragraph (d)(8) of this sec-
shut-off valves serving the devices action, and the safety factor specified in
tually in use are locked open, or the paragraph (d)(10) of this section must
shut-off valves are interlocked so that be considered in this aspect of the de-
at least one of the duplicate devices is sign. Skids, frameworks, cradles or
always operable and capable of meeting other similar structures are accept-
the requirements of paragraph (f)(1) of able. If the pressure receptacles and
this section. No obstruction is per- service equipment are so constructed
mitted in an opening leading to or as to withstand impact and over-
leaving from a vent or pressure-relief turning, additional protective support
device that might restrict or cut-off structure is not required (see para-
the flow from the pressure receptacle graph (h)(4) of this section).
to that device. The opening through all (2) The combined stresses caused by
piping and fittings must have at least pressure receptacle mountings (e.g.
the same flow area as the inlet of the cradles, frameworks, etc.) and MEGC
pressure relief device to which it is lifting and tie-down attachments must
connected. The nominal size of the dis- not cause excessive stress in any pres-
charge piping must be at least as large sure receptacle. Permanent lifting and
as that of the pressure relief device. tie-down attachments must be
(3) Location of pressure-relief de- equipped to all MEGCs. Any welding of
vices: For liquefied gases, each pres- mountings or attachments onto the
sure relief device must, under max- pressure receptacles is prohibited.

imum filling conditions, be in commu- (3) The effects of environmental cor-
nication with the vapor space of the rosion must be taken into account in
pressure receptacles. The devices, when the design of supports and frameworks.
99
§ 178.75 49 CFR Ch. I (10–1–18 Edition)
(4) When MEGCs are not protected resenting each design type. The proto-
during transport as specified in para- type MEGC must be shown to be capa-
graph (h)(1) of this section, the pres- ble of absorbing the forces resulting
sure receptacles and service equipment from an impact not less than 4 times (4
must be protected against damage re- g) the MPGM of the fully loaded
sulting from lateral or longitudinal im- MEGC, at a duration typical of the me-
pact or overturning. External fittings chanical shocks experienced in rail
must be protected against release of transport. A listing of acceptable
the pressure receptacles’ contents upon methods for performing the impact test
impact or overturning of the MEGC on is provided in the UN Recommenda-
its fittings. Particular attention must tions (IBR, see § 171.7 of this sub-
be paid to the protection of the mani- chapter).
fold. Examples of protection include: (j) Marking. (1) Each MEGC must be
(i) Protection against lateral impact, equipped with a corrosion resistant
which may consist of longitudinal bars; metal plate permanently attached to
(ii) Protection against overturning, the MEGC in a conspicuous place read-
which may consist of reinforcement ily accessible for inspection. The pres-
rings or bars fixed across the frame; sure receptacles must be marked ac-
(iii) Protection against rear impact, cording to this section. Affixing the
which may consist of a bumper or metal plate to a pressure receptacle is
frame; prohibited. At a minimum, the fol-
(iv) Protection of the pressure recep- lowing information must be marked on
tacles and service equipment against the plate by stamping or by any other
damage from impact or overturning by equivalent method:
use of an ISO frame according to the
Country of manufacture
relevant provisions of ISO 1496–3. (IBR,
see § 171.7 of this subchapter). UN
(i) Initial inspection and test. The pres-
sure receptacles and items of equip-
ment of each MEGC must be inspected
and tested before being put into service
for the first time (initial inspection
and test). This initial inspection and
test of an MEGC must include the fol-
lowing:
(1) A check of the design characteris-
tics.
(2) An external examination of the
MEGC and its fittings, taking into ac-
count the hazardous materials to be
transported.
(3) A pressure test performed at the Approval Country
test pressures specified in Approval Number
§ 173.304b(b)(1) and (2) of this sub-
Alternate Arrangements (see § 178.75(b))
chapter. The pressure test of the mani-
fold may be performed as a hydraulic MEGC Manufacturer’s name or mark
test or by using another liquid or gas. MEGC’s serial number
A leakproofness test and a test of the Approval agency (Authorized body for
satisfactory operation of all service the design approval)
equipment must also be performed be-
fore the MEGC is placed into service. Year of manufacture
When the pressure receptacles and Test pressure: lll bar gauge
their fittings have been pressure-tested Design temperature range lll °C to
separately, they must be subjected to a lll °C
leakproof test after assembly.
Number of pressure receptacles lll
(4) An MEGC that meets the defini-

tion of ‘‘container’’ in the CSC (see 49 Total water capacity lll liters
CFR 450.3(a)(2)) must be subjected to an Initial pressure test date and identi-
impact test using a prototype rep- fication of the Approval Agency
100
ER12JN06.002</GPH>
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, Subpt. C, App. A
Date and type of most recent periodic Name of the operator

tests Maximum permissible load mass lll
Year lll Monthlll Type lll kg
(e.g. 2004–05, AE/UE, where ‘‘AE’’ rep- Working pressure at 15 °C: lll bar
resents acoustic emission and ‘‘UE’’ gauge
represents ultrasonic examination) Maximum permissible gross mass
Stamp of the approval agency who (MPGM) lll kg
performed or witnessed the most recent Unladen (tare) mass lll kg
test [71 FR 33892, June 12, 2006, as amended at 73
(2) The following information must FR 4719, Jan. 28, 2008; 77 FR 60943, Oct. 5, 2012;
be marked on a metal plate firmly se- 80 FR 1168, Jan. 8, 2015; 82 FR 15896, Mar. 30,
cured to the MEGC: 2017]
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:
101
Pt. 178, Subpt. C, App. A 49 CFR Ch. I (10–1–18 Edition)
102
ER08AU02.013</GPH>
103
ER08AU02.014</GPH>
104
ER08AU02.015</GPH>
105
ER08AU02.016</GPH>
[67 FR 51654, Aug. 8, 2002]

106
ER08AU02.017</GPH>
Pipeline and Hazardous Materials Safety Admin., DOT § 178.255–6
Subparts D–G [Reserved] § 178.255–3 Expansion domes.

(a) Expansion domes, if applied, must
Subpart H—Specifications for have a minimum capacity of one per-
Portable Tanks cent of the combined capacity of the
tank and dome.
SOURCE: 29 FR 18972, Dec. 29, 1964, unless (b) [Reserved]
otherwise noted. Redesignated at 32 FR 5606,
Apr. 5, 1967. § 178.255–4 Closures for manholes and
domes.
§§ 178.251—178.253–5 [Reserved] (a) The manhole cover shall be de-
§ 178.255 Specification 60; steel port- signed to provide a secure closure of
able tanks. the manhole. All covers, not hinged to
the tanks, shall be attached to the out-
§ 178.255–1 General requirements. side of the dome by at least 1⁄8 inch
chain or its equivalent. Closures shall
(a) Tanks must be of fusion welded
be made tight against leakage of vapor
construction, cylindrical in shape with
and liquid by use of gaskets of suitable
seamless heads concave to the pres-
material.
sure. Tank shells may be of seamless
construction. (b) [Reserved]
(b) Tanks must be designed, con-
§ 178.255–5 Bottom discharge outlets.
structed, certified, and stamped in ac-
cordance with Section VIII of the (a) Bottom discharge outlets prohib-
ASME Code (IBR, see § 171.7 of this sub- ited, except on tanks used for ship-
chapter). ments of sludge acid and alkaline cor-
(c) Tanks including all permanent at- rosive liquids.
tachments must be postweld heat (b) If installed, bottom outlets or
treated as a unit. bottom washout chambers shall be of
(d) Requirements concerning types of metal not subject to rapid deteriora-
valves, retesting, and qualification of tion by the lading, and each shall be
portable tanks contained in §§ 173.32 provided with a valve or plug at its
and 173.315 of this chapter must be ob- upper end and liquid-tight closure at it
served. lower end. Each valve or plug shall be
designed to insure against unseating
[29 FR 18972, Dec. 29, 1964. Redesignated at 32
due to stresses or shocks incident to
FR 5606, Apr. 5, 1967, and amended by Amdt.
178–7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750, transportation. Bottom outlets shall be
Dec. 31, 2003] adequately protected against handling
damage and outlet equipment must not
§ 178.255–2 Material. extend to within less than one inch of
the bottom bearing surface of the skids
(a) Material used in the tank must be
or tank mounting.
steel of good weldable quality and con-
form with the requirements in Sections [29 FR 18972, Dec. 29, 1964. Redesignated at 32
V, VIII, and IX of the ASME Code (IBR, FR 5606, Apr. 5, 1967, as amended by Amdt.
see § 171.7 of this subchapter). 178–104, 59 FR 49135, Sept. 26, 1994]
(b) The minimum thickness of metal,
exclusive of lining material, for shell § 178.255–6 Loading and unloading ac-
and heads of tanks shall be as follows: cessories.
(a) When installed, gauging, loading
Minimum
Tank capacity thickness and air inlet devices, including their
(inch) valves, shall be provided with adequate
means for their secure closure; and
Not more than 1,200 gallons ............................... 14 ⁄
Over 1,200 to 1,800 gallons ................................ ⁄
5 16 means shall also be provided for the
Over 1,800 gallons .............................................. 38 ⁄ closing of pipe connections of valves.
(b) Interior heater coils, if installed,
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 must be of extra heavy pipe and so con-
FR 5606, Apr. 5, 1967, and amended by Amdt. structed that breaking off of exterior
178–7, 34 FR 18250, Nov. 14, 1969; 68 FR 75750, connections will not cause leakage of
Dec. 31, 2003] tanks.
107
§ 178.255–7 49 CFR Ch. I (10–1–18 Edition)
§ 178.255–7 Protection of valves and devices shall be deemed to comply with

accessories. this requirement.
(a) All valves, fittings, accessories, (b) All tank mountings such as skids,
safety devices, gauging devices, and the fastenings, brackets, cradles, lifting
like shall be adequately protected lugs, etc., intended to carry loadings
against mechanical damage by a hous- shall be permanently secured to tanks
ing closed with a cover plate. in accordance with the requirements
(b) Protective housing shall comply under which the tanks are fabricated,
with the requirements under which the and shall be designed with a factor of
tanks are fabricated with respect to de- safety of four, and built to withstand
sign and construction, and shall be de- loadings in any direction equal to two
signed with a minimum factor of safety times the weight of the tanks and at-
of four to withstand loadings in any di- tachments when filled to the maximum
rection equal to two times the weight permissible loaded weight.
of the tank and attachments when (c) Lifting lugs or side hold-down
filled with water. lugs shall be provided on the tank
mountings in a manner suitable for at-
§ 178.255–8 Safety devices. taching lifting gear and hold-down de-
(a) See § 173.315(i) of this subchapter. vices. Lifting lugs and hold-down lugs
(b) [Reserved] welded directly to the tank shall be of
the pad-eye type. Doubling plates weld-
[Amdt. 178–83, 50 FR 11066, Mar. 19, 1985] ed to the tank and located at the
§ 178.255–9 Compartments. points of support shall be deemed to
comply with this requirement.
(a) When the interior of the tank is (d) All tank mountings shall be so de-
divided into compartments, each com- signed as to prevent the concentration
partment shall be designed, con- of excessive loads on the tank shell.
structed and tested as a separate tank.
Thickness of shell and compartment § 178.255–12 Pressure test.
heads shall be determined on the basis
(a) Each completed portable tank
of total tank capacity.
prior to application of lining shall be
(b) [Reserved]
tested before being put into transpor-
§ 178.255–10 Lining. tation service by completely filling the
tank with water or other liquid having
(a) If a lining is required, the mate-
a similar viscosity, the temperature of
rial used for lining the tank shall be
which shall not exceed 100 °F during
homogeneous, nonporous, imperforate
the test, and applying a pressure of 60
when applied, not less elastic than the
psig. The tank shall be capable of hold-
metal of the tank proper. It shall be of
ing the prescribed pressure for at least
substantially uniform thickness, not
10 minutes without leakage, evidence
less than 1⁄32 inch thick if metallic, and
of impending failure, or failure. All clo-
not less than 1⁄16 inch thick if non-
sures shall be in place while the test is
metallic, and shall be directly bonded
made and the pressure shall be gauged
or attached by other equally satisfac-
at the top of the tank. Safety devices
tory means. Rubber lining shall be not
and/or vents shall be plugged during
less than 3⁄16 inch thick. Joints and
this test.
seams in the lining shall be made by
(b) [Reserved]
fusing the material together or by
other equally satisfactory means. The [29 FR 18972, Dec. 29, 1964. Redesignated at 32
interior of the tank shall be free from FR 5606, Apr. 5, 1967, as amended by Amdt.
scale, oxidation, moisture and all for- 178–104, 59 FR 49135, Sept. 26, 1994]
eign matter during the lining oper-
ation. § 178.255–13 Repair of tanks.
(b) [Reserved] (a) Tanks failing to meet the test
may be repaired and retested, provided
§ 178.255–11 Tank mountings.
that repairs are made in complete com-

(a) Tanks shall be designed and fab- pliance with the requirements of this
ricated with mountings to provide a se- specification.
cure base in transit. ‘‘Skids’’ or similar (b) [Reserved]
108
§ 178.255–14 Marking. § 178.273 Approval of Specification UN

portable tanks.
(a) In addition to markings required
by Section VIII of the ASME Code (a) Application for approval. (1) An
(IBR, see § 171.7 of this subchapter), owner or manufacturer of a portable
every tank shall bear permanent marks tank shall apply for approval to a des-
at least 1/8-inch high stamped into the ignated approval agency authorized to
metal near the center of one of the approve the portable tank in accord-
tank heads or stamped into a plate per- ance with the procedures in subpart E,
manently attached to the tank by part 107 of this subchapter.
means of brazing or welding or other (2) Each application for approval
suitable means as follows: must contain the following informa-
tion:
Manufacturer’s name lllllll Serial (i) Two complete copies of all engi-
No. llllllllllllllllllll
neering drawings, calculations, and
DOT specification llllllllllllll
Nominal capacity lllllll (gallons) test data necessary to ensure that the
Tare weight lllllll (pounds) design meets the relevant specifica-
Date of manufacture llllllllllll tion.
(ii) The manufacturer’s serial number
(b) [Reserved] that will be assigned to each portable
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 tank.
FR 5606, Apr. 5, 1967, and amended by Amdt. (iii) A statement as to whether the
178–67, 46 FR 49906, Oct. 8, 1981; 68 FR 75750, design type has been examined by any
Dec. 31, 2003] approval agency previously and judged
unacceptable. Affirmative statements
§ 178.255–15 Report.
must be documented with the name of
(a) A copy of the manufacturer’s data the approval agency, reason for non-
report required by Section VIII of the acceptance, and the nature of modifica-
ASME Code (IBR, see § 171.7 of this sub- tions made to the design type.
chapter) under which the tank is fab- (b) Action by approval agency. The ap-
ricated must be furnished to the owner proval agency must perform the fol-
for each new tank. lowing activities:
Place ——————————————— (1) Review the application for ap-
Date ———————————————— proval to determine whether it is com-
Portable tank plete and conforms with the require-
Manufactured for lllllll Company ments of paragraph (a) of this section.
Location llllllllllllllllll If an application is incomplete, it will
Manufactured by lllllll Company be returned to the applicant with an
Location llllllllllllllllll
Consigned to lllllllll Company
explanation as to why the application
Location llllllllllllllllll is incomplete.
Size lll feet outside diameter by lll (2) Review all drawings and calcula-
long. tions to ensure that the design is in
Marks on tank as prescribed by § 178.255–14 of compliance with all requirements of
this specification are as follows: the relevant specification. If the appli-
Manufacturer’s name llllllllllll cation is approved, one set of the ap-
Serial number llllllllllllllll proved drawings, calculations, and test
Owner’s serial number lllllllllll
DOT specification llllllllllllll data shall be returned to the applicant.
ASME Code Symbol (par U–201) lllllll The second (inspector’s copy) set of ap-
Date of manufacture llllllllllll proved drawings, calculations, and test
Nominal capacity lllllll gallons. data shall be retained by the approval
It is hereby certified that this tank is in agency. Maintain drawings and ap-
complete compliance with the requirements proval records for as long as the port-
of DOT specification No. 60. able tank remains in service. The draw-
(Signed) ———————————————
Manufacturer or owner
ings and records must be provided to
the Department of Transportation
(b) [Reserved] (DOT) upon request.
[29 FR 18972, Dec. 29, 1964. Redesignated at 32 (3) Witness all tests required for the
FR 5606, Apr. 5, 1967, and amended by Amdt. approval of the portable tank specified
178–83, 50 FR 11066, Mar. 19, 1985; 68 FR 75750, in this section and part 180, subpart G
Dec. 31, 2003] of this subchapter.
109
§ 178.273 49 CFR Ch. I (10–1–18 Edition)
(4) Ensure, through appropriate in- series of identical portable tanks man-
spection that each portable tank is fab- ufactured to a single design type, for
ricated in all respects in conformance each series of portable tanks. The ap-
with the approved drawings, calcula- proval certificate must include all the
tions, and test data. information required to be displayed on
(5) Determine and ensure that the the metal identification plate required
portable tank is suitable for its in- by § 178.274(i). The approval certificate
tended use and that it conforms to the must certify that the approval agency
requirements of this subchapter. designated to approve the portable
(6) For UN portable tanks intended tank has approved the portable tank in
for non-refrigerated and refrigerated accordance with the procedures in sub-
liquefied gases and Division 6.1 liquids part E of part 107 of this subchapter
which meet the inhalation toxicity cri- and that the portable tank is suitable
teria (Zone A or B) as defined in for its intended purpose and meets the
§ 173.132 of this subchapter, or that are requirements of this subchapter. When
designated as toxic by inhalation mate- a series of portable tanks is manufac-
rials in the § 172.101 Table of this sub- tured without change in the design
chapter, the approval agency must en- type, the certificate may be valid for
sure that: the entire series of portable tanks rep-
(i) The portable tank has been de- resenting a single design type. For UN
signed, constructed, certified, and portable tanks, the certificate must
stamped in accordance with the re- refer to the prototype test report, the
quirements in Division 1 of Section hazardous material or group of haz-
VIII of the ASME Code (IBR, see § 171.7 ardous materials allowed to be trans-
of this subchapter). Other design codes ported, the materials of construction of
may be used if approved by the Asso- the shell and lining (when applicable)
ciate Administrator (see § 178.274(b)(1)); and an approval number. The approval
(ii) All applicable provisions of the number must consist of the distin-
design and construction have been met guishing sign or mark of the country
to the satisfaction of the designated (‘‘USA’’ for the United States of Amer-
approval agency in accordance with the ica) where the approval was granted
rules established in the ASME Code and a registration number.
and that the portable tank meets the (iii) Retain a copy of each approval
requirements of the ASME Code and all certificate.
the applicable requirements specified (8) For UN portable tanks, the ap-
in this subchapter; proval certificate must also include the
(iii) The inspector has carried out all following:
the inspections specified by the rules (i) The results of the applicable
established in the ASME Code; and framework and rail impact test speci-
(iv) The portable tank is marked fied in part 180, subpart G, of this sub-
with a U stamp code symbol under the chapter; and
authority of the authorized inde- (ii) The results of the initial inspec-
pendent inspector. tion and test in § 178.274(j).
(7) Upon successful completion of all (9) The approval agency shall be inde-
requirements of this subpart, the ap- pendent from the manufacturer. The
proval agency must: approval agency and the authorized in-
(i) Apply its name, identifying mark spector may be the same entity.
or identifying number, and the date (c) Manufacturers’ responsibilities. The
upon which the approval was issued, to manufacturer is responsible for compli-
the metal identification marking plate ance with the applicable specifications
attached to the portable tank. Any ap- for the design and construction of port-
provals for UN portable tanks author- able tanks. In addition to responsi-
izing design or construction alter- bility for compliance, manufacturers
natives (Alternate Arrangements) ap- are responsible for ensuring that the
proved by the Associate Administrator contracted approval agency and au-
(see § 178.274(a)(2)) must be indicated on thorized inspector, if applicable, are

the plate as specified in § 178.274(i). qualified, reputable and competent.
(ii) Issue an approval certificate for The manufacturer of a portable tank
each portable tank or, in the case of a shall—
110
(1) Comply with all the applicable re- (2) A statement as to whether the in-
quirements of the ASME Code and of tended modification has been examined
this subpart including, but not limited and determined to be unacceptable by
to, ensuring that the quality control, any approval agency. The written
design calculations and required tests statement must include the name of
are performed and that all aspects of the approving agency, the reason for
the portable tank meet the applicable nonacceptance, and the nature of
requirements. changes made to the modification since
(2) Obtain and use a designated ap- its original rejection.
proval agency, if applicable, and obtain (3) The approval agency shall review
and use a DOT-designated approval the request for modification, and if it
agency to approve the design, construc- is determined that the proposed modi-
tion and certification of the portable fication is in full compliance with the
tank. relevant DOT specification, including a
(3) Provide a statement in the manu- UN portable tank, the request shall be
facturers’ data report certifying that approved and the approval agency shall
each portable tank that is manufac- perform the following activities:
tured complies with the relevant speci- (i) Return one set of the approved re-
fication and all the applicable require- vised drawings, calculations, and test
ments of this subchapter. data to the applicant. The second and
(4) Maintain records of the qualifica- third sets of the approved revised draw-
tion of portable tanks for at least 5 ings, calculations, and data shall be re-
years and provide copies to the ap- tained by the approval agency as re-
proval agency, the owner or lessee of quired in § 107.404(a)(3) of this sub-
the tank. Upon request, provide these chapter.
records to a representative of DOT.
(ii) Ensure through appropriate in-
(d) Denial of application for approval.
spection that all modifications con-
If an approval agency finds that a port-
form to the revised drawings, calcula-
able tank cannot be approved for any
tions, and test data.
reason, it shall notify the applicant in
writing and shall provide the applicant (iii) Determine the extent to which
with the reasons for which the ap- retesting of the modified tank is nec-
proval is denied. A copy of the notifica- essary based on the nature of the pro-
tion letter shall be provided to the As- posed modification, and ensure that all
sociate Administrator. An applicant required retests are satisfactorily per-
aggrieved by a decision of an approval formed.
agency may appeal the decision in (iv) If modification to an approved
writing, within 90 days of receipt, to tank alters any information on the ap-
the Associate Administrator. proval certificate, issue a new approval
(e) Modifications to approved portable certificate for the modified tank and
tanks. (1) Prior to modification of any ensure that any necessary changes are
UN portable tank which may affect made to the metal identification plate.
conformance and the safe use of the A copy of each newly issued approval
portable tank, which may involve a certificate shall be retained by the ap-
change to the design type or which proval agency and by the owner of each
may affect its ability to retain haz- portable tank.
ardous material in transportation, the (4) If the approval agency determines
person desiring to make such modifica- that the proposed modification is not
tion shall inform the approval agency in compliance with the relevant DOT
that issued the initial approval of the specification, the approval agency
portable tank (or if unavailable, an- shall deny the request in accordance
other approval agency) of the nature of with paragraph (d) of this section.
the modification and request approval (f) Termination of Approval Certificate.
of the modification. The person desir- (1) The Associate Administrator may
ing to modify the tank must supply the terminate an approval issued under
approval agency with three sets of all this section if he determines that—
revised drawings, calculations, and test (i) Information upon which the ap-
data relative to the intended modifica- proval was based is fraudulent or sub-
tion. stantially erroneous; or
111
§ 178.274 49 CFR Ch. I (10–1–18 Edition)
(ii) Termination of the approval is tanks may be varied if approved by the

necessary to adequately protect Associate Administrator and the port-
against risks to life and property; or able tank is shown to provide a level of
(iii) The approval was not issued by safety equal to or exceeding the re-
the approval agency in good faith; or quirements of this subchapter. Port-
(iv) The portable tank does not meet able tanks approved to alternative
the specification. technical requirements must be
(2) Before an approval is terminated, marked ‘‘Alternative Arrangement’’ as
the Associate Administrator gives the specified in paragraph (i) of this sec-
interested party(ies): tion.
(i) Written notice of the facts or con- (3) Definitions. The following defini-
duct believed to warrant the termi- tions apply for the purposes of design
nation; and construction of UN portable tanks
(ii) Opportunity to submit oral and under this subpart:
written evidence; and Alternate Arrangement portable tank
(iii) Opportunity to demonstrate or
means a UN portable tank that has
achieve compliance with the applicable
been approved to alternative technical
requirements.
requirements or testing methods other
(3) If the Associate Administrator de-
than those specified for UN portable
termines that a certificate of approval
tanks in part 178 or part 180 of this sub-
must be terminated to preclude a sig-
chapter.
nificant and imminent adverse affect
on public safety, he may terminate the Approval agency means the des-
certificate immediately. In such cir- ignated approval agency authorized to
cumstances, the opportunities of para- approve the portable tank in accord-
graphs (f)(2) (ii) and (iii) of this section ance with the procedures in subpart E
need not be provided prior to termi- of part 107 of this subchapter.
nation of the approval, but shall be Design pressure is defined according
provided as soon as practicable there- to the hazardous materials intended to
after. be transported in the portable tank.
See §§ 178.275, 178.276 and 178.277, as ap-
[66 FR 33439, June 21, 2001, as amended at 67 plicable.
FR 61016, Sept. 27, 2002; 68 FR 75748, 75751,
Dec. 31, 2003; 72 FR 55695, Oct. 1, 2007]
Design type means a portable tank or
series of portable tanks made of mate-
§ 178.274 Specifications for UN port- rials of the same material specifica-
able tanks. tions and thicknesses, manufactured
(a) General. (1) Each UN portable by a single manufacturer, using the
tank must meet the requirements of same fabrication techniques (for exam-
this section. In addition to the require- ple, welding procedures) and made with
ments of this section, requirements equivalent structural equipment, clo-
specific to UN portable tanks used for sures, and service equipment.
liquid and solid hazardous materials, Fine grain steel means steel that has a
non-refrigerated liquefied gases and re- ferritic grain size of 6 or finer when de-
frigerated liquefied gases are provided termined in accordance with ASTM E
in §§ 178.275, 178.276 and 178.277, respec- 112–96 (IBR, see § 171.7 of this sub-
tively. Requirements for approval, chapter).
maintenance, inspection, testing and Fusible element means a non-reclosing
use are provided in § 178.273 and part pressure relief device that is thermally
180, subpart G, of this subchapter. Any activated and that provides protection
portable tank which meets the defini- against excessive pressure buildup in
tion of a ‘‘container’’ within the terms the portable tank developed by expo-
of the International Convention for sure to heat, such as from a fire (see
Safe Containers (CSC) must meet the § 178.275(g)).
requirements of the CSC as amended Jacket means the outer insulation
and 49 CFR parts 450 through 453 and cover or cladding which may be part of
must have a CSC safety approval plate. the insulation system.

(2) In recognition of scientific and Leakage test means a test using gas to
technological advances, the technical subject the shell and its service equip-
requirements applicable to UN portable ment to an internal pressure.
112
Maximum allowable working pressure (b) General design and construction re-
(MAWP) is defined according to the quirements. (1) The design temperature
hazardous materials intended to be range for the shell must be ¥40 °C to 50
transported in the portable tank. See °C (¥40 °F to 122 °F) for hazardous ma-
§§ 178.275, 178.276 and 178.277, as applica- terials transported under normal con-
ble. ditions of transportation, except for
Maximum permissible gross mass portable tanks used for refrigerated
(MPGM) means the sum of the tare liquefied gases where the minimum de-
mass of the portable tank and the sign temperature must not be higher
heaviest hazardous material authorized than the lowest (coldest) temperature
for transportation. (for example, service temperature) of
Mild steel means a steel with a guar- the contents during filling, discharge
anteed minimum tensile strength of 360 or transportation. For hazardous mate-
N/mm2 to 440 N/mm2 and a guaranteed rials handled under elevated tempera-
minimum elongation at fracture as ture conditions, the design tempera-
specified in paragraph (c)(10) of this ture must not be less than the max-
section. imum temperature of the hazardous
Offshore portable tank means a port- material during filling, discharge or
able tank specially designed for re- transportation. More severe design
peated use in the transportation of haz- temperatures must be considered for
ardous materials to, from and between portable tanks subjected to severe cli-
offshore facilities. An offshore portable matic conditions (for example, portable
tank is designed and constructed in ac- tanks transported in arctic regions).
cordance with the Guidelines for the Shells must be designed and con-
Approval of Containers Handled in structed in accordance with the re-
Open Seas specified in the IMDG Code quirements in Section VIII of the
(IBR, see § 171.7 of this subchapter). ASME Code (IBR, see § 171.7 of this sub-
Reference steel means a steel with a chapter), except as limited or modified
tensile strength of 370 N/mm2 and an in this subchapter. For portable tanks
elongation at fracture of 27%. used for liquid or solid hazardous mate-
Service equipment means measuring rials, a design code other than the
instruments and filling, discharge, ASME Code may be used if approved by
venting, safety, heating, cooling and the Associate Administrator. Portable
insulating devices. tanks must have an ASME certifi-
Shell means the part of the portable cation and U stamp when used for Haz-
tank which retains the hazardous ma- ard Zone A or B toxic by inhalation liq-
terials intended for transportation, in- uids, or when used for non-refrigerated
cluding openings and closures, but does or refrigerated liquefied compressed
not include service equipment or exter- gases. Shells must be made of metallic
nal structural equipment. materials suitable for forming. Non-
Structural equipment means the rein- metallic materials may be used for the
forcing, fastening, protective and stabi- attachments and supports between the
lizing members external to the shell. shell and jacket, provided their mate-
Test pressure means the maximum rial properties at the minimum and
gauge pressure at the top of the shell maximum design temperatures are
during the hydraulic pressure test proven to be sufficient. For welded
equal to not less than 1.5 times the de- shells, only a material whose
sign pressure for liquids and 1.3 for liq- weldability has been fully dem-
uefied compressed gases and refrig- onstrated may be used. Welds must be
erated liquefied gases. In some in- of high quality and conform to a level
stances a pneumatic test is authorized of integrity at least equivalent to the
as an alternative to the hydraulic test. welding requirements specified in Sec-
The minimum test pressures for port- tion VIII of the ASME Code for the
able tanks intended for specific liquid welding of pressure vessels. When the
and solid hazardous materials are spec- manufacturing process or the materials
ified in the applicable portable tank T make it necessary, the shells must be
codes (such as T1–T23) assigned to suitably heat-treated to guarantee ade-
these hazardous materials in the quate toughness in the weld and in the
§ 172.101 Table of this subchapter. heat-affected zones. In choosing the
113
§ 178.274 49 CFR Ch. I (10–1–18 Edition)
material, the design temperature range perforations, sufficiently elastic and

must be taken into account with re- compatible with the thermal expansion
spect to risk of brittle fracture, stress characteristics of the shell. The lining
corrosion cracking, resistance to im- of every shell, shell fittings and piping
pact, and suitability for the hazardous must be continuous and must extend
materials intended for transportation around the face of any flange. Where
in the portable tank. When fine grain external fittings are welded to the
steel is used, the guaranteed value of tank, the lining must be continuous
the yield strength must be not more through the fitting and around the face
than 460 N/mm2 and the guaranteed of external flanges. Joints and seams in
value of the upper limit of the tensile the lining must be made by fusing the
strength must be not more than 725 N/ material together or by other equally
mm2 according to the material speci- effective means.
fication. Aluminum may not be used as (5) Contact between dissimilar met-
a construction material for the shells als which could result in damage by
of portable tanks intended for the galvanic action must be prevented by
transport of non-refrigerated liquefied appropriate measures.
gases. For portable tanks intended for (6) The construction materials of the
the transport of liquid or solid haz- portable tank, including any devices,
ardous materials, aluminum may only gaskets, linings and accessories, must
be used as a construction material for not adversely affect or react with the
portable tank shells if approved by the hazardous materials intended to be
Associate Administrator. Portable transported in the portable tank.
tank materials must be suitable for the (7) Portable tanks must be designed
external environment where they will and constructed with supports that
be transported, taking into account the provide a secure base during transpor-
determined design temperature range. tation and with suitable lifting and tie-
Portable tanks shall be designed to down attachments.
withstand, without loss of contents, at (c) Design criteria. (1) Portable tanks
least the internal pressure due to the and their fastenings must, under the
contents and the static, dynamic and maximum permissible loads and max-
thermal loads during normal condi- imum permissible working pressures,
tions of handling and transportation. be capable of absorbing the following
The design must take into account the separately applied static forces (for
effects of fatigue, caused by repeated calculation purposes, acceleration due
application of these loads through the to gravity (g) = 9.81m/s2):
expected life of the portable tank. (i) In the direction of travel: 2g
(2) Portable tank shells, fittings, and (twice the MPGM multiplied by the ac-
pipework shall be constructed from celeration due to gravity);
materials that are: (ii) Horizontally at right angles to
(i) Compatible with the hazardous the direction of travel: 1g (the MPGM
materials intended to be transported; multiplied by the acceleration due to
or gravity);
(ii) Properly passivated or neutral- (iii) Vertically upwards: 1g (the
ized by chemical reaction, if applica- MPGM multiplied by the acceleration
ble; or due to gravity); and
(iii) For portable tanks used for liq- (iv) Vertically downwards: 2g (twice
uid and solid materials, lined with cor- the MPGM multiplied by the accelera-
rosion-resistant material directly tion due to gravity).
bonded to the shell or attached by (2) Under each of the forces specified
equivalent means. in paragraph (c)(1) of this section, the
(3) Gaskets and seals shall be made of safety factor must be as follows:
materials that are compatible with the (i) For metals having a clearly de-
hazardous materials intended to be fined yield point, a design margin of 1.5
transported. in relation to the guaranteed yield
(4) When shells are lined, the lining strength; or

must be compatible with the hazardous (ii) For metals with no clearly de-
materials intended to be transported, fined yield point, a design margin of 1.5
homogeneous, non-porous, free from in relation to the guaranteed 0.2%
114
proof strength and, for austenitic Re = yield strength in N/mm2, or 0.2%

steels, the 1% proof strength. proof strength or, for austenitic
(3) The values of yield strength or steels, 1% proof strength;
proof strength must be the values ac- Rm = minimum tensile strength in N/
cording to recognized material stand- mm2.
ards. When austenitic steels are used, (8) The values of Re and Rm to be
the specified minimum values of yield used must be the specified minimum
strength or proof strength according to values according to recognized mate-
the material standards may be in- rial standards. When austenitic steels
creased by up to 15% for portable tanks are used, the specified minimum values
used for liquid and solid hazardous ma- for Re and Rm according to the mate-
terials, other than toxic by inhalation rial standards may be increased by up
liquids meeting the criteria of Hazard to 15% when greater values are at-
Zone A or Hazard Zone B (see § 173.133 tested in the material inspection cer-
of this subchapter), when these greater tificate.
values are attested in the material in- (9) Steels which have a Re/Rm ratio
spection certificate. of more than 0.85 are not allowed for
(4) Portable tanks must be capable of the construction of welded shells. The
being electrically grounded to prevent values of Re and Rm to be used in de-
dangerous electrostatic discharge when termining this ratio must be the values
they are used for Class 2 flammable specified in the material inspection
gases or Class 3 flammable liquids, in- certificate.
cluding elevated temperature mate- (10) Steels used in the construction of
rials transported at or above their shells must have an elongation at frac-
flash point. ture, in percentage, of not less than
(5) For shells of portable tanks used 10,000/Rm with an absolute minimum of
for liquefied compressed gases, the 16% for fine grain steels and 20% for
shell must consist of a circular cross other steels.
section. Shells must be of a design ca- (11) For the purpose of determining
pable of being stress-analyzed mathe- actual values for materials for sheet
metal, the axis of the tensile test speci-
matically or experimentally by resist-
men must be at right angles (trans-
ance strain gauges as specified in UG–
versely) to the direction of rolling. The
101 of Section VIII of the ASME Code,
permanent elongation at fracture must
or other methods approved by the As-
be measured on test specimens of rec-
sociate Administrator.
tangular cross sections in accordance
(6) Shells must be designed and con- with ISO 6892 (IBR, see § 171.7 of this
structed to withstand a hydraulic test subchapter), using a 50 mm gauge
pressure of not less than 1.5 times the length.
design pressure for portable tanks used (d) Minimum shell thickness. (1) The
for liquids and 1.3 times the design minimum shell thickness must be the
pressure for portable tanks used for liq- greatest thickness of the following:
uefied compressed gases. Specific re- (i) the minimum thickness deter-
quirements are provided for each haz- mined in accordance with the require-
ardous material in the applicable T ments of paragraphs (d)(2) through
Code or portable tank special provision (d)(7) of this section;
specified in the § 172.101 Table of this (ii) the minimum thickness deter-
subchapter. The minimum shell thick- mined in accordance with Section VIII
ness requirements must also be taken of the ASME Code or other approved
into account. pressure vessel code; or
(7) For metals exhibiting a clearly (iii) the minimum thickness specified
defined yield point or characterized by in the applicable T code or portable
a guaranteed proof strength (0.2% proof tank special provision indicated for
strength, generally, or 1% proof each hazardous material in the § 172.101
strength for austenitic steels), the pri- Table of this subchapter.
mary membrane stress s (sigma) in the (2) Shells (cylindrical portions, heads
shell must not exceed 0.75 Re or 0.50 and manhole covers) not more than 1.80
Rm, whichever is lower, at the test m in diameter may not be less than 5
pressure, where: mm thick in the reference steel or of
115
§ 178.274 49 CFR Ch. I (10–1–18 Edition)
equivalent thickness in the metal to be d1 = 1.8m, unless the formula is used to de-
used. Shells more than 1.80 m in diame- termine the equivalent minimum thick-
ter may not be less than 6 mm (0.2 ness for a portable tank shell that is re-
quired to have a minimum thickness of
inches) thick in the reference steel or 8mm or 10mm according to the applica-
of equivalent thickness in the metal to ble T code indicated in the § 172.101 Table
be used. For portable tanks used only of this subchapter. When reference steel
for the transportation of powdered or thicknesses of 8mm or 10mm are speci-
granular solid hazardous materials of fied, d1 is equal to the actual diameter of
Packing Group II or III, the minimum the shell but not less than 1.8m;
thickness requirement may be reduced Rm1 = guaranteed minimum tensile strength
to 5 mm in the reference steel or of (in N/mm 2) of the metal to be used;
A1 = guaranteed minimum elongation at
equivalent thickness in the metal to be fracture (in %) of the metal to be used
used regardless of the shell diameter. according to recognized material stand-
For vacuum-insulated tanks, the ag- ards.
gregate thickness of the jacket and the
shell must correspond to the minimum (6) The wall and all parts of the shell
thickness prescribed in this paragraph, may not have a thickness less than
with the thickness of the shell itself that prescribed in paragraphs (d)(2),
not less than the minimum thickness (d)(3) and (d)(4) of this section. This
prescribed in paragraph (d)(3) of this thickness must be exclusive of any cor-
section. rosion allowance.
(3) When additional protection (7) There must be no sudden change
against shell damage is provided in the of plate thickness at the attachment of
case of portable tanks used for liquid the heads to the cylindrical portion of
and solid hazardous materials requir- the shell.
ing test pressures less than 2.65 bar (e) Service equipment. (1) Service
(265.0 kPa), subject to certain limita- equipment must be arranged so that it
tions specified in the UN Recommenda- is protected against the risk of me-
tions (IBR, see § 171.7 of this sub- chanical damage by external forces
chapter), the Associate Administrator during handling and transportation.
may approve a reduced minimum shell When the connections between the
thickness. frame and the shell allow relative
(4) The cylindrical portions, heads movement between the sub-assemblies,
and manhole covers of all shells must the equipment must be fastened to
not be less than 3 mm (0.1 inch) thick allow such movement without risk of
regardless of the material of construc- damage to any working part. The ex-
ternal discharge fittings (pipe sockets,
tion, except for portable tanks used for
shut-off devices) and the internal stop-
liquefied compressed gases where the
valve and its seating must be protected
cylindrical portions, ends (heads) and
against mechanical damage by exter-
manhole covers of all shells must not
nal forces (for example, by using shear
be less than 4 mm (0.2 inch) thick re-
sections). Each internal self-closing
gardless of the material of construc-
stop-valve must be protected by a
tion.
shear section or sacrificial device lo-
(5) When steel is used, that has char-
cated outboard of the valve. The shear
acteristics other than that of reference
section or sacrificial device must break
steel, the equivalent thickness of the
at no more than 70% of the load that
shell and heads must be determined ac-
would cause failure of the internal self-
cording to the following formula: closing stop valve. The filling and dis-
charge devices (including flanges or
21.4e 0 d1
e1 = threaded plugs) and any protective
1.8m 3 Rm1 × A1 caps must be capable of being secured
against unintended opening.
Where:
(2) Each filling or discharge opening
e1 = required equivalent thickness (in mm) of of a portable tank must be clearly
the metal to be used;
e0 = minimum thickness (in mm) of the ref-
marked to indicate its function.
erence steel specified in the applicable T (3) Each stop-valve or other means of
code or portable tank special provision closure must be designed and con-
indicated for each material in the structed to a rated pressure not less
§ 172.101 Table of this subchapter; than the MAWP of the shell taking
116
EN21JN01.005</MATH>
into account the temperatures ex- and ISO 4126–7 (IBR, see § 171.7 of this
pected during transport. All stop- subchapter); and
valves with screwed spindles must (vi) The cross sectional flow areas of
close by a clockwise motion of the the spring loaded pressure relief de-
handwheel. For other stop-valves, the vices, frangible discs, and fusible ele-
position (open and closed) and direc- ments in mm2; and
tion of closure must be clearly indi- (vii) When practicable, the device
cated. All stop-valves must be designed must show the manufacturer’s name
to prevent unintentional opening. and product number.
(4) Piping must be designed, con- (2) Connections to pressure relief de-
structed and installed to avoid the risk vices. Connections to pressure relief de-
of damage due to thermal expansion vices must be of sufficient size to en-
and contraction, mechanical shock and able the required discharge to pass un-
vibration. All piping must be of a suit- restricted to the safety device. No stop-
able metallic material. Welded pipe valve may be installed between the
joints must be used wherever possible. shell and the pressure relief devices ex-
(5) Joints in copper tubing must be cept where duplicate devices are pro-
brazed or have an equally strong metal vided for maintenance or other reasons
union. The melting point of brazing and the stop-valves serving the devices
materials must be no lower than 525 °C actually in use are locked open or the
(977 °F). The joints must not decrease stop-valves are interlocked so that at
the strength of the tubing, such as may least one of the devices is always in
happen when cutting threads. Brazed use. There must be no obstruction in
joints are not authorized for portable an opening leading to a vent or pres-
tanks intended for refrigerated lique- sure relief device which might restrict
fied gases. or cut-off the flow from the shell to
(6) The burst pressure of all piping that device. Vents or pipes from the
and pipe fittings must be greater than pressure relief device outlets, when
the highest of four times the MAWP of used, must deliver the relieved vapor or
the shell or four times the pressure to liquid to the atmosphere in conditions
which it may be subjected in service by of minimum back-pressure on the re-
the action of a pump or other device lieving devices.
(except pressure relief devices). (3) Location of pressure relief devices.
(7) Ductile metals must be used in (i) Each pressure relief device inlet
the construction of valves and acces- must be situated on top of the shell in
sories. a position as near the longitudinal and
(f) Pressure relief devices—(1) Marking transverse center of the shell as rea-
of pressure relief devices. Every pressure sonably practicable. All pressure relief
relief device must be clearly and per- device inlets must, under maximum
manently marked with the following: filling conditions, be situated in the
(i) the pressure (in bar or kPa) or vapor space of the shell and the devices
temperature for fusible elements (in must be so arranged as to ensure that
°C) at which it is set to discharge; any escaping vapor is not restricted in
(ii) the allowable tolerance at the any manner. For flammable hazardous
discharge pressure for reclosing de- materials, the escaping vapor must be
vices; directed away from the shell in such a
(iii) the reference temperature cor- manner that it cannot impinge upon
responding to the rated pressure for the shell. For refrigerated liquefied
frangible discs; gases, the escaping vapor must be di-
(iv) the allowable temperature toler- rected away from the tank and in such
ance for fusible elements; a manner that it cannot impinge upon
(v) The rated flow capacity of the the tank. Protective devices which de-
spring loaded pressure relief devices, flect the flow of vapor are permissible
frangible disc or fusible elements in provided the required relief-device ca-
standard cubic meters of air per second pacity is not reduced.
(m3/s). For spring loaded pressure relief (ii) Provisions must be implemented
devices, the rated flow capacity must to prevent unauthorized persons from
be determined according to ISO 4126–1 access to the pressure relief devices
(including Technical Corrigendum 1) and to protect the devices from damage
117
§ 178.274 49 CFR Ch. I (10–1–18 Edition)
caused by the portable tank over- (ii) The distance between forklift
turning. pockets (measured from the center of
(g) Gauging devices. Unless a portable each pocket) is at least half of the
tank is intended to be filled by weight, maximum length of the portable tank.
it must be equipped with one or more (5) During transport, portable tanks
gauging devices. Glass level-gauges and must be adequately protected against
gauges made of other fragile material, damage to the shell, and service equip-
which are in direct communication ment resulting from lateral and longi-
with the contents of the tank are pro- tudinal impact and overturning, or the
hibited. A connection for a vacuum shell and service equipment must be
gauge must be provided in the jacket of constructed to withstand the forces re-
a vacuum-insulated portable tank. sulting from impact or overturning.
(h) Portable tank supports, frameworks, External fittings must be protected so
lifting and tie-down attachments. (1) as to preclude the release of the shell
Portable tanks must be designed and contents upon impact or overturning of
the portable tank on its fittings. Ex-
constructed with a support structure to
amples of protection include:
provide a secure base during transport.
(i) Protection against lateral impact
The forces and safety factors specified
which may consist of longitudinal bars
in paragraphs (c)(1) and (c)(2) of this
protecting the shell on both sides at
section, respectively, must be taken
the level of the median line;
into account in this aspect of the de-
(ii) Protection of the portable tank
sign. Skids, frameworks, cradles or against overturning which may consist
other similar structures are accept- of reinforcement rings or bars fixed
able. across the frame;
(2) The combined stresses caused by (iii) Protection against rear impact
portable tank mountings (for example, which may consist of a bumper or
cradles, framework, etc.) and portable frame;
tank lifting and tie-down attachments (iv) Protection of the shell against
must not cause stress that would dam- damage from impact or overturning by
age the shell in a manner that would use of an ISO frame in accordance with
compromise its lading retention capa- ISO 1496–3 (IBR, see § 171.7 of this sub-
bility. Permanent lifting and tie-down chapter); and
attachments must be fitted to all port- (v) Protection of the portable tank
able tanks. Preferably they should be from impact or damage that may re-
fitted to the portable tank supports sult from overturning by an insulation
but may be secured to reinforcing jacket.
plates located on the shell at the (i) Marking. (1) Every portable tank
points of support. Each portable tank must be fitted with a corrosion resist-
must be designed so that the center of ant metal plate permanently attached
gravity of the filled tank is approxi- to the portable tank in a conspicuous
mately centered within the points of place and readily accessible for inspec-
attachment for lifting devices. tion. When the plate cannot be perma-
(3) In the design of supports and nently attached to the shell, the shell
frameworks, the effects of environ- must be marked with at least the infor-
mental corrosion must be taken into mation required by Section VIII of the
account. ASME Code. At a minimum, the fol-
(4) Forklift pockets must be capable lowing information must be marked on
of being closed off. The means of clos- the plate by stamping or by any other
ing forklift pockets must be a perma- equivalent method:
nent part of the framework or perma- Country of manufacture
nently attached to the framework. Sin- UN
gle compartment portable tanks with a Approval Country
length less than 3.65 m (12 ft.) need not Approval Number
have forklift pockets that are capable Alternative Arrangements (see § 178.274(a)(2))
‘‘AA’’
of being closed off provided that:

Manufacturer’s name or mark
(i) The shell, including all the fit- Manufacturer’s serial number
tings, are well protected from being hit Approval Agency (Authorized body for the
by the forklift blades; and design approval)
118
Owner’s registration number ‘‘OFFSHORE PORTABLE TANK’’ must
Year of manufacture be marked on the identification plate.
Pressure vessel code to which the shell is de-
signed
(j) Initial inspection and test. The ini-
Test pressurellllbar gauge. tial inspection and test of a portable
MAWPllllbar gauge. tank must include the following:
External design pressure (not required for (1) A check of the design characteris-
portable tanks used for refrigerated lique- tics.
fied gases)llllbar gauge. (2) An internal and external examina-
Design temperature rangellll °C
tollll °C. (For portable tanks used for
tion of the portable tank and its fit-
refrigerated liquefied gases, the minimum tings, taking into account the haz-
design temperature must be marked.) ardous materials to be transported. For
Water capacity at 20 °C/llllliters. UN portable tanks used for refrigerated
Water capacity of each compartment at 20 liquefied gases, a pressure test using an
°Cllllliters. inert gas may be conducted instead of
Initial pressure test date and witness identi- a hydrostatic test. An internal inspec-
fication.
MAWP for heating/cooling systemllllbar tion is not required for a portable tank
gauge. used for the dedicated transportation
Shell material(s) and material standard ref- of refrigerated liquefied gases that are
erence(s). not filled with an inspection opening.
Equivalent thickness in reference (3) A pressure test as specified in
steelllllmm. paragraph (i) of this section.
Lining material (when applicable).
Date and type of most recent periodic test(s). (4) A leakage test.
MonthllllYearllll Test (5) A test of the satisfactory oper-
pressurellllbar gauge. ation of all service equipment includ-
Stamp of approval agency that performed or ing pressure relief devices must also be
witnessed the most recent test. performed. When the shell and its fit-
For portable tanks used for refrigerated tings have been pressure-tested sepa-
liquefied gases: rately, they must be subjected to a
Either ‘‘thermally insulated’’ or ‘‘vacuum in- leakage test after reassembly. All
sulated’’llll. welds, subject to full stress level in the
Effectiveness of the insulation system (heat
influx)llllWatts (W).
shell, must be inspected during the ini-
Reference holding timelllldays or hours tial test by radiographic, ultrasonic, or
and initial pressurellllbar/kPa gauge another suitable non-destructive test
and degree of fillingllllin kg for each method. This does not apply to the
refrigerated liquefied gas permitted for jacket.
transportation. (6) Effective January 1, 2008, each
(2) The following information must new UN portable tank design type
be marked either on the portable tank meeting the definition of ‘‘container’’
itself or on a metal plate firmly se- in the Convention for Safe Containers
cured to the portable tank: (CSC) (see 49 CFR 450.3(a)(2)) must be
subjected to the dynamic longitudinal
Name of the operator.
impact test prescribed in Part IV, Sec-
Name of hazardous materials being trans-
ported and maximum mean bulk tempera- tion 40 of the UN Manual of Tests and
ture (except for refrigerated liquefied Criteria (see IBR, § 171.7 of this sub-
gases, the name and temperature are only chapter). A UN portable tank design
required when the maximum mean bulk type impact-tested prior to January 1,
temperature is higher than 50 °C). 2008, in accordance with the require-
Maximum permissible gross mass ments of this section in effect on Octo-
(MPGM)llllkg. ber 1, 2005, need not be retested. UN
Unladen (tare) massllllkg.
portable tanks used for the dedicated
NOTE TO PARAGRAPH (i)(2): For the identi- transportation of ‘‘Helium, refrigerated
fication of the hazardous materials being liquid,’’ UN1963, and ‘‘Hydrogen, refrig-
transported refer to part 172 of this sub- erated liquid,’’ UN1966, that are
chapter.
marked ‘‘NOT FOR RAIL TRANS-
(3) If a portable tank is designed and PORT’’ in letters of a minimum height

approved for open seas operations, such of 10 cm (4 inches) on at least two sides
as offshore oil exploration, in accord- of the portable tank are excepted from
ance with the IMDG Code, the words the dynamic longitudinal impact test.
119
§ 178.275 49 CFR Ch. I (10–1–18 Edition)
(7) The following tests must be com- (ii) The sum of—
pleted on a portable tank or a series of (A) The absolute vapor pressure (in
portable tanks designed and con- bar) of the hazardous material at 65 °C,
structed to a single design type that is minus 1 bar (149 °F, minus 100 kPa);
also a CSC container without leakage (B) The partial pressure (in bar) of
or deformation that would render the air or other gases in the ullage space,
portable tank unsafe for transportation resulting from their compression dur-
and use: ing filling without pressure relief by a
(i) Longitudinal inertia. The portable maximum ullage temperature of 65 °C
tank loaded to its maximum gross (149 °F) and a liquid expansion due to
weight must be positioned with its lon- an increase in mean bulk temperature
gitudinal axis vertical. It shall be held of 35 °C (95 °F); and
in this position for five minutes by sup- (C) A head pressure determined on
port at the lower end of the base struc- the basis of the forces specified in
ture providing vertical and lateral re- § 178.274(c) of this subchapter, but not
straint and by support at the upper end less than 0.35 bar (35 kPa).
of the base structure providing lateral (2) Maximum allowable working pres-
restraint only. sure (MAWP) means a pressure that
(ii) Lateral inertia. The portable tank must not be less than the highest of
loaded to its maximum gross weight the following pressures measured at
must be positioned for five minutes the top of the shell while in operating
with its transverse axis vertical. It position:
shall be held in this position for five (i) The maximum effective gauge
minutes by support at the lower side of pressure allowed in the shell during
the base structure providing vertical filling or discharge; or
and lateral restraint and by support at (ii) The maximum effective gauge
the upper side of the base structure pressure to which the shell is designed
providing lateral restraint only. which must be not less than the design
[66 FR 33440, June 21, 2001, as amended at 67 pressure.
FR 15744, Apr. 3, 2002; 68 FR 45041, July 31, (c) Service equipment. (1) In addition
2003; 68 FR 57633, Oct. 6, 2003; 68 FR 75751, to the requirements specified in
Dec. 31, 2003; 69 FR 76185, Dec. 20, 2004; 70 FR § 178.274, for service equipment, all
34399, June 14, 2005; 71 FR 78634, Dec. 29, 2006; openings in the shell, intended for fill-
72 FR 55696, Oct. 1, 2007; 73 FR 4719, Jan. 28,
ing or discharging the portable tank
2008; 78 FR 1096, Jan. 7, 2013]
must be fitted with a manually oper-
EDITORIAL NOTE: At 68 FR 57633, Oct. 6, ated stop-valve located as close to the
2003, § 178.274 was amended in paragraph shell as reasonably practicable. Other
(b)(1); however, the amendment could not be
incorporated due to inaccurate amendatory
openings, except for openings leading
instruction. to venting or pressure relief devices,
must be equipped with either a stop-
§ 178.275 Specification for UN Portable valve or another suitable means of clo-
Tanks intended for the transpor- sure located as close to the shell as
tation of liquid and solid hazardous reasonably practicable.
materials. (2) All portable tanks must be fitted
(a) In addition to the requirements of with a manhole or other inspection
§ 178.274, this section sets forth defini- openings of a suitable size to allow for
tions and requirements that apply to internal inspection and adequate ac-
UN portable tanks intended for the cess for maintenance and repair of the
transportation of liquid and solid haz- interior. Compartmented portable
ardous materials. tanks must have a manhole or other
(b) Definitions and requirements—(1) inspection openings for each compart-
Design pressure means the pressure to ment.
be used in calculations required by the (3) For insulated portable tanks, top
recognized pressure vessel code. The fittings must be surrounded by a spill
design pressure must not be less than collection reservoir with suitable
the highest of the following pressures: drains.

(i) The maximum effective gauge (4) Piping must be designed, con-
pressure allowed in the shell during structed and installed to avoid the risk
filling or discharge; or of damage due to thermal expansion
120
and contraction, mechanical shock and (D) Except for portable tanks having
vibration. All piping must be of a suit- a capacity less than 1,000 liters (264.2
able metallic material. Welded pipe gallons), it must be possible to close
joints must be used wherever possible. the valve from an accessible position
(d) Bottom openings. (1) Certain haz- on the portable tank that is remote
ardous materials may not be trans- from the valve itself within 30 seconds
ported in portable tanks with bottom of actuation; and
openings. When the applicable T code (E) The valve must continue to be ef-
or portable tank special provision, as fective in the event of damage to the
referenced for materials in the § 172.101 external device for controlling the op-
Table of this subchapter, specifies that eration of the valve;
bottom openings are prohibited, there (ii) An external stop-valve fitted as
must be no openings below the liquid close to the shell as reasonably prac-
level of the shell when it is filled to its ticable;
maximum permissible filling limit. (iii) A liquid tight closure at the end
When an existing opening is closed, it of the discharge pipe, which may be a
must be accomplished by internally bolted blank flange or a screw cap; and
and externally welding one plate to the (iv) For UN portable tanks, with bot-
shell. tom outlets, used for the transpor-
(2) Bottom discharge outlets for port- tation of liquid hazardous materials
able tanks carrying certain solid, crys- that are Class 3, PG I or II, or PG III
tallizable or highly viscous hazardous with a flash point of less than 100 °F (38
materials must be equipped with at °C); Division 5.1, PG I or II; or Division
least two serially fitted and mutually 6.1, PG I or II, the remote means of clo-
independent shut-off devices. Use of sure must be capable of thermal acti-
only two shut-off devices is only au- vation. The thermal means of activa-
thorized when this paragraph is ref- tion must activate at a temperature of
erenced in the applicable T Code indi- not more than 250 °F (121 °C).
cated for each hazardous material in (e) Pressure relief devices. All portable
the § 172.101 Table of this subchapter. tanks must be fitted with at least one
The design of the equipment must be to pressure relief device. All relief devices
the satisfaction of the approval agency must be designed, constructed and
and must include: marked in accordance with the require-
(i) An external stop-valve fitted as ments of this subchapter.
close to the shell as reasonably prac- (f) Vacuum-relief devices. (1) A shell
ticable; and which is to be equipped with a vacuum-
(ii) A liquid tight closure at the end relief device must be designed to with-
of the discharge pipe, which may be a stand, without permanent deformation,
bolted blank flange or a screw cap. an external pressure of not less than
(3) Except as provided in paragraph 0.21 bar (21.0 kPa). The vacuum-relief
(d)(2) of this section, every bottom dis- device must be set to relieve at a vacu-
charge outlet must be equipped with um setting not greater than ¥0.21 bar
three serially fitted and mutually inde- (¥21.0 kPa) unless the shell is designed
pendent shut-off devices. The design of for a higher external over pressure, in
the equipment must include: which case the vacuum-relief pressure
(i) A self-closing internal stop-valve, of the device to be fitted must not be
which is a stop-valve within the shell greater than the tank design vacuum
or within a welded flange or its com- pressure. A shell that is not fitted with
panion flange, such that: a vacuum-relief device must be de-
(A) The control devices for the oper- signed to withstand, without perma-
ation of the valve are designed to pre- nent deformation, an external pressure
vent any unintended opening through of not less than 0.4 bar (40.0 kPa).
impact or other inadvertent act; (2) Vacuum-relief devices used on
(B) The valve is operable from above portable tanks intended for the trans-
or below; portation of hazardous materials meet-

(C) If possible, the setting of the ing the criteria of Class 3, including
valve (open or closed) must be capable elevated temperature hazardous mate-
of being verified from the ground; rials transported at or above their
121
§ 178.275 49 CFR Ch. I (10–1–18 Edition)
flash point, must prevent the imme- pressure 10% above the start-to-dis-
diate passage of flame into the shell or charge pressure of the reclosable pres-
the portable tank must have a shell ca- sure relief device.
pable of withstanding, without leak- (4) Every portable tank with a capac-
age, an internal explosion resulting ity less than 1,900 liters (501.9 gallons)
from the passage of flame into the must be fitted with a pressure relief de-
shell. vice which, except as provided in para-
(g) Pressure relief devices. (1) Each graph (g)(3) of this section, may be a
portable tank with a capacity not less frangible disc when this disc is set to
than 1,900 liters (501.9 gallons) and rupture at a nominal pressure equal to
every independent compartment of a the test pressure at any temperature
portable tank with a similar capacity, within the design temperature range.
must be provided with one or more
(5) When the shell is fitted for pres-
pressure relief devices of the reclosing
sure discharge, a suitable pressure re-
type. Such portable tanks may, in ad-
dition, have a frangible disc or fusible lief device must provide the inlet line
element in parallel with the reclosing to the portable tank and set to operate
devices, except when the applicable T at a pressure not higher than the
code assigned to a hazardous material MAWP of the shell, and a stop-valve
requires that the frangible disc precede must be fitted as close to the shell as
the pressure relief device, according to practicable to minimize the potential
paragraph (g)(3) of this section, or for damage.
when no bottom openings are allowed. (6) Setting of pressure relief devices. (i)
The pressure relief devices must have Pressure relief devices must operate
sufficient capacity to prevent rupture only in conditions of excessive rise in
of the shell due to over pressurization temperature. The shell must not be
or vacuum resulting from filling, dis- subject to undue fluctuations of pres-
charging, heating of the contents or sure during normal conditions of trans-
fire. portation.
(2) Pressure relief devices must be de- (ii) The required pressure relief de-
signed to prevent the entry of foreign vice must be set to start to discharge
matter, the leakage of liquid and the at a nominal pressure of five-sixths of
development of any dangerous excess the test pressure for shells having a
pressure. test pressure of not more than 4.5 bar
(3) When required for certain haz- (450 kPa) and 110% of two-thirds of the
ardous materials by the applicable T test pressure for shells having a test
code or portable tank special provision pressure of more than 4.5 bar (450 kPa).
specified for a hazardous material in A self-closing relief device must close
the § 172.101 Table of this subchapter,
at a pressure not more than 10% below
portable tanks must have a pressure
the pressure at which the discharge
relief device consistent with the re-
starts. The device must remain closed
quirements of this subchapter. Except
for a portable tank in dedicated service at all lower pressures. This require-
that is fitted with an approved relief ment does not prevent the use of vacu-
device constructed of materials com- um-relief or combination pressure re-
patible with the hazardous material, lief and vacuum-relief devices.
the relief device system must include a (h) Fusible elements. Fusible elements
frangible disc preceding (such as, be- must operate at a temperature between
tween the lading and the reclosing 110 °C (230 °F) and 149 °C (300.2 °F), pro-
pressure relief device) a reclosing pres- vided that the pressure in the shell at
sure relief device. A pressure gauge or the fusing temperature will not exceed
suitable tell-tale indicator for the de- the test pressure. They must be placed
tection of disc rupture, pin-holing or at the top of the shell with their inlets
leakage must be provided in the space in the vapor space and in no case may
between the frangible disc and the they be shielded from external heat.
pressure relief device to allow the port- Fusible elements must not be utilized
able tank operator to check to deter- on portable tanks with a test pressure
mine if the disc is leak free. The fran- which exceeds 2.65 bar (265.0 kPa); how-
gible disc must rupture at a nominal ever, fusible elements are authorized
122
on portable tanks for the transpor- U = thermal conductance of the insulation,

tation of certain organometallic mate- in kW m¥2K¥1, at 38 °C (100 °F); and t =
rials in accordance with § 172.102, spe- actual temperature of the hazardous ma-
terial during filling (in °C) or when this
cial provision TP36 of this subchapter. temperature is unknown, let t = 15 °C (59
Fusible elements used on portable °F). The value of F given in this para-
tanks intended for the transport of ele- graph (i)(2)(i)(A) for insulated shells may
vated temperature hazardous materials only be used if the insulation is in con-
must be designed to operate at a tem- formance with paragraph (i)(2)(iv) of this
perature higher than the maximum section;
temperature that will be experienced A = total external surface area of shell in
square meters;
during transport and must be designed Z = the gas compressibility factor in the ac-
to the satisfaction of the approval cumulating condition (when this factor
agency. is unknown, let Z equal 1.0);
(i) Capacity of pressure relief devices. T = absolute temperature in Kelvin (°C + 273)
(1) The reclosing pressure relief device above the pressure relief devices in the
required by paragraph (g)(1) of this sec- accumulating condition;
L = the latent heat of vaporization of the liq-
tion must have a minimum cross sec-
uid, in kJ/kg, in the accumulating condi-
tional flow area equivalent to an ori- tion;
fice of 31.75 mm (1.3 inches) diameter. M = molecular weight of the hazardous mate-
Vacuum-relief devices, when used, rial.
must have a cross sectional flow area
(B) The constant C, as shown in the
not less than 284 mm 2 (11.2 inches 2).
formula in paragraph (i)(2)(i)(A) of this
(2) The combined delivery capacity of
section, is derived from one of the fol-
the pressure relief system (taking into
lowing formulas as a function of the
account the reduction of the flow when
ratio k of specific heats:
the portable tank is fitted with fran-
gible-discs preceding spring-loaded
pressure-relief devices or when the cp
spring-loaded pressure-relief devices
k=
cv
are provided with a device to prevent
the passage of the flame), in condition Where:
of complete fire engulfment of the cp is the specific heat at constant pressure;
portable tank must be sufficient to and
limit the pressure in the shell to 20% cv is the specific heat at constant volume.
above the start to discharge pressure (C) When k >1:
limiting device (pressure relief device).
The total required capacity of the re- k +1
lief devices may be determined using ⎛ 2 ⎞ k −1
the formula in paragraph (i)(2)(i)(A) of C = k⎜ ⎟
this section or the table in paragraph ⎝ k +1⎠
(i)(2)(iii) of this section. (D) When k = 1 or k is unknown, a
(i)(A) To determine the total re- value of 0.607 may be used for the con-
quired capacity of the relief devices, stant C. C may also be taken from the
which must be regarded as being the following table:
sum of the individual capacities of all
the contributing devices, the following C CONSTANT VALUE TABLE
formula must be used:
k C
0.82 1.00 0.607

FA ZT
Q = 12.4 1.02
1.04
0.611
0.615
LC M
ER01OC08.002</MATH>
1.06 0.620
Where: 1.08 0.624
1.10 0.628
Q = minimum required rate of discharge in 1.12 0.633
cubic meters of air per second (m3/s) at 1.14 0.637
conditions: 1 bar and 0 °C (273 °K); 1.16 0.641
1.18 0.645
F = for uninsulated shells: 1; for insulated
ER01OC08.001</MATH>
1.20 0.649
shells: U(649¥t)/13.6 but in no case is less 1.22 0.652
than 0.25 1.24 0.656
Where: 1.26 0.660
123
ER01OC08.000</MATH>
§ 178.276 49 CFR Ch. I (10–1–18 Edition)
C CONSTANT VALUE TABLE—Continued MINIMUM EMERGENCY VENT CAPACITY—

Continued
k C
[Q Values]
1.28 0.664
1.30 0.667 A Q A Q
1.32 0.671 Exposed area (Cubic me- Exposed area (Cubic me-
(square meters of air (square meters of air
1.34 0.674 ters) per second) ters) per second)
1.36 0.678
1.38 0.681 22.5 1.670 75 4.483
1.40 0.685 25 1.821 80 4.726
1.42 0.688
27.5 1.969 85 4.967
1.44 0.691
30 2.115 90 5.206
1.46 0.695
1.48 0.698 32.5 2.258 95 5.442
1.50 0.701 35 2.400 100 5.676
1.52 0.704
1.54 0.707 (iv) Insulation systems, used for the
1.56 0.710
1.58 0.713
purpose of reducing venting capacity,
1.60 0.716 must be specifically approved by the
1.62 0.719 approval agency. In all cases, insula-
1.64 0.722
1.66 0.725
tion systems approved for this purpose
1.68 0.728 must—
1.70 0.731 (A) Remain effective at all tempera-
2.00 0.770 tures up to 649 °C (1200 °F); and
2.20 0.793
(B) Be jacketed with a material hav-
ing a melting point of 700 °C (1292 °F) or
(ii) As an alternative to the formula greater.
in paragraph (i)(2)(i)(A) of this section, (j) Approval, inspection and testing.
relief devices for shells used for trans- Approval procedures for UN portable
porting liquids may be sized in accord- tanks are specified in § 178.273. Inspec-
ance with the table in paragraph tion and testing requirements are spec-
(i)(2)(iii) of this section. The table in ified in § 180.605 of this subchapter.
paragraph (i)(2)(iii) of this section as- [66 FR 33445, June 21, 2001, as amended at 68
sumes an insulation value of F = 1 and FR 32414, May 30, 2003; 69 FR 76185, Dec. 20,
must be adjusted accordingly when the 2004; 73 FR 57006, Oct. 1, 2008; 76 FR 3388, Jan.
shell is insulated. Other values used in 19, 2011]
determining the table in paragraph
(i)(2)(iii) of this section are: L = 334.94 § 178.276 Requirements for the design,
kJ/kg; M = 86.7; T = 394 °K; Z = 1; and construction, inspection and testing
C = 0.607. of portable tanks intended for the
transportation of non-refrigerated
(iii) Minimum emergency vent capac- liquefied compressed gases.
ity, Q, in cubic meters of air per second
at 1 bar and 0 °C (273 °K) shown in the (a) In addition to the requirements of
following table: § 178.274 applicable to UN portable
tanks, the following requirements
MINIMUM EMERGENCY VENT CAPACITY apply to UN portable tanks used for
[Q Values] non-refrigerated liquefied compressed
gases. In addition to the definitions in
A Q A Q
Exposed area (Cubic me- Exposed area (Cubic me- § 178.274, the following definitions
(square meters of air (square meters of air apply:
ters) per second) ters) per second)
(1) Design pressure means the pressure
2 0.230 37.5 2.539 to be used in calculations required by
3 0.320 40 2.677 the ASME Code, Section VIII (IBR, see
4 0.405 42.5 2.814
5 0.487 45 2.949 § 171.7 of this subchapter). The design
6 0.565 47.5 3.082 pressure must be not less than the
7 0.641 50 3.215 highest of the following pressures:
8 0.715 52.5 3.346
9 0.788 55 3.476
(i) The maximum effective gauge
10 0.859 57.5 3.605 pressure allowed in the shell during
12 0.998 60 3.733 filling or discharge; or

14 1.132 62.5 3.860 (ii) The sum of:
16 1.263 65 3.987
18 1.391 67.5 4.112 (A) The maximum effective gauge
20 1.517 70 4.236 pressure to which the shell is designed
124
as defined in this paragraph under capacity greater than 450 liters (118.9
‘‘MAWP’’; and gallons). Shells must be designed, con-
(B) A head pressure determined on structed, certified and stamped in ac-
the basis of the dynamic forces speci- cordance with the ASME Code, Section
fied in paragraph (h) of this section, VIII.
but not less than 0.35 bar (35 kPa). (2) Portable tanks must be postweld
(2) Design reference temperature means heat-treated and radiographed as pre-
the temperature at which the vapor scribed in Section VIII of the ASME
pressure of the contents is determined Code, except that each portable tank
for the purpose of calculating the constructed in accordance with part
MAWP. The value for each portable UHT of the ASME Code must be
tank type is as follows: postweld heat-treated. Where postweld
(i) Shell with a diameter of 1.5 meters heat treatment is required, the port-
(4.9 ft.) or less: 65 °C (149 °F); or able tank must be treated as a unit
(ii) Shell with a diameter of more after completion of all the welds in
than 1.5 meters (4.9 ft.): and/or to the shell and heads. The
(A) Without insulation or sun shield: method must be as prescribed in the
60 °C (140 °F); ASME Code. Welded attachments to
(B) With sun shield: 55 °C (131 °F); and pads may be made after postweld heat
(C) With insulation: 50 °C (122 °F). treatment is made. A portable tank
(3) Filling density means the average used for anhydrous ammonia must be
mass of liquefied compressed gas per
postweld heat-treated. The postweld
liter of shell capacity (kg/l).
heat treatment must be as prescribed
(4) Maximum allowable working pres-
in the ASME Code, but in no event at
sure (MAWP) means a pressure that
less than 1050 °F tank metal tempera-
must be not less than the highest of
ture. Additionally, portable tanks con-
the following pressures measured at
structed in accordance with part UHT
the top of the shell while in operating
of the ASME Code must conform to the
position, but in no case less than 7 bar
following requirements:
(700 kPa):
(i) The maximum effective gauge (i) Welding procedure and welder per-
pressure allowed in the shell during formance tests must be made annually
filling or discharge; or in accordance with Section IX of the
(ii) The maximum effective gauge ASME Code. In addition to the essen-
pressure to which the shell is designed, tial variables named therein, the fol-
which must be: lowing must be considered to be essen-
(A) Not less than the pressure speci- tial variables: number of passes, thick-
fied for each liquefied compressed gas ness of plate, heat input per pass, and
listed in the UN Portable Tank Table manufacturer’s identification of rod
for Liquefied Compressed Gases in and flux. The number of passes, thick-
§ 173.313; and ness of plate and heat input per pass
(B) Not less than the sum of: may not vary more than 25 percent
(1) The absolute vapor pressure (in from the qualified procedure. Records
bar) of the liquefied compressed gas at of the qualification must be retained
the design reference temperature for at least 5 years by the portable
minus 1 bar; and tank manufacturer or his designated
(2) The partial pressure (in bar) of air agent and, upon request, made avail-
or other gases in the ullage space able to a representative of the Depart-
which is determined by the design ref- ment of Transportation or the owner of
erence temperature and the liquid the tank.
phase expansion due to the increase of (ii) Impact tests must be made on a
the mean bulk temperature of tr¥tf (tf lot basis. A lot is defined as 100 tons or
= filling temperature, usually 15 °C, tr = less of the same heat and having a
50 °C maximum mean bulk tempera- thickness variation no greater than
ture). plus or minus 25 percent. The minimum
(b) General design and construction re- impact required for full-sized speci-
quirements. (1) Shells must be of seam- mens shall be 20 foot-pounds (or 10
less or welded steel construction, or foot-pounds for half-sized specimens) at
combination of both, and have a water 0 °F (¥17.8 °F) Charpy V-Notch in both
125
§ 178.276 49 CFR Ch. I (10–1–18 Edition)
the longitudinal and transverse direc- flow, specified by the manufacturer, is

tion. If the lot test does not pass this reached. Connections and accessories
requirement, individual plates may be leading to or from such a valve must
accepted if they individually meet this have a capacity for a flow more than
impact requirement. the excess flow valve’s rated flow.
(3) When the shells intended for the (3) For filling and discharge openings
transportation of non-refrigerated liq- that are located below the liquid level,
uefied compressed gases are equipped the first shut-off device must be an in-
with thermal insulation, a device must ternal stop-valve and the second must
be provided to prevent any dangerous be a stop-valve placed in an accessible
pressure from developing in the insu- position on each discharge and filling
lating layer in the event of a leak, pipe.
when the protective covering is closed (4) For filling and discharge openings
it must be gas tight. The thermal insu- located below the liquid level of port-
lation must not inhibit access to the able tanks intended for the transpor-
fittings and discharge devices. In addi- tation of flammable and/or toxic lique-
tion, the thermal insulation systems fied compressed gases, the internal
must satisfy the following require- stop-valve must be a self-closing safety
ments: device that fully closes automatically
(i) consist of a shield covering not during filling or discharge in the event
less than the upper third, but not more of fire engulfment. The device shall
than the upper half of the surface of fully close within 30 seconds of actu-
the shell, and separated from the shell ation and the thermal means of closure
by an air space of approximately 40 mm must actuate at a temperature of not
(1.7 inches) across; or more than 121 °C (250 °F). Except for
(ii) consist of a complete cladding of portable tanks having a capacity less
insulating materials. The insulation than 1,000 liters (264.2 gallons), this de-
must be of adequate thickness and con-
vice must be operable by remote con-
structed to prevent the ingress of mois-
trol.
ture and damage to the insulation. The
(5) In addition to filling, discharge
insulation and cladding must have a
thermal conductance of not more than and gas pressure equalizing orifices,
0.67 (W·m¥2·K¥1) under normal condi- shells may have openings in which
tions of transportation. gauges, thermometers and manometers
(c) Service equipment. (1) Each opening can be fitted. Connections for such in-
with a diameter of more than 1.5 mm struments must be made by suitable
(0.1 inch) in the shell of a portable welded nozzles or pockets and may not
tank, except openings for pressure-re- be connected by screwed connections
lief devices, inspection openings and through the shell.
closed bleed holes, must be fitted with (6) All portable tanks must be fitted
at least three mutually independent with manholes or other inspection
shut-off devices in series: the first openings of suitable size to allow for
being an internal stop-valve, excess internal inspection and adequate ac-
flow valve, integral excess flow valve, cess for maintenance and repair of the
or excess flow feature (see § 178.337– interior.
1(g)), the second being an external (7) Inlets and discharge outlets on chlo-
stop-valve and the third being a blank rine portable tanks. The inlet and dis-
flange, thread cap, plug or equivalent charge outlets on portable tanks used
tight liquid closure device. to transport chlorine must meet the re-
(2) When a portable tank is fitted quirements of § 178.337–1(c)(2) and must
with an excess flow valve, the excess be fitted with an internal excess flow
flow valve must be so fitted that its valve. In addition to the internal ex-
seating is inside the shell or inside a cess flow valve, the inlet and discharge
welded flange or, when fitted exter- outlets must be equipped with an ex-
nally, its mountings must be designed ternal stop valve (angle valve). Excess
so that in the event of impact it main- flow valves must conform to the stand-
tains its effectiveness. The excess flow ards of The Chlorine Institute, Inc.
valves must be selected and fitted so as (IBR, see § 171.7 of this subchapter) as
to close automatically when the rated follows:
126
(i) A valve conforming to Drawing than the MAWP and be fully open at a
101–7, dated July 1993, must be installed pressure equal to 110% of the MAWP.
under each liquid angle valve. These devices must, after discharge,
(ii) A valve conforming to Drawing close at a pressure not less than 10%
106–6, dated July 1993, must be installed below the pressure at which discharge
under each gas angle valve. For port- starts and must remain closed at all
able tanks used to transport non-re- lower pressures. The pressure relief de-
frigerated liquefied gases. vices must be of a type that will resist
(8) External fittings must be grouped dynamic forces including liquid surge.
together as close as reasonably prac- A frangible disc may only be used in se-
ticable. The following openings may be ries with a reclosing pressure relief de-
installed at locations other than on the vice.
top or end of the tank: (2) Pressure relief devices must be de-
(i) The openings for liquid level gaug- signed to prevent the entry of foreign
ing devices, pressure gauges, or for matter, the leakage of gas and the de-
safety devices, may be installed sepa- velopment of any dangerous excess
rately at the other location or in the pressure.
side of the shell; (3) A portable tank intended for the
(ii) One plugged opening of 2-inch Na- transportation of certain liquefied
tional Pipe Thread or less provided for compressed gases identified in the UN
maintenance purposes may be located Portable Tank Table for Liquefied
elsewhere; Compressed Gases in § 173.313 of this
(iii) An opening of 3-inch National subchapter must have a pressure relief
Pipe Size or less may be provided at device which conforms to the require-
another location, when necessary, to ments of this subchapter. Unless a
facilitate installation of condensing portable tank, in dedicated service, is
coils. fitted with a relief device constructed
(9) Filling and discharge connections of materials compatible with the haz-
are not required to be grouped and may ardous material, the relief device must
be installed below the normal liquid be comprised of a frangible disc pre-
level of the tank if: ceded by a reclosing device. The space
(i) The portable tank is permanently between the frangible disc and the de-
mounted in a full framework for con- vice must be provided with a pressure
tainerized transport; gauge or a suitable tell-tale indicator.
(ii) For each portable tank design, a This arrangement must facilitate the
prototype portable tank, meets the re- detection of disc rupture, pinholing or
quirements of parts 450 through 453 of leakage which could cause a malfunc-
this title for compliance with the re- tion of the pressure relief device. The
quirements of Annex II of the Inter- frangible disc must rupture at a nomi-
national Convention for Safe Con- nal pressure 10% above the start-to-dis-
tainers; and charge pressure of the relief device.
(iii) Each filling and discharge outlet (4) In the case of portable tanks used
meets the requirements of paragraph for more than one gas, the pressure re-
(c)(4) of this section. lief devices must open at a pressure in-
(d) Bottom openings. Bottom openings dicated in paragraph (e)(1) of this sec-
are prohibited on portable tanks when tion for the gas having the highest
the UN Portable Tank Table for Lique- maximum allowable pressure of the
fied Compressed Gases in § 173.313 of gases allowed to be transported in the
this subchapter indicates that bottom portable tank.
openings are not allowed. In this case, (f) Capacity of relief devices. The com-
there may be no openings located bined delivery capacity of the relief de-
below the liquid level of the shell when vices must be sufficient so that, in the
it is filled to its maximum permissible event of total fire engulfment, the
filling limit. pressure inside the shell cannot exceed
(e) Pressure relief devices. (1) Portable 120% of the MAWP. Reclosing relief de-
tanks must be provided with one or vices must be used to achieve the full
more reclosing pressure relief devices. relief capacity prescribed. In the case
The pressure relief devices must open of portable tanks used for more than
automatically at a pressure not less gas, the combined delivery capacity of
127
§ 178.277 49 CFR Ch. I (10–1–18 Edition)
the pressure relief devices must be design and construction of the shell
taken for the liquefied compressed gas not higher than the lowest (coldest)
which requires the highest delivery ca- service temperature of the contents
pacity of the liquefied compressed during normal conditions of filling, dis-
gases allowed to be transported in the charge and transportation.
portable tank. The total required ca- Shell means the part of the portable
pacity of the relief devices must be de- tank which retains the refrigerated liq-
termined according to the require- uefied gas intended for transport, in-
ments in § 178.275(i). These require- cluding openings and their closures,
ments apply only to liquefied com- but does not include service equipment
pressed gases which have critical tem- or external structural equipment.
peratures well above the temperature Tank means a construction which
at the accumulating condition. For normally consists of either:
gases that have critical temperatures (1) A jacket and one or more inner
near or below the temperature at the shells where the space between the
accumulating condition, the calcula- shell(s) and the jacket is exhausted of
tion of the pressure relief device deliv- air (vacuum insulation) and may incor-
ery capacity must consider the addi- porate a thermal insulation system; or
tional thermodynamic properties of the (2) A jacket and an inner shell with
gas, for example see CGA S–1.2 (IBR, an intermediate layer of solid ther-
see § 171.7 of this subchapter). mally insulating material (for exam-
ple, solid foam).
[66 FR 33448, June 21, 2001, as amended at 68
FR 75748, 75752, Dec. 31, 2003; 69 FR 54046, (b) General design and construction re-
Sept. 7, 2004; 69 FR 76185, Dec. 20, 2004] quirements. (1) Portable tanks must be
of seamless or welded steel construc-
§ 178.277 Requirements for the design, tion and have a water capacity of more
construction, inspection and testing than 450 liters (118.9 gallons). Portable
of portable tanks intended for the tanks must be designed, constructed,
transportation of refrigerated lique- certified and stamped in accordance
fied gases. with Section VIII of the ASME Code.
(a) In addition to the requirements of (2) Portable tanks must be postweld
§ 178.274 applicable to UN portable heat treated and radiographed as pre-
tanks, the following requirements and scribed in Sections V and VIII of the
definitions apply to UN portable tanks ASME Code except that each tank con-
used for refrigerated liquefied gases: structed in accordance with part UHT
Design pressure For the purpose of in Section VIII of the ASME Code must
this section the term ‘‘design pressure’’ be postweld heat treated. Where
is consistent with the definition for de- postweld heat treatment is required,
sign pressure in the ASME Code, Sec- the tank must be treated as a unit
tion VIII (IBR, see § 171.7 of this sub- after completion of all the welds to the
chapter). shell and heads. The method must be as
Holding time is the time, as deter- prescribed in the ASME Code. Welded
mined by testing, that will elapse from attachments to pads may be made after
loading until the pressure of the con- postweld heat treatment is made. The
tents, under equilibrium conditions, postweld heat treatment must be as
reaches the lowest set pressure of the prescribed in Section VIII of the ASME
pressure limiting device(s) (for exam- Code, but in no event at less than 1,050
ple, pressure control valve or pressure °F tank metal temperature.
relief device). Holding time must be de- (3) Welding procedure and welder per-
termined as specified in § 178.338–9. formance tests must be made annually
Maximum allowable working pressure in accordance with Section IX of the
(MAWP) means the maximum effective ASME Code (IBR, see § 171.7 of this sub-
gauge pressure permissible at the top chapter). In addition to the essential
of the shell of a loaded portable tank in variables named in the ASME Code, the
its operating position including the following must be considered as essen-
highest effective pressure during filling tial variables: number of passes, thick-
and discharge; ness of plate, heat input per pass, and
Minimum design temperature means the specified rod and flux. The number
the temperature which is used for the of passes, thickness of plate and heat
128
input per pass may not vary more than (10) A reference holding time must be
25% from the procedure qualification. determined for each refrigerated lique-
Records of the qualification must be fied gas intended for transport in a
retained for at least 5 years by the portable tank. The reference holding
portable tank manufacturer and made time must be determined by testing in
available to the approval agency and accordance with the requirements of
the owner of the portable tank as spec- § 178.338–9, considering the following
ified in § 178.273. factors:
(4) Shells and jackets must be made (i) The effectiveness of the insulation
of metallic materials suitable for form- system, determined in accordance with
ing. Jackets must be made of steel. paragraph (b)(11) of this section;
Non-metallic materials may be used (ii) The lowest set pressure of the
for the attachments and supports be- pressure limiting device;
tween the shell and jacket, provided (iii) The initial filling conditions;
their material properties at the min- (iv) An assumed ambient tempera-
imum design temperature are proven ture of 30 °C (86 °F);
to be sufficient. In choosing the mate- (v) The physical properties of the in-
rial, the minimum design temperature dividual refrigerated liquefied gas in-
must be taken into account with re- tended to be transported.
spect to risk of brittle fracture, to hy- (11) The effectiveness of the insula-
drogen embrittlement, to stress corro- tion system (heat influx in watts) may
sion cracking and to resistance to im- be determined by type testing the port-
pact. able tank in accordance with a proce-
(5) Any part of a portable tank, in- dure specified in § 178.338–9(c) or by
cluding fittings, gaskets and pipe- using the holding time test in § 178.338–
work, which can be expected normally 9(b). This test must consist of either:
to come into contact with the refrig- (i) A constant pressure test (for ex-
erated liquefied gas transported must ample, at atmospheric pressure) when
be compatible with that refrigerated the loss of refrigerated liquefied gas is
liquefied gas. measured over a period of time; or
(6) The thermal insulation system (ii) A closed system test when the
must include a complete covering of rise in pressure in the shell is measured
the shell with effective insulating ma- over a period of time.
terials. External insulation must be (12) When performing the constant
protected by a jacket so as to prevent pressure test, variations in atmos-
the ingress of moisture and other dam- pheric pressure must be taken into ac-
age under normal transport conditions. count. When performing either test,
(7) When a jacket is so closed as to be corrections must be made for any vari-
gas-tight, a device must be provided to ation of the ambient temperature from
prevent any dangerous pressure from the assumed ambient temperature ref-
developing in the insulation space. erence value of 30 °C (86 °F).
(8) Materials which may react with (13) The jacket of a vacuum-insulated
oxygen or oxygen enriched double-wall tank must have either an
atmospheres in a dangerous manner external design pressure not less than
may not be used in portable tanks in- 100 kPa (1 bar) gauge pressure cal-
tended for the transport of refrigerated culated in accordance with Section
liquefied gases having a boiling point VIII of the ASME Code or a calculated
below minus 182 °C at atmospheric critical collapsing pressure of not less
pressure in locations with the thermal than 200 kPa (2 bar) gauge pressure. In-
insulation where there is a risk of con- ternal and external reinforcements
tact with oxygen or with oxygen en- may be included in calculating the
riched fluid. ability of the jacket to resist the exter-
(9) Insulating materials must not de- nal pressure.
teriorate to an extent that the effec- NOTE TO PARAGRAPH (b): For the deter-
tiveness of the insulation system, as mination of the actual holding time, as indi-
determined in accordance with para- cated by paragraphs (b)(10), (11), (12), and
graph (b)(11) of this section, would be (13), before each journey, refer to § 178.338–
reduced in service. 9(b).
129
§ 178.277 49 CFR Ch. I (10–1–18 Edition)
(c) Design criteria. For shells with (7) Vacuum insulated portable tanks
vacuum insulation, the test pressure are not required to have an inspection
must not be less than 1.3 times the sum opening.
of the MAWP and 100 kPa (1 bar). In no (e) Pressure relief devices. (1) Every
case may the test pressure be less than shell must be provided with not less
300 kPa (3 bar) gauge pressure. than two independent reclosing pres-
(d) Service equipment. (1) Each filling sure relief devices. The pressure relief
and discharge opening in portable devices must open automatically at a
tanks used for the transport of flam- pressure not less than the MAWP and
mable refrigerated liquefied gases must be fully open at a pressure equal to
be fitted with at least three mutually 110% of the MAWP. These devices
independent shut-off devices in series: must, after discharge, close at a pres-
the first being a stop-valve situated as
sure not lower than 10% below the pres-
close as reasonably practicable to the
sure at which discharge starts and
jacket, the second being a stop-valve
must remain closed at all lower pres-
and the third being a blank flange or
sures. The pressure relief devices must
equivalent device. The shut-off device
closest to the jacket must be a self- be of the type that will resist dynamic
closing device, which is capable of forces including surge.
being closed from an accessible posi- (2) Except for portable tanks used for
tion on the portable tank that is re- oxygen, portable tanks for non-flam-
mote from the valve within 30 seconds mable refrigerated liquefied gases (ex-
of actuation. This device must actuate cept oxygen) and hydrogen may in ad-
at a temperature of not more than 121 dition have frangible discs in parallel
°C (250 °F). with the reclosing devices as specified
(2) Each filling and discharge opening in paragraphs (e)(4)(ii) and (e)(4)(iii) of
in portable tanks used for the trans- this section.
port of non-flammable refrigerated liq- (3) Pressure relief devices must be de-
uefied gases must be fitted with at signed to prevent the entry of foreign
least two mutually independent shut- matter, the leakage of gas and the de-
off devices in series: the first being a velopment of any dangerous excess
stop-valve situated as close as reason- pressure.
ably practicable to the jacket and the (4) Capacity and setting of pressure re-
second a blank flange or equivalent de- lief devices. (i) In the case of the loss of
vice. vacuum in a vacuum-insulated tank or
(3) For sections of piping which can of loss of 20% of the insulation of a
be closed at both ends and where liquid portable tank insulated with solid ma-
product can be trapped, a method of terials, the combined capacity of all
automatic pressure relief must be pro-
pressure relief devices installed must
vided to prevent excess pressure build-
be sufficient so that the pressure (in-
up within the piping.
cluding accumulation) inside the shell
(4) Each filling and discharge opening
does not exceed 120% of the MAWP.
on a portable tank must be clearly
marked to indicate its function. (ii) For non-flammable refrigerated
(5) When pressure-building units are liquefied gases (except oxygen) and hy-
used, the liquid and vapor connections drogen, this capacity may be achieved
to that unit must be provided with a by the use of frangible discs in parallel
valve as close to the jacket as reason- with the required safety-relief devices.
ably practicable to prevent the loss of Frangible discs must rupture at nomi-
contents in case of damage to the pres- nal pressure equal to the test pressure
sure-building unit. A check valve may of the shell.
be used for this purpose if it is located (iii) Under the circumstances de-
on the vapor side of the pressure build- scribed in paragraphs (e)(4)(i) and
up coil. (e)(4)(ii) of this section, together with
(6) The materials of construction of complete fire engulfment, the com-
valves and accessories must have satis- bined capacity of all pressure relief de-
factory properties at the lowest oper- vices installed must be sufficient to
ating temperature of the portable limit the pressure in the shell to the
tank. test pressure.
130
(iv) The required capacity of the re- event to come in contact with any of
lief devices must be calculated in ac- the caps. Space shall be provided so
cordance with CGA Pamphlet S–1.2 that each detonator of whatever nature
(IBR, see § 171.7 of this subchapter). may be inserted in an individual cell in
[66 FR 33450, June 21, 2001, as amended at 68 the body of the container, into which
FR 75748, 75752, Dec. 31, 2003] each such cap shall snugly fit. There
shall be provided no more than twenty
Subpart I [Reserved] (20) such cellular spaces. Space may be
provided into which a plurality of per-
cussion caps may be carried, provided
Subpart J—Specifications for Con- that such space may be closed with a
tainers for Motor Vehicle screw cap, and further provided that
Transportation each or any such space is entirely sepa-
rate from any space provided for any
SOURCE: 29 FR 18975, Dec. 29, 1964, unless detonator. Each cellular space into
otherwise noted. Redesignated at 32 FR 5606, which a detonator is to be inserted and
Apr. 5, 1967. carried shall be capable of being cov-
§ 178.318 Specification MC 201; con- ered by a rotary cover so arranged as
tainer for detonators and percus- to expose not more than one cell at any
sion caps. time, and capable of rotation to such a
place that all cells will be covered at
§ 178.318–1 Scope. the same time, at which place means
(a) This specification pertains to a shall be provided to lock the cover in
container to be used for the transpor- place. Means shall be provided to lock
tation of detonators and percussion in place the cover for the cells provided
caps in connection with the transpor- for the carrying of detonators. The re-
tation of liquid nitroglycerin, desen- quirement that not more than one cell
sitized liquid nitroglycerin or be exposed at one time need not apply
diethylene glycol dinitrate, where any in the case of detonators, although
or all of such types of caps may be used spaces for such caps and detonators
for the detonation of liquid nitroglyc- shall be separate. Sufficient annular
erin, desentitized liquid nitroglycerin space shall be provided inside the cover
or diethylene glycol dinitrate in blast- for such detonators that, when the
ing operations. This specification is cover is closed, there will be sufficient
not intended to take the place of any space to accommodate the wires cus-
shipping or packing requirements of tomarily attached to such caps. If the
this Department where the caps in material is of such a nature as to re-
question are themselves articles of quire treatment to prevent the absorp-
commerce. tion of moisture, such treatment shall
(b) [Reserved] be applied as shall be necessary in
[29 FR 18975, Dec. 29, 1964. Redesignated at 32 order to provide against the penetra-
FR 5606, Apr. 5, 1967, and amended by Amdt. tion of water by permeation. A suitable
178–60, 44 FR 70733, Dec. 10, 1979] carrying handle shall be provided, ex-
cept for which handle no part of the
§ 178.318–2 Container. container may project beyond the exte-
(a) Every container for detonators rior of the body.
and percussion caps coming within the (b) Exhibited in plates I and II are
scope of this specification shall be con- line drawings of a container for deto-
structed entirely of hard rubber, nators and percussion caps, illustrative
phenolresinous or other resinous mate- of the requirements set forth in
rial, or other nonmetallic, nonsparking § 178.318–2(a). These plates shall not be
material, except that metal parts may construed as a part of this specifica-
be used in such locations as not in any tion.
131
§ 178.318–3 49 CFR Ch. I (10–1–18 Edition)
§ 178.318–3 Marking. tention or containment function and

provides no structural support to the
Each container must be marked as
cargo tank.
prescribed in § 178.2(b).
Baffle means a non-liquid-tight trans-
[Amdt. 178–40, 41 FR 38181, Sept. 9, 1976, as verse partition device that deflects,
amended at 66 FR 45185, Aug. 28, 2001] checks or regulates fluid motion in a
tank.
§ 178.320 General requirements appli- Bulkhead means a liquid-tight trans-
cable to all DOT specification cargo verse closure at the ends of or between
tank motor vehicles.
cargo tanks.
(a) Definitions. For the purpose of this Cargo tank means a bulk packaging
subchapter: that:
Appurtenance means any attachment (1) Is a tank intended primarily for
to a cargo tank that has no lading re- the carriage of liquids, gases, solids, or
132
EC02MR91.076</GPH>
semi-solids and includes appur- (3) To the same engineering drawings

tenances, reinforcements, fittings, and and calculations, except for minor
closures (for tank, see §§ 178.337–1, variations in piping that do not affect
178.338–1, or 178.345–1, as applicable); the lading retention capability of the
(2) Is permanently attached to or cargo tank;
forms a part of a motor vehicle, or is (4) Of the same materials of construc-
not permanently attached to a motor tion;
vehicle but that, by reason of its size, (5) To the same cross-sectional di-
construction, or attachment to a mensions;
motor vehicle, is loaded or unloaded (6) To a length varying by no more
without being removed from the motor than 5 percent;
vehicle; and (7) With the volume varying by no
(3) Is not fabricated under a speci- more than 5 percent (due to a change in
fication for cylinders, intermediate length only); and
bulk containers, multi-unit tank car (8) For the purposes of § 178.338 only,
tanks, portable tanks, or tank cars. with the same insulation system.
Cargo tank motor vehicle means a External self-closing stop valve means a
motor vehicle with one or more cargo self-closing stop valve designed so that
tanks permanently attached to or the self-stored energy source is located
forming an integral part of the motor outside the cargo tank and the welded
vehicle. flange.
Cargo tank wall means those parts of Extreme dynamic loading means the
the cargo tank that make up the pri- maximum loading a cargo tank motor
mary lading retention structure, in- vehicle may experience during its ex-
cluding shell, bulkheads, and fittings pected life, excluding accident loadings
and, when closed, yield the minimum resulting from an accident, such as
volume of a completed cargo tank overturn or collision.
motor vehicle. Flange means the structural ring for
Charging line means a hose, tube, guiding or attachment of a pipe or fit-
pipe, or a similar device used to pres- ting with another flange (companion
surize a tank with material other than flange), pipe, fitting or other attach-
the lading. ment.
Companion flange means one of two Inspection pressure means the pres-
mating flanges where the flange faces sure used to determine leak tightness
are in contact or separated only by a of the cargo tank when testing with
thin leak-sealing gasket and are se- pneumatic pressure.
cured to one another by bolts or Internal self-closing stop valve means a
clamps. self-closing stop valve designed so that
Connecting structure means the struc- the self-stored energy source is located
ture joining two cargo tanks. inside the cargo tank or cargo tank
Constructed and certified in accordance sump, or within the welded flange, and
with the ASME Code means a cargo the valve seat is located within the
tank is constructed and stamped in ac- cargo tank or within one inch of the
cordance with Section VIII of the external face of the welded flange or
ASME Code (IBR, see § 171.7 of this sub- sump of the cargo tank.
chapter), and is inspected and certified Lading means the hazardous material
by an Authorized Inspector. contained in a cargo tank.
Constructed in accordance with the Loading/unloading connection means
ASME Code means a cargo tank is con- the fitting in the loading/unloading
structed in accordance with Section line farthest from the loading/unload-
VIII of the ASME Code with authorized ing outlet to which the loading/unload-
exceptions (see §§ 178.346 through ing hose, pipe, or device is attached.
178.348) and is inspected and certified Loading/unloading outlet means a
by a Registered Inspector. cargo tank outlet used for normal load-
Design type means one or more cargo ing/unloading operations.

tanks that are made— Loading/unloading stop valve means
(1) To the same specification; the stop valve farthest from the cargo
(2) By the same manufacturer; tank loading/unloading outlet to which
133
§ 178.320 49 CFR Ch. I (10–1–18 Edition)
the loading/unloading connection is at- Multi-specification cargo tank motor ve-

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

(3) The thickness as computed per of a shell and heads, that forms a pres-
the ASME Code requirements (if appli- sure tight vessel having openings de-
cable). signed to accept pressure tight fittings
134
or closures, but excludes any appur- (c) Exceptions to the ASME Code. Un-
tenances, reinforcements, fittings, or less otherwise specified, when excep-
closures. tions are provided in this subpart from
Test pressure means the pressure to compliance with certain paragraphs of
which a tank is subjected to determine the ASME Code, compliance with those
structural integrity. paragraphs is not prohibited.
Toughness of material means the capa- [Amdt. 178–89, 55 FR 37055, Sept. 7, 1990, as
bility of a material to absorb energy amended by Amdt. 178–98, 58 FR 33306, June
represented by the area under a stress 16, 1993; Amdt. 178–118, 61 FR 51339, Oct. 1,
strain curve (indicating the energy ab- 1996; 68 FR 19277, Apr. 18, 2003; 68 FR 52370,
sorbed per unit volume of the material) Sept. 3, 2003; 68 FR 75752, Dec. 31, 2003; 76 FR
up to the point of rupture. 43532, July 20, 2011]
Vacuum cargo tank means a cargo
tank that is loaded by reducing the § 178.337 Specification MC 331; cargo
tank motor vehicle primarily for
pressure in the cargo tank to below at- transportation of compressed gases
mospheric pressure. as defined in subpart G of part 173
Variable specification cargo tank of this subchapter.
means a cargo tank that is constructed
in accordance with one specification, § 178.337–1 General requirements.
but that may be altered to meet an- (a) ASME Code construction. Tanks
other specification by changing relief must be—
device, closures, lading discharge de- (1) Seamless or welded construction,
vices, and other lading retention de- or a combination of both;
vices. (2) Designed, constructed, certified,
Void means the space between tank and stamped in accordance with Sec-
heads or bulkheads and a connecting tion VIII of the ASME Code (IBR, see
structure. § 171.7 of this subchapter);
Welded flange means a flange at- (3) Made of steel or aluminum; how-
tached to the tank by a weld joining ever, if aluminum is used, the cargo
the tank shell to the cylindrical outer tank must be insulated and the haz-
surface of the flange, or by a fillet weld ardous material to be transported must
joining the tank shell to a flange be compatible with the aluminum (see
shaped to fit the shell contour. §§ 178.337–1(e)(2), 173.315(a) table, and
(b) Design certification. (1) Each cargo 178.337–2(a)(1) of this subchapter); and
tank or cargo tank motor vehicle de- (4) Covered with a steel jacket if the
sign type, including its required acci- cargo tank is insulated and used to
dent damage protection device, must transport a flammable gas (see
be certified to conform to the specifica- § 173.315(a) table Note 11 of this sub-
tion requirements by a Design Certi- chapter).
fying Engineer who is registered in ac- (b) Design pressure. The design pres-
cordance with subpart F of part 107 of sure of a cargo tank authorized under
this title. An accident damage protec- this specification shall be not less than
tion device is a rear-end protection, the vapor pressure of the commodity
overturn protection, or piping protec- contained therein at 115 °F. or as pre-
tion device. scribed for a particular commodity in
(2) The Design Certifying Engineer § 173.315(a) of this subchapter, except
shall furnish to the manufacturer a that in no case shall the design pres-
certificate to indicate compliance with sure of any cargo tank be less than 100
the specification requirements. The p.s.i.g. nor more than 500 p.s.i.g.
certificate must include the sketches,
drawings, and calculations used for cer- NOTE 1: The term design pressure as used in
tification. Each certificate, including this specification, is identical to the term
MAWP as used in the ASME Code.
sketches, drawings, and calculations,
shall be signed by the Design Certi- (c) Openings. (1) Excess pressure relief
fying Engineer. valves shall be located in the top of the
(3) The manufacturer shall retain the cargo tank or heads.

design certificate at his principal place (2) A chlorine cargo tank shall have
of business for as long as he manufac- only one opening. That opening shall
tures DOT specification cargo tanks. be in the top of the cargo tank and
135
§ 178.337–1 49 CFR Ch. I (10–1–18 Edition)
shall be fitted with a nozzle that meets provisions in Section VIII of the ASME
the following requirements: Code under which it is constructed.
(i) On a cargo tank manufactured on Where postweld heat treatment is re-
or before December 31, 1974, the nozzle quired, the cargo tank must be treated
shall be protected by a dome cover as a unit after completion of all the
plate which conforms to either the welds in and/or to the shells and heads.
standard of The Chlorine Institute, The method must be as prescribed in
Inc., Dwg. 103–3, dated January 23, 1958, Section VIII of the ASME Code. Welded
or to the standard specified in para- attachments to pads may be made after
graph (c) (2) (ii) of this section. postweld heat treatment. A cargo tank
(ii) On a cargo tank manufactured on used for anhydrous ammonia must be
or after January 1, 1975, the nozzle postweld heat treated. The postweld
shall be protected by a manway cover heat treatment must be as prescribed
which conforms to the standard of The in Section VIII of the ASME Code, but
Chlorine Institute, Inc., Dwg. 103–4, in no event at less than 1,050 § F cargo
dated September 1, 1971. tank metal temperature.
(d) Reflective design. Every (g) Definitions. The following defini-
uninsulated cargo tank permanently tions apply to §§ 178.337–1 through
attached to a cargo tank motor vehicle 178.337–18:
shall, unless covered with a jacket Emergency discharge control means the
made of aluminum, stainless steel, or ability to stop a cargo tank unloading
other bright nontarnishing metal, be operation in the event of an uninten-
painted a white, aluminum or similar tional release. Emergency discharge
reflecting color on the upper two-thirds control can utilize passive or off-truck
of area of the cargo tank. remote means to stop the unloading
(e) Insulation. (1) Each cargo tank re- operation. A passive means of emer-
quired to be insulated must conform gency discharge control automatically
with the use and performance require- shuts off the flow of product without
ments contained in §§ 173.315(a) table the need for human intervention with-
and 178.337–1 (a)(3) and (e)(2) of this in 20 seconds of an unintentional re-
subchapter. lease caused by a complete separation
(2) Each cargo tank intended for of the liquid delivery hose. An off-
chlorine; carbon dioxide, refrigerated truck remote means of emergency dis-
liquid; or nitrous oxide, refrigerated charge control permits a qualified per-
liquid service must have suitable insu- son attending the unloading operation
lation of such thickness that the over- to close the cargo tank’s internal self-
all thermal conductance is not more closing stop valve and shut off all mo-
than 0.08 Btu per square foot per °F dif- tive and auxiliary power equipment at
ferential per hour. The conductance a distance from the cargo tank motor
must be determined at 60 °F. Insulation vehicle.
material used on cargo tanks for ni- Excess flow valve, integral excess flow
trous oxide, refrigerated liquid must be valve, or excess flow feature means a
noncombustible. Insulating material component that will close automati-
used on cargo tanks for chlorine must cally if the flow rate of a gas or liquid
be corkboard or polyurethane foam, through the component reaches or ex-
with a minimum thickness of 4 inches, ceeds the rated flow of gas or liquid
or 2 inches minimum thickness of ce- specified by the original valve manu-
ramic fiber/fiberglass of 4 pounds per facturer when piping mounted directly
cubic foot minimum density covered by on the valve is sheared off before the
2 inches minimum thickness of fiber. first valve, pump, or fitting down-
(f) Postweld heat treatment. Postweld stream from the valve.
heat treatment must be as prescribed Internal self-closing stop valve means a
in the ASME Code except that each primary shut off valve installed in a
cargo tank constructed in accordance product discharge outlet of a cargo
with Part UHT of Section VIII of the tank and designed to be kept closed by
ASME Code must be postweld heat self-stored energy.

treated. Each chlorine cargo tank must Primary discharge control system
be fully radiographed and postweld means a primary shut-off installed at a
heat treated in accordance with the product discharge outlet of a cargo
136
tank consisting of an internal self-clos- identified representatives of the De-

ing stop valve that may include an in- partment of Transportation.
tegral excess flow valve or an excess (4) The direction of final rolling of
flow feature, together with linkages the shell material shall be the circum-
that must be installed between the ferential orientation of the cargo tank
valve and remote actuator to provide shell.
manual and thermal on-truck remote (b) For a chlorine cargo tank. Plates,
means of closure. the manway nozzle, and anchorage
[Order 59–B, 30 FR 579, Jan. 16, 1965. Redesig- shall be made of carbon steel which
nated at 32 FR 5606, Apr. 5, 1967] meets the following requirements:
(1) For a cargo tank manufactured on
EDITORIAL NOTE: For FEDERAL REGISTER ci-
or before December 31, 1974—
tations affecting § 178.337–1, see the List of
CFR Sections Affected, which appears in the (i) Material shall conform to ASTM A
Finding Aids section of the printed volume 300, ‘‘Steel Plates for Pressure Vessels
and at www.fdsys.gov. for Service at Low Temperatures’’
(IBR, see § 171.7 of this subchapter);
§ 178.337–2 Material. (ii) Material shall be Class 1, Grade
(a) General. (1) All material used for A, flange or firebox quality;
construction of the cargo tank and ap- (iii) Plate impact test specimens, as
purtenances must be suitable for use required under paragraph (a) of this
with the commodities to be trans- section, shall be of the Charpy keyhole
ported therein and must conform to notch type; and
the requirements in Section II of the (iv) Plate impact test specimens
ASME Code (IBR, see § 171.7 of this sub- shall meet the impact test require-
chapter) and/or requirements of the ments in paragraph (a) of this section
American Society for Testing and Ma- in both the longitudinal and transverse
terials in all respects. directions of rolling at a temperature
(2) Impact tests are required on steel of minus 45.5 C. (¥50 °F.).
used in the fabrication of each cargo (2) For a cargo tank manufactured on
tank constructed in accordance with or after January 1, 1975—
part UHT in Section VIII of the ASME (i) Material shall conform to ASTM A
Code. The tests must be made on a lot 612 (IBR, see § 171.7 of this subchapter),
basis. A lot is defined as 100 tons or less Grade B or A 516/A 516M (IBR, see § 171.7
of the same heat treatment processing of this subchapter), Grade 65 or 70;
lot having a thickness variation no (ii) Material shall meet the Charpy
greater than plus or minus 25 percent. V-notch test requirements of ASTM A
The minimum impact required for full 20/A 20M (IBR, see § 171.7 of this sub-
size specimens must be 20 foot-pounds chapter); and
in the longitudinal direction at ¥30 (iii) Plate impact test specimens
°F., Charpy V-Notch and 15 foot-pounds shall meet the impact test require-
in the transverse direction at ¥30 °F., ments in paragraph (a) of this section
Charpy V-Notch. The required values in both the longitudinal and transverse
for subsize specimens must be reduced directions of rolling at a temperature
in direct proportion to the cross-sec- of minus 40 °C. (¥40 °F.).
tional area of the specimen beneath the (c) A cargo tank in anhydrous ammo-
notch. If a lot does not meet this re- nia service must be constructed of
quirement, individual plates may be steel. The use of copper, silver, zinc or
accepted if they individually meet this their alloys is prohibited. Baffles made
requirement. from aluminum may be used only if
(3) The fabricator shall record the joined to the cargo tank by a process
heat, and slab numbers, and the cer- not requiring postweld heat treatment
tified Charpy impact values, where re- of the cargo tank.
quired, of each plate used in each cargo [Order 59–B, 30 FR 579, Jan. 16, 1965. Redesig-
tank on a sketch showing the location nated at 32 FR 5606, Apr. 5, 1967]
of each plate in the shell and heads of
the cargo tank. Copies of each sketch tations affecting § 178.337–2, see the List of
shall be provided to the owner and re- CFR Sections Affected, which appears in the
tained for at least five years by the Finding Aids section of the printed volume
fabricator and made available to duly and at www.fdsys.gov.
137
§ 178.337–3 49 CFR Ch. I (10–1–18 Edition)
§ 178.337–3 Structural integrity. (c) Shell design. Shell stresses result-

(a) General requirements and accept- ing from static or dynamic loadings, or
ance criteria. (1) Except as provided in combinations thereof, are not uniform
paragraph (d) of this section, the max- throughout the cargo tank motor vehi-
imum calculated design stress at any cle. The vertical, longitudinal, and lat-
point in the cargo tank may not exceed eral normal operating loadings can
the maximum allowable stress value occur simultaneously and must be
prescribed in Section VIII of the ASME combined. The vertical, longitudinal
Code (IBR, see § 171.7 of this sub- and lateral extreme dynamic loadings
chapter), or 25 percent of the tensile occur separately and need not be com-
strength of the material used. bined.
(2) The relevant physical properties (1) Normal operating loadings. The fol-
of the materials used in each cargo lowing procedure addresses stress in
tank may be established either by a the tank shell resulting from normal
certified test report from the material operating loadings. The effective stress
manufacturer or by testing in conform- (the maximum principal stress at any
ance with a recognized national stand- point) must be determined by the fol-
ard. In either case, the ultimate tensile lowing formula:
strength of the material used in the de- S = 0.5(Sy + Sx) ±[0.25(Sy ¥ Sx)2 + Ss2]0.5
sign may not exceed 120 percent of the
ultimate tensile strength specified in Where:
either the ASME Code or the ASTM (i) S = effective stress at any given
standard to which the material is man- point under the combination of static
ufactured. and normal operating loadings that can
(3) The maximum design stress at occur at the same time, in psi.
any point in the cargo tank must be (ii) Sy = circumferential stress gen-
calculated separately for the loading erated by the MAWP and external pres-
conditions described in paragraphs (b), sure, when applicable, plus static head,
(c), and (d) of this section. Alternate in psi.
test or analytical methods, or a com- (iii) Sx = The following net longitu-
bination thereof, may be used in place dinal stress generated by the following
of the procedures described in para- static and normal operating loading
graphs (b), (c), and (d) of this section, if conditions, in psi:
the methods are accurate and (A) The longitudinal stresses result-
verifiable. ing from the MAWP and external pres-
(4) Corrosion allowance material may sure, when applicable, plus static head,
not be included to satisfy any of the in combination with the bending stress
design calculation requirements of this generated by the static weight of the
section. fully loaded cargo tank motor vehicle,
(b) Static design and construction. (1) all structural elements, equipment and
The static design and construction of appurtenances supported by the cargo
each cargo tank must be in accordance tank wall;
with Section VIII of the ASME Code. (B) The tensile or compressive stress
The cargo tank design must include resulting from normal operating longi-
calculation of stresses generated by de- tudinal acceleration or deceleration. In
sign pressure, the weight of lading, the each case, the forces applied must be
weight of structure supported by the 0.35 times the vertical reaction at the
cargo tank wall, and the effect of tem- suspension assembly, applied at the
perature gradients resulting from lad- road surface, and as transmitted to the
ing and ambient temperature extremes. cargo tank wall through the suspension
When dissimilar materials are used, assembly of a trailer during decelera-
their thermal coefficients must be used tion; or the horizontal pivot of the
in calculation of thermal stresses. truck tractor or converter dolly fifth
(2) Stress concentrations in tension, wheel, or the drawbar hinge on the
bending and torsion which occur at fixed dolly during acceleration; or an-
pads, cradles, or other supports must choring and support members of a

be considered in accordance with ap- truck during acceleration and decelera-
pendix G in Section VIII of the ASME tion, as applicable. The vertical reac-
Code. tion must be calculated based on the
138
static weight of the fully loaded cargo (C) The lateral shear stress generated
tank motor vehicle, all structural ele- by a normal operating lateral accelera-
ments, equipment and appurtenances tive force equal to 0.2 times the
supported by the cargo tank wall. The vertical reaction at each suspension as-
following loadings must be included: sembly of a trailer, applied at the road
(1) The axial load generated by a surface, and as transmitted to the
decelerative force; cargo tank wall through the suspension
(2) The bending moment generated by assembly of a trailer, and the hori-
a decelerative force; zontal pivot of the upper coupler (fifth
(3) The axial load generated by an ac- wheel) or turntable; or anchoring and
support members of a truck, as applica-
celerative force; and
ble. The vertical reaction must be cal-
(4) The bending moment generated by culated based on the static weight of
an accelerative force; and the fully loaded cargo tank motor vehi-
(C) The tensile or compressive stress cle, all structural elements, equipment
generated by the bending moment re- and appurtenances supported by the
sulting from normal operating vertical cargo tank wall; and
accelerative force equal to 0.35 times (D) The torsional shear stress gen-
the vertical reaction at the suspension erated by the same lateral forces as de-
assembly of a trailer; or the horizontal scribed in paragraph (c)(1)(iv)(C) of this
pivot of the upper coupler (fifth wheel) section.
or turntable; or anchoring and support (2) Extreme dynamic loadings. The fol-
members of a truck, as applicable. The lowing procedure addresses stress in
vertical reaction must be calculated the tank shell resulting from extreme
based on the static weight of the fully dynamic loadings. The effective stress
loaded cargo tank motor vehicle, all (the maximum principal stress at any
structural elements, equipment and ap- point) must be determined by the fol-
purtenances supported by the cargo lowing formula:
tank wall.
S = 0.5(Sy + Sx) ±[0.25(Sy ¥ Sx)2 + Ss2]0.5
(iv) Ss = The following shear stresses
generated by the following static and Where:
normal operating loading conditions, (i) S = effective stress at any given
in psi: point under a combination of static
(A) The static shear stress resulting and extreme dynamic loadings that can
from the vertical reaction at the sus- occur at the same time, in psi.
pension assembly of a trailer, and the (ii) Sy = circumferential stress gen-
horizontal pivot of the upper coupler erated by MAWP and external pressure,
(fifth wheel) or turntable; or anchoring when applicable, plus static head, in
and support members of a truck, as ap- psi.
plicable. The vertical reaction must be (iii) Sx = the following net longitu-
calculated based on the static weight dinal stress generated by the following
of the fully loaded cargo tank motor static and extreme dynamic loading
vehicle, all structural elements, equip- conditions, in psi:
ment and appurtenances supported by (A) The longitudinal stresses result-
the cargo tank wall; ing from the MAWP and external pres-
(B) The vertical shear stress gen- sure, when applicable, plus static head,
erated by a normal operating accelera- in combination with the bending stress
tive force equal to 0.35 times the generated by the static weight of the
vertical reaction at the suspension as- fully loaded cargo tank motor vehicle,
sembly of a trailer; or the horizontal all structural elements, equipment and
pivot of the upper coupler (fifth wheel) appurtenances supported by the tank
or turntable; or anchoring and support wall;
members of a truck, as applicable. The (B) The tensile or compressive stress
vertical reaction must be calculated resulting from extreme longitudinal
based on the static weight of the fully acceleration or deceleration. In each
loaded cargo tank motor vehicle, all case the forces applied must be 0.7
structural elements, equipment and ap- times the vertical reaction at the sus-
purtenances supported by the cargo pension assembly, applied at the road
tank wall; surface, and as transmitted to the
139
§ 178.337–3 49 CFR Ch. I (10–1–18 Edition)
cargo tank wall through the suspension or turntable; or anchoring and support
assembly of a trailer during decelera- members of a truck, as applicable. The
tion; or the horizontal pivot of the vertical reaction must be calculated
truck tractor or converter dolly fifth based on the static weight of the fully
wheel, or the drawbar hinge on the loaded cargo tank motor vehicle, all
fixed dolly during acceleration; or the structural elements, equipment and ap-
anchoring and support members of a purtenances supported by the cargo
truck during acceleration and decelera- tank wall;
tion, as applicable. The vertical reac- (C) The lateral shear stress generated
tion must be calculated based on the by an extreme lateral accelerative
static weight of the fully loaded cargo force equal to 0.4 times the vertical re-
tank motor vehicle, all structural ele- action at the suspension assembly of a
ments, equipment and appurtenances trailer, applied at the road surface, and
supported by the cargo tank wall. The as transmitted to the cargo tank wall
following loadings must be included: through the suspension assembly of a
(1) The axial load generated by a trailer, and the horizontal pivot of the
decelerative force; upper coupler (fifth wheel) or turn-
(2) The bending moment generated by table; or anchoring and support mem-
a decelerative force; bers of a truck, as applicable. The
(3) The axial load generated by an ac- vertical reaction must be calculated
celerative force; and based on the static weight of the fully
(4) The bending moment generated by loaded cargo tank motor vehicle, all
an accelerative force; and structural elements, equipment and ap-
(C) The tensile or compressive stress purtenances supported by the cargo
generated by the bending moment re- tank wall; and
sulting from an extreme vertical accel-
(D) The torsional shear stress gen-
erative force equal to 0.7 times the
erated by the same lateral forces as de-
vertical reaction at the suspension as-
scribed in paragraph (c)(2)(iv)(C) of this
sembly of a trailer, and the horizontal
section.
pivot of the upper coupler (fifth wheel)
or turntable; or the anchoring and sup- (d) In order to account for stresses
port members of a truck, as applicable. due to impact in an accident, the de-
The vertical reaction must be cal- sign calculations for the cargo tank
culated based on the static weight of shell and heads must include the load
the fully loaded cargo tank motor vehi- resulting from the design pressure in
cle, all structural elements, equipment combination with the dynamic pres-
and appurtenances supported by the sure resulting from a longitudinal de-
cargo tank wall. celeration of ‘‘2g’’. For this loading
(iv) Ss = The following shear stresses condition the stress value used may
generated by static and extreme dy- not exceed the lesser of the yield
namic loading conditions, in psi: strength or 75 percent of the ultimate
(A) The static shear stress resulting tensile strength of the material of con-
from the vertical reaction at the sus- struction. For cargo tanks constructed
pension assembly of a trailer, and the of stainless steel the maximum design
horizontal pivot of the upper coupler stress may not exceed 75 percent of the
(fifth wheel) or turntable; or anchoring ultimate tensile strength of the type
and support members of a truck, as ap- steel used.
plicable. The vertical reaction must be (e) The minimum metal thickness for
calculated based on the static weight the shell and heads on tanks with a de-
of the fully loaded cargo tank motor sign pressure of 100 psig or more must
vehicle, all structural elements, equip- be 4.75 mm (0.187 inch) for steel and 6.86
ment and appurtenances supported by mm (0.270 inch) for aluminum, except
the cargo tank wall; for chlorine and sulfur dioxide tanks.
(B) The vertical shear stress gen- In all cases, the minimum thickness of
erated by an extreme vertical accelera- the tank shell and head shall be deter-
tive force equal to 0.7 times the mined using structural design require-
vertical reaction at the suspension as- ments in Section VIII of the ASME
sembly of a trailer, and the horizontal Code or 25% of the tensile strength of
pivot of the upper coupler (fifth wheel) the material used. For a cargo tank
140
used in chlorine or sulfur dioxide serv- there will be no adverse effect upon the
ice, the cargo tank must be made of lading retention integrity of the cargo
steel. A corrosion allowance of 20 per- tank if any force less than that pre-
cent or 2.54 mm (0.10 inch), whichever scribed in paragraph (b)(1) of this sec-
is less, must be added to the thickness tion is applied from any direction. The
otherwise required for sulfur dioxide thickness of the mounting pad may not
and chlorine tank material. In chlorine be less than that of the shell wall or
cargo tanks, the wall thickness must head wall to which it is attached, and
be at least 1.59 cm (0.625 inch), includ- not more than 1.5 times the shell or
ing corrosion allowance. head thickness. However, a pad with a
(f) Where a cargo tank support is at- minimum thickness of 0.25 inch may be
tached to any part of the cargo tank
used when the shell or head thickness
wall, the stresses imposed on the cargo
is over 0.25 inch. If weep holes or tell-
tank wall must meet the requirements
in paragraph (a) of this section. tale holes are used, the pad must be
(g) The design, construction, and in- drilled or punched at the lowest point
stallation of an attachment, appur- before it is welded to the tank. Each
tenance to the cargo tank, structural pad must—
support member between the cargo (i) Be fabricated from material deter-
tank and the vehicle or suspension mined to be suitable for welding to
component, or accident protection de- both the cargo tank material and the
vice must conform to the following re- material of the appurtenance or struc-
quirements: tural support member; a Design Certi-
(1) Structural members, the suspen- fying Engineer must make this deter-
sion sub-frame, accident protection mination considering chemical and
structures, and external circumferen- physical properties of the materials
tial reinforcement devices must be and must specify filler material con-
used as sites for attachment of appur- forming to the requirements in Section
tenances and other accessories to the VIII of the ASME Code (IBR, see § 171.7
cargo tank, when practicable. of this subchapter).
(2) A lightweight attachment to the (ii) Be preformed to an inside radius
cargo tank wall such as a conduit clip, no greater than the outside radius of
brake line clip, skirting structure,
the cargo tank at the attachment loca-
lamp mounting bracket, or placard
tion.
holder must be of a construction hav-
ing lesser strength than the cargo tank (iii) Extend at least 2 inches in each
wall materials and may not be more direction from any point of attachment
than 72 percent of the thickness of the of an appurtenance or structural sup-
material to which it is attached. The port member. This dimension may be
lightweight attachment may be se- measured from the center of the at-
cured directly to the cargo tank wall if tached structural member.
the device is designed and installed in (iv) Have rounded corners, or other-
such a manner that, if damaged, it will wise be shaped in a manner to mini-
not affect the lading retention integ- mize stress concentrations on the shell
rity of the tank. A lightweight attach- or head.
ment must be secured to the cargo (v) Be attached by continuous fillet
tank shell or head by a continuous welding. Any fillet weld discontinuity
weld or in such a manner as to preclude may only be for the purpose of pre-
formation of pockets which may be- venting an intersection between the fil-
come sites for corrosion. Attachments let weld and a tank or jacket seam
meeting the requirements of this para- weld.
graph are not authorized for cargo
tanks constructed under part UHT in [Amdt. 178–89, 55 FR 37056, Sept. 7, 1990, as
Section VIII of the ASME Code. amended by Amdt. 178–104, 59 FR 49135, Sept.
(3) Except as prescribed in para- 26, 1994; Amdt. 178–105, 60 FR 17401, Apr. 5,
1995; Amdt. 178–118, 61 FR 51340, Oct. 1, 1996;
graphs (g)(1) and (g)(2) of this section,

the welding of any appurtenance to the 65 FR 58631, Sept. 29, 2000; 68 FR 19279, Apr.
18, 2003; 68 FR 52370, Sept. 3, 2003; 68 FR 75753,
cargo tank wall must be made by at-
Dec. 31, 2003]
tachment of a mounting pad so that
141
§ 178.337–4 49 CFR Ch. I (10–1–18 Edition)
§ 178.337–4 Joints. § 178.337–5 Bulkheads, baffles and ring

stiffeners.
(a) Joints shall be as required in Sec-
tion VIII of the ASME Code (IBR, see (a) Not a specification requirement.
§ 171.7 of this subchapter), with all un- (b) [Reserved]
dercutting in shell and head material [Order 59–B, 30 FR 580, Jan. 16, 1965. Redesig-
repaired as specified therein. nated at 32 FR 5606, Apr. 5, 1967]
(b) Welding procedure and welder per-
formance must be in accordance with § 178.337–6 Closure for manhole.
Section IX of the ASME Code. In addi- (a) Each cargo tank marked or cer-
tion to the essential variables named tified after April 21, 1994, must be pro-
therein, the following must be consid- vided with a manhole conforming to
ered as essential variables: Number of paragraph UG–46(g)(1) and other appli-
passes; thickness of plate; heat input cable requirements in Section VIII of
per pass; and manufacturer’s identi- the ASME Code (IBR, see § 171.7 of this
fication of rod and flux. When fabrica- subchapter), except that a cargo tank
tion is done in accordance with part constructed of NQT steel having a ca-
UHT in Section VIII of the ASME Code, pacity of 3,500 water gallons or less
filler material containing more than may be provided with an inspection
0.08 percent vanadium must not be opening conforming to paragraph UG–
used. The number of passes, thickness 46 and other applicable requirements of
of plate, and heat input per pass may the ASME Code instead of a manhole.
not vary more than 25 percent from the (b) The manhole assembly of cargo
procedure or welder qualifications. tanks constructed after June 30, 1979,
Records of the qualifications must be may not be located on the front head of
retained for at least 5 years by the the cargo tank.
cargo tank manufacturer and must be
made available to duly identified rep- [Amdt. 178–7, 34 FR 18250, Nov. 14, 1969, as
resentatives of the Department and the
18, 1978; Amdt. 178–89, 54 FR 25017, June 12,
owner of the cargo tank. 1989; 55 FR 21038, May 22, 1990; 56 FR 27876,
(c) All longitudinal shell welds shall June 17, 1991; 58 FR 12905, Mar. 8, 1993; Amdt.
be located in the upper half of the 178–118, 61 FR 51340, Oct. 1, 1996; 68 FR 75753,
cargo tank. Dec. 31, 2003]
(d) Edge preparation of shell and
head components may be by machine § 178.337–7 Overturn protection.
heat processes, provided such surfaces (a) See § 178.337–10.
are remelted in the subsequent welding (b) [Reserved]
process. Where there will be no subse-
[Order 59–B, 30 FR 580, Jan. 16, 1965. Redesig-
quent remelting of the prepared surface
nated at 32 FR 5606, Apr. 5, 1967]
as in a tapered section, the final 0.050
inch of material shall be removed by § 178.337–8 Openings, inlets, and out-
mechanical means. lets.
(e) The maximum tolerance for mis-
(a) General. The requirements in this
alignment and butting up shall be in
paragraph (a) apply to MC 331 cargo
accordance with the requirement in
tanks except for those used to trans-
Section VIII of the ASME Code.
port chlorine. The requirements for in-
(f) Substructures shall be properly lets and outlets on chlorine cargo
fitted before attachment, and the weld- tanks are in paragraph (b) of this sec-
ing sequence shall be such as to mini- tion.
mize stresses due to shrinkage of (1) An opening must be provided on
welds. each cargo tank used for the transpor-
[Order 59–B, 30 FR 580, Jan. 16, 1965. Redesig- tation of liquefied materials to permit
nated at 32 FR 5606, Apr. 5, 1967] complete drainage.
(2) Except for gauging devices, ther-
tations affecting § 178.337–4, see the List of mometer wells, pressure relief valves,
CFR Sections Affected, which appears in the manhole openings, product inlet open-
Finding Aids section of the printed volume ings, and product discharge openings,
and at www.fdsys.gov. each opening in a cargo tank must be
142
closed with a plug, cap, or bolted ing connection area. The loading/un-
flange. loading connection area is where hoses
(3) Except as provided in paragraph or hose reels are connected to the per-
(b) of this section, each product inlet manent metal piping. Linkages be-
opening, including vapor return lines, tween closures and remote operators
must be fitted with a back flow check must be corrosion resistant and effec-
valve or an internal self-closing stop tive in all types of environmental con-
valve located inside the cargo tank or ditions incident to discharge of prod-
inside a welded nozzle that is an inte- uct.
gral part of the cargo tank. The valve (iii) All parts of a valve inside a
seat must be located inside the cargo cargo tank or within a welded flange
tank or within 2.54 cm (one inch) of the must be made of material that will not
external face of the welded flange.
corrode or deteriorate in the presence
Damage to parts exterior to the cargo
of the lading.
tank or mating flange must not pre-
vent effective seating of the valve. All (iv) An excess flow valve, integral ex-
parts of a valve inside a cargo tank or cess flow valve, or excess flow feature
welded flange must be made of mate- must close if the flow reaches the rated
rial that will not corrode or deteriorate flow of a gas or liquid specified by the
in the presence of the lading. original valve manufacturer when pip-
(4) Except as provided in paragraphs ing mounted directly on the valve is
(a)(5), (b), and (c) of this section, each sheared off before the first valve,
liquid or vapor discharge outlet must pump, or fitting downstream from the
be fitted with a primary discharge con- excess flow valve, integral excess flow
trol system as defined in § 178.337–1(g). valve, or excess flow feature.
Thermal remote operators must acti- (v) An integral excess flow valve or
vate at a temperature of 121.11 °C (250 the excess flow feature of an internal
°F) or less. Linkages between closures self-closing stop valve may be designed
and remote operators must be corro- with a bypass, not to exceed 0.1016 cm
sion resistant and effective in all types (0.040 inch) diameter opening, to allow
of environmental conditions incident equalization of pressure.
to discharging of product. (vi) The internal self-closing stop
(i) On a cargo tank over 13,247.5 L valve must be designed so that the self-
(3,500 gallons) water capacity, thermal stored energy source and the valve seat
and mechanical means of remote clo- are located inside the cargo tank or
sure must be installed at the ends of within 2.54 cm (one inch) of the exter-
the cargo tank in at least two diagonal face of the welded flange. Damage
nally opposite locations. If the loading/ to parts exterior to the cargo tank or
unloading connection at the cargo tank mating flange must not prevent effec-
is not in the general vicinity of one of tive seating of the valve.
the two locations specified in the first (5) A primary discharge control sys-
sentence of this paragraph (a)(4)(i), ad- tem is not required on the following:
ditional means of thermal remote clo-
(i) A vapor or liquid discharge open-
sure must be installed so that heat
ing of less than 11⁄4 NPT equipped with
from a fire in the loading/unloading
connection area or the discharge pump an excess flow valve together with a
will activate the primary discharge manually operated external stop valve
control system. The loading/unloading in place of an internal self-closing stop
connection area is where hoses or hose valve.
reels are connected to the permanent (ii) An engine fuel line on a truck-
metal piping. mounted cargo tank of not more than
3⁄4 NPT equipped with a valve having an
(ii) On a cargo tank of 13,247.5 L (3,500
gallons) water capacity or less, a ther- integral excess flow valve or excess
mal means of remote closure must be flow feature.
installed at or near the internal self- (iii) A cargo tank motor vehicle used
closing stop valve. A mechanical to transport refrigerated liquids such

means of remote closure must be in- as argon, carbon dioxide, helium, kryp-
stalled on the end of the cargo tank ton, neon, nitrogen, and xenon, or mix-
furthest away from the loading/unload- tures thereof.
143
§ 178.337–9 49 CFR Ch. I (10–1–18 Edition)
(6) In addition to the internal self- lief devices, must be at least 4 times
closing stop valve, each filling and dis- the design pressure of the cargo tank.
charge line must be fitted with a stop Additionally, the burst pressure may
valve located in the line between the not be less than 4 times any higher
internal self-closing stop valve and the pressure to which each pipe, pipe fit-
hose connection. A back flow check ting, hose or other pressure part may
valve or excess flow valve may not be be subjected to in service. For chlorine
used to satisfy this requirement. service, see paragraph (b)(7) of this sec-
(7) An excess flow valve may be de- tion.
signed with a bypass, not to exceed a (2) Pipe joints must be threaded,
0.1016 centimeter (0.040 inch) diameter welded, or flanged. If threaded pipe is
opening, to allow equalization of pres-
used, the pipe and fittings must be
sure.
Schedule 80 weight or heavier, except
(b) Inlets and discharge outlets on chlo-
for sacrificial devices. Malleable metal,
rine tanks. The inlet and discharge out-
lets on a cargo tank used to transport stainless steel, or ductile iron must be
chlorine must meet the requirements used in the construction of primary
of § 178.337–1(c)(2) and must be fitted valve body parts and fittings used in
with an internal excess flow valve. In liquid filling or vapor equalization.
addition to the internal excess flow Stainless steel may be used for internal
valve, the inlet and discharge outlets components such as shutoff discs and
must be equipped with an external stop springs except where incompatible with
valve (angle valve). Excess flow valves the lading to be transported. Where
must conform to the standards of The copper tubing is permitted, joints must
Chlorine Institute, Inc., as follows: be brazed or be of equally strong metal
(1) A valve conforming to The Chlo- union type. The melting point of the
rine Institute, Inc., Dwg. 101–7 (IBR, brazing material may not be lower
see § 171.7 of this subchapter), must be than 538 °C (1,000 °F). The method of
installed under each liquid angle valve. joining tubing may not reduce the
(2) A valve conforming to The Chlo- strength of the tubing.
rine Institute, Inc., Dwg. 106–6 (IBR, (3) Each hose coupling must be de-
see § 171.7 of this subchapter), must be signed for a pressure of at least 120 per-
installed under each gas angle valve. cent of the hose design pressure and so
(c) Discharge outlets on carbon dioxide, that there will be no leakage when con-
refrigerated liquid, cargo tanks. A dis- nected.
charge outlet on a cargo tank used to (4) Piping must be protected from
transport carbon dioxide, refrigerated damage due to thermal expansion and
liquid is not required to be fitted with contraction, jarring, and vibration.
an internal self-closing stop valve. Slip joints are not authorized for this
[64 FR 28049, May 24, 1999, as amended at 66 purpose.
FR 45387, Aug. 28, 2001; 68 FR 19279, Apr. 18, (5) [Reserved]
2003; 68 FR 75753, Dec. 31, 2003] (6) Cargo tank manufacturers and
§ 178.337–9 Pressure relief devices, fabricators must demonstrate that all
piping, valves, hoses, and fittings. piping, valves, and fittings on a cargo
tank are free from leaks. To meet this
(a) Pressure relief devices. (1) See
requirement, the piping, valves, and
§ 173.315(i) of this subchapter.
fittings must be tested after installa-
(2) On cargo tanks for carbon dioxide
or nitrous oxide see § 173.315 (i) (9) and tion at not less than 80 percent of the
(10) of this subchapter. design pressure marked on the cargo
(3) Each valve must be designed, con- tank.
structed, and marked for a rated pres- (7) A hose assembler must:
sure not less than the cargo tank de- (i) Permanently mark each hose as-
sign pressure at the temperature ex- sembly with a unique identification
pected to be encountered. number.
(b) Piping, valves, hose, and fittings. (1) (ii) Demonstrate that each hose as-
The burst pressure of all piping, pipe sembly is free from leaks by per-
fittings, hose and other pressure parts, forming the tests and inspections in
except for pump seals and pressure re- § 180.416(f) of this subchapter.
144
(iii) Mark each hose assembly with § 178.337–10 Accident damage protec-
the month and year of its original pres- tion.
sure test. (a) All valves, fittings, pressure relief
(8) Chlorine cargo tanks. Angle valves devices, and other accessories to the
on cargo tanks intended for chlorine tank proper shall be protected in ac-
service must conform to the standards cordance with paragraph (b) of this sec-
of the Chlorine Institute, Inc., Dwg. tion against such damage as could be
104–8 or ‘‘Section 3, Pamphlet 166, caused by collision with other vehicles
Angle Valve Guidelines for Chlorine or objects, jack-knifing and over-
Bulk Transportation.’’ (IBR, see § 171.7 turning. In addition, pressure relief
of this subchapter). Before installation, valves shall be so protected that in the
each angle valve must be tested for event of overturn of the vehicle onto a
leakage at not less than 225 psig using hard surface, their opening will not be
dry air or inert gas. prevented and their discharge will not
(c) Marking inlets and outlets. Except be restricted.
for gauging devices, thermometer (b) The protective devices or housing
wells, and pressure relief valves, each must be designed to withstand static
cargo tank inlet and outlet must be loading in any direction equal to twice
marked ‘‘liquid’’ or ‘‘vapor’’ to des- the weight of the tank and attach-
ignate whether it communicates with ments when filled with the lading,
liquid or vapor when the cargo tank is using a safety factor of not less than
filled to the maximum permitted fill- four, based on the ultimate strength of
ing density. A filling line that commu- the material to be used, without dam-
nicates with vapor may be marked age to the fittings protected, and must
‘‘spray-fill’’ instead of ‘‘vapor.’’ be made of metal at least 3⁄16-inch
(d) Refrigeration and heating coils. (1) thick.
Refrigeration and heating coils must (c) Rear-end tank protection. Rear-end
be securely anchored with provisions tank protection devices must:
for thermal expansion. The coils must (1) Consist of at least one rear bump-
be pressure tested externally to at er designed to protect the cargo tank
least the cargo tank test pressure, and and all valves, piping and fittings lo-
internally to either the tank test pres- cated at the rear of the cargo tank
sure or twice the working pressure of from damage that could result in loss
the heating/refrigeration system, of lading in the event of a rear end col-
whichever is higher. A cargo tank may lision. The bumper design must trans-
not be placed in service if any leakage mit the force of the collision directly
occurs or other evidence of damage is to the chassis of the vehicle. The rear
found. The refrigerant or heating me- bumper and its attachments to the
dium to be circulated through the coils chassis must be designed to withstand
must not be capable of causing any ad- a load equal to twice the weight of the
verse chemical reaction with the cargo loaded cargo tank motor vehicle and
tank lading in the event of leakage. attachments, using a safety factor of
The unit furnishing refrigeration may four based on the tensile strength of
the materials used, with such load
be mounted on the motor vehicle.
being applied horizontally and parallel
(2) Where any liquid susceptible to
to the major axis of the cargo tank.
freezing, or the vapor of any such liq- The rear bumper dimensions must also
uid, is used for heating or refrigera- meet the requirements of § 393.86 of this
tion, the heating or refrigeration sys- title; or
tem shall be arranged to permit com-
(2) Conform to the requirements of
plete drainage. § 178.345–8(d).
[Order 59–B, 30 FR 580, Jan. 16, 1965. Redesig- (d) Chlorine tanks. A chlorine tank
nated at 32 FR 5606, Apr. 5, 1967] must be equipped with a protective
EDITORIAL NOTE: For FEDERAL REGISTER ci- housing and a manway cover to permit
tations affecting § 178.337–9, see the List of the use of standard emergency kits for
CFR Sections Affected, which appears in the controlling leaks in fittings on the
Finding Aids section of the printed volume dome cover plate. For tanks manufac-
and at www.fdsys.gov. tured on or after October 1, 2009, the
145
§ 178.337–11 49 CFR Ch. I (10–1–18 Edition)
housing and manway cover must con- § 178.337–12 [Reserved]

form to the Chlorine Institute, Inc.,
Dwg. 137–5 (IBR, see § 171.7 of this sub- § 178.337–13 Supporting and anchor-
chapter). ing.
(e) Piping and fittings. Piping and fit- (a) A cargo tank that is not perma-
tings must be grouped in the smallest nently attached to or integral with a
practicable space and protected from
vehicle chassis must be secured by the
damage as required in this section.
(f) Shear section. A shear section or use of restraining devices designed to
sacrificial device is required for the prevent relative motion between the
valves specified in the following loca- cargo tank and the vehicle chassis
tions: when the vehicle is in operation. Such
(1) A section that will break under restraining devices must be readily ac-
strain must be provided adjacent to or cessible for inspection and mainte-
outboard of each valve specified in nance.
§ 178.337–8(a)(3) and (4). (b) On a cargo tank motor vehicle de-
(2) Each internal self-closing stop signed and constructed so that the
valve, excess flow valve, and check cargo tank constitutes in whole or in
valve must be protected by a shear sec- part the structural member used in
tion or other sacrificial device. The place of a motor vehicle frame, the
sacrificial device must be located in cargo tank must be supported by exter-
the piping system outboard of the stop nal cradles. A cargo tank mounted on a
valve and within the accident damage motor vehicle frame must be supported
protection to prevent any accidental
by external cradles or longitudinal
loss of lading. The failure of the sac-
members. Where used, the cradles must
rificial device must leave the protected
lading protection device and its attach- subtend at least 120 degrees of the shell
ment to the cargo tank wall intact and circumference.
capable of retaining product. (c) The design calculations of the
support elements must satisfy the re-
[Order 59–B, 30 FR 581, Jan. 16, 1965. Redesig-
quirements of § 178.337–3, (a), (b), (c),
nated at 32 FR 5606, Apr. 5, 1967]
and (d).
EDITORIAL NOTE: For FEDERAL REGISTER ci- (d) Where any cargo tank support is
CFR Sections Affected, which appears in the attached to any part of a cargo tank
Finding Aids section of the printed volume head, the stresses imposed upon the
and at www.fdsys.gov. head must be provided for as required
in paragraph (c) of this section.
§ 178.337–11 Emergency discharge con-
trol. [68 FR 19280, Apr. 18, 2003]
(a) Emergency discharge control equip-
§ 178.337–14 Gauging devices.
ment. Emergency discharge control
equipment must be installed in a liquid (a) Liquid level gauging devices. See
discharge line as specified by product § 173.315(h) of this subchapter.
and service in § 173.315(n) of this sub- (b) Pressure gauges. (1) See § 173.315(h)
chapter. The performance and certifi- of this subchapter.
cation requirements for emergency dis- (2) Each cargo tank used in carbon
charge control equipment are specified dioxide, refrigerated liquid or nitrous
in § 173.315(n) of this subchapter and are oxide, refrigerated liquid service must
not a part of the cargo tank motor ve- be provided with a suitable pressure
hicle certification made under this
gauge. A shut-off valve must be in-
specification.
stalled between the pressure gauge and
(b) Engine fuel lines. On a truck-
mounted cargo tank, emergency dis- the cargo tank.
charge control equipment is not re- (c) Orifices. See § 173.315(h) (3) and (4)
quired on an engine fuel line of not of this subchapter.
more than 3⁄4 NPT equipped with a
[Amdt. 178–29, 38 FR 27599, Oct. 5, 1973, as

valve having an integral excess flow amended by Amdt. 178–89, 54 FR 25018, June
valve or excess flow feature. 12, 1989; Amdt. 178–118, 61 FR 51340, Oct. 1,
[64 FR 28050, May 24, 1999] 1996]
146
§ 178.337–15 Pumps and compressors. method, or ultrasonic testing in ac-

cordance with appendix 12 in Section
(a) Liquid pumps or gas compressors,
if used, must be of suitable design, ade- VIII of the ASME Code. Permanent
quately protected against breakage by magnets must not be used to perform
collision, and kept in good condition. the magnetic particle inspection.
They may be driven by motor vehicle (c) All defects found shall be re-
power take-off or other mechanical, paired, the cargo tanks shall then
electrical, or hydraulic means. Unless again be postweld heat treated, if such
they are of the centrifugal type, they heat treatment was previously per-
shall be equipped with suitable pres- formed, and the repaired areas shall
sure actuated by-pass valves permit- again be tested.
ting flow from discharge to suction or [Order 59–B, 30 FR 582, Jan. 16, 1965. Redesig-
to the cargo tank. nated at 32 FR 5606, Apr. 5, 1967, and amended
(b) A liquid chlorine pump may not by Amdt. 178–7, 34 FR 18250, Nov. 14, 1969;
be installed on a cargo tank intended Amdt. 178–99, 58 FR 51534, Oct. 1, 1993; Amdt.
for the transportation of chlorine. 178–118, 61 FR 51340, Oct. 1, 1996; 68 FR 75753,
Dec. 31, 2003]
[Amdt. 178–89, 54 FR 25018, June 12, 1989, as
amended by Amdt. 178–118, 61 FR 51340, Oct.
1, 1996] § 178.337–17 Marking.
(a) General. Each cargo tank certified
§ 178.337–16 Testing. after October 1, 2004 must have a corro-
(a) Inspection and tests. Inspection of sion-resistant metal name plate
materials of construction of the cargo (ASME Plate); and each cargo tank
tank and its appurtenances and origi- motor vehicle certified after October 1,
nal test and inspection of the finished 2004 must have a specification plate,
cargo tank and its appurtenances must permanently attached to the cargo
be as required by Section VIII of the tank by brazing, welding, or other suit-
ASME Code (IBR, see § 171.7 of this sub- able means on the left side near the
chapter) and as further required by this front, in a place accessible for inspec-
specification, except that for cargo tion. If the specification plate is at-
tanks constructed in accordance with tached directly to the cargo tank wall
part UHT in Section VIII of the ASME by welding, it must be welded to the
Code the original test pressure must be tank before the cargo tank is postweld
at least twice the cargo tank design heat treated.
pressure. (1) The plates must be legibly marked
(b) Weld testing and inspection. (1) by stamping, embossing, or other
Each cargo tank constructed in accord- means of forming letters into the
ance with part UHT in Section VIII of
metal of the plate, with the informa-
the ASME Code must be subjected,
tion required in paragraphs (b) and (c)
after postweld heat treatment and hy-
of this section, in addition to that re-
drostatic tests, to a wet fluorescent
quired by the ASME Code, in char-
magnetic particle inspection to be
acters at least 3⁄16 inch high (parenthet-
made on all welds in or on the cargo
tank shell and heads both inside and ical abbreviations may be used). All
out. The method of inspection must plates must be maintained in a legible
conform to appendix 6 in Section VIII condition.
of the ASME Code except that perma- (2) Each insulated cargo tank must
nent magnets shall not be used. have additional plates, as described, at-
(2) On cargo tanks of over 3,500 gal- tached to the jacket in the location
lons water capacity other than those specified unless the specification plate
described in paragraph (b)(1) of this is attached to the chassis and has the
section unless fully radiographed, a information required in paragraphs (b)
test must be made of all welds in or on and (c) of this section.
the shell and heads both inside and (3) The information required for both
outside by either the wet fluorescent the name and specification plate may
magnetic particle method conforming be displayed on a single plate. If the in-
to appendix U in Section VIII of the formation required by this section is
ASME Code, liquid dye penetrant displayed on a plate required by the
147
§ 178.337–18 49 CFR Ch. I (10–1–18 Edition)
ASME, the information need not be re- (c) Specification plate. The following
peated on the name and specification information must be marked on the
plates. specification plate in accordance with
(4) The specification plate may be at- this section:
tached to the cargo tank motor vehicle (1) Cargo tank motor vehicle manu-
chassis rail by brazing, welding, or facturer (CTMV mfr.).
other suitable means on the left side (2) Cargo tank motor vehicle certifi-
near the front head, in a place acces- cation date (CTMV cert. date).
sible for inspection. If the specification (3) Cargo tank manufacturer (CT
plate is attached to the chassis rail, mfr.).
then the cargo tank serial number as- (4) Cargo tank date of manufacture
signed by the cargo tank manufacturer (CT date of mfr.), month and year.
must be included on the plate. (5) Maximum weight of lading (Max.
(b) Name plate. The following infor- Payload), in pounds
mation must be marked on the name (6) Lining materials (Lining), if ap-
plate in accordance with this section: plicable.
(1) DOT-specification number MC 331 (7) Heating system design pressure
(DOT MC 331). (Heating sys. press.), in psig, if applica-
(2) Original test date (Orig. Test ble.
Date). (8) Heating system design tempera-
(3) MAWP in psig. ture (Heating sys. temp.), in °F, if ap-
(4) Cargo tank design temperature plicable.
(Design Temp. Range) lll °F to (9) Cargo tank serial number, as-
lll °F. signed by cargo tank manufacturer (CT
(5) Nominal capacity (Water Cap.), in serial), if applicable.
pounds. NOTE 1 TO PARAGRAPH (c): See § 173.315(a) of
(6) Maximum design density of lading this chapter regarding water capacity.
(Max. Lading density), in pounds per NOTE 2 TO PARAGRAPH (c): When the shell
gallon. and head materials are the same thickness,
(7) Material specification number— they may be combined (Shell & head matl,
yyy***).
shell (Shell matl, yyy***), where ‘‘yyy’’
is replaced by the alloy designation (d) The design weight of lading used
and ‘‘***’’ is replaced by the alloy type. in determining the loading in §§ 178.337–
(8) Material specification number— 3(b), 178.337–10(b) and (c), and 178.337–
heads (Head matl. yyy***), where 13(a) and (b), must be shown as the
‘‘yyy’’ is replaced by the alloy designa- maximum weight of lading marking re-
tion and ‘‘***’’ by the alloy type. quired by paragraph (c) of this section.
(9) Minimum Thickness—shell (Min. [68 FR 19280, Apr. 18, 2003; 68 FR 52370, Sept.
Shell-thick), in inches. When minimum 3, 2003, as amended at 68 FR 57633, Oct. 6,
shell thicknesses are not the same for 2003; 81 FR 35544, June 2, 2016]
different areas, show (topll, sidell,
bottomll, in inches). § 178.337–18 Certification.
(10) Minimum thickness—heads (Min. (a) At or before the time of delivery,
heads thick.), in inches. the cargo tank motor vehicle manufac-
(11) Manufactured thickness—shell turer must supply and the owner must
(Mfd. Shell thick.), topll, sidell, obtain, a cargo tank motor vehicle
bottomll, in inches. (Required when manufacturer’s data report as required
additional thickness is provided for by Section VIII of the ASME Code
corrosion allowance.) (IBR, see § 171.7 of this subchapter), and
(12) Manufactured thickness—heads a certificate stating that the com-
(Mfd. Heads thick.), in inches. (Re- pleted cargo tank motor vehicle con-
quired when additional thickness is forms in all respects to Specification
provided for corrosion allowance.) MC 331 and the ASME Code. The reg-
(13) Exposed surface area, in square istration numbers of the manufacturer,
feet. the Design Certifying Engineer, and
NOTE TO PARAGRAPH (b): When the shell and the Registered Inspector, as appro-
head materials are the same thickness, they priate, must appear on the certificates
may be combined, (Shell&head matl, (see subpart F, part 107 in subchapter A
yyy***). of this chapter).
148
(1) For each design type, the certifi- certificate, or certificates, will include
cate must be signed by a responsible of- sufficient sketches, drawings, and
ficial of the manufacturer and a Design other information to indicate the loca-
Certifying Engineer; and tion, make, model, and size of each
(2) For each cargo tank motor vehi- valve and the arrangement of all piping
cle, the certificate must be signed by a associated with the cargo tank.
responsible official of the manufac- (6) The certificate must contain a
turer and a Registered Inspector. statement indicating whether or not
(3) When a cargo tank motor vehicle the cargo tank was postweld heat
is manufactured in two or more stages, treated for anhydrous ammonia as
each manufacturer who performs a specified in § 178.337–1(f).
manufacturing function or portion (b) The owner shall retain the copy of
thereof on the incomplete cargo tank the data report and certificates and re-
motor vehicle must provide to the suc- lated papers in his files throughout his
ceeding manufacturer, at or before the ownership of the cargo tank motor ve-
time of delivery, a certificate that hicle and for at least one year there-
states the function performed by the after; and in the event of change in
manufacturer, including any certifi- ownership, retention by the prior
cates received from previous manufac- owner of nonfading photographically
turers, Registered Inspectors, and De- reproduced copies will be deemed to
sign Certifying Engineers. satisfy this requirement. Each motor
(4) Specification shortages. When a carrier using the cargo tank motor ve-
cargo tank motor vehicle is manufac- hicle, if not the owner thereof, shall
tured in two or more stages, the manu- obtain a copy of the data report and
facturer of the cargo tank must attach certificate and retain them in his files
the name plate and specification plate during the time he uses the cargo tank
as required by § 178.337–17(a) and (b) motor vehicle and for at least one year
without the original date of certifi- thereafter.
cation stamped on the specification [Order 59–B, 30 FR 583, Jan. 16, 1965. Redesig-
plate. Prior manufacturers must list nated at 32 FR 5606, Apr. 5, 1967]
the specification requirements that are
not completed on the Certificate of EDITORIAL NOTE: For FEDERAL REGISTER ci-
Compliance. When the cargo tank
CFR Sections Affected, which appears in the
motor vehicle is brought into full com- Finding Aids section of the printed volume
pliance with the applicable specifica- and at www.fdsys.gov.
tion, the cargo tank motor vehicle
manufacturer must have a Registered § 178.338 Specification MC–338; insu-
Inspector stamp the date of certifi- lated cargo tank motor vehicle.
cation on the specification plate and
issue a Certificate of Compliance to the § 178.338–1 General requirements.
owner of the cargo tank motor vehicle. (a) For the purposes of this section—
The Certificate of Compliance must (1) Design pressure means the
list the actions taken to bring the ‘‘MAWP’’ as used in Section VIII of the
cargo tank motor vehicle into full ASME Code (IBR, see § 171.7 of this sub-
compliance. In addition, the certificate chapter), and is the gauge pressure at
must include the date of certification the top of the tank.
and the person (manufacturer, carrier (2) Design service temperature means
or repair organization) accomplishing the coldest temperature for which the
compliance. tank is suitable (see §§ 173.318 (a)(1) and
(5) The certificate must state wheth- (f) of this subchapter).
er or not it includes certification that (b) Each cargo tank must consist of a
all valves, piping, and protective de- suitably supported welded inner vessel
vices conform to the requirements of enclosed within an outer shell or jack-
the specification. If it does not so cer- et, with insulation between the inner
tify, the installer of any such valve, vessel and outer shell or jacket, and
piping, or device shall supply and the having piping, valves, supports and
owner shall obtain a certificate assert- other appurtenances as specified in this
ing complete compliance with these subchapter. For the purpose of this
specifications for such devices. The specification, tank means inner vessel
149
§ 178.338–2 49 CFR Ch. I (10–1–18 Edition)
and jacket means either the outer shell § 178.338–3(b), may not exceed 25 percent
or insulation cover. of the minimum specified tensile
(c) Each tank must be designed, con- strength.
structed, certified, and stamped in ac- [Amdt. 178–77, 48 FR 27703, June 16, 1983, as
cordance with Section VIII of the amended at 49 FR 24316, June 12, 1984; Amdt.
ASME Code. 178–104, 59 FR 49135, Sept. 26, 1994; 66 FR
(d) The exterior surface of the tank 45387, Aug. 28, 2001; 68 FR 75754, Dec. 31, 2003]
must be insulated with a material com-
patible with the lading. § 178.338–2 Material.
(1) Each cargo tank must have an in- (a) All material used in the construc-
sulation system that will prevent the tion of a tank and its appurtenances
tank pressure from exceeding the pres- that may come in contact with the lad-
sure relief valve set pressure within the ing must be compatible with the lading
specified holding time when the tank is to be transported. All material used for
loaded with the specific cryogenic liq- tank pressure parts must conform to
uid at the design conditions of— the requirements in Section II of the
(i) The specified temperature and ASME Code (IBR, see § 171.7 of this sub-
pressure of the cryogenic liquid, and chapter). All material used for evacu-
(ii) The exposure of the filled cargo ated jacket pressure parts must con-
tank to an average ambient tempera- form to the chemistry and steelmaking
ture of 85 °F. practices of one of the material speci-
(2) For a cargo tank used to transport fications of Section II of the ASME
oxygen, the insulation may not sustain Code or the following ASTM Specifica-
combustion in a 99.5 percent oxygen at- tions (IBR, see § 171.7 of this sub-
mosphere at atmospheric pressure chapter): A 242, A 441, A 514, A 572, A
when contacted with a continuously
588, A 606, A 633, A 715, A 1008/A 1008M,
heated glowing platinum wire. The
A 1011/A 1011M.
cargo tank must be marked in accord- (b) All tie-rods, mountings, and other
ance with § 178.338–18(b)(7). appurtenances within the jacket and
(3) Each vacuum-insulated cargo
all piping, fittings and valves must be
tank must be provided with a connec-
of material suitable for use at the low-
tion for a vacuum gauge to indicate the
est temperature to be encountered.
absolute pressure within the insulation (c) Impact tests are required on all
space. tank materials, except materials that
(e) The insulation must be com-
are excepted from impact testing by
pletely covered by a metal jacket. The
the ASME Code, and must be per-
jacket or the insulation must be so
formed using the procedure prescribed
constructed and sealed as to prevent
in Section VIII of the ASME Code.
moisture from coming into contact (d) The direction of final rolling of
with the insulation (see § 173.318(a)(3) of the shell material must be the circum-
this subchapter). Minimum metal ferential orientation of the tank shell.
thicknesses are as follows: (e) Each tank constructed in accord-
Jacket evacu- Jacket not ance with part UHT in Section VIII of
ated evacuated the ASME Code must be postweld heat
Type metal
Gauge Inches Gauge Inches treated as a unit after completion of
all welds to the shell and heads. Other
Stainless steel .............. 18 0.0428 22 0.0269
Low carbon mild steel .. 12 0.0946 14 0.0677 tanks must be postweld heat treated as
Aluminum ..................... ........... 0.125 ........... 0.1000 required in Section VIII of the ASME
Code. For all tanks the method must
(f) An evacuated jacket must be in be as prescribed in the ASME Code.
compliance with the following require- Welded attachments to pads may be
ments: made after postweld heat treatment.
(1) The jacket must be designed to (f) The fabricator shall record the
sustain a minimum critical collapsing heat and slab numbers and the certified
pressure of 30 psig. Charpy impact values of each plate
(2) If the jacket also supports addi- used in the tank on a sketch showing
tional loads, such as the weight of the the location of each plate in the shell
tank and lading, the combined stress, and heads of the tank. A copy of the
computed according to the formula in sketch must be provided to the owner
150
of the cargo tank and a copy must be tank wall, and the effect of tempera-
retained by the fabricator for at least ture gradients resulting from lading
five years and made available, upon re- and ambient temperature extremes.
quest, to any duly identified represent- When dissimilar materials are used,
ative of the Department. their thermal coefficients must be used
(Approved by the Office of Management and
in calculation of the thermal stresses.
Budget under control number 2137–0017) (2) Stress concentrations in tension,
bending, and torsion which occur at
[Amdt. 178–77, 48 FR 27703, 27713, June 16, pads, cradles, or other supports must
1983, as amended at 49 FR 24316, June 12, 1984;
68 FR 19281, Apr. 18, 2003; 68 FR 75754, Dec. 31,
be considered in accordance with ap-
2003; 70 FR 34076, June 13, 2005] pendix G in Section VIII of the ASME
Code.
§ 178.338–3 Structural integrity. (c) Stresses resulting from static and
(a) General requirements and accept- dynamic loadings, or a combination
ance criteria. (1) Except as permitted in thereof, are not uniform throughout
paragraph (d) of this section, the max- the cargo tank motor vehicle. The fol-
imum calculated design stress at any lowing is a simplified procedure for cal-
point in the tank may not exceed the culating the effective stress in the
lesser of the maximum allowable stress tank resulting from static and dynamic
value prescribed in Section VIII of the loadings. The effective stress (the max-
ASME Code (IBR, see § 171.7 of this sub- imum principal stress at any point)
chapter), or 25 percent of the tensile must be determined by the following
strength of the material used. formula:
(2) The relevant physical properties S = 0.5 (Sy + Sx) ±(0.25(Sy ¥ Sx)2 + Ss2) 0.5
of the materials used in each tank may
be established either by a certified test Where:
report from the material manufacturer (1) S = effective stress at any given
or by testing in conformance with a point under the most severe combina-
recognized national standard. In either tion of static and dynamic loadings
case, the ultimate tensile strength of that can occur at the same time, in psi.
the material used in the design may (2) Sy = circumferential stress gen-
not exceed 120 percent of the minimum erated by internal and external pres-
ultimate tensile strength specified in sure when applicable, in psi.
either the ASME Code or the ASTM (3) Sx = the net longitudinal stress, in
standard to which the material is man- psi, generated by the following loading
ufactured. conditions:
(3) The maximum design stress at (i) The longitudinal tensile stress
any point in the tank must be cal- generated by internal pressure;
culated separately for the loading con- (ii) The tensile or compressive stress
ditions described in paragraphs (b), (c), generated by the axial load resulting
and (d) of this section. Alternate test from a decelerative force applied inde-
or analytical methods, or a combina- pendently to each suspension assembly
tion thereof, may be used in lieu of the at the road surface using applicable
procedures described in paragraphs (b), static loadings specified in § 178.338–13
(c), and (d) of this section, if the meth- (b);
ods are accurate and verifiable. (iii) The tensile or compressive stress
(4) Corrosion allowance material may generated by the bending moment re-
not be included to satisfy any of the sulting from a decelerative force ap-
design calculation requirements of this plied independently to each suspension
section. assembly at the road surface using ap-
(b) Static design and construction. (1) plicable static loadings specified in
The static design and construction of § 178.338–13 (b);
each tank must be in accordance with (iv) The tensile or compressive stress
appendix G in Section VIII of the generated by the axial load resulting
ASME Code (IBR, see § 171.7 of this sub- from an accelerative force applied to
chapter). The tank design must include the horizontal pivot of the fifth wheel
calculation of stress due to the design supporting the vehicle using applicable
pressure, the weight of lading, the static loadings specified in § 178.338–13
weight of structures supported by the (b);
151
§ 178.338–3 49 CFR Ch. I (10–1–18 Edition)
(v) The tensile or compressive stress component or accident protection de-

generated by the bending moment re- vice must conform to the following re-
sulting from an accelerative force ap- quirements:
plied to the horizontal pivot of the (1) Structural members, the suspen-
fifth wheel supporting the vehicle sion subframe, accident protection
using applicable static loadings speci- structures and external circumferen-
fied in § 178.338–13 (b); and tial reinforcement devices must be
(vi) The tensile or compressive stress used as sites for attachment of appur-
generated by a bending moment pro- tenances and other accessories to the
duced by a vertical force using applica- cargo tank, when practicable.
ble static loadings specified in § 178.338– (2) A lightweight attachment to the
13 (b). cargo tank wall such as a conduit clip,
(4) Ss = The following shear stresses brakeline clip, skirting structure, lamp
that apply, in psi,: The vectorial sum mounting bracket, or placard holder
of the applicable shear stresses in the must be of a construction having lesser
plane under consideration, including strength than the cargo tank wall ma-
direct shear generated by the static terials and may not be more than 72
vertical loading; direct lateral and tor- percent of the thickness of the mate-
sional shear generated by a lateral ac- rial to which it is attached. The light-
celerative force applied at the road sur- weight attachment may be secured di-
face, using applicable static loads spec- rectly to the cargo tank wall if the de-
ified in § 178.338–13 (b) vice is designed and installed in such a
(d) In order to account for stresses manner that, if damaged, it will not af-
due to impact in an accident, the defect the lading retention integrity of
sign calculations for the tank shell and the tank. A lightweight attachment
heads must include the load resulting must be secured to the cargo tank shell
from the design pressure in combina- or head by a continuous weld or in such
tion with the dynamic pressure result- a manner as to preclude formation of
ing from a longitudinal deceleration of pockets that may become sites for cor-
‘‘2g’’. For this loading condition the rosion. Attachments meeting the re-
stress value used may not exceed the quirements of this paragraph are not
lesser of the yield strength or 75 per- authorized for cargo tanks constructed
cent of the ultimate tensile strength of under part UHT in Section VIII of the
the material of construction. For a ASME Code.
cargo tank constructed of stainless (3) Except as prescribed in para-
steel, the maximum design stress may graphs (g)(1) and (g)(2) of this section,
not exceed 75 percent of the ultimate the welding of any appurtenance the
tensile strength of the type steel used. cargo tank wall must be made by at-
(e) The minimum thickness of the tachment of a mounting pad so that
shell or heads of the tank must be 0.187 there will be no adverse effect upon the
inch for steel and 0.270 inch for alu- lading retention integrity of the cargo
minum. However, the minimum thick- tank if any force less than that pre-
ness for steel may be 0.110 inches pro- scribed in paragraph (b)(1) of this sec-
vided the cargo tank is: tion is applied from any direction. The
(1) Vacuum insulated, or thickness of the mounting pad may not
(2) Double walled with a load bearing be less than that of the shell or head to
jacket designed to carry a propor- which it is attached, and not more
tionate amount of structural loads pre- than 1.5 times the shell or head thick-
scribed in this section. ness. However, a pad with a minimum
(f) Where a tank support is attached thickness of 0.187 inch may be used
to any part of the tank wall, the when the shell or head thickness is
stresses imposed on the tank wall must over 0.187 inch. If weep holes or tell-
meet the requirements in paragraph (a) tale holes are used, the pad must be
of this section. drilled or punched at the lowest point
(g) The design, construction and in- before it is welded to the tank. Each
stallation of an attachment, appur- pad must:

tenance to the cargo tank or structural (i) Be fabricated from material deter-
support member between the cargo mined to be suitable for welding to
tank and the vehicle or suspension both the cargo tank material and the
152
material of the appurtenance or struc- (d) Substructures must be properly

tural support member; a Design Certi- fitted before attachment and the weld-
fying Engineer must make this deter- ing sequence must minimize stresses
mination considering chemical and due to shrinkage of welds.
physical properties of the materials (e) Filler material containing more
and must specify filler material con- than 0.05 percent vanadium may not be
forming to the requirements in Section used with quenched and tempered steel.
IX of the ASME Code (IBR, see § 171.7 of (f) All tank nozzle-to-shell and noz-
this subchapter). zle-to-head welds must be full penetra-
(ii) Be preformed to an inside radius tion welds.
no greater than the outside radius of (Approved by the Office of Management and
the cargo tank at the attachment loca- Budget under control number 2137–0017)
tion. [Amdt. 178–77, 48 FR 27704, 27713, June 16,
(iii) Extend at least 2 inches in each 1983, as amended at 49 FR 24316, June 12, 1984;
direction from any point of attachment 68 FR 75754, Dec. 31, 2003]
of an appurtenance or structural sup-
port member. This dimension may be § 178.338–5 Stiffening rings.
measured from the center of the at- (a) A tank is not required to be pro-
tached structural member. vided with stiffening rings, except as
(iv) Have rounded corners, or other- prescribed in Section VIII of the ASME
wise be shaped in a manner to mini- Code (IBR, see § 171.7 of this sub-
mize stress concentrations on the shell chapter).
or head. (b) If a jacket is evacuated, it must
(v) Be attached by continuous fillet be constructed in compliance with
welding. Any fillet weld discontinuity § 178.338–1(f). Stiffening rings may be
may only be for the purpose of pre- used to meet these requirements.
venting an intersection between the fil- [Amdt. 178–77, 48 FR 27704, June 16, 1983, as
let weld and a tank or jacket seam amended at 68 FR 75754, Dec. 31, 2003]
weld.
§ 178.338–6 Manholes.
[Amdt. 178–89, 55 FR 37057, Sept. 7, 1990, as
amended by Amdt. 178–89, 56 FR 27876, June (a) Each tank in oxygen service must
17, 1991; 56 FR 46354, Sept. 11, 1991; 68 FR be provided with a manhole as pre-
19281, Apr. 18, 2003; 68 FR 57633, Oct. 6, 2003; 68 scribed in Section VIII of the ASME
FR 75754, Dec. 31, 2003; 81 FR 25618, Apr. 29, Code (IBR, see § 171.7 of this sub-
2016] chapter).
(b) Each tank having a manhole must
§ 178.338–4 Joints. be provided with a means of entrance
(a) All joints in the tank, and in the and exit through the jacket, or the
jacket if evacuated, must be as pre- jacket must be marked to indicate the
scribed in Section VIII of the ASME manway location on the tank.
Code (IBR, see § 171.7 of this sub- (c) A manhole with a bolted closure
chapter), except that a butt weld with may not be located on the front head of
one plate edge offset is not authorized. the tank.
(b) Welding procedure and welder per- [Amdt. 178–77, 48 FR 27704, June 16, 1983, as
formance tests must be made in ac- amended at 49 FR 24316, June 12, 1984; 68 FR
cordance with Section IX of the ASME 75754, Dec. 31, 2003]
Code. Records of the qualification must
be retained by the tank manufacturer § 178.338–7 Openings.
for at least five years and must be (a) The inlet to the liquid product
made available, upon request, to any discharge opening of each tank in-
duly identified representative of the tended for flammable ladings must be
Department, or the owner of the cargo at the bottom centerline of the tank.
tank. (b) If the leakage of a single valve,
(c) All longitudinal welds in tanks except a pressure relief valve, pressure
and load bearing jackets must be lo- control valve, full trycock or gas phase
cated so as not to intersect nozzles or manual vent valve, would permit loss
supports other than load rings and of flammable material, an additional
stiffening rings. closure that is leak tight at the tank
153
§ 178.338–8 49 CFR Ch. I (10–1–18 Edition)
design pressure must be provided out- (7) All fittings must be rated for the
board of such valve. maximum tank pressure and suitable
[Amdt. 178–77, 48 FR 27704, June 16, 1983]
for the coldest temperature to which
they will be subjected in actual serv-
§ 178.338–8 Pressure relief devices, ice.
piping, valves, and fittings. (8) All piping, valves, and fittings
(a) Pressure relief devices. Each tank must be grouped in the smallest prac-
pressure relief device must be designed, ticable space and protected from dam-
constructed, and marked in accordance age as required by § 178.338–10.
with § 173.318(b) of this subchapter. (9) When a pressure-building coil is
(b) Piping, valves, and fittings. (1) The used on a tank designed to handle oxy-
burst pressure of all piping, pipe fit- gen or flammable ladings, the vapor
tings, hoses and other pressure parts, connection to that coil must be pro-
except for pump seals and pressure re- vided with a valve or check valve as
lief devices, must be at least 4 times close to the tank shell as practicable to
the design pressure of the tank. Addi- prevent the loss of vapor from the tank
tionally, the burst pressure may not be in case of damage to the coil. The liq-
less than 4 times any higher pressure uid connection to that coil must also
to which each pipe, pipe fitting, hose or be provided with a valve.
other pressure part may be subjected [Amdt. 178–77, 48 FR 27704, June 16, 1983, as
to in service. amended by Amdt. 178–89, 54 FR 25019, June
(2) Pipe joints must be threaded, 12, 1989]
welded or flanged. If threaded pipe is
used, the pipe and fittings must be § 178.338–9 Holding time.
Schedule 80 weight or heavier. Malle- (a) ‘‘Holding time’’ is the time, as de-
able metals must be used in the con- termined by testing, that will elapse
struction of valves and fittings. Where from loading until the pressure of the
copper tubing is permitted, joints shall contents, under equilibrium conditions,
be brazed or be of equally strong metal reaches the level of the lowest pressure
union type. The melting point of the control valve or pressure relief valve
brazing materials may not be lower setting.
than 1000 °F. The method of joining (b) Holding time test. (1) The test to
tubing may not reduce the strength of determine holding time must be per-
the tubing, such as by the cutting of formed by charging the tank with a
threads. cryogenic liquid having a boiling point,
(3) Each hose coupling must be de- at a pressure of one atmosphere, abso-
signed for a pressure of at least 120 per- lute, no lower than the design service
cent of the hose design pressure and so temperature of the tank. The tank
that there will be no leakage when con- must be charged to its maximum per-
nected. mitted filling density with that liquid
(4) Piping must be protected from and stabilized to the lowest practical
damage due to thermal expansion and pressure, which must be equal to or
contraction, jarring, and vibration. less than the pressure to be used for
Slip joints are not authorized for this loading. The cargo tank together with
purpose. its contents must then be exposed to
(5) All piping, valves and fittings on a ambient temperature.
cargo tank must be proved free from (2) The tank pressure and ambient
leaks. This requirement is met when temperature must be recorded at 3-
such piping, valves, and fittings have hour intervals until the pressure level
been tested after installation with gas of the contents reaches the set-to-dis-
or air and proved leak tight at not less charge pressure of the pressure control
than the design pressure marked on the valve or pressure relief valve with the
cargo tank. This requirement is appli- lowest setting. This total time lapse in
cable to all hoses used in a cargo tank, hours represents the measured holding
except that hose may be tested before time at the actual average ambient
or after installation on the tank. temperature. This measured holding

(6) Each valve must be suitable for time for the test cryogenic liquid must
the tank design pressure at the tank be adjusted to an equivalent holding
design service temperature. time for each cryogenic liquid that is
154
to be identified on or adjacent to the tf = equilibrium temperature of test fluid at

specification plate, at an average ambi- one atmosphere, °F.
ent temperature of 85 °F. This is the (ii) The rated holding time (RHT)
rated holding time (RHT). The marked must be calculated as follows:
rated holding time (MRHT) displayed
on or adjacent to the specification RHT = [(U2 ¥ U1) W] / q
plate (see § 178.338–18(c)(10)) may not ex- Where:
ceed this RHT. RHT = rated holding time, in hours
(c) Optional test regimen. (1) If more U1 and U2 = internal energy for the combined
than one cargo tank is made to the liquid and vapor lading at the pressure
same design, only one cargo tank must offered for transportation, and the set
pressure of the applicable pressure con-
be subjected to the full holding time
trol valve or pressure relief valve, respec-
test at the time of manufacture. How- tively, Btu/lb.
ever, each subsequent cargo tank made W = total weight of the combined liquid and
to the same design must be perform- vapor lading in the cargo tank, pounds.
ance tested during its first trip. The q = calculated heat transfer rate to cargo
holding time determined in this test tank with lading, Btu/hr.
may not be less than 90 percent of the (iii) The MRHT (see § 178.338–18(b)(9)
marked rated holding time. This test of this subchapter) may not exceed the
must be performed in accordance with RHT.
§§ 173.318(g)(3) and 177.840(h) of this sub-
chapter, regardless of the classification [Amdt. 178–77, 48 FR 27704, June 16, 1983; 48
FR 50442, Nov. 1, 1983, as amended at 49 FR
of the cryogenic liquid. 24316, June 12, 1984; 49 FR 43965, Nov. 1, 1984;
(2) Same design. The term ‘‘same de- 59 FR 55173, Nov. 3, 1994; Amdt. 178–118, 61 FR
sign’’ as used in this section means 51340, Oct. 1, 1996; 68 FR 57634, Oct. 6, 2003; 71
cargo tanks made to the same design FR 54397, Sept. 14, 2006]
type. See § 178.320(a) for definition of
‘‘design type’’. § 178.338–10 Accident damage protec-
(3) For a cargo tank used in nonflam- tion.
mable cryogenic liquid service, in place (a) All valves, fittings, pressure relief
of the holding time tests prescribed in devices and other accessories to the
paragraph (b) of this section, the tank proper, which are not isolated
marked rated holding time (MRHT) from the tank by closed intervening
may be determined as follows: shut-off valves or check valves, must
(i) While the cargo tank is sta- be installed within the motor vehicle
tionary, the heat transfer rate must be framework or within a suitable colli-
determined by measuring the normal sion resistant guard or housing, and
evaporation rate (NER) of the test appropriate ventilation must be pro-
cryogenic liquid (preferably the lading, vided. Each pressure relief device must
where feasible) maintained at approxi- be protected so that in the event of the
mately one atmosphere. The calculated upset of the vehicle onto a hard sur-
heat transfer rate must be determined face, the device’s opening will not be
from: prevented and its discharge will not be
restricted.
q = [n(D h)(85¥t1)] / [ts ¥ tf] (b) Each protective device or housing,
Where: and its attachment to the vehicle
q = calculated heat transfer rate to cargo structure, must be designed to with-
tank with lading, Btu/hr. stand static loading in any direction
n = normal evaporation rate (NER), which is that it may be loaded as a result of
the rate of evaporation, determined by front, rear, side, or sideswipe collision,
the test of a test cryogenic liquid in a or the overturn of the vehicle. The
cargo tank maintained at a pressure of static loading shall equal twice the
approximately one atmosphere, absolute, loaded weight of the tank and attach-
lb/hr.
ments. A safety factor of four, based on
D h = latent heat of vaporization of test fluid
at test pressure, Btu/lb. the tensile strength of the material,
ts = average temperature of outer shell dur- shall be used. The protective device or
ing test, °F. the housing must be made of steel at
t1 = equilibrium temperature of lading at least 3⁄16-inch thick, or other material
maximum loading pressure, °F. of equivalent strength.
155
§ 178.338–11 49 CFR Ch. I (10–1–18 Edition)
(c) Rear-end tank protection. Rear-end control must be of fail-safe design and
tank protections devices must: spring-biased to stop the admission of
(1) Consist of at least one rear bump- such pressure into the cargo tank. If
er designed to protect the cargo tank the jacket is not evacuated, the seat of
and piping in the event of a rear-end the valve must be inside the tank, in
collision. The rear-end tank protection the opening nozzle or flange, or in a
device design must transmit the force companion flange bolted to the nozzle.
of the collision directly to the chassis If the jacket is evacuated, the re-
of the vehicle. The rear-end tank pro- motely controlled valve must be lo-
tection device and its attachments to cated as close to the tank as prac-
the chassis must be designed to with- ticable.
stand a load equal to twice the weight
(2) Each remotely controlled shut off
of the loaded cargo tank and attach-
valve must be provided with on-vehicle
ments, using a safety factor of four
remote means of automatic closure,
based on the tensile strength of the
materials used, with such load being both mechanical and thermal. One
applied horizontally and parallel to the means may be used to close more than
major axis of the cargo tank. The rear- one remotely controlled valve. Cable
end tank protection device dimensions linkage between closures and remote
must meet the requirements of § 393.86 operators must be corrosion resistant
of this title and extend vertically to a and effective in all types of environ-
height adequate to protect all valves ment and weather. The thermal means
and fittings located at the rear of the must consist of fusible elements actu-
cargo tank from damage that could re- ated at a temperature not exceeding
sult in loss of lading; or 121 °C (250 °F), or equivalent devices.
(2) Conform to the requirements of The loading/unloading connection area
§ 178.345–8(b). is where hoses are connected to the
(d) Every part of the loaded cargo permanent metal piping. The number
tank, and any associated valve, pipe, and location of remote operators and
enclosure, or protective device or thermal devices shall be as follows:
structure (exclusive of wheel assem- (i) On a cargo tank motor vehicle
blies), must be at least 14 inches above over 3,500 gallons water capacity, re-
level ground. mote means of automatic closure must
[Amdt. 178–77, 48 FR 27705, June 16, 1983, as be installed at the ends of the cargo
amended at 49 FR 24316, June 12, 1984; Amdt. tank in at least two diagonally oppo-
178–99, 58 FR 51534, Oct. 1, 1993; 68 FR 19282, site locations. If the loading/unloading
Apr. 18, 2003; 68 FR 52371, Sept. 3, 2003] connection at the cargo tank is not in
§ 178.338–11 Discharge control devices. the general vicinity of one of these lo-
cations, at least one additional ther-
(a) Excess-flow valves are not re- mal device must be installed so that
quired. heat from a fire in the loading/unload-
(b) Each liquid filling and liquid dis- ing connection area will activate the
charge line must be provided with a emergency control system.
shut-off valve located as close to the
(ii) On a cargo tank motor vehicle of
tank as practicable. Unless this valve
3,500 gallons water capacity or less, at
is manually operable at the valve, the
least one remote means of automatic
line must also have a manual shut-off
closure must be installed on the end of
valve.
(c) Except for a cargo tank that is the cargo tank farthest away from the
used to transport argon, carbon diox- loading/unloading connection area. At
ide, helium, krypton, neon, nitrogen, least one thermal device must be in-
xenon, or mixtures thereof, each liquid stalled so that heat from a fire in the
filling and liquid discharge line must loading/unloading connection area will
be provided with an on-vehicle re- activate the emergency control sys-
motely controlled self-closing shutoff tem.
valve. [Amdt. 178–77, 48 FR 27705, June 16, 1983, as

(1) If pressure from a reservoir or amended by Amdt. 178–105, 59 FR 55173, Nov.
from an engine-driven pump or com- 3, 1994; 60 FR 17402, Apr. 5, 1995; 68 FR 19282,
pressor is used to open this valve, the Apr. 18, 2003]
156
§ 178.338–12 Shear section. (2) For any other insulated cargo

tank—
Unless the valve is located in a rear (i) Vertically downward of 3;
cabinet forward of and protected by the (ii) Vertically upward of 2;
bumper (see § 178.338–10(c)), the design (iii) Longitudinally of 2; and
and installation of each valve, damage (iv) Laterally of 2.
to which could result in loss of liquid (b) When a loaded tank is supported
or vapor, must incorporate a shear sec- within the vacuum jacket by struc-
tion or breakage groove adjacent to, tural members, the design calculations
and outboard of, the valve. The shear for the tank and its structural mem-
section or breakage groove must yield bers must be based on a safety factor of
or break under strain without damage four and the tensile strength of the ma-
to the valve that would allow the loss terial at ambient temperature. The en-
of liquid or vapor. The protection spec- hanced tensile strength of the material
ified in § 178.338–10 is not a substitute at actual operating temperature may
for a shear section or breakage groove. be substituted for the tensile strength
[Amdt. 178–77, 49 FR 24316, June 12, 1984]
at ambient temperature to the extent
recognized in the ASME Code for static
§ 178.338–13 Supporting and anchor- loadings. Static loadings must take
ing. into consideration the weight of the
tank and the structural members when
(a) On a cargo tank motor vehicle de- the tank is filled to the design weight
signed and constructed so that the of lading (see Appendix G of Section
cargo tank constitutes in whole or in VIII, Division 1 of the ASME Code),
part the structural member used in multiplied by the following factors.
place of a motor vehicle frame, the Static loadings must take into consid-
cargo tank or the jacket must be sup- eration the weight of the tank and the
ported by external cradles or by load structural members when the tank is
rings. For a cargo tank mounted on a filled to the design weight of lading
motor vehicle frame, the tank or jack- (see appendix G in Section VIII of the
et must be supported by external cra- ASME Code), multiplied by the fol-
dles, load rings, or longitudinal mem- lowing factors. When load rings in the
bers. If cradles are used, they must jacket are used for supporting the
subtend at least 120 degrees of the tank, they must be designed to carry
cargo tank circumference. The design the fully loaded tank at the specified
calculations for the supports and load- static loadings, plus external pressure.
bearing tank or jacket, and the support Minimum static loadings must be as
attachments must include beam stress, follows:
shear stress, torsion stress, bending (1) Vertically downward of 2;
moment, and acceleration stress for (2) Vertically upward of 11⁄2;
the loaded vehicle as a unit, using a (3) Longitudinally of 11⁄2; and, (4) Lat-
safety factor of four, based on the ten- erally of 11⁄2.
sile strength of the material, and static
[68 FR 19282, Apr. 18, 2003, as amended at 68
loading that uses the weight of the FR 75754, Dec. 31, 2003]
cargo tank and its attachments when
filled to the design weight of the lading § 178.338–14 Gauging devices.
(see appendix G in Section VIII of the (a) Liquid level gauging devices. (1) Un-
ASME Code) (IBR, see § 171.7 of this less a cargo tank is intended to be
subchapter), multiplied by the fol- filled by weight, it must be equipped
lowing factors. The effects of fatigue with one or more gauging devices,
must also be considered in the calcula- which accurately indicate the max-
tions. Minimum static loadings must imum permitted liquid level at the
be as follows: loading pressure, in order to provide a
(1) For a vacuum-insulated cargo minimum of two percent outage below
tank— the inlet of the pressure control valve
(i) Vertically downward of 2;
or pressure relief valve at the condition

(ii) Vertically upward of 2; of incipient opening of that valve. A
(iii) Longitudinally of 2; and fixed-length dip tube, a fixed trycock
(iv) Laterally of 2. line, or a differential pressure liquid
157
§ 178.338–15 49 CFR Ch. I (10–1–18 Edition)
level gauge must be used as the pri- remove any contaminants likely to
mary control for filling. Other gauging react with the lading.
devices, except gauge glasses, may be [68 FR 75755, Dec. 31, 2003]
used, but not as the primary control
for filling. § 178.338–16 Inspection and testing.
(2) The design pressure of each liquid
(a) General. The material of construc-
level gauging device must be at least
tion of a tank and its appurtenances
that of the tank.
(3) If a fixed length dip tube or must be inspected for conformance to
trycock line gauging device is used, it Section VIII of the ASME Code (IBR,
must consist of a pipe or tube of small see § 171.7 of this subchapter). The tank
diameter equipped with a valve at or must be subjected to either a hydro-
near the jacket and extending into the static or pneumatic test. The test pres-
cargo tank to a specified filling height. sure must be one and one-half times
The fixed height at which the tube ends the sum of the design pressure, plus
in the cargo tank must be such that static head of lading, plus 101.3 kPa
the device will function when the liq- (14.7 psi) if subjected to external vacu-
uid reaches the maximum level per- um, except that for tanks constructed
mitted in loading. in accordance with Part UHT in Sec-
(4) The liquid level gauging device tion VIII of the ASME Code the test
used as a primary control for filling pressure must be twice the design pres-
must be designed and installed to accu- sure.
rately indicate the maximum filling (b) Additional requirements for pneu-
level at the point midway of the tank matic test. A pneumatic test may be
both longitudinally and laterally. used in place of the hydrostatic test.
(b) Pressure gauges. Each cargo tank Due regard for protection of all per-
must be provided with a suitable pres- sonnel should be taken because of the
sure gauge indicating the lading pres- potential hazard involved in a pneu-
sure and located on the front of the matic test. The pneumatic test pres-
jacket so it can be read by the driver in sure in the tank must be reached by
gradually increasing the pressure to
the rear view mirror. Each gauge must
one-half of the test pressure. There-
have a reference mark at the cargo
after, the test pressure must be in-
tank design pressure or the set pres-
creased in steps of approximately one-
sure of the pressure relief valve or pres-
tenth of the test pressure until the re-
sure control valve, whichever is lowest.
quired test pressure has been reached.
(c) Orifices. All openings for dip tube
Then the pressure must be reduced to a
gauging devices and pressure gauges in
value equal to four-fifths of the test
flammable cryogenic liquid service
pressure and held for a sufficient time
must be restricted at or inside the
to permit inspection of the cargo tank
jacket by orifices no larger than 0.060-
for leaks.
inch diameter. Trycock lines, if pro- (c) Weld inspection. All tank shell or
vided, may not be greater than 1⁄2-inch head welds subject to pressure shall be
nominal pipe size. radiographed in accordance with Sec-
[Amdt. 178–77, 48 FR 27706, June 16, 1983, as tion VIII of the ASME Code. A tank
amended at 49 FR 24317, June 12, 1984] which has been subjected to inspection
by the magnetic particle method, the
§ 178.338–15 Cleanliness. liquid penetrant method, or any meth-
A cargo tank constructed for oxygen od involving a material deposit on the
service must be thoroughly cleaned to interior tank surface, must be cleaned
remove all foreign material in accord- to remove any such residue by scrub-
ance with CGA G–4.1 (IBR, see § 171.7 of bing or equally effective means, and all
this subchapter). All loose particles such residue and cleaning solution
from fabrication, such as weld beads, must be removed from the tank prior
dirt, grinding wheel debris, and other to final closure of the tank.
loose materials, must be removed prior (d) Defect repair. All cracks and other
to the final closure of the manhole of defects must be repaired as prescribed

the tank. Chemical or solvent cleaning in Section VIII of the ASME Code. The
with a material compatible with the welder and the welding procedure must
intending lading must be performed to be qualified in accordance with Section
158
IX of the ASME Code (IBR, see § 171.7 of means of forming letters into the
this subchapter). After repair, the tank metal of the plate, with the informa-
must again be postweld heat-treated, if tion required in paragraphs (b) and (c)
such heat treatment was previously of this section, in addition to that re-
performed, and the repaired areas must quired by Section VIII of the ASME
be retested. Code (IBR, see § 171.7 of this sub-
(e) Verification must be made of the chapter), in characters at least 3⁄16 inch
interior cleanliness of a tank con- high (parenthetical abbreviations may
structed for oxygen service by means be used). All plates must be maintained
that assure that all contaminants that in a legible condition.
are likely to react with the lading have (2) Each insulated cargo tank must
been removed as required by § 178.338– have additional plates, as described, at-
15. tached to the jacket in the location
[Amdt. 178–77, 48 FR 27706, June 16, 1983, as specified unless the specification plate
amended at 49 FR 24317, June 12, 1984; 49 FR is attached to the chassis and has the
42736, Oct. 24, 1984; 68 FR 75755, Dec. 31, 2003] information required in paragraphs (b)
and (c) of this section.
§ 178.338–17 Pumps and compressors. (3) The information required for both
(a) Liquid pumps and gas compressors, the name and specification plate may
if used, must be of suitable design, ade- be displayed on a single plate. If the in-
quately protected against breakage by formation required by this section is
collision, and kept in good condition. displayed on a plate required by Sec-
They may be driven by motor vehicle tion VIII of the ASME Code, the infor-
power take-off or other mechanical, mation need not be repeated on the
electrical, or hydraulic means. Unless name and specification plates.
they are of the centrifugal type, they (4) The specification plate may be at-
shall be equipped with suitable pres- tached to the cargo tank motor vehicle
sure actuated by-pass valves permit- chassis rail by brazing, welding, or
ting flow from discharge to suction to other suitable means on the left side
the tank. near the front head, in a place acces-
(b) A valve or fitting made of alu- sible for inspection. If the specification
minum with internal rubbing or abrad- plate is attached to the chassis rail,
ing aluminum parts that may come in then the cargo tank serial number as-
contact with oxygen (cryogenic liquid) signed by the cargo tank manufacturer
may not be installed on any cargo tank must be included on the plate.
used to transport oxygen (cryogenic
(b) Name plate. The following infor-
liquid) unless the parts are anodized in
mation must be marked on the name
accordance with ASTM B 580 (IBR, see
plate in accordance with this section:
§ 171.7 of this subchapter).
(1) DOT-specification number MC 338
[Amdt. 178–89, 54 FR 25020, June 12, 1989, as (DOT MC 338).
amended at 55 FR 37058, Sept. 7, 1990; 67 FR (2) Original test date (Orig, Test
61016, Sept. 27, 2002; 68 FR 75755, Dec. 31, 2003]
Date).
§ 178.338–18 Marking. (3) MAWP in psig.
(a) General. Each cargo tank certified (4) Cargo tank test pressure (Test P),
after October 1, 2004 must have a corro- in psig.
sion-resistant metal name plate (5) Cargo tank design temperature
(ASME Plate) and specification plate (Design Temp. Range) ll °F to ll
permanently attached to the cargo °F.
tank by brazing, welding, or other suit- (6) Nominal capacity (Water Cap.), in
able means on the left side near the pounds.
front, in a place accessible for inspec- (7) Maximum design density of lading
tion. If the specification plate is at- (Max. Lading density), in pounds per
tached directly to the cargo tank wall gallon.
by welding, it must be welded to the (8) Material specification number—
tank before the cargo tank is postweld shell (Shell matl, yyy * * *), where
heat treated. ‘‘yyy’’ is replaced by the alloy designa-
(1) The plates must be legibly marked tion and ‘‘* * *’’ is replaced by the
by stamping, embossing, or other alloy type.
159
§ 178.338–19 49 CFR Ch. I (10–1–18 Edition)
(9) Material specification number— (11) Cargo tank serial number (CT se-
heads (Head matl. yyy * * *), where rial), as assigned by cargo tank manu-
‘‘yyy’’ is replaced by the alloy designa- facturer, if applicable.
tion and ‘‘* * *’’ by the alloy type. NOTE 1 TO PARAGRAPH (c): See § 173.315(a) of
NOTE: When the shell and heads materials this chapter regarding water capacity.
are the same thickness, they may be com- NOTE 2 TO PARAGRAPH (c): When the shell
bined, (Shell & head matl, yyy * * *). and head materials are the same thickness,
they may be combined (Shell & head matl,
(10) Weld material (Weld matl.). yyy***).
(11) Minimum Thickness-shell (Min. (d) The design weight of lading used
Shell-thick), in inches. When minimum in determining the loading in §§ 178.338–
shell thicknesses are not the same for 3 (b), 178.338–10 (b) and (c), and 178.338–
different areas, show (top ll, side 13 (b), must be shown as the maximum
ll, bottom ll, in inches). weight of lading marking required by
(12) Minimum thickness-heads (Min paragraph (c) of this section.
heads thick.), in inches.
[68 FR 19283, Apr. 18, 2003, as amended at 68
(13) Manufactured thickness-shell FR 57634, Oct. 6, 2003; 68 FR 75755, Dec. 31,
(Mfd. Shell thick.), top ll, side ll, 2003]
bottom ll, in inches. (Required when
additional thickness is provided for § 178.338–19 Certification.
corrosion allowance.) (a) At or before the time of delivery,
(14) Manufactured thickness-heads the manufacturer of a cargo tank
(Mfd. Heads thick.), in inches. (Re- motor vehicle shall furnish to the
quired when additional thickness is owner of the completed vehicle the fol-
provided for corrosion allowance.) lowing:
(15) Exposed surface area, in square (1) The tank manufacturer’s data re-
feet. port as required by the ASME Code
(c) Specification plate. The following (IBR, see § 171.7 of this subchapter), and
information must be marked on the a certificate bearing the manufactur-
specification plate in accordance with er’s vehicle serial number stating that
this section: the completed cargo tank motor vehi-
(1) Cargo tank motor vehicle manu- cle conforms to all applicable require-
facturer (CTMV mfr.). ments of Specification MC 338, includ-
(2) Cargo tank motor vehicle certifi- ing Section VIII of the ASME Code
cation date (CTMV cert. date). (IBR, see § 171.7 of this subchapter) in
(3) Cargo tank manufacturer (CT effect on the date (month, year) of cer-
mfr.). tification. The registration numbers of
(4) Cargo tank date of manufacture the manufacturer, the Design Certi-
(CT date of mfr.), month and year. fying Engineer, and the Registered In-
spector, as appropriate, must appear on
(5) Maximum weight of lading (Max.
the certificates (see subpart F, part 107
Payload), in pounds.
in subchapter B of this chapter).
(6) Maximum loading rate in gallons (2) A photograph, pencil rub, or other
per minute (Max. Load rate, GPM). facsimile of the plates required by
(7) Maximum unloading rate in gal- paragraphs (a) and (b) of § 178.338-18.
lons per minute (Max Unload rate). (b) In the case of a cargo tank vehicle
(8) Lining materials (Lining), if ap- manufactured in two or more stages,
plicable. each manufacturer who performs a
(9) ‘‘Insulated for oxygen service’’ or manufacturing operation on the incom-
‘‘Not insulated for oxygen service’’ as plete vehicle or portion thereof shall
appropriate. furnish to the succeeding manufac-
(10) Marked rated holding time for at turer, at or before the time of delivery,
least one cryogenic liquid, in hours, a certificate covering the particular
and the name of that cryogenic liquid operation performed by that manufac-
(MRHT ll hrs, name of cryogenic liq- turer, and any certificates received
uid). Marked rated holding marking for from previous manufacturers, Reg-
additional cryogenic liquids may be istered Inspectors, and Design Certi-
displayed on or adjacent to the specifying Engineers. The certificates must
fication plate. include sufficient sketches, drawings,
160
and other information to indicate the Appurtenance means any cargo tank
location, make, model and size of each accessory attachment that has no lad-
valve and the arrangement of all piping ing retention or containment function
associated with the tank. Each certifi- and provides no structural support to
cate must be signed by an official of the cargo tank.
the manufacturing firm responsible for Baffle means a non-liquid-tight trans-
the portion of the complete cargo tank verse partition device that deflects,
vehicle represented thereby, such as checks or regulates fluid motion in a
basic tank fabrication, insulation, tank.
jacket, or piping. The final manufac- Bulkhead means a liquid-tight trans-
turer shall furnish the owner with all verse closure at the ends of or between
certificates, as well as the documents cargo tanks.
required by paragraph (a) of this sec- Charging line means a hose, tube,
tion. pipe, or similar device used to pres-
(c) The owner shall retain the data surize a tank with material other than
report, certificates, and related papers the lading.
throughout his ownership of the cargo Companion flange means one of two
tank. In the event of change of owner- mating flanges where the flange faces
ship, the prior owner shall retain non- are in contact or separated only by a
fading photographically reproduced thin leak sealing gasket and are se-
copies of these documents for at least cured to one another by bolts or
one year. Each operator using the clamps.
cargo tank vehicle, if not the owner Connecting structure means the struc-
thereof, shall obtain a copy of the data ture joining two cargo tanks.
report and the certificate or certifi- Constructed and certified in conform-
cates and retain them during the time ance with the ASME Code means the
he uses the cargo tank and for at least cargo tank is constructed and stamped
one year thereafter. in accordance with the ASME Code,
(Approved by the Office of Management and and is inspected and certified by an Au-
Budget under control number 2137–0017) thorized Inspector.
Constructed in accordance with the
[Amdt. 178–77, 48 FR 27707, 27713, June 16,
1983, as amended by Amdt. 178–89, 55 FR ASME Code means the cargo tank is
37058, Sept. 7, 1990; Amdt. 178–99, 58 FR 51534, constructed in accordance with the
Oct. 1, 1993; 62 FR 51561, Oct. 1, 1997; 68 FR ASME Code with the authorized excep-
75755, Dec. 31, 2003] tions (see §§ 178.346, 178.347, and 178.348)
and is inspected and certified by a Reg-
§§ 178.340–178.343 [Reserved] istered Inspector.
External self-closing stop-valve means
§ 178.345 General design and construc-
tion requirements applicable to a self-closing stop-valve designed so
Specification DOT 406 (§ 178.346), that the self-stored energy source is lo-
DOT 407 (§ 178.347), and DOT 412 cated outside the cargo tank and the
(§ 178.348) cargo tank motor vehi- welded flange.
cles. Extreme dynamic loading means the
maximum single-acting loading a cargo
§ 178.345–1 General requirements. tank motor vehicle may experience
(a) Specification DOT 406, DOT 407 during its expected life, excluding acci-
and DOT 412 cargo tank motor vehicles dent loadings.
must conform to the requirements of Flange means the structural ring for
this section in addition to the require- guiding or attachment of a pipe or fit-
ments of the applicable specification ting with another flange (companion
contained in §§ 178.346, 178.347 or 178.348. flange), pipe, fitting or other attach-
(b) All specification requirements are ment.
minimum requirements. Inspection pressure means the pres-
(c) Definitions. See § 178.320(a) for the sure used to determine leak tightness
definition of certain terms used in of the cargo tank when testing with
§§ 178.345, 178.346, 178.347, and 178.348. In pneumatic pressure.

addition, the following definitions Internal self-closing stop-valve means a
apply to §§ 178.345, 178.346, 178.347, and self-closing stop-valve designed so that
178.348: the self-stored energy source is located
161
§ 178.345–1 49 CFR Ch. I (10–1–18 Edition)
inside the cargo tank or cargo tank piping or devices in case of a rear end
sump, or within the welded flange, and collision.
the valve seat is located within the Sacrificial device means an element,
cargo tank or within one inch of the such as a shear section, designed to fail
external face of the welded flange or under a load in order to prevent dam-
sump of the cargo tank. age to any lading retention part or de-
Lading means the hazardous material vice. The device must break under
contained in a cargo tank. strain at no more than 70 percent of
Loading/unloading connection means the strength of the weakest piping ele-
the fitting in the loading/unloading ment between the cargo tank and the
line farthest from the loading/unload- sacrificial device. Operation of the sac-
ing outlet to which the loading/unload- rificial device must leave the remaining
ing hose or device is attached. piping and its attachment to the cargo
Loading/unloading outlet means the tank intact and capable of retaining
cargo tank outlet used for normal load- lading.
ing/unloading operations. Self-closing stop-valve means a stop-
Loading/unloading stop-valve means valve held in the closed position by
the stop valve farthest from the cargo means of self-stored energy, which
tank loading/unloading outlet to which opens only by application of an exter-
the loading/unloading connection is at- nal force and which closes when the ex-
tached. ternal force is removed.
MAWP. See § 178.320(a). Shear section means a sacrificial de-
Multi-specification cargo tank motor ve- vice fabricated in such a manner as to
hicle means a cargo tank motor vehicle abruptly reduce the wall thickness of
equipped with two or more cargo tanks the adjacent piping or valve material
fabricated to more than one cargo tank by at least 30 percent.
specification. Shell means the circumferential por-
Normal operating loading means the tion of a cargo tank defined by the
loading a cargo tank motor vehicle basic design radius or radii excluding
may be expected to experience rou- the closing heads.
tinely in operation. Stop-valve means a valve that stops
Nozzle means the subassembly con- the flow of lading.
sisting of a pipe or tubular section with Sump means a protrusion from the
or without a welded or forged flange on bottom of a cargo tank shell designed
one end. to facilitate complete loading and un-
Outlet means any opening in the shell loading of lading.
or head of a cargo tank, (including the Tank means a container, consisting
means for attaching a closure), except of a shell and heads, that forms a pres-
that the following are not outlets: A sure tight vessel having openings de-
threaded opening securely closed dur- signed to accept pressure tight fittings
ing transportation with a threaded or closures, but excludes any appur-
plug or a threaded cap, a flanged open- tenances, reinforcements, fittings, or
ing securely closed during transpor- closures.
tation with a bolted or welded blank Test pressure means the pressure to
flange, a manhole, or gauging devices, which a tank is subjected to determine
thermometer wells, and safety relief pressure integrity.
devices. Toughness of material means the capa-
Outlet stop-valve means the stop-valve bility of a material to absorb the en-
at the cargo tank loading/unloading ergy represented by the area under the
outlet. stress strain curve (indicating the en-
Pipe coupling means a fitting with in- ergy absorbed per unit volume of the
ternal threads on both ends. material) up to the point of rupture.
Rear bumper means the structure de- Vacuum cargo tank means a cargo
signed to prevent a vehicle or object tank that is loaded by reducing the
from under-riding the rear of a motor pressure in the cargo tank to below at-
vehicle. See § 393.86 of this title. mospheric pressure.

Rear-end tank protection device means Variable specification cargo tank
the structure designed to protect a means a cargo tank that is constructed
cargo tank and any lading retention in accordance with one specification,
162
but which may be altered to meet an- in all respects with the specification
other specification by changing relief for which it is certified.
device, closures, lading discharge de- (2) The strength of the connecting
vices, and other lading retention de- structure joining multiple cargo tanks
vices. in a cargo tank motor vehicle must
Void means the space between tank meet the structural design require-
heads or bulkheads and a connecting ments in § 178.345–3. Any void within
structure. the connecting structure must be
Welded flange means a flange at- equipped with a drain located on the
tached to the tank by a weld joining bottom centerline that is accessible
the tank shell to the cylindrical outer and kept open at all times. For carbon
surface of the flange, or by a fillet weld steel, self-supporting cargo tanks, the
joining the tank shell to a flange drain configuration may consist of a
shaped to fit the shell contour. single drain of at least 1.0 inch diame-
(d) A manufacturer of a cargo tank ter, or two or more drains of at least
must hold a current ASME certificate 0.5 inch diameter, 6.0 inches apart, one
of authorization and must be registered of which is located as close to the bot-
with the Department in accordance tom centerline as practicable. Vapors
with part 107, subpart F of this chapter. trapped in a void within the connecting
(e) All construction must be certified structure must be allowed to escape to
by an Authorized Inspector or by a the atmosphere either through the
Registered Inspector as applicable to drain or a separate vent.
the cargo tank. (j) Variable specification cargo tank. A
(f) Each cargo tank must be designed cargo tank that may be physically al-
and constructed in conformance with tered to conform to another cargo tank
the requirements of the applicable specification must have the required
cargo tank specification. Each DOT 412 physical alterations to convert from
cargo tank with a ‘‘MAWP’’ greater one specification to another clearly in-
than 15 psig, and each DOT 407 cargo dicated on the variable specification
tank with a maximum allowable work- plate.
ing pressure greater than 35 psig must
[Amdt. 178–89, 54 FR 25020, June 12, 1989, as
be ‘‘constructed and certified in con- amended at 55 FR 37058, Sept. 7, 1990; Amdt.
formance with Section VIII of the 178–105, 59 FR 55173, Nov. 3, 1994; Amdt. 178–
ASME Code’’ (IBR, see § 171.7 of this 118, 61 FR 51340, Oct. 1, 1996; 66 FR 45387,
subchapter) except as limited or modi- 45389, Aug. 28, 2001; 68 FR 19283, Apr. 18, 2003;
fied by the applicable cargo tank speci- 68 FR 52371, Sept. 3, 2003; 68 FR 75755, Dec. 31,
fication. Other cargo tanks must be 2003; 70 FR 56099, Sept. 23, 2005; 76 FR 43532,
‘‘constructed in accordance with Sec- July 20, 2011]
tion VIII of the ASME Code,’’ except as
§ 178.345–2 Material and material
limited or modified by the applicable thickness.
cargo tank specification.
(g) Requirements relating to parts (a) All material for shell, heads,
and accessories on motor vehicles, bulkheads, and baffles must conform to
which are contained in part 393 of the Section II of the ASME Code (IBR, see
Federal Motor Carrier Safety Regula- § 171.7 of this subchapter) except as fol-
tions of this title, are incorporated lows:
into these specifications. (1) The following steels are also au-
(h) Any additional requirements pre- thorized for cargo tanks ‘‘constructed
scribed in part 173 of this subchapter in accordance with the ASME Code’’,
that pertain to the transportation of a Section VIII.
specific lading are incorporated into ASTM A 569
these specifications. ASTM A 570
(i) Cargo tank motor vehicle composed ASTM A 572
of multiple cargo tanks. (1) A cargo tank ASTM A 622
motor vehicle composed of more than ASTM A 656
ASTM A 715
one cargo tank may be constructed

ASTM A 1008/ A 1008M, ASTM A 1011/A 1011M
with the cargo tanks made to the same
specification or to different specifica- (2) Aluminum alloys suitable for fu-
tions. Each cargo tank must conform sion welding and conforming with the
163
§ 178.345–3 49 CFR Ch. I (10–1–18 Edition)
0, H32 or H34 tempers of one of the fol- together, or by other satisfactory

lowing ASTM specifications may be means.
used for cargo tanks ‘‘constructed in [Amdt. 178–89, 54 FR 25021, June 12, 1989, as
accordance with the ASME Code’’: amended at 55 FR 37059, Sept. 7, 1990; 56 FR
27876, June 17, 1991; Amdt. 178–97, 57 FR 45465,
ASTM B–209 Alloy 5052
Oct. 1, 1992; Amdt. 178–118, 61 FR 51341, Oct.
ASTM B–209 Alloy 5086 1, 1996; 68 FR 19283, Apr. 18, 2003; 68 FR 75755,
ASTM B–209 Alloy 5154 Dec. 31, 2003; 70 FR 34076, June 13, 2005]
ASTM B–209 Alloy 5454 § 178.345–3 Structural integrity.
(a) General requirements and accept-
All heads, bulkheads and baffles must ance criteria. (1) The maximum cal-
be of 0 temper (annealed) or stronger culated design stress at any point in
tempers. All shell materials shall be of the cargo tank wall may not exceed the
maximum allowable stress value pre-
H 32 or H 34 tempers except that the
scribed in Section VIII of the ASME
lower ultimate strength tempers may
Code (IBR, see § 171.7 of this sub-
be used if the minimum shell
chapter), or 25 percent of the tensile
thicknesses in the tables are increased strength of the material used at design
in inverse proportion to the lesser ulti- conditions.
mate strength. (2) The relevant physical properties
(b) Minimum thickness. The minimum of the materials used in each cargo
thickness for the shell and heads (or tank may be established either by a
baffles and bulkheads when used as certified test report from the material
tank reinforcement) must be no less manufacturer or by testing in conform-
than that determined under criteria for ance with a recognized national stand-
minimum thickness specified in ard. In either case, the ultimate tensile
§ 178.320(a). strength of the material used in the de-
(c) Corrosion or abrasion protection. sign may not exceed 120 percent of the
When required by 49 CFR part 173 for a minimum ultimate tensile strength
particular lading, a cargo tank or a specified in either the ASME Code or
part thereof, subject to thinning by the ASTM standard to which the mate-
corrosion or mechanical abrasion due rial is manufactured.
to the lading, must be protected by (3) The maximum design stress at
providing the tank or part of the tank any point in the cargo tank must be
with a suitable increase in thickness of calculated separately for the loading
conditions described in paragraphs (b)
material, a lining or some other suit-
and (c) of this section. Alternate test
able method of protection.
or analytical methods, or a combina-
(1) Corrosion allowance. Material tion thereof, may be used in place of
added for corrosion allowance need not the procedures described in paragraphs
be of uniform thickness if different (b) and (c) of this section, if the meth-
rates of attack can reasonably be ex- ods are accurate and verifiable. TTMA
pected for various areas of the cargo RP 96–01, Structural Integrity of DOT
tank. 406, DOT 407, and DOT 412 Cylindrical
(2) Lining. Lining material must con- Cargo Tanks, may be used as guidance
sist of a nonporous, homogeneous main performing the calculations.
terial not less elastic than the parent (4) Corrosion allowance material may
metal and substantially immune to at- not be included to satisfy any of the
tack by the lading. The lining material design calculation requirements of this
must be bonded or attached by other section.
appropriate means to the cargo tank (b) ASME Code design and construc-
wall and must be imperforate when ap- tion. The static design and construc-
plied. Any joint or seam in the lining tion of each cargo tank must be in ac-
must be made by fusing the materials cordance 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
164
supported by the cargo tank wall and and normal operating loadings that can
the effect of temperature gradients re- occur at the same time, in psi.
sulting from lading and ambient tem- (ii) Sy = circumferential stress gen-
perature extremes. When dissimilar erated by the MAWP and external pres-
materials are used, their thermal coef- sure, when applicable, plus static head,
ficients must be used in the calculation in psi.
of thermal stresses. (iii) Sx = The following net longitu-
(1) Stress concentrations in tension, dinal stress generated by the following
bending and torsion which occur at static and normal operating loading
pads, cradles, or other supports must conditions, in psi:
be considered in accordance with ap- (A) The longitudinal stresses result-
pendix G in Section VIII of the ASME ing from the MAWP and external pres-
Code. sure, when applicable, plus static head,
(2) Longitudinal compressive buck- in combination with the bending stress
ling stress for ASME certified vessels generated by the static weight of the
must be calculated using paragraph fully loaded cargo tank motor vehicle,
UG–23(b) in Section VIII of the ASME all structural elements, equipment and
Code. For cargo tanks not required to appurtenances supported by the cargo
be certified in accordance with the tank wall;
ASME Code, compressive buckling (B) The tensile or compressive stress
stress may be calculated using alter- resulting from normal operating longi-
native analysis methods which are ac- tudinal acceleration or deceleration. In
curate and verifiable. When alternative each case, the forces applied must be
methods are used, calculations must 0.35 times the vertical reaction at the
include both the static loads described suspension assembly, applied at the
in this paragraph and the dynamic road surface, and as transmitted to the
loads described in paragraph (c) of this cargo tank wall through the suspension
section. assembly of a trailer during decelera-
tion; or the horizontal pivot of the
(3) Cargo tank designers and manu-
truck tractor or converter dolly fifth
facturers must consider all of the con-
wheel, or the drawbar hinge on the
ditions specified in § 173.33(c) of this
fixed dolly during acceleration; or an-
subchapter when matching a cargo
choring and support members of a
tank’s performance characteristic to
truck during acceleration and decelera-
the characteristic of each lading trans-
tion, as applicable. The vertical reac-
ported.
tion must be calculated based on the
(c) Shell design. Shell stresses result-
static weight of the fully loaded cargo
ing from static or dynamic loadings, or
tank motor vehicle, all structural ele-
combinations thereof, are not uniform
ments, equipment and appurtenances
throughout the cargo tank motor vehi-
supported by the cargo tank wall. The
cle. The vertical, longitudinal, and lat-
following loadings must be included:
eral normal operating loadings can
(1) The axial load generated by a
occur simultaneously and must be
decelerative force;
combined. The vertical, longitudinal
(2) The bending moment generated by
and lateral extreme dynamic loadings
a decelerative force;
occur separately and need not be com-
(3) The axial load generated by an ac-
bined.
celerative force; and
(1) Normal operating loadings. The fol- (4) The bending moment generated by
lowing procedure addresses stress in an accelerative force; and
the cargo tank shell resulting from (C) The tensile or compressive stress
normal operating loadings. The effec- generated by the bending moment re-
tive stress (the maximum principal sulting from normal operating vertical
stress at any point) must be deter- accelerative force equal to 0.35 times
mined by the following formula: the vertical reaction at the suspension
S = 0.5(Sy + SX) ± [0.25(Sy ¥ SX)2 + SS2]0.5 assembly of a trailer; or the horizontal
pivot of the upper coupler (fifth wheel)

Where: or turntable; or anchoring and support
(i) S = effective stress at any given members of a truck, as applicable. The
point under the combination of static vertical reaction must be calculated
165
§ 178.345–3 49 CFR Ch. I (10–1–18 Edition)
based on the static weight of the fully treme dynamic loadings. The effective
loaded cargo tank motor vehicle, all stress (the maximum principal stress
structural elements, equipment and ap- at any point) must be determined by
purtenances supported by the cargo the following formula:
tank wall.
S = 0.5(Sy + Sx) ±[0.25(Sy ¥ Sx)2 + SS2]0.5
(iv) SS = The following shear stresses
generated by the following static and Where:
normal operating loading conditions,
(i) S = effective stress at any given
in psi:
point under a combination of static
(A) The static shear stress resulting
and extreme dynamic loadings that can
from the vertical reaction at the sus-
occur at the same time, in psi.
pension assembly of a trailer, and the
horizontal pivot of the upper coupler (ii) Sy = circumferential stress gen-
(fifth wheel) or turntable; or anchoring erated by MAWP and external pressure,
and support members of a truck, as ap- when applicable, plus static head, in
plicable. The vertical reaction must be psi.
calculated based on the static weight (iii) Sx = the following net longitu-
of the fully loaded cargo tank motor dinal stress generated by the following
vehicle, all structural elements, equip- static and extreme dynamic loading
ment and appurtenances supported by conditions, in psi:
the cargo tank wall; (A) The longitudinal stresses result-
(B) The vertical shear stress gen- ing from the MAWP and external pres-
erated by a normal operating accelera- sure, when applicable, plus static head,
tive force equal to 0.35 times the in combination with the bending stress
vertical reaction at the suspension as- generated by the static weight of the
sembly of a trailer; or the horizontal fully loaded cargo tank motor vehicle,
pivot of the upper coupler (fifth wheel) all structural elements, equipment and
or turntable; or anchoring and support appurtenances supported by the tank
members of a truck, as applicable. The wall;
vertical reaction must be calculated (B) The tensile or compressive stress
based on the static weight of the fully resulting from extreme longitudinal
loaded cargo tank motor vehicle, all acceleration or deceleration. In each
structural elements, equipment and ap- case the forces applied must be 0.7
purtenances supported by the cargo times the vertical reaction at the sus-
tank wall; pension assembly, applied at the road
(C) The lateral shear stress generated surface, and as transmitted to the
by a normal operating lateral accelera- cargo tank wall through the suspension
tive force equal to 0.2 times the assembly of a trailer during decelera-
vertical reaction at each suspension as- tion; or the horizontal pivot of the
sembly of a trailer, applied at the road truck tractor or converter dolly fifth
surface, and as transmitted to the wheel, or the drawbar hinge on the
cargo tank wall through the suspension fixed dolly during acceleration; or the
assembly of a trailer, and the hori- anchoring and support members of a
zontal pivot of the upper coupler (fifth truck during acceleration and decelera-
wheel) or turntable; or anchoring and tion, as applicable. The vertical reac-
support members of a truck, as application must be calculated based on the
ble. The vertical reaction must be cal- static weight of the fully loaded cargo
culated based on the static weight of tank motor vehicle, all structural ele-
the fully loaded cargo tank motor vehi- ments, equipment and appurtenances
cle, all structural elements, equipment supported by the cargo tank wall. The
and appurtenances supported by the following loadings must be included:
cargo tank wall; and (1) The axial load generated by a
(D) The torsional shear stress gen- decelerative force;
erated by the same lateral forces as de- (2) The bending moment generated by
scribed in paragraph (c)(1)(iv)(C) of this a decelerative force;
section. (3) The axial load generated by an ac-

(2) Extreme dynamic loadings. The fol- celerative force; and
lowing procedure addresses stress in (4) The bending moment generated by
the cargo tank shell resulting from ex- an accelerative force; and
166
(C) The tensile or compressive stress purtenances supported by the cargo

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

based on the static weight of the fully cargo tank wall must be made by at-
loaded cargo tank motor vehicle, all tachment of a mounting pad so that
structural elements, equipment and ap- there will be no adverse effect upon the
167
§ 178.345–4 49 CFR Ch. I (10–1–18 Edition)
lading retention integrity of the cargo § 178.345–4 Joints.

tank if any force less than that pre-
(a) All joints between the cargo tank
scribed in paragraph (b)(1) of this sec-
shell, heads, baffles, baffle attaching
tion is applied from any direction. The
rings, and bulkheads must be welded in
thickness of the mounting pad may not
conformance with Section VIII of the
be less than that of the shell or head to
ASME Code (IBR, see § 171.7 of this sub-
which it is attached, and not more
chapter).
than 1.5 times the shell or head thick-
(b) Where practical all welds must be
ness. However, a pad with a minimum
easily accessible for inspection.
thickness of 0.187 inch may be used
when the shell or head thickness is [Amdt. 178–89, 54 FR 25022, June 12, 1989, as
over 0.187 inch. If weep holes or tell- amended by Amdt. 178–118, 61 FR 51341, Oct.
tale holes are used, the pad must be 1, 1996; 68 FR 75756, Dec. 31, 2003]
drilled or punched at the lowest point
before it is welded to the tank. Each § 178.345–5 Manhole assemblies.
pad must: (a) Each cargo tank with capacity
(i) Be fabricated from material deter- greater than 400 gallons must be acces-
mined to be suitable for welding to sible through a manhole at least 15
both the cargo tank material and the inches in diameter.
material of the appurtenance or struc- (b) Each manhole, fill opening and
tural support member; a Design Certi- washout assembly must be structurally
fying Engineer must make this deter- capable of withstanding, without leak-
mination considering chemical and age or permanent deformation that
physical properties of the materials would affect its structural integrity, a
and must specify filler material con- static internal fluid pressure of at least
forming to the requirements of the 36 psig, or cargo tank test pressure,
ASME Code (incorporated by reference; whichever is greater. The manhole as-
see § 171.7 of this subchapter). sembly manufacturer shall verify com-
(ii) Be preformed to an inside radius pliance with this requirement by
no greater than the outside radius of hydrostatically testing at least one
the cargo tank at the attachment loca- percent (or one manhole closure,
tion. whichever is greater) of all manhole
(iii) Extend at least 2 inches in each closures of each type produced each 3
direction from any point of attachment months, as follows:
of an appurtenance or structural sup- (1) The manhole, fill opening, or
port member. This dimension may be washout assembly must be tested with
measured from the center of the struc- the venting devices blocked. Any leak-
tural member attached. age or deformation that would affect
(iv) Have rounded corners, or other- the product retention capability of the
wise be shaped in a manner to mini- assembly shall constitute a failure.
mize stress concentrations on the shell (2) If the manhole, fill opening, or
or head. washout assembly tested fails, then
five more covers from the same lot
(v) Be attached by continuous fillet
must be tested. If one of these five cov-
welding. Any fillet weld discontinuity
ers fails, then all covers in the lot from
may only be for the purpose of pre-
which the tested covers were selected
venting an intersection between the fil-
are to be 100% tested or rejected for
let weld and the tank or jacket seam
service.
weld.
(c) Each manhole, filler and washout
[Amdt. 178–89, 55 FR 37059, Sept. 7, 1990, as cover must be fitted with a safety de-
amended by Amdt. 178–89, 56 FR 27876, June vice that prevents the cover from open-
17, 1991; Amdt. 178–104, 59 FR 49135, Sept. 26, ing fully when internal pressure is
1994; Amdt. 178–105, 59 FR 55173, 55174, 55175, present.
Nov. 3, 1994; 60 FR 17402, Apr. 5, 1995; Amdt.
178–118, 61 FR 51341, Oct. 1, 1996; 65 FR 58631,
(d) Each manhole and fill cover must
Sept. 29, 2000; 68 FR 19283, Apr. 18, 2003; 68 FR be secured with fastenings that will
75755, Dec. 31, 2003; 74 FR 16143, Apr. 9, 2009; prevent opening of the covers as a re-
78 FR 60755, Oct. 2, 2013; 81 FR 35545, June 2, sult of vibration under normal trans-
2016] portation conditions or shock impact
168
due to a rollover accident on the road- as generated by the loads described in

way or shoulder where the fill cover is § 178.345–3(c).
not struck by a substantial obstacle. [Amdt. 178–89, 54 FR 25023, June 12, 1989, as
(e) On cargo tank motor vehicles amended by Amdt. 178–105, 59 FR 55175, Nov.
manufactured after October 1, 2004, 3, 1994; Amdt. 178–118, 61 FR 51341, Oct. 1,
each manhole assembly must be per- 1996]
manently marked on the outside by
stamping or other means in a location § 178.345–7 Circumferential reinforce-
ments.
visible without opening the manhole
assembly or fill opening, with: (a) A cargo tank with a shell thick-
(1) Manufacturer’s name; ness of less than 3⁄8 inch must be cir-
(2) Test pressure ll psig; cumferentially reinforced with bulk-
heads, baffles, ring stiffeners, or any
(3) A statement certifying that the
combination thereof, in addition to the
manhole cover meets the requirements
cargo tank heads.
in § 178.345–5.
(1) Circumferential reinforcement
(f) All components mounted on a must be located so that the thickness
manhole cover that form part of the and tensile strength of the shell mate-
lading retention structure of the cargo rial in combination with the frame and
tank wall must withstand the same reinforcement produces structural in-
static internal fluid pressure as that tegrity at least equal to that pre-
required for the manhole cover. The scribed in § 178.345–3 and in such a man-
component manufacturer shall verify ner that the maximum unreinforced
compliance using the same test proce- portion of the shell does not exceed 60
dure and frequency of testing as speci- inches. For cargo tanks designed to be
fied in § 178.345–5(b). loaded by vacuum, spacing of circum-
[Amdt. 178–89, 54 FR 25022, June 12, 1989, as ferential reinforcement may exceed 60
amended by Amdt. 178–105, 59 FR 55175, Nov. inches provided the maximum
3, 1994; 68 FR 19284, Apr. 18, 2003; 74 FR 16144, unreinforced portion of the shell con-
Apr. 9, 2009] forms with the requirements in Section
VIII of the ASME Code (IBR, see § 171.7
§ 178.345–6 Supports and anchoring. of this subchapter).
(a) A cargo tank with a frame not in- (2) Where circumferential joints are
tegral to the cargo tank must have the made between conical shell sections, or
tank secured by restraining devices to between conical and cylindrical shell
sections, and the angle between adja-
eliminate any motion between the
cent sections is less than 160 degrees,
tank and frame that may abrade the
circumferential reinforcement must be
tank shell due to the stopping, start-
located within one inch of the shell
ing, or turning of the cargo tank motor
joint, unless otherwise reinforced with
vehicle. The design calculations of the
structural members capable of main-
support elements must include the taining shell stress levels authorized in
stresses indicated in § 178.345–3(b) and § 178.345–3. When the joint is formed by
as generated by the loads described in the large ends of adjacent conical shell
§ 178.345–3(c). Such restraining devices sections, or by the large end of a con-
must be readily accessible for inspec- ical shell and a cylindrical shell sec-
tion and maintenance, except that in- tion, this angle is measured inside the
sulation and jacketing are permitted to shell; when the joint is formed by the
cover the restraining devices. small end of a conical shell section and
(b) A cargo tank designed and con- a cylindrical shell section, it is meas-
structed so that it constitutes, in ured outside the shell.
whole or in part, the structural mem- (b) Except for doubler plates and
ber used in lieu of a frame must be sup- knuckle pads, no reinforcement may
ported in such a manner that the re- cover any circumferential joint.
sulting stress levels in the cargo tank (c) When a baffle or baffle attach-
do not exceed those specified in ment ring is used as a circumferential

§ 178.345–3(a). The design calculations of reinforcement member, it must
the support elements must include the produce structural integrity at least
stresses indicated in § 178.345–3(b) and equal to that prescribed in § 178.345–3
169
§ 178.345–8 49 CFR Ch. I (10–1–18 Edition)
and must be circumferentially welded (4) If configuration of internal or ex-

to the cargo tank shell. The welded ternal ring stiffener encloses an air
portion may not be less than 50 percent space, this air space must be arranged
of the total circumference of the cargo for venting and be equipped with drain-
tank and the length of any unwelded age facilities which must be kept oper-
space on the joint may not exceed 40 ative at all times.
times the shell thickness unless rein- (5) Hat shaped or open channel ring
forced external to the cargo tank. stiffeners which prevent visual inspec-
(d) When a ring stiffener is used as a tion of the cargo tank shell are prohib-
circumferential reinforcement mem- ited on cargo tank motor vehicles con-
ber, whether internal or external, rein- structed of carbon steel.
forcement must be continuous around
[Amdt. 178–89, 55 FR 37060, Sept. 7, 1990, as
the circumference of the cargo tank amended by Amdt. 178–89, 56 FR 27876, June
shell and must be in accordance with 17, 1991; 56 FR 46354, Sept. 11, 1991; Amdt. 178–
the following: 104, 59 FR 49135, Sept. 26, 1994; Amdt. 178–118,
(1) The section modulus about the 61 FR 51341, Oct. 1, 1996; 68 FR 75756, Dec. 31,
neutral axis of the ring section parallel 2003]
to the shell must be at least equal to
that derived from the applicable for- § 178.345–8 Accident damage protec-
mula: tion.
I/C = 0.00027WL, for MS, HSLA and SS; (a) General. Each cargo tank motor
or vehicle must be designed and con-
I/C = 0.000467WL, for aluminum alloys; structed in accordance with the re-
quirements of this section and the ap-
Where: plicable individual specification to
I/C = Section modulus in inches 3 minimize the potential for the loss of
W = Tank width, or diameter, inches lading due to an accident.
L = Spacing of ring stiffener, inches; i.e., the (1) Any dome, sump, or washout
maximum longitudinal distance from the
midpoint of the unsupported shell on one
cover plate projecting from the cargo
side of the ring stiffener to the midpoint tank wall that retains lading in any
of the unsupported shell on the opposite tank orientation, must be as strong
side of the ring stiffener. and tough as the cargo tank wall and
have a thickness at least equal to that
(2) If a ring stiffener is welded to the
specified by the appropriate cargo tank
cargo tank shell, a portion of the shell
specification. Any such projection lo-
may be considered as part of the ring
cated in the lower 1⁄3 of the tank cir-
section for purposes of computing the
cumference (or cross section perimeter
ring section modulus. This portion of
for non-circular cargo tanks) that ex-
the shell may be used provided at least
tends more than half its diameter at
50 percent of the total circumference of
the point of attachment to the tank or
the cargo tank is welded and the length
more than 4 inches from the cargo tank
of any unwelded space on the joint does
wall, or located in the upper 2⁄3 of the
not exceed 40 times the shell thickness.
tank circumference (or cross section
The maximum portion of the shell to
perimeter for non-circular cargo tanks)
be used in these calculations is as fol-
that extends more than 1⁄4 its diameter
lows:
or more than 2 inches from the point of
Number of circum- Shell sec-
attachment to the tank must have ac-
ferential ring stiffener- J1 cident damage protection devices that
tion
to-shell welds
are:
1 .................................. ..................................... 20t (i) As specified in this section;
2 .................................. Less than 20t ............. 20t + J
2 .................................. 20t or more ................. 40t
(ii) 125 percent as strong as the other-
1 where:
wise required accident damage protec-
t = Shell thickness, inches; tion device; or
J = Longitudinal distance between parallel circumferential (iii) Attached to the cargo tank in
ring stiffener-to-shell welds.
accordance with the requirements of
(3) When used to meet the vacuum re- paragraph (a)(3) of this section.
quirements of this section, ring stiff- (2) Outlets, valves, closures, piping,
eners must be as prescribed in Section or any devices that if damaged in an
VIII of the ASME Code. accident could result in a loss of lading
170
from the cargo tank must be protected be calculated at the gross vehicle
by accident damage protection devices weight rating of the cargo tank motor
as specified in this section. vehicle.
(3) Accident damage protection de- (b) Each outlet, projection or piping
vices attached to the wall of a cargo located in the lower 1⁄3 of the cargo
tank must be able to withstand or de- tank circumference (or cross section
flect away from the cargo tank the perimeter for non-circular cargo tanks)
loads specified in this section. They that could be damaged in an accident
must be designed, constructed and in- that may result in the loss of lading
stalled so as to maximize the distribu- must be protected by a bottom damage
tion of loads to the cargo tank wall and protection device, except as provided
to minimize the possibility of ad- by paragraph (a)(1) of this section and
versely affecting the lading retention § 173.33(e) of this subchapter. Outlets,
integrity of the cargo tank. Accident projections and piping may be grouped
induced stresses resulting from the ap- or clustered together and protected by
propriate accident damage protection a single protection device.
device requirements in combination (1) Any bottom damage protection
with the stresses from the cargo tank device must be able to withstand a
operating at the MAWP may not result force of 155,000 pounds (based on the ul-
in a cargo tank wall stress greater timate strength of the material) from
than the ultimate strength of the ma- the front, side, or rear, uniformly dis-
terial of construction using a safety tributed over each surface of the de-
factor of 1.3. Deformation of the pro- vice, over an area not to exceed 6
tection device is acceptable provided square feet, and a width not to exceed
the devices being protected are not 6 feet. Suspension components and
damaged when loads specified in this structural mounting members may be
section are applied. used to provide all, or part, of this pro-
(4) Any piping that extends beyond tection. The device must extend no less
an accident damage protection device than 6 inches beyond any component
must be equipped with a stop-valve and that may contain lading in transit.
a sacrificial device such as a shear sec- (2) A lading discharge opening
tion. The sacrificial device must be lo- equipped with an internal self-closing
cated in the piping system outboard of stop-valve need not conform to para-
the stop-valve and within the accident graph (b)(1) of this section provided it
damage protection device to prevent is protected so as to reasonably assure
any accidental loss of lading. The de- against the accidental loss of lading.
vice must break at no more than 70 This protection must be provided by a
percent of the load that would be re- sacrificial device located outboard of
quired to cause the failure of the pro- each internal self-closing stop-valve
tected lading retention device, part or and within 4 inches of the major radius
cargo tank wall. The failure of the sac- of the cargo tank shell or within 4
rificial device must leave the protected inches of a sump, but in no case more
lading retention device and its attach- than 8 inches from the major radius of
ment to the cargo tank wall intact and the tank shell. The device must break
capable of retaining product. at no more than 70 percent of the load
(5) Minimum road clearance. The min- that would be required to cause the
imum road clearance of any cargo tank failure of the protected lading reten-
motor vehicle component or protection tion device, part or cargo tank wall.
device located between any two adja- The failure of the sacrificial device
cent axles on a vehicle or vehicle com- must leave the protected lading reten-
bination must be at least one-half inch tion device or part and its attachment
for each foot separating the component to the cargo tank wall intact and capa-
or device from the nearest axle of the ble of retaining product.
adjacent pair, but in no case less than (c) Each closure for openings, includ-
twelve (12) inches, except that the mining but not limited to the manhole,
imum road clearance for landing gear filling or inspection openings, and each
or other attachments within ten (10) valve, fitting, pressure relief device,
feet of an axle must be no less than ten vapor recovery stop valve or lading re-
(10) inches. These measurements must taining fitting located in the upper 2⁄3
171
§ 178.345–8 49 CFR Ch. I (10–1–18 Edition)
of a cargo tank circumference (or cross during transit and with any part of the
section perimeter for non-circular rear-end protection device, or with a
tanks) must be protected by being lo- vertical plane passing through the out-
cated within or between adjacent roll- board surface of the protection device.
over damage protection devices, or by (2) The dimensions of the rear-end
being 125 percent of the strength that cargo tank protection device shall con-
would be provided by the otherwise re- form to the following:
quired damage protection device. (i) The bottom surface of the rear-end
(1) A rollover damage protection de- protection device must be at least 4
vice on a cargo tank motor vehicle inches below the lower surface of any
must be designed and installed to with- part at the rear of the cargo tank
stand loads equal to twice the weight motor vehicle which contains lading
of the loaded cargo tank motor vehicle during transit and not more than 60
applied as follows: normal to the cargo inches from the ground when the vehi-
tank shell (perpendicular to the cargo cle is empty.
tank surface); and tangential (perpen- (ii) The maximum width of a notch,
dicular to the normal load) from any indentation, or separation between sec-
direction. The stresses shall not exceed tions of a rear-end cargo tank protec-
the ultimate strength of the material tion device may not exceed 24 inches. A
of construction. These design loads notched, indented, or separated rear-
may be considered to be uniformly dis- end protection device may be used only
tributed and independently applied. If when the piping at the rear of the
more than one rollover protection de- cargo tank is equipped with a sacrifi-
vice is used, each device must be capa- cial device outboard of a shut-off valve.
ble of carrying its proportionate share (iii) The widest part of the motor ve-
of the required loads and in each case hicle at the rear may not extend more
at least one-fourth the total tangential than 18 inches beyond the outermost
load. The design must be proven capa- ends of the device or (if separated) de-
ble of carrying the required loads by vices on either side of the vehicle.
calculations, tests or a combination of (3) The structure of the rear-end pro-
tests and calculations. tection device and its attachment to
(2) A rollover damage protection de- the vehicle must be designed to satisfy
vice that would otherwise allow the ac- the conditions specified in paragraph
cumulation of liquid on the top of the (d)(1) of this section when subjected to
cargo tank, must be provided with a an impact of the cargo tank motor ve-
drain that directs the liquid to a safe hicle at rated payload, at a decelera-
point of discharge away from any tion of 2 ‘‘g’’. Such impact must be
structural component of the cargo considered as being uniformly applied
tank motor vehicle. in the horizontal plane at an angle of
(d) Rear-end tank protection. Each 10 degrees or less to the longitudinal
cargo tank motor vehicle must be pro- axis of the vehicle.
vided with a rear-end tank protection (e) Longitudinal deceleration protec-
device to protect the cargo tank and tion. In order to account for stresses
piping in the event of a rear-end colli- due to longitudinal impact in an acci-
sion and reduce the likelihood of dam- dent, the cargo tank shell and heads
age that could result in the loss of lad- must be able to withstand the load re-
ing. Nothing in this paragraph relieves sulting from the design pressure in
the manufacturer of responsibility for combination with the dynamic pres-
complying with the requirements of sure resulting from a longitudinal de-
§ 393.86 of this title and, if applicable, celeration of 2 ‘‘g’’. For this loading
paragraph (b) of this section. The rear- condition, the allowable stress value
end tank protection device must con- used may not exceed the ultimate
form to the following requirements: strength of the material of construc-
(1) The rear-end cargo tank protection using a safety factor of 1.3. Per-
tion device must be designed so that it formance testing, analytical methods,
can deflect at least 6 inches hori- or a combination thereof, may be used

zontally forward with no contact be- to prove this capability provided the
tween any part of the cargo tank methods are accurate and verifiable.
motor vehicle which contains lading For cargo tanks with internal baffles,
172
the decelerative force may be reduced ment is located outboard of the lading
by 0.25 ‘‘g’’ for each baffle assembly, retention system.
but in no case may the total reduction
[Amdt. 178–89, 54 FR 25025, June 12, 1989, as
in decelerative force exceed 1.0 ‘‘g’’. amended at 55 FR 37061, Sept. 7, 1990, Amdt.
[Amdt. 178–89, 54 FR 25023, June 12, 1989, as 178–89, 56 FR 27877, June 17, 1991; Amdt. 178–
amended at 55 FR 37061, Sept. 7, 1990; Amdt. 118, 61 FR 51341, Oct. 1, 1996]
178–105, 59 FR 55175, Nov. 3, 1994; Amdt. 178–
118, 61 FR 51341, Oct. 1, 1996; 68 FR 19284, Apr. § 178.345–10 Pressure relief.
18, 2003] (a) Each cargo tank must be equipped
to relieve pressure and vacuum condi-
§ 178.345–9 Pumps, piping, hoses and tions in conformance with this section
connections.
and the applicable individual specifica-
(a) Suitable means must be provided tion. The pressure and vacuum relief
during loading or unloading operations system must be designed to operate
to ensure that pressure within a cargo and have sufficient capacity to prevent
tank does not exceed test pressure. cargo tank rupture or collapse due to
(b) Each hose, piping, stop-valve, lad- over-pressurization or vacuum result-
ing retention fitting and closure must ing from loading, unloading, or from
be designed for a bursting pressure of heating and cooling of lading. Pressure
the greater of 100 psig or four times the relief systems are not required to con-
MAWP. form to the ASME Code.
(c) Each hose coupling must be de- (b) Type and construction of relief sys-
signed for a bursting pressure of the tems and devices. (1) Each cargo tank
greater of 120 psig or 4.8 times the must be provided with a primary pres-
MAWP of the cargo tank, and must be sure relief system consisting of one or
designed so that there will be no leak- more reclosing pressure relief valves. A
age when connected. secondary pressure relief system con-
(d) Suitable provision must be made sisting of another pressure relief valve
to allow for and prevent damage due to in parallel with the primary pressure
expansion, contraction, jarring, and vi- relief system may be used to augment
bration. Slip joints may not be used for the total venting capacity of the cargo
this purpose in the lading retention tank. Non-reclosing pressure relief de-
system. vices are not authorized in any cargo
tank except when in series with a re-
(e) Any heating device, when in-
closing pressure relief device. Gravity
stalled, must be so constructed that
actuated reclosing valves are not au-
the breaking of its external connec-
thorized on any cargo tank.
tions will not cause leakage of the
(2) When provided by § 173.33(c)(1)(iii)
cargo tank lading.
of this subchapter, cargo tanks may be
(f) Any gauging, loading or charging
equipped with a normal vent. Such
device, including associated valves,
vents must be set to open at not less
must be provided with an adequate than 1 psig and must be designed to
means of secure closure to prevent prevent loss of lading through the de-
leakage. vice in case of vehicle overturn.
(g) The attachment and construction (3) Each pressure relief system must
of each loading/unloading or charging be designed to withstand dynamic pres-
line must be of sufficient strength, or sure surges in excess of the design set
be protected by a sacrificial device, pressure as specified in paragraphs
such that any load applied by loading/ (b)(3) (i) and (ii) of this section. Set
unloading or charging lines connected pressure is a function of MAWP as set
to the cargo tank cannot cause damage forth in paragraph (d) of this section.
resulting in loss of lading from the (i) Each pressure relief device must
cargo tank. be able to withstand dynamic pressure
(h) Use of a nonmetallic pipe, valve
surge reaching 30 psig above the design

or connection that is not as strong and set pressure and sustained above the
heat resistant as the cargo tank mate- set pressure for at least 60 milliseconds
rial is authorized only if such attach- with a total volume of liquid released
173
§ 178.345–10 49 CFR Ch. I (10–1–18 Edition)
not exceeding one gallon before the re- the required vent capacity is main-
lief device recloses to a leak-tight contained.
dition. This requirement must be met (d) Settings of pressure relief system.
regardless of vehicle orientation. This The set pressure of the pressure relief
capability must be demonstrated by system is the pressure at which it
testing. An acceptable method is out- starts to open, allowing discharge.
lined in TTMA RP No. 81–97 ‘‘Perform- (1) Primary pressure relief system. The
ance of Spring Loaded Pressure Relief set pressure of each primary relief
Valves on MC 306, MC 307, MC 312, DOT valve must be no less than 120 percent
406, DOT 407, and DOT 412 Tanks’’ (in- of the MAWP, and no more than 132
corporated by reference; see § 171.7 of percent of the MAWP. The valve must
this subchapter). reclose at not less than 108 percent of
(ii) After August 31, 1995, each pres- the MAWP and remain closed at lower
sure relief device must be able to with- pressures.
stand a dynamic pressure surge reach- (2) Secondary pressure relief system.
ing 30 psig above the design set pres- The set pressure of each pressure relief
sure and sustained above the design set valve used as a secondary relief device
pressure for at least 60 milliseconds must be not less than 120 percent of the
with a total volume of liquid released MAWP.
not exceeding 1 L before the relief (e) Venting capacity of pressure relief
valve recloses to a leak-tight condi- systems. The pressure relief system (pri-
tion. This requirement must be met re- mary and secondary, including piping)
gardless of vehicle orientation. This must have sufficient venting capacity
capability must be demonstrated by to limit the cargo tank internal pres-
testing. TTMA RP No. 81, cited in para- sure to not more than the cargo tank
graph (b)(3)(i) of this section, is an ac- test pressure. The total venting capac-
ity, rated at not more than the cargo
ceptable test procedure.
tank test pressure, must be at least
(4) Each reclosing pressure relief
that specified in table I, except as pro-
valve must be constructed and in-
vided in § 178.348–4.
stalled in such a manner as to prevent
unauthorized adjustment of the relief TABLE I—MINIMUM EMERGENCY VENT CAPACITY
valve setting. [In cubic feet free air/hour at 60 °F and 1 atm.]
(5) No shut-off valve or other device
Cubic feet
that could prevent venting through the Exposed area in square feet free air per
pressure relief system may be installed hour
in a pressure relief system. 20 ....................................................................... 15,800
(6) The pressure relief system must 30 ....................................................................... 23,700
be mounted, shielded and drainable so 40 ....................................................................... 31,600
50 ....................................................................... 39,500
as to minimize the accumulation of 60 ....................................................................... 47,400
material that could impair the oper- 70 ....................................................................... 55,300
ation or discharge capability of the 80 ....................................................................... 63,300
90 ....................................................................... 71,200
system by freezing, corrosion or block- 100 ..................................................................... 79,100
age. 120 ..................................................................... 94,900
(c) Location of relief devices. Each 140 ..................................................................... 110,700
160 ..................................................................... 126,500
pressure relief device must commu- 180 ..................................................................... 142,300
nicate with the vapor space above the 200 ..................................................................... 158,100
lading as near as practicable to the 225 ..................................................................... 191,300
250 ..................................................................... 203,100
center of the vapor space. For example, 275 ..................................................................... 214,300
on a cargo tank designed to operate in 300 ..................................................................... 225,100
350 ..................................................................... 245,700
a level attitude, the device should be 400 ..................................................................... 265,000
positioned at the horizontal and trans- 450 ..................................................................... 283,200
verse center of the cargo tank; on 500 ..................................................................... 300,600
550 ..................................................................... 317,300
cargo tanks sloped to the rear, the de- 600 ..................................................................... 333,300
vice should be located in the forward 650 ..................................................................... 348,800
half of the cargo tank. The discharge 700 ..................................................................... 363,700

from any device must be unrestricted. 750 ..................................................................... 378,200
800 ..................................................................... 392,200
Protective devices which deflect the 850 ..................................................................... 405,900
flow of vapor are permissible provided 900 ..................................................................... 419,300
174
TABLE I—MINIMUM EMERGENCY VENT percent of the average value for the de-
CAPACITY—Continued vices tested.
[In cubic feet free air/hour at 60 °F and 1 atm.] (3) The rated flow capacity derived
for each device model must be certified
Cubic feet
Exposed area in square feet free air per by a responsible official of the device
hour manufacturer.
950 ..................................................................... 432,300 (h) Marking of pressure relief devices.
1,000 .................................................................. 445,000 Each pressure relief device must be
Note 1: Interpolate for intermediate sizes. permanently marked with the fol-
lowing:
(1) Primary pressure relief system. Un- (1) Manufacturer’s name;
less otherwise specified in the applica-
(2) Model number;
ble individual specification, the pri-
(3) Set pressure, in psig; and
mary relief system must have a min-
imum venting capacity of 12,000 SCFH (4) Rated flow capacity, in SCFH at
per 350 square feet of exposed cargo the rating pressure, in psig.
tank area, but in any case at least one [Amdt. 178–89, 54 FR 25025, June 12, 1989, as
fourth the required total venting ca- amended at 55 FR 21038, May 22, 1990; 55 FR
pacity for the cargo tank. 37062, Sept. 7, 1990; Amdt. 178–89, 56 FR 27877,
(2) Secondary pressure relief system. If June 17, 1991; Amdt. 178–105, 59 FR 55175, Nov.
the primary pressure relief system does 3, 1994; Amdt. 178–118, 61 FR 51341, Oct. 1,
not provide the required total venting 1996; 65 FR 58631, Sept. 29, 2000; 66 FR 45389,
capacity, additional capacity must be Aug. 28, 2001; 68 FR 19284, Apr. 18, 2003]
provided by a secondary pressure relief
§ 178.345–11 Tank outlets.
system.
(f) Certification of pressure relief de- (a) General. As used in this section,
vices. The manufacturer of any pressure ‘‘loading/unloading outlet’’ means any
relief device, including valves, fran- opening in the cargo tank wall used for
gible (rupture) disks, vacuum vents and loading or unloading of lading, as dis-
combination devices must certify that tinguished from outlets such as man-
the device model was designed and hole covers, vents, vapor recovery de-
tested in accordance with this section vices, and similar closures. Cargo tank
and the appropriate cargo tank speci- outlets, closures and associated piping
fication. The certificate must contain must be protected in accordance with
sufficient information to describe the § 178.345–8.
device and its performance. The certifi- (b) Each cargo tank loading/unload-
cate must be signed by a responsible of- ing outlet must be equipped with an in-
ficial of the manufacturer who ap- ternal self-closing stop-valve, or alter-
proved the flow capacity certification. natively, with an external stop-valve
(g) Rated flow capacity certification located as close as practicable to the
test. Each pressure relief device model cargo tank wall. Each cargo tank load-
must be successfully flow capacity cer- ing/unloading outlet must be in accord-
tification tested prior to first use. De- ance with the following provisions:
vices having one design, size and set (1) Each loading/unloading outlet
pressure are considered to be one
must be fitted with a self-closing sys-
model. The testing requirements are as
tem capable of closing all such outlets
follows:
in an emergency within 30 seconds of
(1) At least 3 devices of each specific
actuation. During normal operations
model must be tested for flow capacity
the outlets may be closed manually.
at a pressure not greater than the test
pressure of the cargo tank. For a de- The self-closing system must be de-
vice model to be certified, the capac- signed according to the following:
ities of the devices tested must fall (i) Each self-closing system must in-
within a range of plus or minus 5 per- clude a remotely actuated means of
closure located more than 10 feet from
cent of the average for the devices test-

ed. the loading/unloading outlet where ve-
(2) The rated flow capacity of a de- hicle length allows, or on the end of
vice model may not be greater than 90 the cargo tank farthest away from the
175
§ 178.345–12 49 CFR Ch. I (10–1–18 Edition)
loading/unloading outlet. The actu- liquid level. Gauge glasses are not per-
ating mechanism must be corrosion-re- mitted.
sistant and effective in all types of en- [Amdt. 178–89, 55 FR 37062, Sept. 7, 1990, as
vironment and weather. amended by Amdt. 178–118, 61 FR 51342, Oct.
(ii) If the actuating system is acci- 1, 1996]
dentally damaged or sheared off during
transportation, each loading/unloading § 178.345–13 Pressure and leakage
outlet must remain securely closed and tests.
capable of retaining lading. (a) Each cargo tank must be pressure
(iii) When required by part 173 of this and leakage tested in accordance with
subchapter for materials which are this section and §§ 178.346–5, 178.347–5, or
flammable, pyrophoric, oxidizing, or 178.348–5.
Division 6.1 (poisonous liquid) mate- (b) Pressure test. Each cargo tank or
rials, the remote means of closure cargo tank compartment must be test-
must be capable of thermal activation. ed hydrostatically or pneumatically.
The means by which the self-closing Each cargo tank of a multi-cargo tank
motor vehicle must be tested with the
system is thermally activated must be
adjacent cargo tanks empty and at at-
located as close as practicable to the
mospheric pressure. Each closure, ex-
primary loading/unloading connection
cept pressure relief devices and load-
and must actuate the system at a tem-
ing/unloading venting devices rated at
perature not over 250 °F. In addition,
less than the prescribed test pressure,
outlets on these cargo tanks must be
must be in place during the test. If the
capable of being remotely closed manu- venting device is not removed during
ally or mechanically. the test, such device must be rendered
(2) Bottom loading outlets which dis- inoperative by a clamp, plug or other
charge lading into the cargo tank equally effective restraining device,
through fixed internal piping above the which may not prevent the detection of
maximum liquid level of the cargo leaks, or damage the device. Restrain-
tank need not be equipped with a self- ing devices must be removed imme-
closing system. diately after the test is completed.
(c) Any loading/unloading outlet ex- (1) Hydrostatic method. Each cargo
tending beyond an internal self-closing tank, including its domes, must be
stop-valve, or beyond the innermost ex- filled with water or other liquid having
ternal stop-valve which is part of a similar viscosity, the temperature of
self-closing system, must be fitted with which may not exceed 100 °F. The cargo
another stop-valve or other leak-tight tank must then be pressurized as pre-
closure at the end of such connection. scribed in the applicable specification.
(d) Each cargo tank outlet that is not The pressure must be gauged at the top
a loading/unloading outlet must be of the cargo tank. The prescribed test
equipped with a stop-valve or other pressure must be maintained for at
leak-tight closure located as close as least 10 minutes during which time the
practicable to the cargo tank outlet. cargo tank must be inspected for leak-
Any connection extending beyond this age, bulging, or other defect.
closure must be fitted with another (2) Pneumatic method. A pneumatic
stop-valve or other leak-tight closure test may be used in place of the hydro-
at the end of such connection. static test. However, pneumatic pres-
sure testing may involve higher risk
[Amdt. 178–89, 56 FR 27877, June 17, 1991, as than hydrostatic testing. Therefore,
amended by Amdt. 178–97, 57 FR 45465, Oct. 1, suitable safeguards must be provided to
1992; Amdt. 178–118, 61 FR 51341, Oct. 1, 1996] protect personnel and facilities should
failure occur during the test. The cargo
§ 178.345–12 Gauging devices.
tank must be pressurized with air or an
Each cargo tank, except a cargo tank inert gas. Test pressure must be
intended to be filled by weight, must be reached gradually by increasing the
equipped with a gauging device that in- pressure to one half of test pressure.
dicates the maximum permitted liquid Thereafter, the pressure must be in-
level to within 0.5 percent of the nomi- creased in steps of approximately one
nal capacity as measured by volume or tenth of the test pressure until test
176
pressure is reached. Test pressure must ing, embossing or other means in char-
be held for at least 5 minutes. The pres- acters at least 3⁄16 inch high. The infor-
sure must then be reduced to the in- mation required by paragraphs (b) and
spection pressure which must be main- (c) of this section may be combined on
tained while the entire cargo tank sur- one specification plate.
face is inspected for leakage and other (b) Nameplate. Each cargo tank must
sign of defects. The inspection method have a corrosion resistant nameplate
must consist of coating all joints and permanently attached to it. The fol-
fittings with a solution of soap and lowing information, in addition to any
water or other equally sensitive meth- applicable information required by the
od. ASME Code, must be marked on the
(c) Leakage test. The cargo tank with tank nameplate (parenthetical abbre-
all its accessories in place and operable viations may be used):
must be leak tested at not less than 80 (1) DOT-specification number DOT
percent of tank’s MAWP with the pres- XXX (DOT XXX) where ‘‘XXX’’ is re-
sure maintained for at least 5 minutes. placed with the applicable specification
(d) Any cargo tank that leaks, bulges number. For cargo tanks having a vari-
or shows any other sign of defect must able specification plate, the DOT-speci-
be rejected. Rejected cargo tanks must fication number is replaced with the
be suitably repaired and retested suc- words ‘‘See variable specification
cessfully prior to being returned to plate.’’
service. The retest after any repair (2) Original test date, month and
must use the same method of test year (Orig. Test Date).
under which the cargo tank was origi- (3) Tank MAWP in psig.
nally rejected. (4) Cargo tank test pressure (Test P),
[Amdt. 178–89, 54 FR 25026, June 12, 1989, as in psig.
amended at 55 FR 37063, Sept. 7, 1990; Amdt. (5) Cargo tank design temperature
178–105, 59 FR 55176, Nov. 3, 1994; Amdt. 178– range (Design temp. range),l °F to l
118, 61 FR 51342, Oct. 1, 1996; 65 FR 58631, °F.
Sept. 29, 2000; 68 FR 19284, Apr. 18, 2003] (6) Nominal capacity (Water cap.), in
gallons.
§ 178.345–14 Marking.
(7) Maximum design density of lading
(a) General. The manufacturer shall (Max. lading density), in pounds per
certify that each cargo tank motor ve- gallon.
hicle has been designed, constructed (8) Material specification number—
and tested in accordance with the ap- shell (Shell matl, yyy***), where ‘‘yyy’’
plicable Specification DOT 406, DOT 407 is replaced by the alloy designation
or DOT 412 (§§ 178.345, 178.346, 178.347, and ‘‘***’’ by the alloy type.
178.348) cargo tank requirements and, (9) Material specification number—
when applicable, with Section VIII of heads (Head matl, yyy***), where
the ASME Code (IBR, see § 171.7 of this ‘‘yyy’’ is replaced by the alloy designa-
subchapter). The certification shall be tion and ‘‘***’’ by the alloy type.
accomplished by marking the cargo
tank as prescribed in paragraphs (b) NOTE: When the shell and heads materials
are the same thickness, they may be com-
and (c) of this section, and by pre-
bined, (Shell&head matl, yyy***).
paring the certificate prescribed in
§ 178.345–15. Metal plates prescribed by (10) Weld material (Weld matl.).
paragraphs (b), (c), (d) and (e) of this (11) Minimum thickness—shell (Min.
section, must be permanently attached shell-thick), in inches. When minimum
to the cargo tank or its integral sup- shell thicknesses are not the same for
porting structure, by brazing, welding different areas, show (top l, side l,
or other suitable means. These plates bottom l, in inches).
must be affixed on the left side of the (12) Minimum thickness—heads (Min.
vehicle near the front of the cargo tank heads thick.), in inches.
(or the frontmost cargo tank of a (13) Manufactured thickness—shell
(Mfd. shell thick.), top l, side l, bot-
multi-cargo tank motor vehicle), in a

place readily accessible for inspection. tom l, in inches. (Required when addi-
The plates must be permanently and tional thickness is provided for corro-
plainly marked in English by stamp- sion allowance.)
177
§ 178.345–14 49 CFR Ch. I (10–1–18 Edition)
(14) Manufactured thickness—heads (e) Variable specification cargo tank.

(Mfd. heads thick.), in inches. (Re- Each variable specification cargo tank
quired when additional thickness is must have a corrosion resistant metal
provided for corrosion allowance.) variable specification plate attached to
(15) Exposed surface area, in square it. The mounting of this variable speci-
feet. fication plate must be such that only
(c) Specification plate. Each cargo the plate identifying the applicable
tank motor vehicle must have an addi- specification under which the tank is
tional corrosion resistant metal speci- being operated is legible.
fication plate attached to it. The speci- (1) The following information must
fication plate must contain the fol- be included (parenthetical abbrevia-
lowing information (parenthetical ab- tions are authorized):
breviations may be used):
Specification DOT XXX (DOT XXX), where
(1) Cargo tank motor vehicle manu-
‘‘XXX’’ is replaced with the applicable speci-
facturer (CTMV mfr.). fication number.
(2) Cargo tank motor vehicle certifi-
cation date (CTMV cert. date), if dif- Required
Equipment required
ferent from the cargo tank certifi- rating 1
cation date.
(3) Cargo tank manufacturer (CT Pressure relief devices:
mfr.). Pressure actuated llllll
type.
(4) Cargo tank date of manufacture
Frangible type ........... llllll
(CT date of mfr.), month and year.
Lading discharge de- llllll
(5) Maximum weight of lading (Max. vices.
Payload), in pounds. Top ............................. llllll
(6) Maximum loading rate in gallons Bottom ....................... llllll
per minute (Max. Load rate, GPM). Pressure unloading llllll
(7) Maximum unloading rate in gal- fitting.
lons per minute (Max. Unload rate). Closures:
(8) Lining material (Lining), if appli- Manhole ..................... llllll
cable. Fill openings .............. llllll
(9) Heating system design pressure Discharge openings .... llllll
(Heating sys. press.), in psig, if applica- 1 Required rating—to meet the applicable
ble. specification.
(10) Heating system design tempera- (2) If no change of information in the
ture (Heating sys. temp.), in °F, if ap- specification plate is required, the let-
plicable. ters ‘‘NC’’ must follow the rating re-
(d) Multi-cargo tank motor vehicle. For quired. If the cargo tank is not so
a multi-cargo tank motor vehicle hav- equipped, the word ‘‘None’’ must be in-
ing all its cargo tanks not separated by serted.
any void, the information required by (3) Those parts to be changed or
paragraphs (b) and (c) of this section added must be stamped with the appro-
may be combined on one specification priate MC or DOT Specification mark-
plate. When separated by a void, each ings.
cargo tank must have an individual (4) The alterations that must be
nameplate as required in paragraph (b) made in order for the tank to be modi-
of this section, unless all cargo tanks fied from one specification to another
are made by the same manufacturer must be clearly indicated on the manu-
with the same materials, manufactured facturer’s certificate and on the vari-
thickness, minimum thickness and to able specification plate.
the same specification. The cargo tank
motor vehicle may have a combined [Amdt. 178–89, 54 FR 25027, June 12, 1989, as
nameplate and specification plate. amended at 55 FR 37063, Sept. 7, 1990; Amdt.
When only one plate is used, the plate 178–99, 58 FR 51534, Oct. 1, 1993; Amdt. 178–104,
59 FR 49135, Sept. 26, 1994; Amdt. 178–105, 59
must be visible and not covered by in-
FR 55176, Nov. 3, 1994; 60 FR 17402, Apr. 5,
sulation. The required information 1995; Amdt. 178–118, 61 FR 51342, Oct. 1, 1996;
must be listed on the plate from front 66 FR 45389, Aug. 28, 2001; 68 FR 19284, Apr. 18,
to rear in the order of the cor- 2003; 68 FR 52371, Sept. 3, 2003; 68 FR 75756,
responding cargo tank location. Dec. 31, 2003]
178
§ 178.345–15 Certification. manufacturer, at or before the time of

(a) At or before the time of delivery, delivery, a certificate covering the par-
the manufacturer of a cargo tank ticular operation performed by that
motor vehicle must provide certifi- manufacturer, including any certifi-
cation documents to the owner of the cates received from previous manufac-
cargo tank motor vehicle. The registra- turers, Registered Inspectors, and De-
tion numbers of the manufacturer, the sign Certifying Engineers. Each certifi-
Design Certifying Engineer, and the cate must indicate the portion of the
Registered Inspector, as appropriate, complete cargo tank motor vehicle rep-
must appear on the certificates (see resented thereby, such as basic cargo
subpart F, part 107 in subchapter A of tank fabrication, insulation, jacket,
this chapter). lining, or piping. The final manufac-
(b) The manufacturer of a cargo tank turer shall provide all applicable cer-
motor vehicle made to any of these tificates to the owner.
specifications must provide: (e) Specification shortages. If a cargo
(1) For each design type, a certificate
tank is manufactured which does not
signed by a responsible official of the
meet all applicable specification re-
manufacturer and a Design Certifying
Engineer certifying that the cargo quirements, thereby requiring subse-
tank motor vehicle design meets the quent manufacturing involving the in-
applicable specification; and stallation of additional components,
(2) For each ASME cargo tank, a parts, appurtenances or accessories,
cargo tank manufacturer’s data report the cargo tank manufacturer may affix
as required by Section VIII of the the name plate and specification plate,
ASME Code (IBR, see § 171.7 of this sub- as required by § 178.345–14 (b) and (c),
chapter). For each cargo tank motor without the original date of certifi-
vehicle, a certificate signed by a re- cation stamped on the specification
sponsible official of the manufacturer plate. The manufacturer shall state the
and a Registered Inspector certifying specification requirements not com-
that the cargo tank motor vehicle is plied with on the manufacturer’s Cer-
constructed, tested and completed in tificate of Compliance. When the cargo
conformance with the applicable speci- tank is brought into full compliance
fication. with the applicable specification, the
(c) The manufacturer of a variable Registered Inspector shall stamp the
specification cargo tank motor vehicle date of compliance on the specification
must provide: plate. The Registered Inspector shall
(1) For each design type, a certificate issue a Certificate of Compliance stat-
signed by a responsible official of the ing details of the particular operations
manufacturer and a Design Certifying performed on the cargo tank, and the
Engineer certifying that the cargo date and person (manufacturer, carrier,
tank motor vehicle design meets the
or repair organization) accomplishing
applicable specifications; and
the compliance.
(2) For each variable specification
cargo tank motor vehicle, a certificate [Amdt. 178–89, 55 FR 37063, Sept. 7, 1990, as
signed by a responsible official of the amended by Amdt. 178–98, 58 FR 33306, June
manufacturer and a Registered Inspec- 16, 1993; Amdt. 178–105, 59 FR 55176, Nov. 3,
tor certifying that the cargo tank 1994; Amdt. 178–118, 61 FR 51342, Oct. 1, 1996;
motor vehicle is constructed, tested 68 FR 75756, Dec. 31, 2003]
and completed in conformance with the
applicable specifications. The certifi- § 178.346 Specification DOT 406; cargo
tank motor vehicle.
cate must include all the information
required and marked on the variable § 178.346–1 General requirements.
specification plate.
(d) In the case of a cargo tank motor (a) Each Specification DOT 406 cargo
vehicle manufactured in two or more tank motor vehicle must meet the gen-
stages, each manufacturer who per- eral design and construction require-
forms a manufacturing operation on ments in § 178.345, in addition to the
the incomplete vehicle or portion specific requirements contained in this
thereof shall provide to the succeeding section.
179
§ 178.346–2 49 CFR Ch. I (10–1–18 Edition)
(b) MAWP: The MAWP of each cargo cated farther from the top and bottom
tank must be no lower than 2.65 psig centerline than 16 percent of the shell’s
and no higher than 4 psig. circumference.
(c) Vacuum loaded cargo tanks must (ii) For a self-supporting cargo tank,
not be constructed to this specifica- no more than two such joints may be
tion. used on the top of the tank. They may
(d) Each cargo tank must be ‘‘con- not be located farther from the top
structed in accordance with Section centerline than 12.5 percent of the
VIII of the ASME Code’’ (IBR, see shell’s circumference.
§ 171.7 of this subchapter) except as (iii) Compliance test. Two test speci-
modified herein: mens of the material to be used in the
(1) The record-keeping requirements manufacture of a cargo tank must be
contained in the ASME Code Section tested to failure in tension. The test
VIII do not apply. Parts UG–90 through specimens must be of the same
94 in Section VIII do not apply. Inspec- thicknesses and joint configuration as
tion and certification must be made by the cargo tank, and joined by the same
an inspector registered in accordance welding procedures. The test specimens
with subpart F of part 107. may represent all the tanks that are
(2) Loadings must be as prescribed in made of the same materials and weld-
§ 178.345–3. ing procedures, have the same joint
(3) The knuckle radius of flanged configuration, and are made in the
heads must be at least three times the same facility within 6 months after the
material thickness, and in no case less tests are completed. Before welding,
than 0.5 inch. Stuffed (inserted) heads the fit-up of the joints on the test
may be attached to the shell by a fillet specimens must represent production
weld. The knuckle radius and dish ra- conditions that would result in the
dius versus diameter limitations of least joint strength. Evidence of joint
UG–32 do not apply. Shell sections of
fit-up and test results must be retained
cargo tanks designed with a non-cir-
at the manufacturers’ facility.
cular cross section need not be given a
(iv) Weld joint efficiency. The lower
preliminary curvature, as prescribed in
UG–79(b). value of stress at failure attained in
(4) Marking, certification, data re- the two tensile test specimens shall be
ports, and nameplates must be as pre- used to compute the efficiency of the
scribed in §§ 178.345–14 and 178.345–15. joint as follows: Determine the failure
(5) Manhole closure assemblies must ratio by dividing the stress at failure
conform to §§ 178.345–5 and 178.346–5. by the mechanical properties of the ad-
(6) Pressure relief devices must be as jacent metal; this value, when multi-
prescribed in § 178.346–3. plied by 0.75, is the design weld joint ef-
(7) The hydrostatic or pneumatic test ficiency.
must be as prescribed in § 178.346–5. (10) The requirements of paragraph
(8) The following paragraphs in parts UW–9(d) in Section VIII of the ASME
UG and UW in Section VIII of the Code do not apply.
ASME Code do not apply: UG–11, UG– [Amdt. 178–89, 54 FR 25028, June 12, 1989, as
12, UG–22(g), UG–32(e), UG–34, UG–35, amended at 55 FR 37063, Sept. 7, 1990; Amdt.
UG–44, UG–76, UG–77, UG–80, UG–81, 178–89, 56 FR 27877, June 17, 1991; Amdt. 178–
UG–96, UG–97, UW–13(b)(2), UW–13.1(f) 105, 59 FR 55176, Nov. 3, 1994; 65 FR 58631,
and the dimensional requirements Sept. 29, 2000; 66 FR 45387, Aug. 28, 2001; 68 FR
found in Figure UW–13.1. 19285, Apr. 18, 2003; 68 FR 75756, Dec. 31, 2003]
(9) Single full fillet lap joints with-
out plug welds may be used for arc or § 178.346–2 Material and thickness of
gas welded longitudinal seams without material.
radiographic examination under the The type and thickness of material
following conditions: for DOT 406 specification cargo tanks
(i) For a truck-mounted cargo tank, must conform to § 178.345–2, but in no
no more than two such joints may be case may the thickness be less than
used on the top half of the tank and no that determined by the minimum
more than two joints may be used on thickness requirements in § 178.320(a).
the bottom half. They may not be lo- The following Tables I and II identify
180
the specified minimum thickness val-

ues to be employed in that determina-
tion.
TABLE I—SPECIFIED MINIMUM THICKNESS OF HEADS (OR BULKHEADS AND BAFFLES WHEN USED AS
TANK REINFORCEMENT) USING MILD STEEL (MS), HIGH STRENGTH LOW ALLOY STEEL (HSLA),
AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)—EXPRESSED IN DECIMALS OF AN INCH
AFTER FORMING
Volume capacity in gallons per inch of length
14 or less Over 14 to 23 Over 23

Material
HSLA HSLA HSLA
MS AL MS AL MS AL
SS SS SS
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]
§ 178.346–3 Pressure relief. tion. This requirement must be met re-

(a) Each cargo tank must be equipped gardless of vehicle orientation. This
with a pressure relief system in accord- capability must be demonstrated by
ance with § 178.345–10 and this section. testing. TTMA RP No. 81 (IBR, see
(b) Type and construction. In addition § 171.7 of this subchapter), cited at
to the pressure relief devices required § 178.345–10(b)(3)(i), is an acceptable test
in § 178.345–10: procedure.
(1) Each cargo tank must be equipped (c) Pressure settings of relief valves. (1)
with one or more vacuum relief de- Notwithstanding the requirements in
vices; § 178.345–10(d), the set pressure of each
(2) When intended for use only for primary relief valve must be not less
lading meeting the requirements of than 110 percent of the MAWP or 3.3
§ 173.33(c)(1)(iii) of this subchapter, the psig, whichever is greater, and not
cargo tank may be equipped with a more than 138 percent of the MAWP.
normal vent. Such vents must be set to The valve must close at not less than
open at not less than 1 psig and must the MAWP and remain closed at lower
be designed to prevent loss of lading pressures.
through the device in case of vehicle (2) Each vacuum relief device must
upset; and be set to open at no more than 6 ounces
(3) Notwithstanding the requirements vacuum.
in § 178.345–10(b), after August 31, 1996,
(d) Venting capacities. (1) Notwith-
each pressure relief valve must be able
standing the requirements in § 178.345–
to withstand a dynamic pressure surge
10 (e) and (g), the primary pressure re-
reaching 30 psig above the design set
pressure and sustained above the set lief valve must have a venting capacity
of at least 6,000 SCFH, rated at not
pressure for at least 60 milliseconds

with a total volume of liquid released greater than 125 percent of the tank
not exceeding 1 L before the relief test pressure and not greater than 3
valve recloses to a leak-tight condi-
181
§ 178.346–4 49 CFR Ch. I (10–1–18 Edition)
psig above the MAWP. The venting ca- mination of Vapor Tightness of Gaso-
pacity required in § 178.345–10(e) may be line Delivery Tank Using Pressure-
rated at these same pressures. Vacuum Test’’) may not be used to sat-
(2) Each vacuum relief system must isfy the leakage test requirements of
have sufficient capacity to limit the this paragraph. A cargo tank tested in
vacuum to 1 psig. accordance with 40 CFR 63.425(e) may
(3) If pressure loading or unloading be marked as specified in § 180.415 of
devices are provided, the relief system this subchapter.
must have adequate vapor and liquid
[Amdt. 178–89, 54 FR 25029, June 12, 1989, as
capacity to limit the tank pressure to
amended at 55 FR 37064, Sept. 7, 1990; Amdt.
the cargo tank test pressure at max- 178–105, 59 FR 55176, Nov. 3, 1994. Redesig-
imum loading or unloading rate. The nated by Amdt. 178–112, 61 FR 18934, Apr. 29,
maximum loading and unloading rates 1996; 68 FR 19285, Apr. 18, 2003]
must be included on the metal speci-
fication plate. § 178.347 Specification DOT 407; cargo
tank motor vehicle.
[Amdt. 178–89, 54 FR 25029, June 12, 1989, as
amended at 55 FR 37064, Sept. 7, 1990; Amdt. § 178.347–1 General requirements.
178–105, 59 FR 55176, Nov. 3, 1994. Redesig-
nated by Amdt. 178–112, 61 FR 18934, Apr. 29, (a) Each specification DOT 407 cargo
1996; 66 FR 45389, Aug. 28, 2001; 68 FR 75756, tank motor vehicle must conform to
Dec. 31, 2003] the general design and construction re-
quirements in § 178.345 in addition to
§ 178.346–4 Outlets. the specific requirements contained in
(a) All outlets on each tank must this section.
conform to § 178.345–11 and this section. (b) Each tank must be of a circular
(b) External self-closing stop-valves cross-section and have an MAWP of at
are not authorized as an alternative to least 25 psig.
internal self-closing stop-valves on (c) Any cargo tank motor vehicle
loading/unloading outlets. built to this specification with a
[Amdt. 178–89, 54 FR 25029, June 12, 1989. Re- MAWP greater than 35 psig or any
designated by Amdt. 178–112, 61 FR 18934, cargo tank motor vehicle built to this
Apr. 29, 1996] specification designed to be loaded by
vacuum must be constructed and cer-
§ 178.346–5 Pressure and leakage tests. tified in accordance with Section VIII
(a) Each cargo tank must be tested in of the ASME Code (IBR, see § 171.7 of
accordance with § 178.345–13 and this this subchapter). The external design
section. pressure for a cargo tank loaded by
(b) Pressure test. Test pressure must vacuum must be at least 15 psi.
be as follows: (d) Any cargo tank motor vehicle
(1) Using the hydrostatic test meth- built to this specification with a
od, the test pressure must be the great- MAWP of 35 psig or less or any cargo
er of 5.0 psig or 1.5 times the cargo tank motor vehicle built to this speci-
tank MAWP. fication designed to withstand full vac-
(2) Using the pneumatic test method, uum but not equipped to be loaded by
the test pressure must be the greater of vacuum must be constructed in accord-
5.0 psig or 1.5 times the cargo tank ance with Section VIII of the ASME
MAWP, and the inspection pressure Code.
must be the cargo tank MAWP. (1) The record-keeping requirements
(c) Leakage test. A cargo tank used to contained in Section VIII of the ASME
transport a petroleum distillate fuel Code do not apply. The inspection re-
that is equipped with vapor recovery quirements of parts UG–90 through 94
equipment may be leakage tested in do not apply. Inspection and certifi-
accordance with 40 CFR 63.425(e). To cation must be made by an inspector
satisfy the leakage test requirements registered in accordance with subpart
of this paragraph, the test specified in F of part 107.
40 CFR 63.425(e)(1) must be conducted (2) Loadings must be as prescribed in

using air. The hydrostatic test alter- § 178.345–3.
native permitted under Appendix A to (3) The knuckle radius of flanged
40 CFR Part 60 (‘‘Method 27—Deter- heads must be at least three times the
182
material thickness, and in no case less those to be used in the manufacture of

than 0.5 inch. Stuffed (inserted) heads a cargo tank bulkhead must be tested
may be attached to the shell by a fillet to failure in tension. The test specimen
weld. The knuckle radius and dish ra- must be of the same thickness and
dius versus diameter limitations of joined by the same welding procedure.
UG–32 do not apply for cargo tank The test specimens may represent all
motor vehicles with a MAWP of 35 psig the tanks that are made in the same
or less. facility within 6 months after the tests
(4) Marking, certification, data re-
are completed. Before welding, the fit-
ports and nameplates must be as pre-
up of the joints on the test specimens
scribed in §§ 178.345–14 and 178.345–15.
(5) Manhole closure assemblies must must represent production conditions
conform to § 178.347–3. that would result in the least joint
(6) Pressure relief devices must be as strength. Evidence of joint fit-up and
prescribed in § 178.347–4. test results must be retained at the
(7) The hydrostatic or pneumatic test manufacturer’s facility for at least 5
must be as prescribed in § 178.347–5. years.
(8) The following paragraphs in parts (vi) Acceptance criteria: The ratio of
UG and UW in Section VIII the ASME the actual tensile stress at failure to
Code do not apply: UG–11, UG–12, UG– the actual tensile strength of the adja-
22(g), UG–32(e), UG–34, UG–35, UG–44, cent material of all samples of a test
UG–76, UG–77, UG–80, UG–81, UG–96, lot must be greater than 0.85.
UG–97, UW–12, UW–13(b)(2), UW–13.1(f),
and the dimensional requirements [Amdt. 178–89, 54 FR 25029, June 12, 1989, as
found in Figure UW–13.1. amended at 55 FR 37064, Sept. 7, 1990; Amdt.
(9) UW–12 in Section VIII of the 178–89, 56 FR 27877, June 17, 1991; 65 FR 58632,
Sept. 29, 2000; 66 FR 45387, Aug. 28, 2001; 68 FR
ASME Code does not apply to a weld
19285, Apr. 18, 2003; 68 FR 75756, Dec. 31, 2003;
seam in a bulkhead that has not been 76 FR 3388, Jan. 19, 2011; 76 FR 43532, July 20,
radiographically examined, under the 2011]
following conditions:
(i) The strength of the weld seam is § 178.347–2 Material and thickness of
assumed to be 0.85 of the strength of material.
the bulkhead.
(ii) The welded seam must be a full (a) The type and thickness of mate-
penetration butt weld. rial for DOT 407 specification cargo
(iii) No more than one seam may be tanks must conform to § 178.345–2, but
used per bulkhead. in no case may the thickness be less
(iv) The welded seam must be com- than that determined by the minimum
pleted before forming the dish radius thickness requirements in § 178.320(a).
and knuckle radius. Tables I and II identify the specified
(v) Compliance test: Two test speci- minimum thickness values to be em-
mens of materials representative of ployed in that the determination:
TABLE I—SPECIFIED MINIMUM THICKNESS OF HEADS (OR BULKHEADS AND BAFFLES WHEN USED AS
TANK REINFORCEMENT) USING MILD STEEL (MS), HIGH STRENGTH LOW ALLOY STEEL (HSLA),
AUSTENITIC STAINLESS STEEL (SS), OR ALUMINUM (AL)—EXPRESSED IN DECIMALS OF AN INCH
AFTER FORMING
10 or Over 10 Over 14 Over 18 Over 22 Over 26
Volume capacity in gallons per inch Over 30
less to 14 to 18 to 22 to 26 to 30
Thickness (MS) ....................................................... 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (HSLA) ................................................... 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (SS) ........................................................ 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (AL) ........................................................ 0.160 0.160 0.173 0.187 0.194 0.216 0.237
183
§ 178.347–3 49 CFR Ch. I (10–1–18 Edition)
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 Over 30
less to 14 to 18 to 22 to 26 to 30
Thickness (MS) ....................................................... 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (HSLA) ................................................... 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (SS) ........................................................ 0.100 0.100 0.115 0.129 0.129 0.143 0.156
Thickness (AL) ........................................................ 0.151 0.151 0.160 0.173 0.194 0.216 0.237
(b) [Reserved]
[Amdt. 178–89, 54 FR 25030, June 12, 1989, as amended at 55 FR 37064, Sept. 7, 1990; Amdt. 178–
104, 59 FR 49135, Sept. 26, 1994; 68 FR 19285, Apr. 18, 2003]
§ 178.347–3 Manhole assemblies. must be included on the metal speci-

fication plate.
Each manhole assembly must con-
form to § 178.345–5, except that each [Amdt. 178–89, 54 FR 25030, June 12, 1989, as
manhole assembly must be capable of amended at 55 FR 37064, Sept. 7, 1990. Redes-
withstanding internal fluid pressures of ignated by Amdt. 178–112, 61 FR 18934, Apr.
29, 1996; 76 FR 43532, July 20, 2011]
40 psig or test pressure of the tank,
whichever is greater. § 178.347–5 Pressure and leakage test.
[Amdt. 178–89, 54 FR 25030, June 12, 1989. Re- (a) Each cargo tank must be tested in
designated by Amdt. 178–112, 61 FR 18934, accordance with § 178.345–13 and this
Apr. 29, 1996] section.
(b) Pressure test. Test pressure must
§ 178.347–4 Pressure relief.
be as follows:
(a) Each cargo tank must be equipped (1) Using the hydrostatic test meth-
with a pressure and vacuum relief sys- od, the test pressure must be at least 40
tem in accordance with § 178.345–10 and psig or 1.5 times tank MAWP, which-
this section. ever is greater.
(b) Type and construction. Vacuum re- (2) Using the pneumatic test method,
lief devices are not required for cargo the test pressure must be 40 psig or 1.5
tank motor vehicles that are designed times tank MAWP, whichever is great-
to be loaded by vacuum in accordance er, and the inspection pressure is tank
with § 178.347–1(c) or built to withstand MAWP.
full vacuum in accordance with [Amdt. 178–89, 54 FR 25030, June 12, 1989. Re-
§ 178.347–1(d). designated by Amdt. 178–112, 61 FR 18934,
(c) Pressure settings of relief valves. Apr. 29, 1996]
The setting of pressure relief valves
must be in accordance with § 178.345– § 178.348 Specification DOT 412; cargo
tank motor vehicle.
10(d).
(d) Venting capacities. (1) The vacuum § 178.348–1 General requirements.
relief system must limit the vacuum to
(a) Each specification DOT 412 cargo
less than 80 percent of the design vacu-
tank motor vehicle must conform to
um capability of the cargo tank.
the general design and construction re-
(2) If pressure loading or unloading quirements in § 178.345 in addition to
devices are provided, the relief system the specific requirements of this sec-
must have adequate vapor and liquid tion.
capacity to limit the tank pressure to
(b) The MAWP of each cargo tank

the cargo tank test pressure at max- must be at least 5 psig.
imum loading or unloading rate. The (c) The MAWP for each cargo tank
maximum loading or unloading rate designed to be loaded by vacuum must
184
be at least 25 psig internal and 15 psig tion need not be given a preliminary
external. curvature, as prescribed in UG–79(b).
(d) Each cargo tank having a MAWP (iv) Marking, certification, data re-
greater than 15 psig must be of circular ports, and nameplates must be as pre-
cross-section. scribed in §§ 178.345–14 and 178.345–15.
(e) Each cargo tank having a— (v) Manhole closure assemblies must
(1) MAWP greater than 15 psig must conform to §§ 178.345–5.
be ‘‘constructed and certified in con- (vi) Pressure relief devices must be as
formance with Section VIII of the prescribed in § 178.348–4.
ASME Code’’ (IBR, see § 171.7 of this (vii) The hydrostatic or pneumatic
subchapter); or test must be as prescribed in § 178.348–5.
(viii) The following paragraphs in
(2) MAWP of 15 psig or less must be
parts UG and UW in Section VIII of the
‘‘constructed in accordance with Sec-
ASME Code do not apply: UG–11, UG–
tion VIII of the ASME Code,’’ except as
12, UG–22(g), UG–32(e), UG–34, UG–35,
modified herein:
UG–44, UG–76, UG–77, UG–80, UG–81,
(i) The recordkeeping requirements UG–96, UG–97, UW–13(b)(2), UW–13.1(f),
contained in Section VIII of the ASME and the dimensional requirements
Code do not apply. Parts UG–90 found in Figure UW–13.1.
through 94 in Section VIII do not
apply. Inspection and certification [Amdt. 178–89, 54 FR 25031, June 12, 1989, as
must be made by an inspector reg- amended at 55 FR 37065, Sept. 7, 1990; Amdt.
178–89, 56 FR 27877, June 17, 1991; 65 FR 58632,
istered in accordance with subpart F of Sept. 29, 2000; 68 FR 19285, Apr. 18, 2003; 68 fR
part 107. 75756, Dec. 31, 2003]
(ii) Loadings must be as prescribed in
§ 178.345–3. § 178.348–2 Material and thickness of
(iii) The knuckle radius of flanged material.
heads must be at least three times the (a) The type and thickness of mate-
material thickness, and in no case less rial for DOT 412 specification cargo
than 0.5 inch. Stuffed (inserted) heads tanks must conform to § 178.345–2, but
may be attached to the shell by a fillet in no case may the thickness be less
weld. The knuckle radius and dish ra- than that determined by the minimum
dius versus diameter limitations of thickness requirements in § 178.320(a).
UG–32 do not apply for cargo tank The following Tables I and II identify
motor vehicles with a MAWP of 15 psig the ‘‘Specified Minimum Thickness’’
or less. Shell sections of cargo tanks values to be employed in that deter-
designed with a non-circular cross sec- mination.
185
VerDate Sep<11>2014
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
11:14 Dec 27, 2018

INCH AFTER FORMING
Volume capacity (gallons per inch) 10 or less Over 10 to 14 Over 14 to 18 18 and over
§ 178.348–2
Jkt 244227
Lading density at 60 °F in pounds per gallon ..................................... 10 lbs Over Over Over 10 lbs Over Over Over 10 lbs Over Over 10 lbs Over Over
and 10 to 13 to 16 lbs and 10 to 13 to 16 lbs and 10 to 13 to and 10 to 13 to
less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs less 13 lbs 16 lbs
Thickness (inch), steel ......................................................................... .100 .129 .157 .187 .129 .157 .187 .250 .157 .250 .250 .157 .250 .312
Thickness (inch), aluminum ................................................................. .144 .187 .227 .270 .187 .227 .270 .360 .227 .360 .360 .227 .360 .450
PO 00000
TABLE 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
Frm 00196
Volume capacity in gallons per inch 10 or less Over 10 to 14 Over 14 to 18 18 and over
Lading density at 60 °F in pounds per gallon ..................................... 10 lbs Over Over Over 10 lbs Over Over Over 10 lbs Over Over 10 lbs Over Over
Fmt 8010
and 10 to 13 to 16 lbs and 10 to 13 to 16 lbs and 10 to 13 to and 10 to 13 to
186
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):
Sfmt 8010
36 in. or less ............................................................ .100 .129 .157 .187 .100 .129 .157 .187 .100 .129 .157 .129 .157 .187
Over 36 in. to 54 inches .......................................... .100 .129 .157 .187 .100 .129 .157 .187 .129 .157 .187 .157 .250 .250
Over 54 in. to 60 inches .......................................... .100 .129 .157 .187 .129 .157 .187 .250 .157 .250 .250 .187 .250 .312
Thickness (aluminum):
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
Y:\SGML\244227.XXX
244227
49 CFR Ch. I (10–1–18 Edition)
(b) [Reserved]
[Amdt. 178–89, 54 FR 25031, June 12, 1989; 54 FR 28750, July 7, 1989, as amended at 55 FR 37065,
Sept. 7, 1990; 68 FR 19285, Apr. 18, 2003]
§ 178.348–3 Pumps, piping, hoses and Formula in Nonmetric Units

connections.
Q = 37,980,000 A0.82 (ZT)0.5 / (LC)(M0.5)
Each pump and all piping, hoses and
Where:
connections on each cargo tank motor
Q = The total required venting capacity, in
vehicle must conform to § 178.345–9, ex- cubic meters of air per hour at standard
cept that the use of nonmetallic pipes, conditions of 15.6 °C and 1 atm (cubic feet
valves, or connections are authorized of air per hour at standard conditions of
on DOT 412 cargo tanks. 60 °F and 14.7 psia);
T = The absolute temperature of the vapor at
[Amdt. 178–89, 55 FR 37065, Sept. 7, 1990. Re- the venting conditions—degrees Kelvin
designated by Amdt. 178–112, 61 FR 18934, (°C + 273) [degrees Rankine (°F + 460)];
Apr. 29, 1996] A = The exposed surface area of tank shell—
square meters (square feet);
§ 178.348–4 Pressure relief. L = The latent heat of vaporization of the
lading—calories per gram (BTU/lb);
(a) Each cargo tank must be equipped Z = The compressibility factor for the vapor
with a pressure and vacuum relief sys- (if this factor is unknown, let Z equal
tem in accordance with § 178.345–10 and 1.0);
this section. M = The molecular weight of vapor;
(b) Type and construction. Vacuum re- C = A constant derived from (K), the ratio of
specific heats of the vapor. If (K) is un-
lief devices are not required for cargo known, let C = 315.
tanks designed to be loaded by vacuum
C = 520[K(2/(K + 1))[(K ∂ 1)/(K¥1)]]0.5
or built to withstand full vacuum.
Where:
(c) Pressure settings of relief valves.
K = Cp / Cv
The setting of the pressure relief de- Cp = The specific heat at constant pressure,
vices must be in accordance with in -calories per gram degree centigrade
§ 178.345–10(d), except as provided in (BTU/lb °F.); and
paragraph (d)(3) of this section. Cv = The specific heat at constant volume, in
(d) Venting capacities. (1) The vacuum -calories per gram degree centigrade
relief system must limit the vacuum to (BTU/lb °F.).
less than 80 percent of the design vacu- [Amdt. 178–89, 54 FR 25032, June 12, 1989, as
um capability of the cargo tank. amended at 55 FR 37065, Sept. 7, 1990; Amdt.
178–104, 59 FR 49135, Sept. 26, 1994. Redesig-
(2) If pressure loading or unloading
nated by Amdt. 178–112, 61 FR 18934, Apr. 29,
devices are provided, the pressure relief 1996; 72 FR 55696, Oct. 1, 2007; 72 FR 59146,
system must have adequate vapor and Oct. 18, 2007]
liquid capacity to limit tank pressure
to the cargo tank test pressure at the § 178.348–5 Pressure and leakage test.
maximum loading or unloading rate. (a) Each cargo tank must be tested in
The maximum loading and unloading accordance with § 178.345–13 and this
rates must be included on the metal section.
specification plate. (b) Pressure test. Test pressure must
(3) Cargo tanks used in dedicated be as follows:
service for materials classed as corro- (1) Using the hydrostatic test meth-
sive material, with no secondary haz- od, the test pressure must be at least
ard, may have a total venting capacity 1.5 times MAWP.
which is less than required by § 178.345– (2) Using the pneumatic test method,
10(e). The minimum total venting ca- the test pressure must be at least 1.5
pacity for these cargo tanks must be times tank MAWP, and the inspection
pressure is tank MAWP.
determined in accordance with the fol-

lowing formula (use of approximate [Amdt. 178–89, 54 FR 25032, June 12, 1989. Re-
values given for the formula is accept- designated by Amdt. 178–112, 61 FR 18934,
able): Apr. 29, 1996]
187
§ 178.350 49 CFR Ch. I (10–1–18 Edition)
Subpart K—Specifications for (vii) ‘‘7’’ means a pressure receptacle.

Packagings for Class 7 (Ra- (2) A capital letter indicating the
material of construction, as follows:
dioactive) Materials (i) ‘‘A’’ means steel (all types and
§ 178.350 Specification 7A; general surface treatments).
packaging, Type A. (ii) ‘‘B’’ means aluminum.
(iii) ‘‘C’’ means natural wood.
(a) Each packaging must meet all ap-
(iv) ‘‘D’’ means plywood.
plicable requirements of subpart B of
(v) ‘‘F’’ means reconstituted wood.
part 173 of this subchapter and be de- (vi) ‘‘G’’ means fiberboard.
signed and constructed so that it meets (vii) ‘‘H’’ means plastic.
the requirements of §§ 173.403, 173.410, (viii) ‘‘L’’ means textile.
173.412, 173.415 and 173.465 of this sub- (ix) ‘‘M’’ means paper, multi-wall.
chapter for Type A packaging. (x) ‘‘N’’ means metal (other than
(b) Each Specification 7A packaging steel or aluminum).
must be marked on the outside ‘‘USA (xi) ‘‘P’’ means glass, porcelain or
DOT 7A Type A.’’ stoneware.
(c) Each Specification 7A packaging (3) A numeral indicating the category
must comply with the requirements of of packaging within the kind to which
§§ 178.2 and 178.3. In § 178.3(a)(2) the term the packaging belongs. For example,
‘‘packaging manufacturer’’ means the for steel drums (‘‘1A’’), ‘‘1’’ indicates a
person certifying that the package non-removable head drum ( i.e., ‘‘1A1’’)
meets all requirements of this section. and ‘‘2’’ indicates a removable head
[Amdt. 178–109, 60 FR 50336, Sept. 28, 1995; 60 drum (i.e., ‘‘1A2’’).
FR 54409, Oct. 23, 1995, as amended at 69 FR (b) For composite packagings, two
3696, Jan. 26, 2004; 70 FR 56099, Sept. 23, 2005; capital letters are used in sequence in
79 FR 40618, July 11, 2014] the second position of the code, the
first indicating the material of the
Subpart L—Non-bulk Perform- inner receptacle and the second, that of
ance-Oriented Packaging the outer packaging. For example, a
Standards plastic receptacle in a steel drum is
designated ‘‘6HA1’’.
(c) For combination packagings, only
SOURCE: Amdt. 178–97, 55 FR 52717, Dec. 21,
1990, unless otherwise noted. the code number for the outer pack-
aging is used.
§ 178.500 Purpose, scope and defini- (d) Identification codes are set forth
tions. in the standards for packagings in
(a) This subpart prescribes certain re- §§ 178.504 through 178.523 of this sub-
quirements for non-bulk packagings for part.
hazardous materials. Standards for NOTE TO § 178.502: Plastics materials in-
these packagings are based on the UN clude other polymeric materials such as rub-
Recommendations. ber.
(b) Terms used in this subpart are de- [Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
fined in § 171.8 of this subchapter. amended by Amdt. 178–106, 59 FR 67519, Dec.
29, 1994; 74 FR 2269, Jan. 14, 2009]
§ 178.502 Identification codes for pack-
agings. § 178.503 Marking of packagings.
(a) Identification codes for desig- (a) A manufacturer must mark every
nating kinds of packagings consist of packaging that is represented as manu-
the following: factured to meet a UN standard with
(1) A numeral indicating the kind of the marks specified in this section. The
packaging, as follows: markings must be durable, legible and
(i) ‘‘1’’ means a drum. placed in a location and of such a size
(ii) ‘‘2’’ means a wooden barrel. relative to the packaging as to be read-
(iii) ‘‘3’’ means a jerrican. ily visible, as specified in § 178.3(a). Ex-
(iv) ‘‘4’’ means a box. cept as otherwise provided in this sec-

(v) ‘‘5’’ means a bag. tion, every reusable packaging liable
(vi) ‘‘6’’ means a composite pack- to undergo a reconditioning process
aging. which might obliterate the packaging
188
marks must bear the marks specified designation shall be the maximum
in paragraphs (a)(1) through (a)(6) and gross mass in kilograms;
(a)(9) of this section in a permanent (5)(i) For single and composite pack-
form (e.g. embossed) able to withstand agings intended to contain liquids, the
the reconditioning process. A marking test pressure in kilopascals rounded
may be applied in a single line or in down to the nearest 10 kPa of the hy-
multiple lines provided the correct se- drostatic pressure test that the pack-
quence is used. As illustrated by the aging design type has successfully
examples in paragraph (e) of this sec- passed;
tion, the following information must (ii) For packagings intended to con-
be presented in the correct sequence. tain solids or inner packagings, the let-
Slash marks should be used to separate ter ‘‘S’’;
this information. A packaging con- (6) The last two digits of the year of
forming to a UN standard must be manufacture. Packagings of types 1H
marked as follows: and 3H shall also be marked with the
(1) Except as provided in paragraph month of manufacture in any appro-
(e)(1)(ii) of this section, the United Na- priate manner; this may be marked on
tions symbol as illustrated in para- the packaging in a different place from
graph (e)(1)(i) of this section (for em- the remainder of the markings;
bossed metal receptacles, the letters (7) The state authorizing allocation
‘‘UN’’ may be applied in place of the of the mark. The letters ‘USA’ indicate
symbol); that the packaging is manufactured
(2) A packaging identification code and marked in the United States in
designating the type of packaging, the compliance with the provisions of this
material of construction and, when ap- subchapter;
propriate, the category of packaging (8) The name and address or symbol
under §§ 178.504 through 178.523 of this of the manufacturer or the approval
subpart within the type to which the agency certifying compliance with sub-
packaging belongs. The letter ‘‘V’’ part L and subpart M of this part.
must follow the packaging identifica- Symbols, if used, must be registered
tion code on packagings tested in ac- with the Associate Administrator;
cordance with § 178.601(g)(2); for exam- (9) For metal or plastic drums or
ple, ‘‘4GV’’. The letter ‘‘W’’ must fol- jerricans intended for reuse or recondi-
low the packaging identification code tioning as single packagings or the
on packagings when required by an ap- outer packagings of a composite pack-
proval under the provisions of aging, the thickness of the packaging
§ 178.601(h) of this part; material, expressed in mm (rounded to
the nearest 0.1 mm), as follows:
(3) A letter identifying the perform-
(i) Metal drums or jerricans must be
ance standard under which the pack-
marked with the nominal thickness of
aging design type has been successfully
the metal used in the body. The
tested, as follows:
marked nominal thickness must not
(i) X—for packagings meeting Pack- exceed the minimum thickness of the
ing Group I, II and III tests; steel used by more than the thickness
(ii) Y—for packagings meeting Pack- tolerance stated in ISO 3574 (IBR, see
ing Group II and III tests; or § 171.7 of this subchapter). (See appen-
(iii) Z—for packagings only meeting dix C of this part.) The unit of measure
Packing Group III tests; is not required to be marked. When the
(4) A designation of the specific grav- nominal thickness of either head of a
ity or mass for which the packaging de- metal drum is thinner than that of the
sign type has been tested, as follows: body, the nominal thickness of the top
(i) For packagings without inner head, body, and bottom head must be
packagings intended to contain liquids, marked (e.g., ‘‘1.0–1.2–1.0’’ or ‘‘0.9–1.0–
the designation shall be the specific 1.0’’).
gravity rounded down to the first dec- (ii) Plastic drums or jerricans must
imal but may be omitted when the spe- be marked with the minimum thick-
cific gravity does not exceed 1.2; and ness of the packaging material. Min-
(ii) For packagings intended to con- imum thicknesses of plastic must be as
tain solids or inner packagings, the determined in accordance with
189
§ 178.503 49 CFR Ch. I (10–1–18 Edition)
§ 173.28(b)(4). The unit of measure is not (iii) The last two digits of the year of
required to be marked; reconditioning;
(10) In addition to the markings pre- (iv) The letter ‘‘R’’; and
scribed in paragraphs (a)(1) through (v) For every packaging successfully
(a)(9) of this section, every new metal passing a leakproofness test, the addi-
drum having a capacity greater than tional letter ‘‘L’’.
100 L must bear the marks described in (2) When, after reconditioning, the
paragraphs (a)(1) through (a)(6), and markings required by paragraph (a)(1)
(a)(9)(i) of this section, in a permanent through (a)(5) of this section no longer
form, on the bottom. The markings on appear on the top head or the side of
the top head or side of these pack- the metal drum, the reconditioner
agings need not be permanent, and must apply them in a durable form fol-
need not include the thickness mark lowed by the markings in paragraph
described in paragraph (a)(9) of this (c)(1) of this section. These markings
section. This marking indicates a may identify a different performance
drum’s characteristics at the time it capability than that for which the
was manufactured, and the information original design type had been tested
in paragraphs (a)(1) through (a)(6) of and marked, but may not identify a
this section that is marked on the top greater performance capability. The
head or side must be the same as the markings applied in accordance with
information in paragraphs (a)(1) this paragraph may be different from
through (a)(6) of this section perma- those which are permanently marked
nently marked by the original manu- on the bottom of a drum in accordance
facturer on the bottom of the drum; with paragraph (a)(10) of this section.
and (d) Marking of remanufactured pack-
(11) Rated capacity of the packaging agings. For remanufactured metal
expressed in liters may be marked. drums, if there is no change to the
(b) For a packaging with a removable packaging type and no replacement or
head, the markings may not be applied removal of integral structural compo-
only to the removable head. nents, the required markings need not
(c) Marking of reconditioned pack- be permanent (e.g., embossed). Every
agings. (1) If a packaging is recondi- other remanufactured drum must bear
tioned, it shall be marked by the re- the marks required in paragraphs (a)(1)
conditioner near the marks required in through (a)(6) of this section in a per-
paragraphs (a)(1) through (6) of this manent form (e.g., embossed) on the
section with the following additional top head or side. If the metal thickness
information: marking required in paragraph (a)(9)(i)
(i) The name of the country in which of this section does not appear on the
the reconditioning was performed (in bottom of the drum, or if it is no
the United States, use the letters longer valid, the remanufacturer also
‘‘USA’’); must mark this information in perma-
(ii) The name and address or symbol nent form.
of the reconditioner. Symbols, if used, (e) The following are examples of sym-
must be registered with the Associate bols and required markings.
Administrator; (1)(i) The United Nations symbol is:
190
ER05OC12.059</GPH>
(ii) The circle that surrounds the let- circumference of the circle (72 degrees);
ters ‘‘u’’ and ‘‘n’’ may have small and
breaks provided the following provi- D) The letters ‘‘u’’ and ‘‘n’’ appear
sions are met: exactly as depicted in § 178.503(e)(1)(i)
(A) The total gap space does not ex- with no gaps.
ceed 15 percent of the circumference of (2) Examples of markings for a new
the circle; packaging are as follows:
(B) There are no more than four gaps
(i) For a fiberboard box designed to
in the circle;
contain an inner packaging:
C) The spacing between gaps is sepa-
rated by no less than 20 percent of the
(as in § 178.503 (a)(1) through (9) of this (ii) For a steel drum designed to con-
subpart). tain liquids:
(as in § 178.503 (a)(1) through (10) of this (iii) For a steel drum to transport
subpart). solids or inner packagings:
ER05OC12.061</GPH> ER05OC12.062</GPH>
191
ER05OC12.060</GPH>
§ 178.504 49 CFR Ch. I (10–1–18 Edition)
(as in § 178.503 (a)(1) through (8) of this (3) Examples of markings for recondi-
subpart). tioned packagings are as follows:
(as in § 178.503(c)(1)). quired in paragraph (f)(2) of this sec-

(f) A manufacturer must mark every tion.
UN specification package represented [Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
as manufactured to meet the require- amended at 56 FR 66284, Dec. 20, 1991; Amdt.
ments of § 178.609 for packaging of in- 178–102, 59 FR 28493, June 2, 1994; Amdt. 178–
fectious substances with the marks 106, 59 FR 67520, 67521, Dec. 29, 1994; Amdt.
specified in this section. The markings 178–107, 60 FR 26806, May 18, 1995; 62 FR 51561,
must be durable, legible, and must be Oct. 1, 1997; 66 FR 45386, Aug. 28, 2001; 67 FR
61016, Sept. 27, 2002; 67 FR 53143, Aug. 14, 2002;
readily visible, as specified in § 178.3(a). 68 FR 75757, Dec. 31, 2003; 75 FR 5395, Feb. 2,
An infectious substance packaging that 2010; 75 FR 60339, Sept. 30, 2010; 77 FR 60943,
successfully passes the tests con- Oct. 5, 2012; 78 FR 60755, Oct. 2, 2013]
forming to the UN standard must be
marked as follows: § 178.504 Standards for steel drums.
(1) The United Nations symbol as il- (a) The following are identification
lustrated in paragraph (e) of this sec- codes for steel drums:
tion. (1) 1A1 for a non-removable head
(2) The code designating the type of steel drum; and
packaging and material of construc- (2) 1A2 for a removable head steel
tion according to the identification drum.
codes for packagings specified in (b) Construction requirements for
§ 178.502. steel drums are as follows:
(3) The text ‘‘CLASS 6.2’’. (1) Body and heads must be con-
(4) The last two digits of the year of structed of steel sheet of suitable type
manufacture of the packaging. and adequate thickness in relation to
(5) The country authorizing the allo- the capacity and intended use of the
cation of the mark. The letters ‘‘USA’’ drum. Minimum thickness and mark-
indicate the packaging is manufac- ing requirements in §§ 173.28(b)(4) and
tured and marked in the United States 178.503(a)(9) of this subchapter apply to
in compliance with the provisions of drums intended for reuse.
this subchapter. (2) Body seams must be welded on
(6) The name and address or symbol drums designed to contain more than
of the manufacturer or the approval 40 L (11 gallons) of liquids. Body seams
must be mechanically seamed or weld-
agency certifying compliance with sub-
ed on drums intended to contain only
parts L and M of this part. Symbols, if
solids or 40 L (11 gallons) or less of liq-
used, must be registered with the Asso- uids.
ciate Administrator for Hazardous Ma-
(3) Chimes must be mechanically
terials Safety. seamed or welded. Separate reinforcing
(7) For packagings meeting the re- rings may be applied.
quirements of § 178.609(i)(3), the letter (4) The body of a drum of a capacity
‘‘U’’ must be inserted immediately fol-
greater than 60 L (16 gallons) may have

lowing the marking designating the at least two expanded rolling hoops or
type of packaging and material re- two separate rolling hoops. If there are
separate rolling hoops, they must be
192
ER05OC12.063</GPH>
fitted tightly on the body and so se- ing requirements in §§ 173.28(b)(4) and
cured that they cannot shift. Rolling 178.503(a)(9) of this subchapter apply to
hoops may not be spot-welded. drums intended for reuse.
(5) Openings for filling, emptying and (2) All seams must be welded. Chime
venting in the bodies or heads of non- seams, if any, must be reinforced by
removable head (1A1) drums may not the application of separate reinforcing
exceed 7.0 cm (3 inches) in diameter. rings.
Drums with larger openings are consid- (3) The body of a drum of a capacity
ered to be of the removable head type greater than 60 L (16 gallons) may have
(1A2). Closures for openings in the bod- at least two expanded rolling hoops or
ies and heads of drums must be so de- two separate rolling hoops. If there are
signed and applied that they will re- separate rolling hoops, the hoops must
main secure and leakproof under nor- be fitted tightly on the body and so se-
mal conditions of transport. Closure cured that they cannot shift. Rolling
flanges may be mechanically seamed or hoops may not be spot-welded.
welded in place. Gaskets or other seal- (4) Openings for filling, emptying, or
ing elements must be used with clo- venting in the bodies or heads of non-
sures unless the closure is inherently removable head (1B1) drums may not
leakproof. exceed 7.0 cm (3 inches) in diameter.
(6) Closure devices for removable Drums with larger openings are consid-
head drums must be so designed and ered to be of the removable head type
applied that they will remain secure (1B2). Closures for openings in the bod-
and drums will remain leakproof under ies and heads of drums must be so de-
normal conditions of transport. Gas- signed and applied that they will re-
kets or other sealing elements must be main secure and leakproof under nor-
used with all removable heads. mal conditions of transport. Closure
(7) If materials used for body, heads, flanges may be welded in place so that
closures, and fittings are not in them- the weld provides a leakproof seam.
selves compatible with the contents to Gaskets or other sealing elements
be transported, suitable internal pro- must be used with closures unless the
tective coatings or treatments must be closure is inherently leakproof.
applied. These coatings or treatments (5) Closure devices for removable
must retain their protective properties head drums must be so designed and
under normal conditions of transport. applied that they remain secure and
(8) Maximum capacity of drum: 450 L drums remain leakproof under normal
(119 gallons). conditions of transport. Gaskets or
(9) Maximum net mass: 400 kg (882 other sealing elements must be used
pounds). with all removable heads.
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as (6) Maximum capacity of drum: 450 L
amended at 56 FR 66284, Dec. 20, 1991; Amdt. (119 gallons).
178–110, 60 FR 49111, Sept. 21, 1995] (7) Maximum net mass: 400 kg (882
pounds).
§ 178.505 Standards for aluminum
drums. [Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
(a) The following are the identifica- amended at 56 FR 66284, Dec. 20, 1991; Amdt.
tion codes for aluminum drums: 178–102, 59 FR 28494, June 2, 1994]
(1) 1B1 for a non-removable head alu-
§ 178.506 Standards for metal drums
minum drum; and other than steel or aluminum.
(2) 1B2 for a removable head alu-
minum drum. (a) The following are the identifica-
(b) Construction requirements for tion codes for metal drums other than
aluminum drums are as follows: steel or aluminum:
(1) Body and heads must be con- (1) 1N1 for a non-removable head
structed of aluminum at least 99 per- metal drum; and
cent pure or an aluminum base alloy. (2) 1N2 for a removable head metal
Material must be of suitable type and drum.

adequate thickness in relation to the (b) Construction requirements for
capacity and the intended use of the metal drums other than steel or alu-
drum. Minimum thickness and mark- minum are as follows:
193
§ 178.507 49 CFR Ch. I (10–1–18 Edition)
(1) Body and heads must be con- (1) The wood used must be well-sea-
structed of metal (other than steel or soned, commercially dry and free from
aluminum) of suitable type and ade- any defect likely to lessen the effec-
quate thickness in relation to the ca- tiveness of the drum for the purpose in-
pacity and the intended use of the tended. A material other than plywood,
drum. Minimum thickness and mark- of at least equivalent strength and du-
ing requirements in §§ 173.28(b)(4) and rability, may be used for the manufac-
178.503(a)(9) of this subchapter apply to ture of the heads.
drums intended for reuse. (2) At least two-ply plywood must be
(2) All seams must be welded. Chime used for the body and at least three-ply
seams, if any, must be reinforced by plywood for the heads; the plies must
the application of separate reinforcing be firmly glued together, with their
rings. grains crosswise.
(3) The body of a drum of a capacity (3) The body and heads of the drum
greater than 60 L (16 gallons) may have and their joints must be of a design ap-
at least two expanded rolling hoops or propriate to the capacity of the drum
two separate rolling hoops. If there are and its intended use.
separate rolling hoops, the hoops must (4) In order to prevent sifting of the
be fitted tightly on the body and so se- contents, lids must be lined with kraft
cured that they cannot shift. Rolling paper or some other equivalent mate-
hoops may not be spot-welded. rial which must be securely fastened to
(4) Openings for filling, emptying, or the lid and extend to the outside along
venting in the bodies or heads of non- its full circumference.
(5) Maximum capacity of drum: 250 L
removable head (1N1) drums may not
(66 gallons).
exceed 7.0 cm (3 inches) in diameter.
(6) Maximum net mass: 400 kg (882
Drums with larger openings are consid-
pounds).
ered to be of the removable head type
(1N2). Closures for openings in the bod- [Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
ies and heads of drums must be so de- amended at 57 FR 45465, Oct. 1, 1992]
signed and applied that they will re-
main secure and leakproof under nor- § 178.508 Standards for fiber drums.
mal conditions of transport. Closure (a) The identification code for a fiber
flanges may be welded in place so that drum is 1G.
the weld provides a leakproof seam. (b) Construction requirements for
Gaskets or other sealing elements fiber drums are as follows:
must be used with closures unless the (1) The body of the drum must be
closure is inherently leakproof. constructed of multiple plies of heavy
(5) Closure devices for removable paper or fiberboard (without corruga-
head drums must be so designed and tions) firmly glued or laminated to-
applied that they remain secure and gether and may include one or more
drums remain leakproof under normal protective layers of bitumen, waxed
conditions of transport. Gaskets or kraft paper, metal foil, plastic mate-
other sealing elements must be used rial, or similar materials.
with all removable heads. (2) Heads must be of natural wood, fi-
(6) Maximum capacity of drum: 450 L berboard, metal, plywood, plastics, or
(119 gallons). other suitable material and may in-
(7) Maximum net mass: 400 kg (882 clude one or more protective layers of
pounds). bitumen, waxed kraft paper, metal foil,
plastic material, or similar material.
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as (3) The body and heads of the drum
amended at 56 FR 66285, Dec. 20, 1991; Amdt. and their joints must be of a design ap-
178–102, 59 FR 28494, June 2, 1994] propriate to the capacity and intended
use of the drum.
§ 178.507 Standards for plywood (4) The assembled packaging must be
drums.
sufficiently water-resistant so as not
(a) The identification code for a ply- to delaminate under normal conditions
wood drum is 1D. of transport.
(b) Construction requirements for (5) Maximum capacity of drum: 450 L
plywood drums are as follows: (119 gallons).
194
(6) Maximum net mass: 400 kg (882 (4) The wall thickness at every point
pounds). of the packaging must be appropriate
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
to its capacity and its intended use,
amended by Amdt. 178–106, 59 FR 67521, Dec. taking into account the stresses to
29, 1994] which each point is liable to be ex-
posed. Minimum thickness and mark-
§ 178.509 Standards for plastic drums ing requirements in §§ 173.28(b)(4) and
and jerricans. 178.503(a)(9) of this subchapter apply to
(a) The following are identification drums intended for reuse.
codes for plastic drums and jerricans: (5) Openings for filling, emptying and
(1) 1H1 for a non-removable head venting in the bodies or heads of non-
plastic drum; removable head (1H1) drums and
(2) 1H2 for a removable head plastic jerricans (3H1) may not exceed 7.0 cm (3
drum; inches) in diameter. Drums and
(3) 3H1 for a non-removable head jerricans with larger openings are con-
jerrican; and sidered to be of the removable head
(4) 3H2 for a removable head jerrican. type (1H2 and 3H2). Closures for open-
(b) Construction requirements for ings in the bodies or heads of drums
plastic drums and jerricans are as fol- and jerricans must be so designed and
lows: applied that they remain secure and
(1) The packaging must be manufac- leakproof under normal conditions of
tured from suitable plastic material transport. Gaskets or other sealing ele-
and be of adequate strength in relation ments must be used with closures un-
to its capacity and intended use. No less the closure is inherently leakproof.
used material other than production (6) Closure devices for removable
residues or regrind from the same man- head drums and jerricans must be so
ufacturing process may be used unless designed and applied that they remain
approved by the Associate Adminis- secure and leakproof under normal con-
trator. The packaging must be ade- ditions of transport. Gaskets must be
quately resistant to aging and to deg- used with all removable heads unless
radation caused either by the sub- the drum or jerrican design is such
stance contained or by ultra-violet ra- that when the removable head is prop-
diation. Any permeation of the sub- erly secured, the drum or jerrican is in-
stance contained may not constitute a herently leakproof.
danger under normal conditions of (7) Maximum capacity of drums and
transport. jerricans: 1H1, 1H2: 450 L (119 gallons);
(2) If protection against ultra-violet 3H1, 3H2: 60 L (16 gallons).
radiation is required, it must be pro- (8) Maximum net mass: 1H1, 1H2: 400
vided by the addition of carbon black kg (882 pounds); 3H1, 3H2: 120 kg (265
or other suitable pigments or inhibi- pounds).
tors. These additives must be compat- [Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
ible with the contents and remain ef- amended by Amdt. 178–102, 59 FR 28494, June
fective throughout the life of the pack- 2, 1994; 64 FR 10782, Mar. 5, 1999; 66 FR 45386,
aging. Where use is made of carbon Aug. 28, 2001]
black, pigments or inhibitors other
than those used in the manufacture of § 178.510 Standards for wooden bar-
the design type, retesting may be omit- rels.
ted if the carbon black content does (a) The following are identification
not exceed 2 percent by mass or if the codes for wooden barrels:
pigment content does not exceed 3 per- (1) 2C1 for a bung type wooden barrel;
cent by mass; the content of inhibitors and
of ultra-violet radiation is not limited. (2) 2C2 for a slack type (removable
(3) Additives serving purposes other head) wooden barrel.
than protection against ultra-violet ra- (b) Construction requirements for
diation may be included in the com- wooden barrels are as follows:
position of the plastic material pro- (1) The wood used must be of good
vided they do not adversely affect the quality, straight-grained, well-sea-
chemical and physical properties of the soned and free from knots, bark, rotten
packaging material. wood, sapwood or other defects likely
195
§ 178.511 49 CFR Ch. I (10–1–18 Edition)
to lessen the effectiveness of the barrel jerricans intended to carry 40 L (11 gal-
for the purpose intended. lons) or less must be mechanically
(2) The body and heads must be of a seamed or welded.
design appropriate to the capacity and (4) Openings in jerricans (3A1) may
intended use of the barrel. not exceed 7.0 cm (3 inches) in diame-
(3) Staves and heads must be sawn or ter. Jerricans with larger openings are
cleft with the grain so that no annual considered to be of the removable head
ring extends over more than half the type. Closures must be so designed that
thickness of a stave or head. they remain secure and leakproof
(4) Barrel hoops must be of steel or under normal conditions of transport.
iron of good quality. The hoops of 2C2 Gaskets or other sealing elements
barrels may be of a suitable hardwood. must be used with closures, unless the
(5) For wooden barrels 2C1, the di- closure is inherently leakproof.
ameter of the bung-hole may not ex- (5) If materials used for body, heads,
ceed half the width of the stave in closures and fittings are not in them-
which it is placed.
selves compatible with the contents to
(6) For wooden barrels 2C2, heads
be transported, suitable internal pro-
must fit tightly into crozes.
tective coatings or treatments must be
(7) Maximum capacity of barrel: 250 L
applied. These coatings or treatments
(66 gallons).
must retain their protective properties
pounds). under normal conditions of transport.
(6) Maximum capacity of jerrican: 60
§ 178.511 Standards for aluminum and L (16 gallons).
steel jerricans. (7) Maximum net mass: 120 kg (265
(a) The following are identification pounds).
codes for aluminum and steel jerricans: [Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
(1) 3A1 for a non-removable head amended by Amdt. 178–102, 59 FR 28494, June
steel jerrican; 2, 1994; Amdt. 178–119, 62 FR 24742, May 6,
(2) 3A2 for a removable head steel 1997]
jerrican;
(3) 3B1 for a non-removable head alu- § 178.512 Standards for steel, alu-
minum jerrican; and minum or other metal boxes.
(4) 3B2 for a removable head alu- (a) The following are identification
minum jerrican. codes for steel, aluminum, or other
(b) Construction requirements for metal boxes:
aluminum and steel jerricans are as (1) 4A for a steel box;
follows: (2) 4B for an aluminum box; and
(1) For steel jerricans the body and
(3) 4N for an other metal box.
heads must be constructed of steel
sheet of suitable type and adequate (b) Construction requirements for
thickness in relation to the capacity of steel, aluminum or other metal boxes
the jerrican and its intended use. Min- are as follows:
imum thickness and marking require- (1) The strength of the metal and the
ments in §§ 173.28(b)(4) and 178.503(a)(9) construction of the box must be appro-
of this subchapter apply to jerricans priate to the capacity and intended use
intended for reuse. of the box.
(2) For aluminum jerricans the body (2) Boxes must be lined with fiber-
and heads must be constructed of alu- board or felt packing pieces or must
minum at least 99% pure or of an alu- have an inner liner or coating of suit-
minum base alloy. Material must be of able material in accordance with sub-
a type and of adequate thickness in re- part C of part 173 of this subchapter. If
lation to the capacity of the jerrican a double seamed metal liner is used,
and to its intended use. steps must be taken to prevent the in-
(3) Chimes of all jerricans must be gress of materials, particularly explo-
mechanically seamed or welded. Body sives, into the recesses of the seams.
seams of jerricans intended to carry (3) Closures may be of any suitable
more than 40 L (11 gallons) of liquid type, and must remain secure under
must be welded. Body seams of normal conditions of transport.
196
(4) Maximum net mass: 400 kg (882 material used and the method of con-
pounds). struction must be appropriate to the
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
capacity and intended use of the box.
amended by Amdt. 178–106, 59 FR 67521, Dec. All adjacent plies must be glued with
29, 1994; 78 FR 1096, Jan. 7, 2013] water-resistant adhesive. Other suit-
able materials may be used together
§ 178.513 Standards for boxes of nat- with plywood in the construction of
ural wood. boxes. Boxes must be nailed or secured
(a) The following are the identifica- to corner posts or ends or assembled
tion codes for boxes of natural wood: with other equally suitable devices.
(1) 4C1 for an ordinary box; and (2) Maximum net mass: 400 kg (882
(2) 4C2 for a box with sift-proof walls. pounds).
(b) Construction requirements for
boxes of natural wood are as follows: § 178.515 Standards for reconstituted
(1) The wood used must be well-sea- wood boxes.
soned, commercially dry and free from (a) The identification code for a re-
defects that would materially lessen constituted wood box is 4F.
the strength of any part of the box. The (b) Construction requirements for re-
strength of the material used and the constituted wood boxes are as follows:
method of construction must be appro-
(1) The walls of boxes must be made
priate to the capacity and intended use
of water-resistant, reconstituted wood
of the box. The tops and bottoms may
such as hardboard, particle board, or
be made of water-resistant reconsti-
other suitable type. The strength of
tuted wood such as hard board, particle
the material used and the method of
board or other suitable type.
(2) Fastenings must be resistant to construction must be appropriate to
vibration experienced under normal the capacity of the boxes and their in-
conditions of transportation. End grain tended use.
nailing must be avoided whenever prac- (2) Other parts of the box may be
ticable. Joints which are likely to be made of other suitable materials.
highly stressed must be made using (3) Boxes must be securely assembled
clenched or annular ring nails or equiv- by means of suitable devices.
alent fastenings. (4) Maximum net mass: 400 kg (882
(3) Each part of the 4C2 box must be pounds).
one piece or equivalent. Parts are con-
sidered equivalent to one piece when § 178.516 Standards for fiberboard
one of the following methods of glued boxes.
assembly is used: Linderman joint, (a) The identification code for a fi-
tongue and groove joint, ship lap or berboard box is 4G.
rabbet joint, or butt joint with at least (b) Construction requirements for fi-
two corrugated metal fasteners at each berboard boxes are as follows:
joint. (1) Strong, solid or double-faced cor-
(4) Maximum net mass: 400 kg (882 rugated fiberboard (single or multi-
pounds). wall) must be used, appropriate to the
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as capacity and intended use of the box.
amended by Amdt. 178–106, 59 FR 67521, Dec. The water resistance of the outer sur-
29, 1994] face must be such that the increase in
mass, as determined in a test carried
§ 178.514 Standards for plywood boxes. out over a period of 30 minutes by the
(a) The identification code for a ply- Cobb method of determining water ab-
wood box is 4D. sorption, is not greater than 155 g per
(b) Construction requirements for square meter (0.0316 pounds per square
plywood boxes are as follows: foot)—see ISO 535 (IBR, see § 171.7 of
(1) Plywood used must be at least 3 this subchapter). Fiberboard must have
ply. It shall be made from well-sea- proper bending qualities. Fiberboard
soned rotary cut, sliced or sawn veneer, must be cut, creased without cutting
commercially dry and free from defects through any thickness of fiberboard,
that would materially lessen the and slotted so as to permit assembly
strength of the box. The strength of the without cracking, surface breaks, or
197
§ 178.517 49 CFR Ch. I (10–1–18 Edition)
undue bending. The fluting of cor- tion containing cavities for the inner
rugated fiberboard must be firmly receptacles, and a top section covering
glued to the facings. and interlocking with the bottom sec-
(2) The ends of boxes may have a tion. The top and bottom sections must
wooden frame or be entirely of wood or be so designed that the inner recep-
other suitable material. Reinforce- tacles fit snugly. The closure cap for
ments of wooden battens or other suit- any inner receptacle may not be in
able material may be used. contact with the inside of the top sec-
(3) Manufacturing joints. (i) Manu- tion of the box.
facturing joints in the bodies of boxes (3) For transportation, an expanded
must be— plastic box must be closed with a self-
(A) Taped; adhesive tape having sufficient tensile
(B) Lapped and glued; or strength to prevent the box from open-
(C) Lapped and stitched with metal ing. The adhesive tape must be weath-
staples. er-resistant and its adhesive compat-
(ii) Lapped joints must have an ap- ible with the expanded plastic material
propriate overlap. of the box. Other closing devices at
(4) Where closing is effected by glu- least equally effective may be used.
ing or taping, a water resistant adhe- (4) For solid plastic boxes, protection
sive must be used. against ultra-violet radiation, if re-
(5) Boxes must be designed so as to
quired, must be provided by the addi-
provide a snug fit to the contents.
tion of carbon black or other suitable
pigments or inhibitors. These additives
pounds).
must be compatible with the contents
(7) Authorization to manufacture,
and remain effective throughout the
mark, and sell UN4G combination
life of the box. Where use is made of
packagings with outer fiberboard boxes
carbon black pigment or inhibitors
and with inner fiberboard components
other than those used in the manufac-
that have individual containerboard or
ture of the tested design type, re-
paper wall basis weights that vary by
testing may be waived if the carbon
not more than plus or minus 5% from
black content does not exceed 2 percent
the nominal basis weight reported in
by mass or if the pigment content does
the initial design qualification test re-
not exceed 3 percent by mass; the con-
port.
tent of inhibitors of ultra-violet radi-
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as ation is not limited.
amended by Amdt. 178–99, 58 FR 51534, Oct. 1, (5) Additives serving purposes other
1993; Amdt. 178–106, 59 FR 67521, Dec. 29, 1994; than protection against ultra-violet ra-
68 FR 75758, Dec. 31, 2003; 79 FR 15046, Mar. 18,
2014]
diation may be included in the com-
position of the plastic material if they
§ 178.517 Standards for plastic boxes. do not adversely affect the material of
the box. Addition of these additives
(a) The following are identification
does not change the design type.
codes for plastic boxes:
(1) 4H1 for an expanded plastic box; (6) Solid plastic boxes must have clo-
and sure devices made of a suitable mate-
(2) 4H2 for a solid plastic box. rial of adequate strength and so de-
(b) Construction requirements for signed as to prevent the box from unin-
plastic boxes are as follows: tentionally opening.
(1) The box must be manufactured (7) Maximum net mass 4H1: 60 kg (132
from suitable plastic material and be pounds); 4H2: 400 kg (882 pounds).
of adequate strength in relation to its
§ 178.518 Standards for woven plastic
capacity and intended use. The box bags.
must be adequately resistant to aging
and to degradation caused either by (a) The following are identification
the substance contained or by ultra- codes for woven plastic bags:
violet radiation. (1) 5H1 for an unlined or non-coated

(2) An expanded plastic box must con- woven plastic bag;
sist of two parts made of a molded ex- (2) 5H2 for a sift-proof woven plastic
panded plastic material: a bottom sec- bag; and
198
(3) 5H3 for a water-resistant woven § 178.520 Standards for textile bags.
plastic bag.
(a) The following are identification
(b) Construction requirements for codes for textile bags:
woven plastic fabric bags are as fol-
(1) 5L1 for an unlined or non-coated
lows: textile bag;
(1) Bags must be made from stretched (2) 5L2 for a sift-proof textile bag;
tapes or monofilaments of a suitable and
plastic material. The strength of the
(3) 5L3 for a water-resistant textile
material used and the construction of bag.
the bag must be appropriate to the ca-
(b) Construction requirements for
pacity and intended use of the bag.
textile bags are as follows:
(2) If the fabric is woven flat, the (1) The textiles used must be of good
bags must be made by sewing or some quality. The strength of the fabric and
other method ensuring closure of the the construction of the bag must be ap-
bottom and one side. If the fabric is tu- propriate to the capacity and intended
bular, the bag must be closed by sew- use of the bag.
ing, weaving, or some other equally (2) Bags, sift-proof, 5L2: The bag
strong method of closure. must be made sift-proof, by appropriate
(3) Bags, sift-proof, 5H2 must be made means, such as by the use of paper
sift-proof by appropriate means such as bonded to the inner surface of the bag
use of paper or a plastic film bonded to by a water-resistant adhesive such as
the inner surface of the bag or one or bitumen, plastic film bonded to the
more separate inner liners made of inner surface of the bag, or one or more
paper or plastic material. inner liners made of paper or plastic
(4) Bags, water-resistant, 5H3: To pre- material.
vent the entry of moisture, the bag (3) Bags, water-resistant, 5L3: To pre-
must be made waterproof by appro- vent entry of moisture, the bag must
priate means, such as separate inner be made waterproof by appropriate
liners of water-resistant paper (e.g., means, such as by the use of separate
waxed kraft paper, double-tarred kraft inner liners of water-resistant paper
paper or plastic-coated kraft paper), or (e.g., waxed kraft paper, tarred paper,
plastic film bonded to the inner or or plastic-coated kraft paper), or plas-
outer surface of the bag, or one or more tic film bonded to the inner surface of
inner plastic liners. the bag, or one or more inner liners
(5) Maximum net mass: 50 kg (110 made of plastic material or metalized
pounds). film or foil.
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
amended by Amdt. 178–99, 58 FR 51534, Oct. 1,
pounds).
1993] [Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
amended at 56 FR 66285, Dec. 20, 1991]
§ 178.519 Standards for plastic film
bags. § 178.521 Standards for paper bags.
(a) The identification code for a plas- (a) The following are identification
tic film bag is 5H4. codes for paper bags:
(b) Construction requirements for (1) 5M1 for a multi-wall paper bag;
plastic film bags are as follows: and
(1) Bags must be made of a suitable (2) 5M2 for a multi-wall water-resist-
plastic material. The strength of the ant paper bag.
material used and the construction of (b) Construction requirements for
the bag must be appropriate to the ca- paper bags are as follows:
pacity and the intended use of the bag. (1) Bags must be made of a suitable
Joints and closures must be capable of kraft paper, or of an equivalent paper
withstanding pressures and impacts with at least three plies. The strength
liable to occur under normal conditions of the paper and the construction of
of transportation. the bag must be appropriate to the ca-
(2) Maximum net mass: 50 kg (110 pacity and intended use of the bag.
pounds). Seams and closures must be sift-proof.
199
§ 178.522 49 CFR Ch. I (10–1–18 Edition)
(2) Paper bags 5M2: To prevent the (11) 6HH2 for a plastic receptacle
entry of moisture, a bag of four plies or within a protective plastic box.
more must be made waterproof by the (b) Construction requirements for
use of either a water-resistant ply as composite packagings with inner re-
one of the two outermost plies or a ceptacles of plastic are as follows:
water-resistant barrier made of a suit- (1) Inner receptacles must be con-
able protective material between the structed under the applicable construc-
two outermost plies. A 5M2 bag of tion requirements prescribed in
three plies must be made waterproof by § 178.509(b) (1) through (7) of this sub-
the use of a water-resistant ply as the part.
outermost ply. When there is danger of (2) The inner plastic receptacle must
the lading reacting with moisture, or fit snugly inside the outer packaging,
when it is packed damp, a waterproof
which must be free of any projections
ply or barrier, such as double-tarred
which may abrade the plastic material.
kraft paper, plastics-coated kraft
paper, plastics film bonded to the inner (3) Outer packagings must be con-
surface of the bag, or one or more inner structed as follows:
plastics liners, must also be placed (i) 6HA1 or 6HB1: Protective pack-
next to the substance. Seams and clo- aging must conform to the require-
sures must be waterproof. ments for steel drums in § 178.504(b) of
(3) Maximum net mass: 50 kg (110 this subpart, or aluminum drums in
pounds). § 178.505(b) of this subpart.
(4) UN5M1 and UN5M2 multi wall (ii) 6HA2 or 6HB2: Protective pack-
paper bags that have paper wall basis agings with steel or aluminum crate
weights that vary by not more than must conform to the requirements for
plus or minus 5% from the nominal steel or aluminum boxes found in
basis weight reported in the initial de- § 178.512(b) of this subpart.
sign qualification test report. (iii) 6HC protective packaging must
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
conform to the requirements for wood-
amended at 56 FR 66285, Dec. 20, 1991; Amdt. en boxes in § 178.513(b) of this subpart.
178–106, 59 FR 67521, Dec. 29, 1994; 79 FR 15046, (iv) 6HD1: Protective packaging must
Mar. 18, 2014] conform to the requirements for ply-
wood drums, in § 178.507(b) of this sub-
§ 178.522 Standards for composite part.
packagings with inner plastic re-
ceptacles. (v) 6HD2: Protective packaging must
conform to the requirements of ply-
(a) The following are the identifica- wood boxes, in § 178.514(b) of this sub-
tion codes for composite packagings part.
with inner plastic receptacles: (vi) 6HG1: Protective packaging must
(1) 6HA1 for a plastic receptacle with- conform to the requirements for fiber
in a protective steel drum; drums, in § 178.508(b) of this subpart.
(2) 6HA2 for a plastic receptacle with-
(vii) 6HG2: protective packaging
in a protective steel crate or box;
must conform to the requirements for
(3) 6HB1 for a plastic receptacle with-
fiberboard boxes, in § 178.516(b) of this
in a protective aluminum drum.
subpart.
(4) 6HB2 for a plastic receptacle with-
in a protective aluminum crate or box. (viii) 6HH1: Protective packaging
(5) 6HC for a plastic receptacle within must conform to the requirements for
a protective wooden box. plastic drums, in § 178.509(b).
(6) 6HD1 for a plastic receptacle with- (ix) 6HH2: Protective packaging must
in a protective plywood drum; conform to the requirements for plastic
(7) 6HD2 for a plastic receptacle with- boxes, in § 178.517(b).
in a protective plywood box; (4) Maximum capacity of inner recep-
(8) 6HG1 for a plastic receptacle with- tacles is as follows: 6HA1, 6HB1, 6HD1,
in a protective fiber drum; 6HG1, 6HH1—250 L (66 gallons); 6HA2,
(9) 6HG2 for a plastic receptacle with- 6HB2, 6HC, 6HD2, 6HG2, 6HH2—60 L (16
in a protective fiberboard box; gallons).
(10) 6HH1 for a plastic receptacle (5) Maximum net mass is as follows:
within a protective plastic drum; and 6HA1, 6HB1, 6HD1, 6HG1, 6HH1—400kg
200
(882 pounds); 6HB2, 6HC, 6HD2, 6HG2, (ii) Any part of a closure likely to
6HH2—75 kg (165 pounds). come into contact with the contents of
the receptacle must be resistant to
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as
those contents. Closures must be fitted
29, 1994] so as to be leakproof and secured to
prevent any loosening during transpor-
§ 178.523 Standards for composite tation. Vented closures must conform
packagings with inner glass, por- to § 173.24(f) of this subchapter.
celain, or stoneware receptacles. (2) Protective packagings must con-
(a) The following are identification form to the following requirements:
codes for composite packagings with (i) For receptacles with protective
inner receptacles of glass, porcelain, or steel drum 6PAl, the drum must com-
stoneware: ply with § 178.504(b) of this subpart.
(1) 6PA1 for glass, porcelain, or stone- However, the removable lid required
ware receptacles within a protective for this type of packaging may be in
steel drum; the form of a cap.
(2) 6PA2 for glass, porcelain, or stone- (ii) For receptacles with protective
ware receptacles within a protective packaging of steel crate or steel box
steel crate or box; 6PA2, the protective packaging must
conform to the following:
(3) 6PB1 for glass, porcelain, or stone-
(A) Section 178.512(b) of this subpart.
ware receptacles within a protective
(B) In the case of cylindrical recep-
aluminum drum;
tacles, the protective packaging must,
(4) 6PB2 for glass, porcelain, or stone-
when upright, rise above the receptacle
ware receptacles within a protective
and its closure; and
aluminum crate or box;
(C) If the protective crate surrounds
(5) 6PC for glass, porcelain, or stone- a pear-shaped receptacle and is of
ware receptacles within a protective matching shape, the protective pack-
wooden box; aging must be fitted with a protective
(6) 6PD1 for glass, porcelain, or stone- cover (cap).
ware receptacles within a protective (iii) For receptacles with protective
plywood drum; aluminum drum 6PB1, the require-
(7) 6PD2 for glass, porcelain, or stone- ments of § 178.505(b) of this subpart
ware receptacles within a protective apply to the protective packaging.
wickerwork hamper; (iv) For receptacles with protective
(8) 6PG1 for glass, porcelain, or stone- aluminum box or crate 6PB2, the re-
ware receptacles within a protective quirements of § 178.512(b) of this sub-
fiber drum; part apply to the protective packaging.
(9) 6PG2 for glass, porcelain, or stone- (v) For receptacles with protective
ware receptacles within a protective fi- wooden box 6PC, the requirements of
berboard box; § 178.513(b) of this subpart apply to the
(10) 6PH1 for glass, porcelain, or protective packaging.
stoneware receptacles within a protec- (vi) For receptacles with protective
tive expanded plastic packaging; and plywood drum 6PD1, the requirements
(11) 6PH2 for glass, porcelain, or of § 178.507(b) of this subpart apply to
stoneware receptacles within a protec- the protective packaging.
tive solid plastic packaging. (vii) For receptacles with protective
(b) Construction requirements for wickerwork hamper 6PD2, the
composite packagings with inner re- wickerwork hamper must be properly
ceptacles of glass, porcelain, or stone- made with material of good quality.
ware are as follows: The hamper must be fitted with a pro-
(1) Inner receptacles must conform to tective cover (cap) so as to prevent
the following requirements: damage to the receptacle.
(i) Receptacles must be of suitable (viii) For receptacles with protective
form (cylindrical or pear-shaped), be fiber drum 6PG1, the drum must con-
made of good quality materials free form to the requirements of § 178.508(b)

from any defect that could impair their of this subpart.
strength, and be firmly secured in the (ix) For receptacles with protective
outer packaging. fiberboard box 6PG2, the requirements
201
§ 178.600 49 CFR Ch. I (10–1–18 Edition)
of § 178.516(b) of this subpart apply to with §§ 173.22 and 178.2 of this sub-
the protective packaging. chapter.
(x) For receptacles with protective (c) Definitions. For the purpose of this
solid plastic or expanded plastic pack- subpart:
aging 6PH1 or 6PH2, the requirements (1) Design qualification testing is the
of § 178.517(b) of this subpart apply to performance of the tests prescribed in
the protective packaging. Solid protec- § 178.603, § 178.604, § 178.605, § 178.606,
tive plastic packaging must be manu- § 178.607, § 178.608, or § 178.609, as applica-
factured from high-density poly- ble, for each new or different pack-
ethylene from some other comparable aging, at the start of production of
plastic material. The removable lid re- that packaging.
quired for this type of packaging may (2) Periodic retesting is the perform-
be a cap. ance of the drop, leakproofness, hydro-
(3) Quantity limitations are as fol- static pressure, and stacking tests, as
lows: applicable, as prescribed in § 178.603,
(i) Maximum net capacity for pack- § 178.604, § 178.605, or § 178.606, respec-
aging for liquids: 60 L (16 gallons). tively, at the frequency specified in
(ii) Maximum net mass for pack- paragraph (e) of this section. For infec-
agings for solids: 75 kg (165 pounds). tious substances packagings required
to meet the requirements of § 178.609,
Subpart M—Testing of Non-bulk periodic retesting is the performance of
Packagings and Packages the tests specified in § 178.609 at the fre-
quency specified in paragraph (e) of
SOURCE: Amdt. 178–97, 55 FR 52723, Dec. 21, this section.
1990, unless otherwise noted. (3) Production testing is the perform-
ance of the leakproofness test pre-
§ 178.600 Purpose and scope. scribed in § 178.604 of this subpart on
This subpart prescribes certain test- each single or composite packaging in-
ing requirements for performance-ori- tended to contain a liquid.
ented packagings identified in subpart (4) A different packaging is one that
L of this part. differs (i.e., is not identical) from a pre-
viously produced packaging in struc-
[Amdt. 178–97, 55 FR 52717, Dec. 21, 1990, as tural design, size, material of construc-
amended by Amdt. 178–99, 58 FR 51534, Oct. 1,
1993]
tion, wall thickness or manner of con-
struction but does not include:
§ 178.601 General requirements. (i) A packaging which differs only in
surface treatment;
(a) General. The test procedures pre-
scribed in this subpart are intended to (ii) A combination packaging which
ensure that packages containing haz- differs only in that the outer pack-
ardous materials can withstand normal aging has been successfully tested with
conditions of transportation and are different inner packagings. A variety of
considered minimum requirements. such inner packagings may be assem-
Each packaging must be manufactured bled in this outer packaging without
and assembled so as to be capable of further testing;
successfully passing the prescribed (iii) A plastic packaging which differs
tests and of conforming to the require- only with regard to additives which
ments of § 173.24 of this subchapter at conform to § 178.509(b)(3) or § 178.517(b)
all times while in transportation. (4) or (5) of this part;
(b) Responsibility. It is the responsi- (iv) A combination packaging with
bility of the packaging manufacturer inner packagings conforming to the
to assure that each package is capable provisions of paragraph (g) of this sec-
of passing the prescribed tests. To the tion;
extent that a package assembly func- (v) Packagings which differ from the
tion, including final closure, is per- design type only in their lesser design
formed by the person who offers a haz- height; or

ardous material for transportation, (vi) For a steel drum, variations in
that person is responsible for per- design elements which do not con-
forming the function in accordance stitute a different design type under
202
the provisions of paragraph (g)(8) of mented in writing by the person certi-

this section. fying compliance with this paragraph
(d) Design qualification testing. The and retained in accordance with para-
packaging manufacturer shall achieve graph (l) of this section. Permitted
successful test results for the design variations are as follows:
qualification testing at the start of (i) Inner packagings of equivalent or
production of each new or different smaller size may be used provided—
packaging. (A) The inner packagings are of simi-
(e) Periodic retesting. The packaging lar design to the tested inner pack-
manufacturer must achieve successful
agings (i.e., shape—round, rectangular,
test results for the periodic retesting
etc.);
at intervals established by the manu-
facturer of sufficient frequency to en- (B) The material of construction of
sure that each packaging produced by the inner packagings (glass, plastic,
the manufacturer is capable of passing metal, etc.) offers resistance to impact
the design qualification tests. Changes and stacking forces equal to or greater
in retest frequency are subject to the than that of the originally tested inner
approval of the Associate Adminis- packaging;
trator for Hazardous Materials Safety. (C) The inner packagings have the
For single or composite packagings, same or smaller openings and the clo-
the periodic retests must be conducted sure is of similar design (e.g., screw
at least once every 12 months. For cap, friction lid, etc.);
combination packagings, the periodic (D) Sufficient additional cushioning
retests must be conducted at least once material is used to take up void spaces
every 24 months. For infectious sub- and to prevent significant moving of
stances packagings, the periodic the inner packagings;
retests must be conducted at least once (E) Inner packagings are oriented
every 24 months. within the outer packaging in the same
(f) Test samples. The manufacturer
manner as in the tested package; and,
shall conduct the design qualification
and periodic tests prescribed in this (F) The gross mass of the package
subpart using random samples of pack- does not exceed that originally tested.
agings, in the numbers specified in the (ii) A lesser number of the tested
appropriate test section. In addition, inner packagings, or of the alternative
the leakproofness test, when required, types of inner packagings identified in
shall be performed on each packaging paragraph (g)(1)(i) of this section, may
produced by the manufacturer, and be used provided sufficient cushioning
each packaging prior to reuse under is added to fill void space(s) and to pre-
§ 173.28 of this subchapter, by the re- vent significant moving of the inner
conditioner. packagings.
(g) Selective testing. The selective (2) Selective testing of combination
testing of packagings that differ only packagings. Variation 2. Articles or
in minor respects from a tested type is inner packagings of any type, for solids
permitted as described in this section. or liquids, may be assembled and trans-
For air transport, packagings must ported without testing in an outer
comply with § 173.27(c)(1) and (c)(2) of packaging under the following condi-
this subchapter. tions:
(1) Selective testing of combination (i) The outer packaging must have
packagings. Variation 1. Variations are
been successfully tested in accordance
permitted in inner packagings of a
with § 178.603 with fragile (e.g. glass)
tested combination package, without
further testing of the package, pro- inner packagings containing liquids at
vided an equivalent level of perform- the Packing Group I drop height;
ance is maintained and, when a pack- (ii) The total combined gross mass of
age is altered under Variation 1 after inner packagings may not exceed one-
October 1, 2010, the methodology used half the gross mass of inner packagings
to determine that the inner packaging, used for the drop test;
including closure, maintains an equiva- (iii) The thickness of cushioning ma-
lent level of performance is docu- terial between inner packagings and
203
§ 178.601 49 CFR Ch. I (10–1–18 Edition)
between inner packagings and the out- duced with reductions in external di-
side of the packaging may not be re- mensions (i.e., length, width or diame-
duced below the corresponding thick- ter) of up to 25 percent of the dimen-
ness in the originally tested packaging; sions of a tested packaging may be
and when a single inner packaging was used without further testing provided
used in the original test, the thickness an equivalent level of performance is
of cushioning between inner pack- maintained. The packagings must, in
agings may not be less than the thick- all other respects (including wall
ness of cushioning between the outside thicknesses), be identical to the tested
of the packaging and the inner pack- design-type. The marked gross mass
aging in the original test. When either (when required) must be reduced in
fewer or smaller inner packagings are proportion to the reduction in volume.
used (as compared to the inner pack- (4) Variation 4. Variations are per-
agings used in the drop test), sufficient mitted in outer packagings of a tested
additional cushioning material must be design-type combination packaging,
used to take up void spaces. without further testing, provided an
(iv) The outer packaging must have equivalent level of performance is
successfully passed the stacking test maintained, as follows:
set forth in § 178.606 of this subpart (i) Each external dimension (length,
when empty, i.e., without either inner width and height) is less than or equal
packagings or cushioning materials. to the corresponding dimension of the
The total mass of identical packages tested design-type;
must be based on the combined mass of (ii) The structural design of the test-
inner packagings used for the drop ed outer packaging (i.e., methods of
test; construction, materials of construc-
(v) Inner packagings containing liq- tion, strength characteristics of mate-
uids must be completely surrounded rials of construction, method of closure
with a sufficient quantity of absorbent and material thicknesses) is main-
material to absorb the entire liquid tained;
contents of the inner packagings; (iii) The inner packagings are iden-
(vi) When the outer packaging is in- tical to the inner packagings used in
tended to contain inner packagings for the tested design type except that their
liquids and is not leakproof, or is in- size and mass may be less; and they are
tended to contain inner packagings for oriented within the outer packaging in
solids and is not siftproof, a means of the same manner as in the tested pack-
containing any liquid or solid contents aging;
in the event of leakage must be pro- (iv) The same type or design of ab-
vided in the form of a leakproof liner, sorbent materials, cushioning mate-
plastic bag, or other equally efficient rials and any other components nec-
means of containment. For packagings essary to contain and protect inner
containing liquids, the absorbent mate- packagings, as used in the tested de-
rial required in paragraph (g)(2)(v) of sign type, are maintained. The thick-
this section must be placed inside the ness of cushioning material between
means of containing liquid contents; inner packagings and between inner
and packagings and the outside of the
(vii) Packagings must be marked in packaging may not be less than the
accordance with § 178.503 of this part as thicknesses in the tested design type
having been tested to Packing Group I packaging; and
performance for combination pack- (v) Sufficient additional cushioning
agings. The marked maximum gross material is used to take up void spaces
mass may not exceed the sum of the and to prevent significant moving of
mass of the outer packaging plus one the inner packagings.
half the mass of the filled inner pack- An outer packaging qualifying for use
agings of the tested combination pack- in transport in accordance with all of
aging. In addition, the marking re- the above conditions may also be used
quired by § 178.503(a)(2) of this part without testing to transport inner

must include the letter ‘‘V’’. packagings substituted for the origi-
(3) Variation 3. Packagings other than nally tested inner packagings in ac-
combination packagings which are pro- cordance with the conditions set out in
204
Variation 1 in paragraph (g)(1) of this the specific gravity of the liquid used
section. in the design type tests of the pack-
(5) Variation 5. Single packagings aging with replacement closure devices
(i.e., non-bulk packagings other than or gasketing.)
combination packagings), that differ (6) The provisions in Variations 1, 2,
from a tested design type only to the and 4 in paragraphs (g)(1), (2) and (4) of
extent that the closure device or this section for combination pack-
gasketing differs from that used in the agings may be applied to packagings
originally tested design type, may be containing articles, where the provi-
used without further testing, provided sions for inner packagings are applied
an equivalent level of performance is analogously to the articles. In this
maintained, subject to the following case, inner packagings need not comply
conditions (the qualifying tests): with § 173.27(c)(1) and (c)(2) of this sub-
(i) A packaging with the replacement chapter.
closure devices or gasketing must suc-
(7) Approval of selective testing. In ad-
cessfully pass the drop test specified in
dition to the provisions of § 178.601(g)(1)
§ 178.603 in the orientation which most
through (g)(6) of this subpart, the Asso-
severely tests the integrity of the clo-
ciate Administrator may approve the
sure or gasket;
selective testing of packagings that
(ii) When intended to contain liquids,
a packaging with the replacement clo- differ only in minor respects from a
sure devices or gasketing must success- tested type.
fully pass the leakproofness test speci- (8) For a steel drum with a capacity
fied in § 178.604, the hydrostatic pres- greater than 12 L (3 gallons) manufac-
sure test specified in § 178.605, and the tured from low carbon, cold-rolled
stacking test specified in § 178.606. sheet steel meeting ASTM designations
A 366/A 366M or A 568/A 568M, vari-
Replacement closures and gasketings
ations in elements other than the fol-
qualified under the above test require-
lowing design elements are considered
ments are authorized without addi-
minor and do not constitute a different
tional testing for packagings described
drum design type, or ‘‘different pack-
in paragraph (g)(3) of this section. Re-
aging’’ as defined in paragraph (c) of
placement closures and gasketings
this section for which design qualifica-
qualified under the above test require-
tion testing and periodic retesting are
ments also are authorized without ad-
required. Minor variations authorized
ditional testing for different tested de-
without further testing include
sign types packagings of the same type
changes in the identity of the supplier
as the originally tested packaging, pro-
of component material made to the
vided the original design type tests are
same specifications, or the original
more severe or comparable to tests
manufacturer of a DOT specification or
which would otherwise be conducted on
UN standard drum to be remanufac-
the packaging with the replacement
tured. A change in any one or more of
closures or gasketings. (For example:
the following design elements con-
The packaging used in the qualifying
stitutes a different drum design type:
tests has a lesser packaging wall thick-
ness than the packaging with replace- (i) The packaging type and category
ment closure devices or gasketing; the of the original drum and the remanu-
gross mass of the packaging used in the factured drum, i.e., 1A1 or 1A2;
qualifying drop test equals or exceeds (ii) The style, (i.e., straight-sided or
the mass for which the packaging with tapered);
replacement closure devices or (iii) Except as provided in paragraph
gasketing was tested; the packaging (g)(3) of this section, the rated
used in the qualifying drop test was (marked) capacity and outside dimen-
dropped from the same or greater sions;
height than the height from which the (iv) The physical state for which the
packaging with replacement closure packaging was originally approved
devices or gasketing was dropped in de- (e.g., tested for solids or liquids);
sign type tests; and the specific gravity (v) An increase in the marked level of
of the substance used in the qualifying performance of the original drum (i.e.,
drop test was the same or greater than to a higher packing group, hydrostatic
205
§ 178.601 49 CFR Ch. I (10–1–18 Edition)
test pressure, or specific gravity to pendent testing facility, in accordance

which the packaging has been tested); with this subpart; or
(vi) Type of side seam welding; (2) Supply packagings, in quantities
(vii) Type of steel; sufficient to conduct tests in accord-
(viii) An increase greater than 10% or ance with this subpart, to the Asso-
any decrease in the steel thickness of ciate Administrator or a designated
the head, body, or bottom; representative of the Associate Admin-
(ix) End seam type, (e.g., triple or istrator.
double seam); (j) Coatings. If an inner treatment or
(x) A reduction in the number of roll- coating of a packaging is required for
ing hoops (beads) which equal or exceed safety reasons, the manufacturer shall
the diameter over the chimes; design the packaging so that the treat-
(xi) The location, type or size, and ment or coating retains its protective
material of closures (other than the properties even after withstanding the
cover of UN 1A2 drums); tests prescribed by this subpart.
(xii) The location (e.g., from the head (k) Number of test samples. Except as
to the body), type (e.g., mechanically provided in this section, one test sam-
seamed or welded flange), and mate- ple must be used for each test per-
rials of closure (other than the cover of formed under this subpart.
UN 1A2 drums); and (1) Stainless steel drums. Provided the
(xiii) For UN 1A2 drums: validity of the test results is not af-
(A) Gasket material (e.g., plastic), or fected, a person may perform the de-
properties affecting the performance of sign qualification testing of stainless
the gasket; steel drums using three (3) samples
(B) Configuration or dimensions of rather than the specified eighteen (18)
the gasket; samples under the following provisions:
(C) Closure ring style including bolt (i) The packaging must be tested in
size (e.g., square or round back, 0.625 accordance with this subpart by sub-
inches bolt); and jecting each of the three containers to
(D) Closure ring thickness, the following sequence of tests:
(E) Width of lugs or extensions in (A) The stacking test in § 178.606,
crimp/lug cover. (B) The leakproofness test in § 178.604,
(h) Approval of equivalent packagings. (C) The hydrostatic pressure test in
A packaging having specifications dif- § 178.608, and
ferent from those in §§ 178.504–178.523 of (D) Diagonal top chime and flat on
this part, or which is tested using the side drop tests in § 178.603. Both
methods or test intervals, other than drop tests may be conducted on the
those specified in subpart M of this same sample.
part, may be used if approved by the (ii) For periodic retesting of stainless
Associate Administrator. Such pack- steel drums, a reduced sample size of
agings must be shown to be equally ef- one container is authorized.
fective, and testing methods used must (2) Packagings other than stainless steel
be equivalent. drums. Provided the validity of the test
(i) Proof of compliance. Notwith- results is not affected, several tests
standing the periodic retest intervals may be performed on one sample with
specified in paragraph (e) of this sec- the approval of the Associate Adminis-
tion, the Associate Administrator may trator.
at any time require demonstration of (l) Record retention. Following each
compliance by a manufacturer, design qualification test and each peri-
through testing in accordance with odic retest on a packaging, a test re-
this subpart, that packagings meet the port must be prepared.
requirements of this subpart. As re- (1) The test report must be main-
quired by the Associate Administrator, tained at each location where the pack-
the manufacturer shall either— aging is manufactured, certified, and a
(1) Conduct performance tests, or design qualification test or periodic
have tests conducted by an inde- retest is conducted as follows:
206
Responsible party Duration
Person manufacturing the packaging .......................................... As long as manufactured and two years thereafter.
Person performing design testing ............................................... Design test maintained for a single or composite packaging for
six years after the test is successfully performed and for a
combination packaging or packaging intended for infectious
substances for seven years after the test is successfully per-
formed.
Person performing periodic retesting .......................................... Performance test maintained for a single or composite pack-
aging for one year after the test is successfully performed
and for a combination packaging or packaging intended for
infectious substances for two years after the test is success-
fully performed.
(2) The test report must be made packagings in the case of combination
available to a user of a packaging or a packagings.
representative of the Department upon (b) For the drop and stacking test,
request. The test report, at a min- inner and single-unit receptacles other
imum, must contain the following in- than bags must be filled to not less
formation: than 95% of maximum capacity (see
(i) Name and address of test facility; § 171.8 of this subchapter) in the case of
(ii) Name and address of applicant solids and not less than 98% of max-
(where appropriate); imum in the case of liquids. Bags con-
(iii) A unique test report identifica- taining solids shall be filled to the
tion; maximum mass at which they may be
(iv) Date of the test report; used. The material to be transported in
(v) Manufacturer of the packaging; the packagings may be replaced by a
(vi) Description of the packaging de- non-hazardous material, except for
sign type (e.g., dimensions, materials, chemical compatibility testing or
closures, thickness, etc.), including where this would invalidate the results
methods of manufacture (e.g., blow of the tests.
molding) and which may include draw- (c) If the material to be transported
ing(s) and/or photograph(s); is replaced for test purposes by a non-
(vii) Maximum capacity; hazardous material, the material used
must be of the same or higher specific
(viii) Characteristics of test contents,
gravity as the material to be carried,
e.g., viscosity and relative density for
and its other physical properties
liquids and particle size for solids;
(grain, size, viscosity) which might in-
(ix) Test descriptions and results; and
fluence the results of the required tests
(x) Signed with the name and title of must correspond as closely as possible
signatory. to those of the hazardous material to
[Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as be transported. Water may also be used
amended at 56 FR 66285, Dec. 20, 1991; 57 FR for the liquid drop test under the con-
45465, Oct. 1, 1992; Amdt. 178–102, 59 FR 28494, ditions specified in § 178.603(e) of this
June 2, 1994; Amdt. 178–106, 59 FR 67521, 67522, subpart. It is permissible to use addi-
Dec. 29, 1994; Amdt. 178–117, 61 FR 50628, Sept. tives, such as bags of lead shot, to
26, 1996; 66 FR 45386, Aug. 28, 2001; 67 FR 53143,
achieve the requisite total package
Aug. 14, 2002; 68 FR 75758, Dec. 31, 2003; 68 FR
61942, Oct. 30, 2003; 75 FR 5396, Feb. 2, 2010; 75 mass, so long as they are placed so that
FR 60339, Sept. 30, 2010; 77 FR 60944, Oct. 5, the test results are not affected.
2012; 78 FR 1118, Jan. 7, 2013; 78 FR 14715, Mar. (d) Paper or fiberboard packagings
7, 2013; 78 FR 65487, Oct. 31, 2013] must be conditioned for at least 24
hours immediately prior to testing in
§ 178.602 Preparation of packagings an atmosphere maintained—
and packages for testing. (1) At 50 percent ±2 percent relative
(a) Except as otherwise provided in humidity, and at a temperature of 23
this subchapter, each packaging and °C±2 °C (73 °F±4 °F). Average values
package must be closed in preparation should fall within these limits. Short-
for testing and tests must be carried term fluctuations and measurement
out in the same manner as if prepared limitations may cause individual meas-
for transportation, including inner urements to vary by up to ±5 percent
207
§ 178.603 49 CFR Ch. I (10–1–18 Edition)
relative humidity without significant (f) Bung-type barrels made of natural

impairment of test reproducibility; wood must be left filled with water for
(2) At 65 percent ±2 percent relative at least 24 hours before the tests.
humidity, and at a temperature of 20 [Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as
°C±2 °C (68 °F±4 °F), or 27 °C±2 °C (81 amended at 56 FR 66286, Dec. 20, 1991; Amdt.
°F±4 °F). Average values should fall 178–106, 59 FR 67522, Dec. 29, 1994; 69 FR 76186,
within these limits. Short-term fluc- Dec. 20, 2004; 71 FR 78635, Dec. 29, 2006]
tuations and measurement limitations
may cause individual measurements to § 178.603 Drop test.
vary by up to ±5 percent relative hu- (a) General. The drop test must be
midity without significant impairment conducted for the qualification of all
of test reproducibility; or packaging design types and performed
(3) For testing at periodic intervals periodically as specified in § 178.601(e).
only (i.e., other than initial design For other than flat drops, the center of
qualification testing), at ambient con- gravity of the test packaging must be
ditions. vertically over the point of impact.
(e) Except as otherwise provided, Where more than one orientation is
each packaging must be closed in prep- possible for a given drop test, the ori-
aration for testing in the same manner entation most likely to result in fail-
as if prepared for actual shipment. All ure of the packaging must be used. The
closures must be installed using proper number of drops required and the pack-
techniques and torques. ages’ orientations are as follows:
Packaging No. of tests (samples) Drop orientation of samples
Steel drums, Aluminum drums, Metal Six—(three for each First drop (using three samples): The package must strike the
drums (other than steel or alu- drop). target diagonally on the chime or, if the packaging has no
minum), Steel Jerricans, Plywood chime, on a circumferential seam or an edge. Second drop
drums, Wooden barrels, Fiber (using the other three samples): The package must strike
drums, Plastic drums and Jerricans, the target on the weakest part not tested by the first drop,
Composite packagings which are in for example a closure or, for some 7 cylindrical drums, the
the shape of a drum. welded longitudinal seam of the drum body.
Boxes of natural wood, Plywood Five—(one for each First drop: Flat on the bottom (using the first sample). Second
boxes, Reconstituted wood boxes, drop). drop: Flat on the top (using the second sample). Third drop:
Fiberboard boxes, Plastic boxes, Flat on the long side (using the third sample). Fourth drop:
Steel, aluminum or other metal Flat on the short side (using the fourth sample). Fifth drop:
boxes, Composite packagings that On a corner (using the fifth sample).
are in the shape of a box.
Bags—single-ply with a side seam ..... Three—(three drops First drop: Flat on a wide face (using all three samples). Sec-
per bag). ond drop: Flat on a narrow face (using all three samples).
Third drop: On an end of the bag (using all three samples).
Bags—single-ply without a side seam, Three—(two drops per First drop: Flat on a wide face (using all three samples). Sec-
or multi-ply. bag). ond drop: On an end of the bag (using all three samples).
(b) Exceptions. For testing of single or other than expanded polystyrene boxes,
composite packagings constructed of composite packagings (plastic mate-
stainless steel, nickel, or monel at rial), and combination packagings with
periodic intervals only (i.e., other than plastic inner packagings other than
design qualification testing), the drop plastic bags intended to contain solids
test may be conducted with two sam- or articles must be carried out when
ples, one sample each for the two drop the temperature of the test sample and
orientations. These samples may have its contents has been reduced to ¥18 °C
been previously used for the hydro- (0 °F) or lower. Test liquids must be
static pressure or stacking test. Excep- kept in the liquid state, if necessary,
tions for the number of steel, alu- by the addition of anti-freeze. Water/
minum and other metal packaging anti-freeze solutions with a minimum
samples used for conducting the drop specific gravity of 0.95 for testing at
test are subject to the approval of the ¥18 °C (0 °F) or lower are considered
Associate Administrator. acceptable test liquids. Test samples

(c) Special preparation of test samples prepared in this way are not required
for the drop test. (1) Testing of plastic to be conditioned in accordance with
drums, plastic jerricans, plastic boxes § 178.602(d).
208
(d) Target. The target must be a rigid, (3) For a bag, neither the outermost
non-resilient, flat and horizontal sur- ply nor an outer packaging exhibits
face. any damage likely to adversely affect
(e) Drop height. Drop heights, meas- safety during transport;
ured as the vertical distance from the (4) The packaging or outer packaging
target to the lowest point on the pack- of a composite or combination pack-
age, must be equal to or greater than aging must not exhibit any damage
the drop height determined as follows: likely to affect safety during transport.
(1) For solids and liquids, if the test Inner receptacles, inner packagings, or
is performed with the solid or liquid to articles must remain completely with-
be transported or with a non-hazardous in the outer packaging and there must
material having essentially the same be no leakage of the filling substance
physical characteristic, the drop height from the inner receptacles or inner
must be determined according to pack- packagings;
ing group, as follows: (5) Any discharge from a closure is
(i) Packing Group I: 1.8 m (5.9 feet). slight and ceases immediately after
(ii) Packing Group II: 1.2 m (3.9 feet). impact with no further leakage; and
(iii) Packing Group III: 0.8 m (2.6 (6) No rupture is permitted in pack-
feet). agings for materials in Class 1 which
(2) For liquids in single packagings would permit spillage of loose explo-
and for inner packagings of combina- sive substances or articles from the
tion packagings, if the test is per- outer packaging.
formed with water: [Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as
(i) Where the materials to be carried amended at 56 FR 66286, Dec. 20, 1991; 57 FR
have a specific gravity not exceeding 45465, Oct. 1, 1992; Amdt. 178–99, 58 FR 51534,
1.2, drop height must be determined ac- Oct. 1, 1993; Amdt. 178–106, 59 FR 67522, Dec.
cording to packing group, as follows: 29, 1994; 65 FR 50462, Aug. 18, 2000; 66 FR 45386,
Aug. 28, 2001; 67 FR 61016, Sept. 27, 2002; 69 FR
(A) Packing Group I: 1.8 m (5.9 feet). 76186, Dec. 20, 2004; 76 FR 3389, Jan. 19, 2011;
(B) Packing Group II: 1.2 m (3.9 feet). 78 FR 1097, Jan. 7, 2013]
(C) Packing Group III: 0.8 m (2.6 feet).
(ii) Where the materials to be trans- § 178.604 Leakproofness test.
ported have a specific gravity exceed- (a) General. The leakproofness test
ing 1.2, the drop height must be cal- must be performed with compressed air
culated on the basis of the specific or other suitable gases on all pack-
gravity (SG) of the material to be car- agings intended to contain liquids, ex-
ried, rounded up to the first decimal, as cept that:
follows: (1) The inner receptacle of a com-
(A) Packing Group I: SG × 1.5 m (4.9 posite packaging may be tested with-
feet). out the outer packaging provided the
(B) Packing Group II: SG × 1.0 m (3.3 test results are not affected; and
feet). (2) This test is not required for inner
(C) Packing Group III: SG × 0.67 m packagings of combination packagings.
(2.2 feet). (b) Number of packagings to be tested—
(f) Criteria for passing the test. A pack- (1) Production testing. All packagings
age is considered to successfully pass subject to the provisions of this section
the drop tests if for each sample test- must be tested and must pass the
ed— leakproofness test:
(1) For packagings containing liquid, (i) Before they are first used in trans-
each packaging does not leak when portation; and
equilibrium has been reached between (ii) Prior to reuse, when authorized
the internal and external pressures, ex- for reuse by § 173.28 of this subchapter.
cept for inner packagings of combina- (2) Design qualification and periodic
tion packagings when it is not nec- testing. Three samples of each different
essary that the pressures be equalized; packaging must be tested and must
(2) For removable head drums for sol- pass the leakproofness test. Exceptions
ids, the entire contents are retained by for the number of samples used in con-
an inner packaging (e.g., a plastic bag) ducting the leakproofness test are sub-
even if the closure on the top head of ject to the approval of the Associate
the drum is no longer sift-proof; Administrator.
209
§ 178.605 49 CFR Ch. I (10–1–18 Edition)
(c) Special preparation—(1) For design retesting of packagings. Exceptions for

qualification and periodic testing, the number of aluminum and steel
packagings must be tested with clo- sample packagings used in conducting
sures in place. For production testing, the hydrostatic pressure test are sub-
packagings need not have their clo- ject to the approval of the Associate
sures in place. Removable heads need Administrator.
not be installed during production test- (c) Special preparation of receptacles
ing. for testings. Vented closures must ei-
(2) For testing with closures in place, ther be replaced by similar non-vented
vented closures must either be replaced closures or the vent must be sealed.
by similar non-vented closures or the (d) Test method and pressure to be ap-
vent must be sealed. plied. Metal packagings and composite
(d) Test method. The packaging must packagings other than plastic (e.g.,
be restrained under water while an in- glass, porcelain or stoneware), includ-
ternal air pressure is applied; the ing their closures, must be subjected to
method of restraint must not affect the the test pressure for 5 minutes. Plastic
results of the test. The test must be packagings and composite packagings
conducted, for other than production (plastic material), including their clo-
testing, for a minimum time of five sures, must be subjected to the test
minutes. Other methods, at least pressure for 30 minutes. This pressure
equally effective, may be used in ac- is the one to be marked as required in
cordance with appendix B of this part. § 178.503(a)(5). The receptacles must be
(e) Pressure applied. An internal air supported in a manner that does not
pressure (gauge) must be applied to the invalidate the test. The test pressure
packaging as indicated for the fol- must be applied continuously and even-
lowing packing groups: ly, and it must be kept constant
(1) Packing Group I: Not less than 30 throughout the test period. In addition,
kPa (4 psi). packagings intended to contain haz-
(2) Packing Group II: Not less than 20 ardous materials of Packing Group I
kPa (3 psi). must be tested to a minimum test pres-
(3) Packing Group III: Not less than sure of 250 kPa (36 psig). The hydraulic
20 kPa (3 psi). pressure (gauge) applied, taken at the
(f) Criteria for passing the test. A pack- top of the receptacle, and determined
aging passes the test if there is no by any one of the following methods
leakage of air from the packaging. must be:
[Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as
(1) Not less than the total gauge pres-
amended at 56 FR 66286, Dec. 20, 1991; Amdt. sure measured in the packaging (i.e.,
178–106, 59 FR 67522, Dec. 29, 1994; 66 FR 45386, the vapor pressure of the filling mate-
Aug. 28, 2001] rial and the partial pressure of the air
or other inert gas minus 100 kPa (15
§ 178.605 Hydrostatic pressure test. psi)) at 55 °C (131 °F), multiplied by a
(a) General. The hydrostatic pressure safety factor of 1.5. This total gauge
test must be conducted for the quali- pressure must be determined on the
fication of all metal, plastic, and com- basis of a maximum degree of filling in
posite packaging design types intended accordance with § 173.24a(d) of this sub-
to contain liquids and be performed pe- chapter and a filling temperature of 15
riodically as specified in § 178.601(e). °C (59 °F);
This test is not required for inner (2) Not less than 1.75 times the vapor
packagings of combination packagings. pressure at 50 °C (122 °F) of the mate-
For internal pressure requirements for rial to be transported minus 100 kPa (15
inner packagings of combination pack- psi), but with a minimum test pressure
agings intended for transportation by of 100 kPa (15 psig); or
aircraft, see § 173.27(c) of this sub- (3) Not less than 1.5 times the vapor
chapter. pressure at 55 °C (131 °F) of the mate-
(b) Number of test samples. Three test rial to be transported minus 100 kPa (15
samples are required for each different psi), but with a minimum test pressure
packaging. For packagings constructed of 100 kPa (15 psig).
of stainless steel, monel, or nickel, Packagings intended to contain haz-
only one sample is required for periodic ardous materials of Packing Group I
210
must be tested to a minimum test pres- the test by placing two filled pack-
sure of 250 kPa (36 psig). agings of the same type on the test
(e) Criteria for passing the test. A pack- sample. The stacked packages must
age passes the hydrostatic test if, for maintain their position for one hour.
each test sample, there is no leakage of Plastic packagings must be cooled to
liquid from the package. ambient temperature before this stack-
ing stability assessment.
[Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as
amended at 56 FR 66286, Dec. 20, 1991; Amdt. (2) Periodic retesting. The test sample
178–99, 58 FR 51534, Oct. 1, 1993; Amdt. 178–102, must be tested in accordance with:
59 FR 28494, June 2, 1994; 65 FR 50462, Aug. 18, (i) Section 178.606(c)(1) of this sub-
2000; 66 FR 45386, 45390, Aug. 28, 2001; 73 FR part; or
57007, Oct. 1, 2008; 78 FR 60755, Oct. 2, 2013] (ii) The packaging may be tested
using a dynamic compression testing
§ 178.606 Stacking test. machine. The test must be conducted
(a) General. All packaging design at room temperature on an empty, un-
types other than bags must be sub- sealed packaging. The test sample
jected to a stacking test. must be centered on the bottom platen
(b) Number of test samples. Three test of the testing machine. The top platen
samples are required for each different must be lowered until it comes in con-
packaging. For periodic retesting of tact with the test sample. Compression
packagings constructed of stainless must be applied end to end. The speed
steel, monel, or nickel, only one test of the compression tester must be one-
sample is required. Exceptions for the half inch plus or minus one-fourth inch
number of aluminum and steel sample per minute. An initial preload of 50
packagings used in conducting the pounds must be applied to ensure a
stacking test are subject to the ap- definite contact between the test sam-
proval of the Associate Administrator. ple and the platens. The distance be-
Notwithstanding the provisions of tween the platens at this time must be
§ 178.602(a) of this subpart, combination recorded as zero deformation. The force
packagings may be subjected to the A to then be applied must be calculated
stacking test without their inner pack- using the formula:
agings, except where this would invali- Liquids: A = (n¥1) [w + (s × v × 8.3 ×
date the results of the test. .98)] × 1.5;
(c) Test method—(1) Design qualifica- Solids: A = (n¥1) (m × 2.2 × 1.5)
tion testing. The test sample must be
subjected to a force applied to the top Where:
surface of the test sample equivalent to A = applied load in pounds
the total weight of identical packages m = the certified maximum gross mass for
which might be stacked on it during the container in kilograms.
n = minimum number of containers that,
transport; where the contents of the
when stacked, reach a height of 3 meters.
test sample are non-hazardous liquids s = specific gravity of lading.
with specific gravities different from w = maximum weight of one empty container
that of the liquid to be transported, the in pounds.
force must be calculated based on the v = actual capacity of container (rated ca-
specific gravity that will be marked on pacity + outage) in gallons.
the packaging. The minimum height of And:
the stack, including the test sample, 8.3 corresponds to the weight in pounds of 1.0
must be 3.0 m (10 feet). The duration of gallon of water.
the test must be 24 hours, except that .98 corresponds to the minimum filling per-
plastic drums, jerricans, and composite centage of the maximum capacity for liq-
packagings 6HH intended for liquids uids.
1.5 is a compensation factor that converts
shall be subjected to the stacking test
the static load of the stacking test into
for a period of 28 days at a temperature a load suitable for dynamic compression
of not less than 40 °C (104 °F). Alter- testing.
native test methods which yield equiv- 2.2 is the conversion factor for kilograms to
alent results may be used if approved pounds.

by the Associate Administrator. In (d) Criteria for passing the test. No test
guided load tests, stacking stability sample may leak. In composite pack-
must be assessed after completion of agings or combination packagings,
211
§ 178.607 49 CFR Ch. I (10–1–18 Edition)
there must be no leakage of the filling (0.063 inch) thickness (such as steel
substance from the inner receptacle, or strapping or paperboard) can be passed
inner packaging. No test sample may between the bottom of any package
show any deterioration which could ad- and the platform.
versely affect transportation safety or (4) Immediately following the period
any distortion likely to reduce its of vibration, each package must be re-
strength, cause instability in stacks of moved from the platform, turned on its
packages, or cause damage to inner side and observed for any evidence of
packagings likely to reduce safety in leakage.
transportation. For the dynamic com- (5) Other methods, at least equally
pression test, a container passes the effective, may be used, if approved by
test if, after application of the required the Associate Administrator.
load, there is no buckling of the side- (c) Criteria for passing the test. A pack-
walls sufficient to cause damage to its aging passes the vibration test if there
expected contents; in no case may the is no rupture or leakage from any of
maximum deflection exceed one inch. the packages. No test sample should
show any deterioration which could ad-
[Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as
versely affect transportation safety or
amended at 56 FR 66286, Dec. 20, 1991; 57 FR
45465, Oct. 1, 1992; Amdt. 178–102, 59 FR 28494, any distortion liable to reduce pack-
June 2, 1994; Amdt. 178–106, 59 FR 67522, Dec. aging strength.
29, 1994; 65 FR 58632, Sept. 29, 2000; 66 FR [Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as
45386, Aug. 28, 2001; 70 FR 34076, June 13, 2005; amended at 56 FR 66286, Dec. 20, 1991; 66 FR
72 FR 55696, Oct. 1, 2007] 45386, Aug. 28, 2001]
§ 178.607 Cooperage test for bung-type § 178.609 Test requirements for pack-
wooden barrels. agings for infectious substances.
(a) Number of samples. One barrel is (a) Samples of each packaging must
required for each different packaging. be prepared for testing as described in
(b) Method of testing. Remove all paragraph (b) of this section and then
hoops above the bilge of an empty bar- subjected to the tests in paragraphs (d)
rel at least two days old. through (i) of this section.
(c) Criteria for passing the test. A pack- (b) Samples of each packaging must
aging passes the cooperage test only if be prepared as for transport except
the diameter of the cross-section of the that a liquid or solid infectious sub-
upper part of the barrel does not instance should be replaced by water or,
crease by more than 10 percent. where conditioning at ¥18 °C (0 °F) is
specified, by water/antifreeze. Each pri-
§ 178.608 Vibration standard. mary receptacle must be filled to 98
(a) Each packaging must be capable percent capacity. Packagings for live
of withstanding, without rupture or animals should be tested with the live
leakage, the vibration test procedure animal being replaced by an appro-
outlined in this section. priate dummy of similar mass.
(b) Test method. (1) Three sample (c) Packagings prepared as for trans-
packagings, selected at random, must port must be subjected to the tests in
be filled and closed as for shipment. Table I of this paragraph (c), which, for
(2) The three samples must be placed test purposes, categorizes packagings
on a vibrating platform that has a according to their material character-
vertical or rotary double-amplitude istics. For outer packagings, the head-
(peak-to-peak displacement) of one ings in Table I relate to fiberboard or
inch. The packages should be con- similar materials whose performance
strained horizontally to prevent them may be rapidly affected by moisture;
from falling off the platform, but must plastics that may embrittle at low
be left free to move vertically, bounce temperature; and other materials, such
and rotate. as metal, for which performance is not
(3) The test must be performed for significantly affected by moisture or
one hour at a frequency that causes the temperature. Where a primary recep-
package to be raised from the vibrating tacle and a secondary packaging of an
platform to such a degree that a piece inner packaging are made of different
of material of approximately 1.6 mm materials, the material of the primary
212
receptacle determines the appropriate terial, the material most likely to be

test. In instances where a primary re- damaged determines the appropriate
ceptacle is made of more than one ma- test.
TABLE I—TESTS REQUIRED
Material of Tests required
Outer packaging Inner packaging Refer to para. (d) Refer to

para. (h)
Fiberboard Plastics Other Plastics Other (d) (e) (f) (g)
X X X X When dry ice X

is used
X X X X
X X X X
X X X X
X X X X
X X X X
(d) Samples must be subjected to (f) The sample must be conditioned in

free-fall drops onto a rigid, nonresil- an atmosphere of ¥18 °C (0 °F) or less
ient, flat, horizontal surface from a for a period of at least 24 hours and
height of 9 m (30 feet). within 15 minutes of removal from that
The drops must be performed as fol- atmosphere be subjected to the test de-
lows: scribed in paragraph (d) of this section.
(1) Where the samples are in the Where the sample contains dry ice, the
shape of a box, five samples must be conditioning period may be reduced to
dropped, one in each of the following 4 hours.
orientation:
(g) Where packaging is intended to
(i) Flat on the base;
(ii) Flat on the top; contain dry ice, a test additional to
(iii) Flat on the longest side; that specified in paragraph (d) or (e) or
(iv) Flat on the shortest side; and (f) of this section must be carried out.
(v) On a corner. One sample must be stored so that all
(2) Where the samples are in the the dry ice dissipates and then be sub-
shape of a drum, three samples must be jected to the test described in para-
dropped, one in each of the following graph (d) of this section.
orientations: (h) Packagings with a gross mass of 7
(i) Diagonally on the top chime, with kg (15 pounds) or less should be sub-
the center of gravity directly above the jected to the tests described in para-
point of impact; graph (h)(1) of this section and pack-
(ii) Diagonally on the base chime; agings with a gross mass exceeding 7
and kg (15 pounds) to the tests in paragraph
(iii) Flat on the side. (h)(2) of this section.
(3) While the sample should be re-
(1) Samples must be placed on a
leased in the required orientation, it is
level, hard surface. A cylindrical steel
accepted that for aerodynamic reasons
rod with a mass of at least 7 kg (15
the impact may not take place in that
orientation. pounds), a diameter not exceeding 38
(4) Following the appropriate drop se- mm (1.5 inches), and, at the impact end
quence, there must be no leakage from edges, a radius not exceeding 6 mm (0.2
the primary receptacle(s) which should inches), must be dropped in a vertical
remain protected by absorbent mate- free fall from a height of 1 m (3 feet),
rial in the secondary packaging. measured from the impact end of the
(e) The samples must be subjected to sample’s impact surface. One sample
a water spray to simulate exposure to must be placed on its base. A second
rainfall of approximately 50 mm (2 sample must be placed in an orienta-
inches) per hour for at least one hour. tion perpendicular to that used for the
They must then be subjected to the first. In each instance, the steel rod
test described in paragraph (d) of this must be aimed to impact the primary
section. receptacle(s). For a successful test,
213
§ 178.609 49 CFR Ch. I (10–1–18 Edition)
there must be no leakage from the pri- the same manner as in the tested pack-
mary receptacle(s) following each im- age.
pact. (2) Variation 2. A lesser number of the
(2) Samples must be dropped onto the tested primary receptacles, or of the
end of a cylindrical steel rod. The rod alternative types of primary recep-
must be set vertically in a level, hard tacles identified in paragraph (i)(1) of
surface. It must have a diameter of 38 this section, may be used provided suf-
mm (1.5 inches) and a radius not ex- ficient cushioning is added to fill the
ceeding 6 mm (0.2 inches) at the edges void space(s) and to prevent significant
of the upper end. The rod must pro- movement of the primary receptacles.
trude from the surface a distance at (3) Variation 3. Primary receptacles of
least equal to that between the pri- any type may be placed within a sec-
mary receptacle(s) and the outer sur- ondary packaging and shipped without
face of the outer packaging with a min- testing in the outer packaging provided
imum of 200 mm (7.9 inches). One sam- all of the following conditions are met:
ple must be dropped in a vertical free (i) The secondary and outer pack-
fall from a height of 1 m (3 feet), meas- aging combination must be success-
ured from the top of the steel rod. A fully tested in accordance with para-
second sample must be dropped from graphs (a) through (h) of this section
the same height in an orientation per- with fragile (e.g., glass) inner recep-
pendicular to that used for the first. In tacles.
each instance, the packaging must be (ii) The total combined gross weight
oriented so the steel rod will impact of inner receptacles may not exceed
the primary receptacle(s). For a suc- one-half the gross weight of inner re-
cessful test, there must be no leakage ceptacles used for the drop test in para-
from the primary receptacle(s) fol- graph (d) of this section.
lowing each impact. (iii) The thickness of cushioning ma-
(i) Variations. The following vari- terial between inner receptacles and
ations in the primary receptacles between inner receptacles and the out-
placed within the secondary packaging side of the secondary packaging may
are allowed without additional testing not be reduced below the corresponding
of the completed package. An equiva- thicknesses in the originally tested
lent level of performance must be packaging. If a single inner receptacle
maintained. was used in the original test, the thick-
(1) Variation 1. Primary receptacles of ness of cushioning between the inner
equivalent or smaller size as compared receptacles must be no less than the
to the tested primary receptacles may thickness of cushioning between the
be used provided they meet all of the outside of the secondary packaging and
following conditions: the inner receptacle in the original
(i) The primary receptacles are of test. When either fewer or smaller
similar design to the tested primary re- inner receptacles are used (as com-
ceptacle (e.g., shape: round, rectan- pared to the inner receptacles used in
gular, etc.). the drop test), sufficient additional
(ii) The material of construction of cushioning material must be used to
the primary receptacle (glass, plastics, fill the void.
metal, etc.) offers resistance to impact (iv) The outer packaging must pass
and a stacking force equal to or greater the stacking test in § 178.606 while
than that of the originally tested pri- empty. The total weight of identical
mary receptacle. packages must be based on the com-
(iii) The primary receptacles have bined mass of inner receptacles used in
the same or smaller openings and the the drop test in paragraph (d) of this
closure is of similar design (e.g., screw section.
cap, friction lid, etc.). (v) For inner receptacles containing
(iv) Sufficient additional cushioning liquids, an adequate quantity of ab-
material is used to fill void spaces and sorbent material must be present to
to prevent significant movement of the absorb the entire liquid contents of the
primary receptacles. inner receptacles.
(v) Primary receptacles are oriented (vi) If the outer packaging is in-
within the intermediate packaging in tended to contain inner receptacles for
214
liquids and is not leakproof, or is in- specified in paragraph (a)(1) of this sec-
tended to contain inner receptacles for tion; followed by the capital letter(s)
solids and is not sift proof, a means of specified in paragraph (a)(2) of this sec-
containing any liquid or solid contents tion; followed, when specified in an in-
in the event of leakage must be pro- dividual section, by a numeral indi-
vided. This can be a leakproof liner, cating the category of intermediate
plastic bag, or other equally effective bulk container.
means of containment. (1) IBC code number designations are
(vii) In addition, the marking re- as follows:
quired in § 178.503(f) of this subchapter
must be followed by the letter ‘‘U’’. For solids, discharged
[Amdt. 178–97, 55 FR 52723, Dec. 21, 1990, as Under pres-

Type sure of For liquids
amended by Amdt. 178–111, 60 FR 48787, Sept. by gravity more than
20, 1995; 67 FR 53143, Aug. 14, 2002; 69 FR 54046, 10 kPa
Sept. 7, 2004] (1.45 psig)
Rigid .................. 11 21 31
Subpart N—IBC Performance- Flexible .............. 13
Oriented Standards
(2) Intermediate bulk container code
§ 178.700 Purpose, scope and defini- letter designations are as follows:
tions.
‘‘A’’ means steel (all types and surface treat-
(a) This subpart prescribes requirements).
ments applying to IBCs intended for ‘‘B’’ means aluminum.
the transportation of hazardous mate- ‘‘C’’ means natural wood.
rials. Standards for these packagings ‘‘D’’ means plywood.
are based on the UN Recommendations. ‘‘F’’ means reconstituted wood.
(b) Terms used in this subpart are de- ‘‘G’’ means fiberboard.
fined in § 171.8 of this subchapter and in ‘‘H’’ means plastic.
paragraph (c) of this section. ‘‘L’’ means textile.
(c) The following definitions pertain ‘‘M’’ means paper, multiwall.
to the IBC standards in this subpart. ‘‘N’’ means metal (other than steel or alu-
(1) Body means the receptacle proper minum).
(including openings and their closures, (b) For composite IBCs, two capital
but not including service equipment) letters are used in sequence following
that has a volumetric capacity of not the numeral indicating IBC design
more than 3 cubic meters (3,000 L, 793 type. The first letter indicates the ma-
gallons, or 106 cubic feet). terial of the IBC inner receptacle. The
(2) Service equipment means filling and second letter indicates the material of
discharge, pressure relief, safety, heat- the outer IBC. For example, 31HA1 is a
ing and heat-insulating devices and composite IBC with a plastic inner re-
measuring instruments. ceptacle and a steel outer packaging.
(3) Structural equipment means the re-
inforcing, fastening, handling, protec- [Amdt. 178–103, 59 FR 38068, July 26, 1994, as
tive or stabilizing members of the body amended at 66 FR 45386, Aug. 28, 2001]
or stacking load bearing structural
members (such as metal cages). § 178.703 Marking of IBCs.
(4) Maximum permissible gross mass (a) The manufacturer shall:
means the mass of the body, its service (1) Mark every IBC in a durable and
equipment, structural equipment and clearly visible manner. The marking
the maximum net mass (see § 171.8 of may be applied in a single line or in
this subchapter). multiple lines provided the correct se-
[Amdt. 178–103, 59 FR 38068, July 26, 1994, as quence is followed with the informa-
amended by Amdt. 178–108, 60 FR 40038, Aug. tion required by this section in letters,
4, 1995; 66 FR 45386, 45387, Aug. 28, 2001; 73 FR numerals and symbols of at least 12
57008, Oct. 1, 2008; 75 FR 5396, Feb. 2, 2010] mm in height. This minimum marking
size applies only to IBCs manufactured

§ 178.702 IBC codes. after October 1, 2001). The following in-
(a) Intermediate bulk container code formation is required in the sequence
designations consist of: two numerals presented:
215
§ 178.703 49 CFR Ch. I (10–1–18 Edition)
(i) Except as provided in (C) Z—for IBCs meeting only Packing

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

ids discharged by gravity and made
from woven plastic with a liner:
(iii) For a rigid plastic IBC con- stack load and with a manufacturer’s
taining liquids, made from plastic with symbol in place of the manufacturer’s
structural equipment withstanding the name and address:
ER26JY94.001</GPH>
216
ER26JY94.000</GPH>
(iv) For a composite IBC containing with the symbol of a DOT approved
liquids, with a rigid plastic inner re- third-party test laboratory:
ceptacle and an outer steel body and
(b) Additional marking. In addition to (3) Markings required by paragraph

markings required in paragraph (a) of (b)(1) or (b)(2) of this section may be
this section, each IBC must be marked preceded by the narrative description
as follows in a place near the markings of the marking, e.g. ‘‘Tare Mass: * * *’’
required in paragraph (a) of this sec- where the ‘‘* * *’’ are replaced with the
tion that is readily accessible for in- tare mass in kilograms of the IBC.
spection. Where units of measure are (4) For each fiberboard and wooden
used, the metric unit indicated (e.g., IBC, the tare mass in kg must be
450 L) must also appear. shown.
(1) For each rigid plastic and com-
(5) Each flexible IBC may be marked
posite IBC, the following markings
with a pictogram displaying rec-
must be included:
ommended lifting methods.
(i) Rated capacity in L of water at 20
°C (68 °F); (6) For each composite IBC, the inner
(ii) Tare mass in kilograms; receptacle must be marked with at
least the following information:
(iii) Gauge test pressure in kPa;
(iv) Date of last leakproofness test, if (i) The code number designating the
applicable (month and year); and IBC design type, the name and address
(v) Date of last inspection (month or symbol of the manufacturer, the
and year). date of manufacture and the country
(2) For each metal IBC, the following authorizing the allocation of the mark
markings must be included on a metal as specified in paragraph (a) of this sec-
corrosion-resistant plate: tion;
(i) Rated capacity in L of water at 20 (ii) When a composite IBC is designed
°C (68 °F); in such a manner that the outer casing
(ii) Tare mass in kilograms; is intended to be dismantled for trans-
(iii) Date of last leakproofness test, if port when empty (such as, for the re-
applicable (month and year); turn of the IBC for reuse to the origi-
(iv) Date of last inspection (month nal consignor), each of the parts in-
and year); tended to be detached when so disman-
(v) Maximum loading/discharge pres- tled must be marked with the month
sure, in kPa, if applicable; and year of manufacture and the name
(vi) Body material and its minimum or symbol of the manufacturer.

thickness in mm; and (7) The symbol applicable to an IBC
ER26JY94.003</GPH>
(vii) Serial number assigned by the designed for stacking or not designed
manufacturer. for stacking, as appropriate, must be
217
ER26JY94.002</GPH>
§ 178.704 49 CFR Ch. I (10–1–18 Edition)
marked on all IBCs manufactured, re- (i)

paired or remanufactured after Janu-
ary 1, 2011 as follows:
(ii) Display the symbol in a durable § 178.704 General IBC standards.

and visible manner.
(iii) The symbol must be a square (a) Each IBC must be resistant to, or
with each side being not less than 100 protected from, deterioration due to
mm (3.9 inches) by 100 mm (3.9 inches) exposure to the external environment.
as measured from the corner printer IBCs intended for solid hazardous ma-
marks shown on the figures in para- terials must be sift-proof and water-re-
graph (b)(7)(i) of this section. Where di- sistant.
mensions are not specified, all features (b) All service equipment must be so
must be in approximate proportion to positioned or protected as to minimize
those shown. potential loss of contents resulting
(A) Transitional exception. A marking from damage during IBC handling and
in conformance with the requirements transportation.
of this paragraph in effect on December (c) Each IBC, including attachments,
31, 2014, may continue to be applied to and service and structural equipment,
all IBCs manufactured, repaired or re- must be designed to withstand, without
manufactured between January 1, 2011 loss of hazardous materials, the inter-
and December 31, 2016. nal pressure of the contents and the
(B) For domestic transportation, an stresses of normal handling and trans-
IBC marked prior to January 1, 2017 port. An IBC intended for stacking
and in conformance with the require- must be designed for stacking. Any
ments of this paragraph in effect on lifting or securing features of an IBC
December 31, 2014, may continue in must be of sufficient strength to with-
service until the end of its useful life. stand the normal conditions of han-
(iv) For IBCs designed for stacking, dling and transportation without gross
the maximum permitted stacking load distortion or failure and must be posi-
applicable when the IBC is in use must tioned so as to cause no undue stress in
be displayed with the symbol. The any part of the IBC.
mass in kilograms (kg) marked above (d) An IBC consisting of a packaging
the symbol must not exceed the load within a framework must be so con-
imposed during the design test, as indi- structed that:
cated by the marking in paragraph (1) The body is not damaged by the
(a)(1)(vii) of this section, divided by 1.8. framework;
The letters and numbers indicating the
(2) The body is retained within the
mass must be at least 12 mm (0.48
framework at all times; and
inches).
(3) The service and structural equip-
[Amdt. 178–103, 59 FR 38068, July 26, 1994, as ment are fixed in such a way that they
amended by Amdt. 178–119, 62 FR 24743, May cannot be damaged if the connections
6, 1997; 64 FR 10782, Mar. 5, 1999; 65 FR 50462, between body and frame allow relative
Aug. 18, 2000; 65 FR 58632, Sept. 29, 2000; 66 FR
33451, June 21, 2001; 66 FR 45387, Aug. 28, 2001;

expansion or motion.
74 FR 2269, Jan. 14, 2009; 75 FR 74, Jan. 4, 2010; (e) Bottom discharge valves must be
75 FR 5396, Feb. 2, 2010; 76 FR 3389, Jan. 19, secured in the closed position and the
2011; 80 FR 1168, Jan. 8, 2015] discharge system suitably protected
218
ER04JA10.097</GPH>
from damage. Valves having lever clo- (ii) Aluminum IBCs intended to con-
sures must be secured against acci- tain flammable liquids must have no
dental opening. The open or closed po- movable parts, such as covers and clo-
sition of each valve must be readily ap- sures, made of unprotected steel liable
parent. For each IBC containing a liq- to rust, which might cause a dangerous
uid, a secondary means of sealing the reaction from friction or percussive
discharge aperture must also be pro- contact with the aluminum.
vided, e.g., by a blank flange or equiva- (iii) Metals used in fabricating the
lent device. body of a metal IBC must meet the fol-
(f) IBC design types must be con- lowing requirements:
structed in such a way as to be bottom- (A) For steel, the percentage elon-
lifted or top-lifted as specified in gation at fracture must not be less
§§ 178.811 and 178.812. than 10,000/Rm with a minimum of 20
[Amdt. 178–103, 59 FR 38068, July 26, 1994, as
percent; where Rm = minimum tensile
amended at 66 FR 45386, Aug. 28, 2001; 68 FR strength of the steel to be used, in N/
61942, Oct. 30, 2003] mm2; if U.S. Standard units of psi are
used for tensile strength then the ratio
§ 178.705 Standards for metal IBCs. becomes 10,000 × (145/Rm).
(a) The provisions in this section (B) For aluminum, the percentage
apply to metal IBCs intended to con- elongation at fracture must not be less
tain liquids and solids. Metal IBC types than 10,000/(6Rm) with an absolute min-
are designated: imum of eight percent; if U.S. Standard
(1) 11A, 11B, 11N for solids that are units of psi are used for tensile
loaded or discharged by gravity. strength then the ratio becomes 10,000
(2) 21A, 21B, 21N for solids that are × 145 / (6Rm).
loaded or discharged at a gauge pres- (C) Specimens used to determine the
sure greater than 10 kPa (1.45 psig). elongation at fracture must be taken
(3) 31A, 31B, 31N for liquids. transversely to the direction of rolling
(b) Definitions for metal IBCs: and be so secured that:
(1) Metal IBC means an IBC with a Lo = 5d
metal body, together with appropriate
service and structural equipment. or
(2) Protected means providing the IBC Lo = 5.65 √A
body with additional external protec-
tion against impact and abrasion. For where:
example, a multi-layer (sandwich) or Lo = gauge length of the specimen before the
double wall construction or a frame test
with a metal lattice-work casing. d = diameter
A = cross-sectional area of test specimen.
(c) Construction requirements for
metal IBCs are as follows: (iv) Minimum wall thickness:
(1) Body. The body must be made of (A) For a reference steel having a
ductile metal materials. Welds must be product of Rm × Ao = 10,000, where Ao
made so as to maintain design type in- is the minimum elongation (as a per-
tegrity of the receptacle under condi- centage) of the reference steel to be
tions normally incident to transpor- used on fracture under tensile stress
tation. (Rm × Ao = 10,000 × 145; if tensile
(i) The use of dissimilar metals must strength is in U.S. Standard units of
not result in deterioration that could pounds per square inch), the wall
affect the integrity of the body. thickness must not be less than:
Wall thickness (T) in mm
Capacity (C) in liters 1 Types 11A, 11B, 11N Types 21A, 21B, 21N, 31A, 31B, 31N
Unprotected Protected Unprotected Protected
C≤1000 .......................................................... 2.0 ........................ 1.5 ........................ 2.5 ........................ 2.0

1000<C≤2000 ................................................ T = C/2000 + 1.5 T = C/2000 + 1.0 T = C/2000 + 2.0 T = C/2000 + 1.5
2000<C≤3000 ................................................ T = C/2000 + 1.5 T = C/2000 + 1.0 T = C/1000 + 1.0 T = C/2000 + 1.5
219
§ 178.706 49 CFR Ch. I (10–1–18 Edition)
(B) For metals other than the ref- 1.5 mm (0.059 inches) or as determined
erence steel described in paragraph by use of the following equivalence for-
(c)(1)(iii)(A) of this section, the min- mula:
imum wall thickness is the greater of
21.4 × e 0
e1 = 3
Rm1 × A1
(ii) The start-to-discharge pressure

21.4 × e 0
e1 = may not be higher than 65 kPa (9 psig)
3
( Rm1 × A1 )/145 and no lower than the vapor pressure of
the hazardous material plus the partial
where: pressure of the air or other inert gases,
e1 = required equivalent wall thickness of the
measured in the IBC at 55 °C (131 °F),
metal to be used (in mm or if eo is in determined on the basis of a maximum
inches, use formula for U.S. Standard degree of filling as specified in
units). § 173.35(d) of this subchapter. This does
eo = required minimum wall thickness for not apply to fusible devices unless such
the reference steel (in mm or if eo is in devices are the only source of pressure
inches, use formula for U.S. Standard relief for the IBC. Pressure relief de-
units). vices must be fitted in the vapor space.
Rm1 = guaranteed minimum tensile strength
of the metal to be used (in N/mm2 or for
(d) Metal IBCs may not have a volu-
U.S. Standard units, use psi). metric capacity greater than 3,000 L
A1 = minimum elongation (as a percentage) (793 gallons) or less than 450 L (119 gal-
of the metal to be used on fracture under lons).
tensile stress (see paragraph (c)(1) of this
section). [Amdt. 178–103, 59 FR 38068, July 26, 1994, as
amended by Amdt. 178–108, 60 FR 40038, Aug.
(C) For purposes of the calculation 4, 1995; Amdt. 178–117, 61 FR 50629, Sept. 26,
described in paragraph (c)(1)(iv)(B) of 1996; 66 FR 33452, June 21, 2001; 66 FR 45386,
this section, the guaranteed minimum 45387, Aug. 28, 2001; 68 FR 45041, July 31, 2003;
75 FR 5396, Feb. 2, 2010; 78 FR 1097, Jan. 7,
tensile strength of the metal to be used
2013]
(Rm1) must be the minimum value ac-
cording to material standards. How- § 178.706 Standards for rigid plastic
ever, for austenitic (stainless) steels, IBCs.
the specified minimum value for Rm,
according to the material standards, (a) The provisions in this section
may be increased by up to 15% when a apply to rigid plastic IBCs intended to
greater value is provided in the mate- contain solids or liquids. Rigid plastic
rial inspection certificate. When no IBC types are designated:
material standard exists for the mate- (1) 11H1 fitted with structural equip-
rial in question, the value of Rm must ment designed to withstand the whole
be the minimum value indicated in the load when IBCs are stacked, for solids
material inspection certificate. which are loaded or discharged by grav-
(2) Pressure relief. The following pres- ity.
sure relief requirements apply to IBCs (2) 11H2 freestanding, for solids which
intended for liquids: are loaded or discharged by gravity.
(i) IBCs must be capable of releasing (3) 21H1 fitted with structural equip-
a sufficient amount of vapor in the ment designed to withstand the whole
event of fire engulfment to ensure that load when IBCs are stacked, for solids
no rupture of the body will occur due which are loaded or discharged under
to pressure build-up. This can be pressure.

EP26JN96.001</MATH>
achieved by spring-loaded or non-re- (4) 21H2 freestanding, for solids which

closing pressure relief devices or by are loaded or discharged under pres-
other means of construction. sure.
220
EP26JN96.000</MATH>
(5) 31H1 fitted with structural equip- L (793 gallons) or less than 450 L (119
ment designed to withstand the whole gallons).
load when IBCs are stacked, for liquids.
[Amdt. 178–103, 59 FR 38068, July 26, 1994, as
(6) 31H2 freestanding, for liquids. amended at 66 FR 45386, 45387, Aug. 28, 2001;
(b) Rigid plastic IBCs consist of a 75 FR 5396, Feb. 2, 2010]
rigid plastic body, which may have
structural equipment, together with § 178.707 Standards for composite
appropriate service equipment. IBCs.
(c) Rigid plastic IBCs must be manu- (a) The provisions in this section
factured from plastic material of apply to composite IBCs intended to
known specifications and be of a contain solids and liquids. To complete
strength relative to its capacity and to the marking codes listed below, the
the service it is required to perform. In letter ‘‘Z’’ must be replaced by a cap-
addition to conformance to § 173.24 of ital letter in accordance with
this subchapter, plastic materials must § 178.702(a)(2) to indicate the material
be resistant to aging and to degrada- used for the outer packaging. Com-
tion caused by ultraviolet radiation. posite IBC types are designated:
(1) If protection against ultraviolet (1) 11HZ1 Composite IBCs with a rigid
radiation is necessary, it must be pro- plastic inner receptacle for solids load-
vided by the addition of a pigment or ed or discharged by gravity.
inhibiter such as carbon black. These (2) 11HZ2 Composite IBCs with a
additives must be compatible with the flexible plastic inner receptacle for sol-
contents and remain effective through- ids loaded or discharged by gravity.
out the life of the IBC body. Where use (3) 21HZ1 Composite IBCs with a rigid
is made of carbon black, pigments or plastic inner receptacle for solids load-
inhibitors, other than those used in the ed or discharged under pressure.
manufacture of the tested design type, (4) 21HZ2 Composite IBCs with a
retesting may be omitted if changes in flexible plastic inner receptacle for sol-
the carbon black content, the pigment ids loaded or discharged under pres-
content or the inhibitor content do not sure.
adversely affect the physical properties (5) 31HZ1 Composite IBCs with a rigid
of the material of construction. plastic inner receptacle for liquids.
(2) Additives may be included in the (6) 31HZ2 Composite IBCs with a
composition of the plastic material to flexible plastic inner receptacle for liq-
improve the resistance to aging or to uids.
serve other purposes, provided they do (b) Definitions for composite IBC
not adversely affect the physical or types:
chemical properties of the material of (1) A composite IBC is an IBC which
construction. consists of a rigid outer packaging en-
(3) No used material other than pro- closing a plastic inner receptacle to-
duction residues or regrind from the gether with any service or other struc-
same manufacturing process may be tural equipment. The outer packaging
used in the manufacture of rigid plastic of a composite IBC is designed to bear
the entire stacking load. The inner re-
IBCs.
ceptacle and outer packaging form an
(4) Rigid plastic IBCs intended for the
integral packaging and are filled,
transportation of liquids must be capa- stored, transported, and emptied as a
ble of releasing a sufficient amount of unit.
vapor to prevent the body of the IBC (2) The term plastic means polymeric
from rupturing if it is subjected to an materials (i.e., plastic or rubber).
internal pressure in excess of that for
(3) A ‘‘rigid’’ inner receptacle is an
which it was hydraulically tested. This inner receptacle which retains its gen-
may be achieved by spring-loaded or eral shape when empty without clo-
non-reclosing pressure relief devices or
sures in place and without benefit of

by other means of construction. the outer casing. Any inner receptacle
(d) Rigid plastic IBCs may not have a that is not ‘‘rigid’’ is considered to be
volumetric capacity greater than 3,000 ‘‘flexible.’’
221
§ 178.707 49 CFR Ch. I (10–1–18 Edition)
(c) Construction requirements for (iv) Composite IBCs intended for the
composite IBCs with plastic inner re- transportation of liquids must be capa-
ceptacles are as follows: ble of releasing a sufficient amount of
(1) The outer packaging must consist vapor to prevent the body of the IBC
of rigid material formed so as to pro- from rupturing if it is subjected to an
tect the inner receptacle from physical internal pressure in excess of that for
damage during handling and transpor- which it was hydraulically tested. This
tation, but is not required to perform may be achieved by spring-loaded or
the secondary containment function. It non-reclosing pressure relief devices or
includes the base pallet where appro- by other means of construction.
priate. The inner receptacle is not in- (4) The strength of the construction
tended to perform a containment func- material comprising the outer pack-
tion without the outer packaging. aging and the manner of construction
(2) A composite IBC with a fully en- must be appropriate to the capacity of
closing outer packaging must be de- the composite IBC and its intended use.
signed to permit assessment of the in- The outer packaging must be free of
tegrity of the inner container following any projection that might damage the
the leakproofness and hydraulic tests. inner receptacle.
The outer packaging of 31HZ2 com- (i) Outer packagings of natural wood
posite IBCs must enclose the inner re- must be constructed of well seasoned
ceptacles on all sides. wood that is commercially dry and free
(3) The inner receptacle must be from defects that would materially
manufactured from plastic material of lessen the strength of any part of the
known specifications and be of a outer packaging. The tops and bottoms
strength relative to its capacity and to may be made of water-resistant recon-
the service it is required to perform. In stituted wood such as hardboard or
addition to conformance with the re- particle board. Materials other than
quirements of § 173.24 of this sub- natural wood may be used for construc-
chapter, the material must be resistant tion of structural equipment of the
to aging and to degradation caused by outer packaging.
ultraviolet radiation. The inner recep- (ii) Outer packagings of plywood
tacle of 31HZ2 composite IBCs must must be made of well-seasoned, rotary
consist of at least three plies of film. cut, sliced, or sawn veneer, commer-
(i) If necessary, protection against cially dry and free from defects that
ultraviolet radiation must be provided would materially lessen the strength of
by the addition of pigments or inhibi- the casing. All adjacent plies must be
tors such as carbon black. These addi- glued with water-resistant adhesive.
tives must be compatible with the con- Materials other than plywood may be
tents and remain effective throughout used for construction of structural
the life of the inner receptacle. Where equipment of the outer packaging.
use is made of carbon black, pigments, Outer packagings must be firmly
or inhibitors, other than those used in nailed or secured to corner posts or
the manufacture of the tested design ends or be assembled by equally suit-
type, retesting may be omitted if the able devices.
carbon black content, the pigment con- (iii) Outer packagings of reconsti-
tent, or the inhibitor content do not tuted wood must be constructed of
adversely affect the physical properties water-resistant reconstituted wood
of the material of construction. such as hardboard or particle board.
(ii) Additives may be included in the Materials other than reconstituted
composition of the plastic material of wood may be used for the construction
the inner receptacle to improve resist- of structural equipment of reconsti-
ance to aging, provided they do not ad- tuted wood outer packaging.
versely affect the physical or chemical (iv) Fiberboard outer packagings
properties of the material. must be constructed of strong, solid, or
(iii) No used material other than pro- double-faced corrugated fiberboard
duction residues or regrind from the (single or multiwall).

same manufacturing process may be (A) Water resistance of the outer sur-
used in the manufacture of inner recep- face must be such that the increase in
tacles. mass, as determined in a test carried
222
out over a period of 30 minutes by the (6) Intermediate IBCs of type 31HZ2
Cobb method of determining water ab- must be limited to a capacity of not
sorption, is not greater than 155 grams more than 1,250 L.
per square meter (0.0316 pounds per (d) Composite IBCs may not have a
square foot)—see ISO 535 (E) (IBR, see volumetric capacity greater than 3,000
§ 171.7 of this subchapter). Fiberboard L (793 gallons) or less than 450 L (119
must have proper bending qualities. Fi- gallons).
berboard must be cut, creased without
cutting through any thickness of fiber- [Amdt. 178–103, 59 FR 38068, July 26, 1994, as
amended by Amdt. 178–119, 62 FR 24743, May
board, and slotted so as to permit as-
6, 1997; 66 FR 45387, Aug. 28, 2001; 67 FR 61016,
sembly without cracking, surface Sept. 27, 2002; 68 FR 75758, Dec. 31, 2003; 69 FR
breaks, or undue bending. The fluting 54046, Sept. 7, 2004; 75 FR 5396, Feb. 2, 2010]
of corrugated fiberboard must be firm-
ly glued to the facings. § 178.708 Standards for fiberboard
(B) The ends of fiberboard outer IBCs.
packagings may have a wooden frame
(a) The provisions of this section
or be constructed entirely of wood.
apply to fiberboard IBCs intended to
Wooden battens may be used for rein-
contain solids that are loaded or dis-
forcements.
charged by gravity. Fiberboard IBCs
(C) Manufacturers’ joints in the bod-
are designated: 11G.
ies of outer packagings must be taped,
(b) Definitions for fiberboard IBC
lapped and glued, or lapped and
types:
stitched with metal staples.
(D) Lapped joints must have an ap- (1) Fiberboard IBCs consist of a fiber-
propriate overlap. board body with or without separate
(E) Where closing is effected by glu- top and bottom caps, appropriate serv-
ing or taping, a water-resistant adhe- ice and structural equipment, and if
sive must be used. necessary an inner liner (but no inner
(F) All closures must be sift-proof. packaging).
(v) Outer packagings of plastic mate- (2) Liner means a separate tube or
rials must be constructed in accord- bag, including the closures of its open-
ance with the relevant provisions of ings, inserted in the body but not form-
paragraph (c)(3) of this section. ing an integral part of it.
(5) Any integral pallet base forming (c) Construction requirements for fi-
part of an IBC, or any detachable pal- berboard IBCs are as follows:
let, must be suitable for the mechan- (1) Top lifting devices are prohibited
ical handling of an IBC filled to its in fiberboard IBCs.
maximum permissible gross mass. (2) Fiberboard IBCs must be con-
(i) The pallet or integral base must structed of strong, solid or double-
be designed to avoid protrusions that faced corrugated fiberboard (single or
may cause damage to the IBC in han- multiwall) that is appropriate to the
dling. capacity of the outer packaging and its
(ii) The outer packaging must be se- intended use. Water resistance of the
cured to any detachable pallet to en- outer surface must be such that the in-
sure stability in handling and transpor- crease in mass, as determined in a test
tation. Where a detachable pallet is carried out over a period of 30 minutes
used, its top surface must be free from by the Cobb method of determining
sharp protrusions that might damage water absorption, is not greater than
the IBC. 155 grams per square meter (0.0316
(iii) Strengthening devices, such as pounds per square foot)—see ISO 535 (E)
timber supports to increase stacking (IBR, see § 171.7 of this subchapter). Fi-
performance, may be used but must be berboard must have proper bending
external to the inner receptacle. qualities. Fiberboard must be cut,
(iv) The load-bearing surfaces of IBCs creased without cutting through any
intended for stacking must be designed thickness of fiberboard, and slotted so
to distribute loads in a stable manner. as to permit assembly without crack-

An IBC intended for stacking must be ing, surface breaks, or undue bending.
designed so that loads are not sup- The fluting of corrugated fiberboard
ported by the inner receptacle. must be firmly glued to the facings.
223
§ 178.709 49 CFR Ch. I (10–1–18 Edition)
(i) The walls, including top and bot- tain solids that are loaded or dis-
tom, must have a minimum puncture charged by gravity. Wooden IBC types
resistance of 15 Joules (11 foot-pounds are designated:
of energy) measured according to ISO (1) 11C Natural wood with inner liner.
3036 (IBR, see § 171.7 of this subchapter). (2) 11D Plywood with inner liner.
(ii) Manufacturers’ joints in the bod- (3) 11F Reconstituted wood with
ies of IBCs must be made with an ap- inner liner.
propriate overlap and be taped, glued, (b) Definitions for wooden IBCs:
stitched with metal staples or fastened (1) Wooden IBCs consist of a rigid or
by other means at least equally effec- collapsible wooden body together with
tive. Where joints are made by gluing an inner liner (but no inner packaging)
or taping, a water-resistant adhesive and appropriate service and structural
must be used. Metal staples must pass equipment.
completely through all pieces to be fas- (2) Liner means a separate tube or
tened and be formed or protected so bag, including the closures of its open-
that any inner liner cannot be abraded ings, inserted in the body but not form-
or punctured by them. ing an integral part of it.
(3) The strength of the material used (c) Construction requirements for
and the construction of the liner must wooden IBCs are as follows:
be appropriate to the capacity of the (1) Top lifting devices are prohibited
IBC and the intended use. Joints and in wooden IBCs.
closures must be sift-proof and capable (2) The strength of the materials used
of withstanding pressures and impacts and the method of construction must
liable to occur under normal conditions be appropriate to the capacity and in-
of handling and transport. tended use of the IBC.
(4) Any integral pallet base forming (i) Natural wood used in the con-
part of an IBC, or any detachable pal- struction of an IBC must be well-sea-
let, must be suitable for the mechan- soned, commercially dry, and free from
ical handling of an IBC filled to its defects that would materially lessen
maximum permissible gross mass. the strength of any part of the IBC.
(i) The pallet or integral base must Each IBC part must consist of uncut
be designed to avoid protrusions that wood or a piece equivalent in strength
may cause damage to the IBC in han- and integrity. IBC parts are equivalent
dling. to one piece when a suitable method of
(ii) The outer packaging must be se- glued assembly is used (i.e., a
cured to any detachable pallet to en- Lindermann joint, tongue and groove
sure stability in handling and trans- joint, ship lap or rabbet joint, or butt
port. Where a detachable pallet is used, joint with at least two corrugated
its top surface must be free from sharp metal fasteners at each joint, or when
protrusions that might damage the other methods at least equally effec-
IBC. tive are used). Materials other than
(iii) Strengthening devices, such as natural wood may be used for the con-
timber supports to increase stacking struction of structural equipment of
performance, may be used but must be the outer packaging.
external to the inner liner. (ii) Plywood used in construction of
(iv) The load-bearing surfaces of IBCs bodies must be at least 3-ply. Plywood
intended for stacking must be designed must be made of well-seasoned, rotary-
to distribute loads in a stable manner. cut, sliced or sawn veneer, commer-
(d) Fiberboard IBCs may not have a cially dry, and free from defects that
volumetric capacity greater than 3,000 would materially lessen the strength of
L (793 gallons) or less than 450 L (119 the body. All adjacent plies must be
gallons). glued with water-resistant adhesive.
[Amdt. 178–103, 59 FR 38068, July 26, 1994, as Materials other than plywood may be
amended at 66 FR 45386, Aug. 28, 2001; 68 FR used for the construction of structural
75758, Dec. 31, 2003; 75 FR 5396, Feb. 2, 2010] equipment of the outer packaging.
(iii) Reconstituted wood used in con-

§ 178.709 Standards for wooden IBCs. struction of bodies must be water re-
(a) The provisions in this section sistant reconstituted wood such as
apply to wooden IBCs intended to con- hardboard or particle board. Materials
224
other than reconstituted wood may be (6) 13L1 textile without coating or
used for the construction of structural liner.
equipment of the outer packaging. (7) 13L2 textile, coated.
(iv) Wooden IBCs must be firmly (8) 13L3 textile with liner.
nailed or secured to corner posts or (9) 13L4 textile, coated and with
ends or be assembled by similar de- liner.
vices. (10) 13M1 paper, multiwall.
(3) The strength of the material used (11) 13M2 paper, multiwall, water re-
and the construction of the liner must sistant.
be appropriate to the capacity of the (b) Definitions for flexible IBCs:
IBC and its intended use. Joints and (1) Flexible IBCs consist of a body con-
closures must be sift-proof and capable structed of film, woven plastic, woven
of withstanding pressures and impacts fabric, paper, or combination thereof,
liable to occur under normal conditions together with any appropriate service
of handling and transportation. equipment and handling devices, and if
(4) Any integral pallet base forming necessary, an inner coating or liner.
part of an IBC, or any detachable pal- (2) Woven plastic means a material
let, must be suitable for the mechan- made from stretched tapes or
ical handling of an IBC filled to its monofilaments.
maximum permissible gross mass. (3) Handling device means any sling,
(i) The pallet or integral base must loop, eye, or frame attached to the
be designed to avoid protrusions that body of the IBC or formed from a con-
may cause damage to the IBC in han- tinuation of the IBC body material.
dling. (c) Construction requirements for
(ii) The outer packaging must be se- flexible IBCs are as follows:
cured to any detachable pallet to en- (1) The strength of the material and
sure stability in handling and transpor- the construction of the flexible IBC
tation. Where a detachable pallet is must be appropriate to its capacity and
used, its top surface must be free from its intended use.
sharp protrusions that might damage (2) All materials used in the con-
the IBC. struction of flexible IBCs of types 13M1
(iii) Strengthening devices, such as and 13M2 must, after complete immer-
timber supports to increase stacking sion in water for not less than 24 hours,
performance, may be used but must be retain at least 85 percent of the tensile
external to the inner liner. strength as measured originally on the
(iv) The load-bearing surfaces of IBCs material conditioned to equilibrium at
intended for stacking must be designed 67 percent relative humidity or less.
to distribute loads in a stable manner. (3) Seams must be stitched or formed
(d) Wooden IBCs may not have a vol- by heat sealing, gluing or any equiva-
umetric capacity greater than 3,000 L lent method. All stitched seam-ends
(793 gallons) or less than 450 L (119 gal- must be secured.
lons). (4) In addition to conformance with
the requirements of § 173.24 of this sub-
[Amdt. 178–103, 59 FR 38068, July 26, 1994, as chapter, flexible IBCs must be resistant
amended at 66 FR 45386, Aug. 28, 2001; 75 FR to aging and degradation caused by ul-
5397, Feb. 2, 2010] traviolet radiation.
(5) For plastic flexible IBCs, if nec-
§ 178.710 Standards for flexible IBCs.
essary, protection against ultraviolet
(a) The provisions of this section radiation must be provided by the addi-
apply to flexible IBCs intended to con- tion of pigments or inhibitors such as
tain solid hazardous materials. Flexi- carbon black. These additives must be
ble IBC types are designated: compatible with the contents and re-
(1) 13H1 woven plastic without coat- main effective throughout the life of
ing or liner. the container. Where use is made of
(2) 13H2 woven plastic, coated. carbon black, pigments, or inhibitors,
(3) 13H3 woven plastic with liner. other than those used in the manufac-
(4) 13H4 woven plastic, coated and ture of the tested design type, re-
with liner. testing may be omitted if the carbon
(5) 13H5 plastic film. black content, the pigment content or
225
§ 178.800 49 CFR Ch. I (10–1–18 Edition)
the inhibitor content does not ad- an IBC assembly function, including
versely affect the physical properties final closure, is performed by the per-
of the material of construction. Addi- son who offers a hazardous material for
tives may be included in the composi- transportation, that person is respon-
tion of the plastic material to improve sible for performing the function in ac-
resistance to aging, provided they do cordance with §§ 173.22 and 178.2 of this
not adversely affect the physical or subchapter.
chemical properties of the material. (c) Definitions. For the purpose of this
(6) No used material other than pro- subpart:
duction residues or regrind from the (1) IBC design type refers to an IBC
same manufacturing process may be that does not differ in structural de-
used in the manufacture of plastic sign, size, material of construction,
flexible IBCs. This does not preclude wall thickness, manner of construction
the re-use of component parts such as and representative service equipment.
fittings and pallet bases, provided such (2) Design qualification testing is the
components have not in any way been performance of the drop, leakproofness,
damaged in previous use. hydrostatic pressure, stacking, bot-
(7) When flexible IBCs are filled, the tom-lift or top-lift, tear, topple, right-
ratio of height to width may not be ing and vibration tests, as applicable,
more than 2:1. prescribed in this subpart, for each dif-
(d) Flexible IBCs: (1) May not have a ferent IBC design type, at the start of
volumetric capacity greater than 3,000 production of that packaging.
L (793 gallons) or less than 56 L (15 gal- (3) Periodic design requalification test is
lons); and the performance of the applicable tests
(2) Must be designed and tested to a specified in paragraph (c)(2) of this sec-
capacity of no less than 50 kg (110 tion on an IBC design type, in order to
pounds). requalify the design for continued pro-
[Amdt. 178–103, 59 FR 38068, July 26, 1994, as duction at the frequency specified in
amended by Amdt. 178–108, 60 FR 40038, Aug. paragraph (e) of this section.
4, 1995; 66 FR 45386, Aug. 28, 2001; 75 FR 5397, (4) Production inspection is the inspec-
Feb. 2, 2010] tion that must initially be conducted
on each newly manufactured IBC.
Subpart O—Testing of IBCs (5) Production testing is the perform-
ance of the leakproofness test in ac-
§ 178.800 Purpose and scope. cordance with paragraph (f) of this sec-
This subpart prescribes certain test- tion on each IBC intended to contain
ing requirements for IBCs identified in solids discharged by pressure or in-
subpart N of this part. tended to contain liquids.
[Amdt. 178–103, 59 FR 38074, July 26, 1994, as (6) Periodic retest and inspection is per-
amended by 66 FR 45386, Aug. 28, 2001] formance of the applicable test and in-
spections on each IBC at the frequency
§ 178.801 General requirements. specified in § 180.352 of this subchapter.
(a) General. The test procedures pre- (7) Different IBC design type is one
scribed in this subpart are intended to that differs from a previously qualified
ensure that IBCs containing hazardous IBC design type in structural design,
materials can withstand normal condi- size, material of construction, wall
tions of transportation and are consid- thickness, or manner of construction,
ered minimum requirements. Each but does not include:
packaging must be manufactured and (i) A packaging which differs in sur-
assembled so as to be capable of suc- face treatment;
cessfully passing the prescribed tests (ii) A rigid plastic IBC or composite
and of conforming to the requirements IBC which differs with regard to addi-
of § 173.24 of this subchapter at all tives used to comply with §§ 178.706(c),
times while in transportation. 178.707(c) or 178.710(c);
(b) Responsibility. It is the responsi- (iii) A packaging which differs only

bility of the IBC manufacturer to as- in its lesser external dimensions (i.e.,
sure that each IBC is capable of passing height, width, length) provided mate-
the prescribed tests. To the extent that rials of construction and material
226
thicknesses or fabric weight remain (i) The IBC need not have its closures
the same; fitted, except that the IBC must be
(iv) A packaging which differs in fitted with its primary bottom closure.
service equipment. (ii) The inner receptacle of a com-
(d) Design qualification testing. The posite IBC may be tested without the
packaging manufacturer shall achieve outer IBC body, provided the test re-
successful test results for the design sults are not affected.
qualification testing at the start of (2) Applicable inspection require-
production of each new or different IBC ments in § 180.352 of this subchapter
design type. The service equipment se- must be performed on each IBC ini-
tially after production.
lected for this design qualification
(g) Test samples. The IBC manufac-
testing shall be representative of the
turer shall conduct the design quali-
type of service equipment that will be
fication and periodic design requali-
fitted to any finished IBC body under
fication tests prescribed in this subpart
the design. Application of the certifi- using random samples of IBCs, accord-
cation mark by the manufacturer shall ing to the appropriate test section.
constitute certification that the IBC (h) Selective testing of IBCs. Variation
design type passed the prescribed tests of a tested IBC design type is permitted
in this subpart. without further testing, provided selec-
(e) Periodic design requalification test- tive testing demonstrates an equiva-
ing. (1) Periodic design requalification lent or greater level of safety than the
must be conducted on each qualified design type tested and which has been
IBC design type if the manufacturer is approved by the Associate Adminis-
to maintain authorization for contin- trator.
ued production. The IBC manufacturer (i) Approval of equivalent packagings.
shall achieve successful test results for An IBC differing from the standards in
the periodic design requalification at subpart N of this part, or tested using
sufficient frequency to ensure each methods other than those specified in
packaging produced by the manufac- this subpart, may be used if approved
turer is capable of passing the design by the Associate Administrator. Such
qualification tests. Design requalifica- IBCs must be shown to be equally effec-
tion tests must be conducted at least tive, and testing methods used must be
once every 12 months. equivalent.
(2) Changes in the frequency of design (j) Proof of compliance. Notwith-
requalification testing specified in standing the periodic design requali-
paragraph (e)(1) of this section are au- fication testing intervals specified in
thorized if approved by the Associate paragraph (e) of this section, the Asso-
Administrator. These requests must be ciate Administrator, or a designated
based on: representative, may at any time re-
quire demonstration of compliance by
(i) Detailed quality assurance pro-
a manufacturer, through testing in ac-
grams that assure that proposed de-
cordance with this subpart, that pack-
creases in test frequency maintain the
agings meet the requirements of this
integrity of originally tested IBC de- subpart. As required by the Associate
sign types; and Administrator, or a designated rep-
(ii) Demonstrations that each IBC resentative, the manufacturer shall ei-
produced is capable of withstanding ther:
higher standards (e.g., increased drop (1) Conduct performance tests or
height, hydrostatic pressure, wall have tests conducted by an inde-
thickness, fabric weight). pendent testing facility, in accordance
(f) Production testing and inspection. with this subpart; or
(1) Production testing consists of the (2) Make a sample IBC available to
leakproofness test prescribed in the Associate Administrator, or a des-
§ 178.813 of this subpart and must be ignated representative, for testing in
performed on each IBC intended to con- accordance with this subpart.

tain solids discharged by pressure or (k) Coatings. If an inner treatment or
intended to contain liquids. For this coating of an IBC is required for safety
test: reasons, the manufacturer shall design
227
§ 178.802 49 CFR Ch. I (10–1–18 Edition)
the IBC so that the treatment or coat- odic retest on an IBC, a test report
ing retains its protective properties must be prepared.
even after withstanding the tests pre- (1) The test report must be main-
scribed by this subpart. tained at each location where the pack-
(l) Record retention. Following each aging is manufactured, certified, and a
design qualification test and each peri- design qualification test or periodic
retest is conducted as follows:
formed.
fully performed.
(2) The test report must be made must be conditioned for at least 24
available to a user of a packaging or a hours in an atmosphere maintained:
representative of the Department upon (1) At 50 percent ±2 percent relative
request. The test report, at a min- humidity, and at a temperature of 23°
imum, must contain the following in- ±2 °C (73 °F ±4 °F); or
formation: (2) At 65 percent ±2 percent relative
(i) Name and address of test facility; humidity, and at a temperature of 20°
(ii) Name and address of the person
±2 °C (68 °F ±4 °F), or 27 °C ±2 °C (81 °F
certifying the IBC;
(iii) A unique test report identifica- ±4 °F).
tion; (b) Average values for temperature
(iv) Date of test report; and humidity must fall within the lim-
(v) Manufacturer of the IBC; its in paragraph (a) of this section.
(vi) Description of the IBC design Short-term fluctuations and measure-
type (e.g., dimensions, materials, clo- ment limitations may cause individual
sures, thickness, representative service measurements to vary by up to ±5 per-
equipment, etc.); cent relative humidity without signifi-
(vii) Maximum IBC capacity; cant impairment of test reproduc-
(viii) Characteristics of test contents; ibility.
(ix) Test descriptions and results (in- (c) For purposes of periodic design re-
cluding drop heights, hydrostatic pres- qualification only, fiberboard IBCs or
sures, tear propagation length, etc.); composite IBCs with fiberboard outer
and
packagings may be at ambient condi-
(x) The signature of the person con-
tions.
ducting the test, and name of the per-
son responsible for testing. [Amdt. 178–103, 59 FR 38074, July 26, 1994, as
amended at 66 FR 45386, Aug. 28, 2001]
[Amdt. 178–103, 59 FR 38074, July 26, 1994, as
4, 1995; 66 FR 45386, Aug. 28, 2001; 66 FR 33452, § 178.803 Testing and certification of
June 21, 2001; 68 FR 75758, Dec. 31, 2003; 73 FR IBCs.
57008, Oct. 1, 2008; 74 FR 2269, Jan. 14, 2009; 75 Tests required for the certification of
FR 5397, Feb. 2, 2010; 78 FR 14715, Mar. 7, 2013;
78 FR 65487, Oct. 31, 2013; 80 FR 72929, Nov. 23,
each IBC design type are specified in
2015] the following table. The letter X indi-
cates that one IBC (except where
§ 178.802 Preparation of fiberboard noted) of each design type must be sub-
IBCs for testing. jected to the tests in the order pre-

(a) Fiberboard IBCs and composite sented:
IBCs with fiberboard outer packagings
228
IBC type
Performance test Rigid plastic Composite Fiber-board
Metal IBCs Wooden IBCs Flexible IBCs
IBCs IBCs IBCs
Vibration ........................ 6 X 6 X 6 X 6X 6X 1.5 X

Bottom lift ...................... 2 X X X X X
Top lift ........................... 2 X 2 X 2 X 25 X
Stacking ......................... 7 X 7 X 7 X 7 X 7 X 5 X
Leakproofness ............... 3 X 3 X 3 X
Hydrostatic .................... 3 X 3 X 3 X
Drop ............................... 4 X 4 X 4 X 4 X 4 X 5 X
Topple ........................... 5 X
Righting ......................... 25 X
Tear ............................... 5 X
1 Flexible IBCs must be capable of withstanding the vibration test.
2 This test must be performed only if IBCs are designed to be handled this way. For metal IBCs, at least one of the bottom lift
or top lift tests must be performed.
3 The leakproofness and hydrostatic pressure tests are required only for IBCs intended to contain liquids or intended to contain
solids loaded or discharged under pressure.
4 Another IBC of the same design type may be used for the drop test set forth in § 178.810 of this subchapter.
5 Another different flexible IBC of the same design type may be used for each test.
6 The vibration test may be performed in another order for IBCs manufactured and tested under provisions of an exemption be-
fore October 1, 1994 and for non-DOT specification portable tanks tested before October 1, 1994, intended for export.
7 This test must be performed only if the IBC is designed to be stacked.
[Amdt. 178–108, 60 FR 40039, Aug. 4, 1995, as amended at 64 FR 51919, Sept. 27, 1999; 66 FR 45386,
45390, Aug. 28, 2001]
§ 178.810 Drop test. ceptable test liquids, and may be con-

sidered equivalent to water for test
(a) General. The drop test must be
purposes. IBCs conditioned in this way
conducted for the qualification of all
are not required to be conditioned in
IBC design types and performed peri-
accordance with § 178.802.
odically as specified in § 178.801(e) of (c) Test method. (1) Samples of all IBC
this subpart. design types must be dropped onto a
(b) Special preparation for the drop test. rigid, non-resilient, smooth, flat and
(1) Metal, rigid plastic, and composite horizontal surface. The point of impact
IBCs intended to contain solids must must be the most vulnerable part of
be filled to not less than 95 percent of the base of the IBC being tested. Fol-
their maximum capacity, or if intended lowing the drop, the IBC must be re-
to contain liquids, to not less than 98 stored to the upright position for ob-
percent of their maximum capacity. servation.
Pressure relief devices must be re- (2) IBC design types with a capacity
moved and their apertures plugged or of 0.45 cubic meters (15.9 cubic feet) or
rendered inoperative. less must be subject to an additional
(2) Fiberboard and wooden IBCs must drop test.
be filled with a solid material to not (d) Drop height. (1) For all IBCs, drop
less than 95 percent of their maximum heights are specified as follows:
capacity; the contents must be evenly (i) Packing Group I: 1.8 m (5.9 feet).
distributed. (ii) Packing Group II: 1.2 m (3.9 feet).
(3) Flexible IBCs must be filled to the (iii) Packing Group III: 0.8 m (2.6
maximum permissible gross mass; the feet).
contents must be evenly distributed. (2) Drop tests are to be performed
(4) Rigid plastic IBCs and composite with the solid or liquid to be trans-
IBCs with plastic inner receptacles ported or with a non-hazardous mate-
must be conditioned for testing by re- rial having essentially the same phys-
ducing the temperature of the pack- ical characteristics.
aging and its contents to ¥18 °C (0 °F) (3) The specific gravity and viscosity
or lower. Test liquids must be kept in of a substituted non-hazardous mate-
the liquid state, if necessary, by the rial used in the drop test for liquids
addition of anti-freeze. Water/anti- must be similar to the hazardous mate-

freeze solutions with a minimum spe- rial intended for transportation. Water
cific gravity of 0.95 for testing at ¥18 also may be used for the liquid drop
°C (0 °F) or lower are considered ac- test under the following conditions:
229
§ 178.811 49 CFR Ch. I (10–1–18 Edition)
(i) Where the substances to be carried (d) Criteria for passing the test. For all
have a specific gravity not exceeding IBC design types designed to be lifted
1.2, the drop heights must be those from the base, there may be no perma-
specified in paragraph (d)(1) of this sec- nent deformation which renders the
tion for each IBC design type; and IBC unsafe for transportation and no
(ii) Where the substances to be car- loss of contents.
ried have a specific gravity exceeding [Amdt. 178–103, 59 FR 38074, July 26, 1994, as
1.2, the drop heights must be as fol- amended at 66 FR 45386, Aug. 28, 2001]
lows:
(A) Packing Group I: SG × 1.5 m (4.9 § 178.812 Top lift test.
feet). (a) General. The top lift test must be
(B) Packing Group II: SG × 1.0 m (3.3 conducted for the qualification of all
feet). IBC design types designed to be lifted
(C) Packing Group III: SG × 0.67 m from the top or, for flexible IBCs, from
(2.2 feet). the side.
(e) Criteria for passing the test. For all (b) Special preparation for the top lift
IBC design types, there may be no dam- test. (1) Metal, rigid plastic, and com-
age which renders the IBC unsafe to be posite IBC design types must be loaded
transported for salvage or for dispos- to twice the maximum permissible
able, and no loss of contents. The IBC gross mass with the load being evenly
shall be capable of being lifted by an distributed.
appropriate means until clear of the (2) Flexible IBC design types must be
floor for five minutes. A slight dis- filled to six times the maximum net
charge from a closure upon impact is mass, the load being evenly distrib-
not considered to be a failure of the uted.
IBC provided that no further leakage (c) Test method. (1) A metal or flexible
occurs. A slight discharge (e.g., from IBC must be lifted in the manner for
closures or stitch holes) upon impact is which it is designed until clear of the
not considered a failure of the flexible floor and maintained in that position
IBC provided that no further leakage for a period of five minutes.
occurs after the IBC has been raised (2) Rigid plastic and composite IBC
clear of the ground. design types must be:
(i) Lifted by each pair of diagonally
[Amdt. 178–103, 59 FR 38074, July 26, 1994, as opposite lifting devices, so that the
amended at 66 FR 45386, Aug. 28, 2001; 69 FR hoisting forces are applied vertically,
76186, Dec. 20, 2004; 71 FR 78635, Dec. 29, 2006; for a period of five minutes; and
74 FR 2269, Jan. 14, 2009; 75 FR 5397, Feb. 2,
2010]
(ii) Lifted by each pair of diagonally
opposite lifting devices, so that the
§ 178.811 Bottom lift test. hoisting forces are applied towards the
center at 45° to the vertical, for a pe-
(a) General. The bottom lift test must riod of five minutes.
be conducted for the qualification of (3) If not tested as indicated in para-
all IBC design types designed to be lift- graph (c)(1) of this section, a flexible
ed from the base. IBC design type must be tested as fol-
(b) Special preparation for the bottom lows:
lift test. The IBC must be loaded to 1.25 (i) Fill the flexible IBC to 95% full
times its maximum permissible gross with a material representative of the
mass, the load being evenly distrib- product to be shipped.
uted. (ii) Suspend the flexible IBC by its
(c) Test method. All IBC design types lifting devices.
must be raised and lowered twice by a (iii) Apply a constant downward force
lift truck with the forks centrally posi- through a specially designed platen.
tioned and spaced at three quarters of The platen will be a minimum of 60%
the dimension of the side of entry (un- and a maximum of 80% of the cross sec-
less the points of entry are fixed). The tional surface area of the flexible IBC.
forks must penetrate to three quarters (iv) The combination of the mass of
of the direction of entry. The test must the filled flexible IBC and the force ap-
be repeated from each possible direc- plied through the platen must be a
tion of entry. minimum of six times the maximum
230
net mass of the flexible IBC. The test contain liquids, there may be no leak-
must be conducted for a period of five age of air from the IBC.
minutes. [Amdt. 178–103, 59 FR 38074, July 26, 1994, as
(v) Other equally effective methods amended at 64 FR 10782, Mar. 5, 1999; 66 FR
of top lift testing and preparation may 45185, 45386, Aug. 28, 2001]
be used with approval of the Associate
Administrator. § 178.814 Hydrostatic pressure test.
(d) Criteria for passing the test. For all (a) General. The hydrostatic pressure
IBC design types designed to be lifted test must be conducted for the quali-
from the top, there may be no perma- fication of all metal, rigid plastic, and
nent deformation which renders the composite IBC design types intended to
IBC, including the base pallets when contain solids that are loaded or dis-
applicable, unsafe for transportation, charged under pressure or intended to
contain liquids.
and no loss of contents.
(b) Special preparation for the hydro-
[Amdt. 178–103, 59 FR 38074, July 26, 1994, as static pressure test. For metal IBCs, the
amended at 66 FR 33452, June 21, 2001; 66 FR test must be carried out before the fit-
45386, Aug. 28, 2001; 68 FR 45042, July 31, 2003] ting of any thermal insulation equip-
ment. For all IBCs, pressure relief de-
§ 178.813 Leakproofness test. vices and vented closures must be re-
(a) General. The leakproofness test moved and their apertures plugged or
must be conducted for the qualification rendered inoperative.
of all IBC design types and on all pro- (c) Test method. Hydrostatic gauge
duction units intended to contain sol- pressure must be measured at the top
ids that are loaded or discharged under of the IBC. The test must be carried
pressure or intended to contain liquids. out for a period of at least 10 minutes
applying a hydrostatic gauge pressure
(b) Special preparation for the
not less than that indicated in para-
leakproofness test. Vented closures must graph (d) of this section. The IBCs may
either be replaced by similar non-vent- not be mechanically restrained during
ed closures or the vent must be sealed. the test.
For metal IBC design types, the initial (d) Hydrostatic gauge pressure applied.
test must be carried out before the fit- (1) For metal IBC design types, 31A,
ting of any thermal insulation equip- 31B, 31N: 65 kPa gauge pressure (9.4
ment. The inner receptacle of a com- psig).
posite IBC may be tested without the (2) For metal IBC design types 21A,
outer packaging provided the test re- 21B, 21N, 31A, 31B, 31N: 200 kPa (29
sults are not affected. psig). For metal IBC design types 31A,
(c) Test method and pressure applied. 31B and 31N, the tests in paragraphs
The leakproofness test must be carried (d)(1) and (d)(2) of this section must be
out for a suitable length of time using conducted consecutively.
air at a gauge pressure of not less than (3) For metal IBCs design types 21A,
20 kPa (2.9 psig). Leakproofness of IBC 21B, and 21N, for Packing Group I sol-
design types must be determined by ids: 250 kPa (36 psig) gauge pressure.
coating the seams and joints with a (4) For rigid plastic IBC design types
21H1 and 21H2 and composite IBC de-
heavy oil, a soap solution and water, or
sign types 21HZ1 and 21HZ2: 75 kPa (11
other methods suitable for the purpose
psig).
of detecting leaks. Other methods, if at (5) For rigid plastic IBC design types
least equally effective, may be used in 31H1 and 31H2 and composite IBC de-
accordance with appendix B of this sign types 31HZ1 and 31HZ2: whichever
part, or if approved by the Associate is the greater of:
Administrator, as provided in (i) The pressure determined by any
§ 178.801(i)). one of the following methods:
(d) Criterion for passing the test. For (A) The gauge pressure (pressure in
all IBC design types intended to con- the IBC above ambient atmospheric
tain solids that are loaded or dis- pressure) measured in the IBC at 55 °C
charged under pressure or intended to (131 °F) multiplied by a safety factor of
1.5. This pressure must be determined
231
§ 178.815 49 CFR Ch. I (10–1–18 Edition)
on the basis of the IBC being filled and (2) The flexible IBC must be filled to
closed to no more than 98 percent ca- not less than 95 percent of its capacity
pacity at 15 °C (60 °F); and to its maximum net mass, with the
(B) If absolute pressure (vapor pres- load being evenly distributed.
sure of the hazardous material plus at- (c) Test method. (1) Design Qualifica-
mospheric pressure) is used, 1.5 multi- tion Testing. All IBCs must be placed on
plied by the vapor pressure of the haz- their base on level, hard ground and
ardous material at 55 °C (131 °F) minus subjected to a uniformly distributed
100 kPa (14.5 psi). If this method is cho- superimposed test load for a period of
sen, the hydrostatic test pressure ap-
at least five minutes (see paragraph
plied must be at least 100 kPa gauge
(c)(5) of this section).
pressure (14.5 psig); or
(C) If absolute pressure (vapor pres- (2) Fiberboard, wooden and composite
sure of the hazardous material plus at- IBCs with outer packagings con-
mospheric pressure) is used, 1.75 multi- structed of other than plastic mate-
plied by the vapor pressure of the haz- rials must be subject to the test for 24
ardous material at 50 °C (122 °F) minus hours.
100 kPa (14.5 psi). If this method is cho- (3) Rigid plastic IBC types and com-
sen, the hydrostatic test pressure ap- posite IBC types with plastic outer
plied must be at least 100 kPa gauge packagings (11HH1, 11HH2, 21HH1,
pressure (14.5 psig); or 21HH2, 31HH1 and 31HH2) which bear
(ii) Twice the greater of: (A) The the stacking load must be subjected to
static pressure of the hazardous mate- the test for 28 days at 40 °C (104 °F).
rial on the bottom of the IBC filled to (4) For all IBCs, the load must be ap-
98 percent capacity; or plied by one of the following methods:
(B) The static pressure of water on (i) One or more IBCs of the same type
the bottom of the IBC filled to 98 per- loaded to their maximum permissible
cent capacity. gross mass and stacked on the test
(e) Criteria for passing the test(s). (1) IBC;
For metal IBCs, subjected to the 65
(ii) The calculated superimposed test
kPa (9.4 psig) test pressure specified in
load weight loaded on either a flat
paragraph (d)(1) of this section, there
plate or a reproduction of the base of
may be no leakage or permanent defor-
the IBC, which is stacked on the test
mation that would make the IBC un-
safe for transportation. IBC.
(2) For metal IBCs intended to con- (5) Calculation of superimposed test
tain liquids, when subjected to the 200 load. For all IBCs, the load to be placed
kPa (29 psig) and the 250 kPa (36 psig) on the IBC must be 1.8 times the com-
test pressures specified in paragraphs bined maximum permissible gross mass
(d)(2) and (d)(3) of this section, respec- of the number of similar IBCs that may
tively, there may be no leakage. be stacked on top of the IBC during
(3) For rigid plastic IBC types 21H1, transportation.
21H2, 31H1, and 31H2, and composite (d) Periodic Retest. (1) The package
IBC types 21HZ1, 21HZ2, 31HZ1, and must be tested in accordance with
31HZ2, there may be no leakage and no paragraph (c) of this section; or
permanent deformation which renders (2) The packaging may be tested
the IBC unsafe for transportation. using a dynamic compression testing
[Amdt. 178–103, 59 FR 38074, July 26, 1994, as machine. The test must be conducted
amended at 66 FR 45185, 45386, Aug. 28, 2001] at room temperature on an empty, un-
sealed packaging. The test sample
§ 178.815 Stacking test. must be centered on the bottom platen
(a) General. The stacking test must of the testing machine. The top platen
be conducted for the qualification of must be lowered until it comes in con-
all IBC design types intended to be tact with the test sample. Compression
stacked. must be applied end to end. The speed
(b) Special preparation for the stacking of the compression tester must be one-
test. (1) All IBCs except flexible IBC de- half inch plus or minus one-fourth inch
sign types must be loaded to their max- per minute. An initial preload of 50
imum permissible gross mass. pounds must be applied to ensure a
232
definite contact between the test sam- not less than 95 percent of its capacity
ple and the platens. The distance be- and to its maximum net mass, with the
tween the platens at this time must be load being evenly distributed.
recorded as zero deformation. The force (c) Test method. A flexible IBC must
‘‘A’’ then to be applied must be cal- be toppled onto any part of its top
culated using the applicable formula: upon a rigid, non-resilient, smooth,
Liquids: A = (1.8)(n ¥ 1) [w + (s × v × 8.3 flat, and horizontal surface.
× .98)] × 1.5; (d) Topple height. For all flexible
IBCs, the topple height is specified as
or follows:
Solids: A = (1.8)(n ¥ 1) [w + (s × v × 8.3 (1) Packing Group I: 1.8 m (5.9 feet).
× .95)] × 1.5 (2) Packing Group II: 1.2 m (3.9 feet).
(3) Packing Group III: 0.8 m (2.6 feet).
Where:
(e) Criteria for passing the test. For all
A = applied load in pounds.
n = maximum number of IBCs being stacked
flexible IBCs, there may be no loss of
during transportation. contents. A slight discharge (e.g., from
w = maximum weight of one empty container closures or stitch holes) upon impact is
in pounds. not considered to be a failure, provided
s = specific gravity (liquids) or density (sol- no further leakage occurs.
ids) of the lading.
v = actual capacity of container (rated ca- [Amdt. 178–103, 59 FR 38074, July 26, 1994, as
pacity + outage) in gallons. amended at 66 FR 45386, Aug. 28, 2001]
and:
8.3 corresponds to the weight in pounds of 1.0 § 178.817 Righting test.
gallon of water. (a) General. The righting test must be
1.5 is a compensation factor converting the conducted for the qualification of all
static load of the stacking test into a load
flexible IBCs designed to be lifted from
suitable for dynamic compression testing.
the top or side.
(e) Criteria for passing the test. (1) For (b) Special preparation for the righting
metal, rigid plastic, and composite test. The flexible IBC must be filled to
IBCs, there may be no permanent de- not less than 95 percent of its capacity
formation, which renders the IBC un- and to its maximum net mass, with the
safe for transportation, and no loss of load being evenly distributed.
contents. (c) Test method. The flexible IBC,
(2) For fiberboard and wooden IBCs, lying on its side, must be lifted at a
there may be no loss of contents and no speed of at least 0.1 m/second (0.33 ft/s)
permanent deformation, which renders to an upright position, clear of the
the whole IBC, including the base pal- floor, by one lifting device, or by two
let, unsafe for transportation. lifting devices when four are provided.
(3) For flexible IBCs, there may be no (d) Criterion for passing the test. For
deterioration, which renders the IBC all flexible IBCs, there may be no dam-
unsafe for transportation, and no loss age to the IBC or its lifting devices
of contents. which renders the IBC unsafe for trans-
(4) For the dynamic compression portation or handling.
test, a container passes the test if,
[Amdt. 178–103, 59 FR 38074, July 26, 1994, as
after application of the required load,
amended at 66 FR 45386, Aug. 28, 2001]
there is no permanent deformation to
the IBC, which renders the whole IBC, § 178.818 Tear test.
including the base pallet, unsafe for
(a) General. The tear test must be
transportation; in no case may the
maximum deflection exceed one inch.
flexible IBC design types.
[75 FR 5397, Feb. 2, 2010] (b) Special preparation for the tear test.
The flexible IBC must be filled to not
§ 178.816 Topple test. less than 95 percent of its capacity and
(a) General. The topple test must be to its maximum net mass, the load
conducted for the qualification of all being evenly distributed.

flexible IBC design types. (c) Test method. Once the IBC is
(b) Special preparation for the topple placed on the ground, a 100-mm (4-inch)
test. The flexible IBC must be filled to knife score, completely penetrating the
233
§ 178.819 49 CFR Ch. I (10–1–18 Edition)
wall of a wide face, is made at a 45° (c) Criteria for passing the test. An IBC
angle to the principal axis of the IBC, passes the vibration test if there is no
halfway between the bottom surface rupture or leakage.
and the top level of the contents. The [Amdt. 178–103, 59 FR 38074, July 26, 1994, as
IBC must then be subjected to a uni- amended by Amdt. 178–108, 60 FR 40038, Aug.
formly distributed superimposed load 4, 1995; Amdt. 178–110, 60 FR 49111, Sept. 21,
equivalent to twice the maximum net 1995; 66 FR 45386, Aug. 28, 2001; 75 FR 5397,
Feb. 2, 2010]
mass. The load must be applied for at
least five minutes. An IBC which is de-
signed to be lifted from the top or the Subpart P—Large Packagings
side must, after removal of the super- Standards
imposed load, be lifted clear of the
floor and maintained in that position SOURCE: 75 FR 5397, Feb. 2, 2010, unless oth-
for a period of five minutes. erwise noted.
(d) Criterion for passing the test. The § 178.900 Purpose and scope.
IBC passes the tear test if the cut does
not propagate more than 25 percent of (a) This subpart prescribes require-
its original length. ments for Large Packaging intended
for the transportation of hazardous
[Amdt. 178–103, 59 FR 38074, July 26, 1994, as materials. Standards for these pack-
amended at 66 FR 45386, Aug. 28, 2001] agings are based on the UN Rec-
ommendations.
§ 178.819 Vibration test. (b) Terms used in this subpart are de-
(a) General. The vibration test must fined in § 171.8 of this subchapter.
be conducted for the qualification of
§ 178.905 Large Packaging identifica-
all rigid IBC design types. Flexible IBC tion codes.
design types must be capable of with-
standing the vibration test. Large packaging code designations
consist of: two numerals specified in
(b) Test method. (1) A sample IBC, se-
paragraph (a) of this section; followed
lected at random, must be filled and
by the capital letter(s) specified in
closed as for shipment. IBCs intended paragraph (b) of this section.
for liquids may be tested using water (a) Large packaging code number
as the filling material for the vibration designations are as follows: 50 for rigid
test. Large Packagings; or 51 for flexible
(2) The sample IBC must be placed on Large Packagings.
a vibrating platform with a vertical or (b) Large Packagings code letter des-
rotary double-amplitude (peak-to-peak ignations are as follows:
displacement) of one inch. The IBC (1) ‘‘A’’ means steel (all types and
must be constrained horizontally to surface treatments).
prevent it from falling off the plat- (2) ‘‘B’’ means aluminum.
form, but must be left free to move (3) ‘‘C’’ means natural wood.
vertically and bounce. (4) ‘‘D’’ means plywood.
(3) The test must be performed for (5) ‘‘F’’ means reconstituted wood.
(6) ‘‘G’’ means fiberboard.
one hour at a frequency that causes the
(7) ‘‘H’’ means plastic.
package to be raised from the vibrating
(8) ‘‘M’’ means paper, multiwall.
platform to such a degree that a piece (9) ‘‘N’’ means metal (other than
of material of approximately 1.6-mm steel or aluminum).
(0.063-inch) thickness (such as steel
strapping or paperboard) can be passed § 178.910 Marking of Large Pack-
between the bottom of the IBC and the agings.
platform. Other methods at least (a) The manufacturer must:
equally effective may be used (see (1) Mark every Large Packaging in a
§ 178.801(i)). durable and clearly visible manner.
The marking may be applied in a single

line or in multiple lines provided the
correct sequence is followed with the
information required by this section, in
234
letters, numerals, and symbols of at design type has been successfully test-
least 12 mm in height. This minimum ed, as follows:
marking size requirement applies only (A) X—for Large Packagings meeting
to large packages manufactured after Packing Groups I, II and III tests;
January 1, 2014. The following informa- (B) Y—for Large Packagings meeting
tion is required in the sequence pre- Packing Groups II and III tests; and
sented: (C) Z—for Large Packagings meeting
(i) Except as provided in Packing Group III test.
§ 178.503(e)(1)(ii), the United Nations (iv) The month (designated numeri-
packaging symbol as illustrated in cally) and year (last two digits) of
§ 178.503(e)(1)(i). For metal Large Pack- manufacture;
agings on which the marking is (v) The country authorizing the allo-
stamped or embossed, the capital let- cation of the mark. The letters ‘‘USA’’
ters ‘‘UN’’ may be applied instead of indicate that the Large Packaging is
manufactured and marked in the
the symbol;
United States in compliance with the
(ii) The code number designating the
provisions of this subchapter.
Large Packaging design type according to (vi) The name and address or symbol
§ 178.905. The letters ‘‘T’’ or ‘‘W’’ may of the manufacturer or the approval
follow the Large Packaging design type agency certifying compliance with sub-
identification code on a Large Pack- part P and subpart Q of this part. Sym-
aging. Large Salvage Packagings con- bols, if used, must be registered with
forming to the requirements of subpart the Associate Administrator.
P of this part must be marked with the (vii) The stacking test load in kilo-
letter ‘‘T’’. Large Packagings must be grams (kg). For Large Packagings not
marked with the letter ‘‘W’’ when the designed for stacking the figure ‘‘0’’
Large Packaging differs from the re- must be shown.
quirements in subpart P of this part, or (viii) The maximum permissible
is tested using methods other than gross mass or for flexible Large Pack-
those specified in this subpart, and is agings, the maximum net mass, in kg.
approved by the Associate Adminis- (2) The following are examples of
trator in accordance with the provi- symbols and required markings:
sions in § 178.955; (i) For a steel Large Packaging suit-
(iii) A capital letter identifying the able for stacking; stacking load: 2,500
performance standard under which the kg; maximum gross mass: 1,000 kg.
(ii) For a plastic Large Packaging

not suitable for stacking; maximum
gross mass: 800 kg.
ER02FE10.003</GPH> ER02FE10.004</GPH>
235
§ 178.910 49 CFR Ch. I (10–1–18 Edition)
(iii) For a Flexible Large Packaging

not suitable for stacking; maximum
gross mass: 500 kg.
(iv) For a steel Large Salvage Pack- load: 2,500 kg; maximum gross mass:
aging suitable for stacking; stacking 1,000 kg.
(b) All Large Packagings manufac- side being not less than 100 mm (3.9
tured, repaired or remanufactured after inches) by 100 mm (3.9 inches) as meas-
January 1, 2015 must be marked with ured from the corner printer marks
the symbol applicable to a Large Pack- shown on the following figures. Where
aging designed for stacking or not de- dimensions are not specified, all fea-
signed for stacking, as appropriate. tures must be in approximate propor-
The symbol must be a square with each tion to those shown.
(1) Transitional exception—A marking effect on December 31, 2014, may con-
in conformance with the requirements tinue in service until the end of its use-
of this paragraph in effect on December ful life.
31, 2014, may continue to be applied to
[75 FR 5397, Feb. 2, 2010, as amended at 75 FR
ER07JA13.001</GPH>
all Large Packagings manufactured, 60339, Sept. 30, 2010; 78 FR 1097, Jan. 7, 2013;
repaired or remanufactured between 80 FR 1168, Jan. 8, 2015]
January 1, 2015 and December 31, 2016.
(2) For domestic transportation, a

Large Packaging marked prior to Jan-
ER02FE10.005</GPH> ER08JA15.003</GPH>
uary 1, 2017 and in conformance with

the requirements of this paragraph in
236
§ 178.915 General Large Packaging perature performance must be taken

standards. into account when appropriate.
(a) Each Large Packaging must be re- (c) The use of dissimilar metals must
sistant to, or protected from, deterio- not result in deterioration that could
ration due to exposure to the external affect the integrity of the Large Pack-
environment. Large Packagings in- aging.
tended for solid hazardous materials (d) Metal Large Packagings may not
must be sift-proof and water-resistant. have a volumetric capacity greater
(b) All service equipment must be po- than 3,000 L (793 gallons) and not less
sitioned or protected to minimize po- than 450 L (119 gallons).
tential loss of contents resulting from
damage during Large Packaging han- § 178.925 Standards for rigid plastic
Large Packagings.
dling and transportation.
(c) Each Large Packaging, including (a) The provisions in this section
attachments and service and structural apply to rigid plastic Large Packagings
equipment, must be designed to with- intended to contain liquids and solids.
stand, without loss of hazardous mate- Rigid plastic Large Packaging types
rials, the internal pressure of the con- are designated:
tents and the stresses of normal han- (1) 50H rigid plastics.
dling and transport. A Large Pack- (2) [Reserved]
aging intended for stacking must be de- (b) A rigid plastic Large Packaging
signed for stacking. Any lifting or se- must be manufactured from plastic
curing features of a Large Packaging material of known specifications and
must be sufficient strength to with- be of a strength relative to its capacity
stand the normal conditions of han- and to the service it is required to per-
dling and transportation without gross form. In addition to conformance to
distortion or failure and must be posi- § 173.24 of this subchapter, plastic mate-
tioned so as to cause no undue stress in rials must be resistant to aging and to
any part of the Large Packaging. degradation caused by ultraviolet radi-
(d) A Large Packaging consisting of ation.
packagings within a framework must (1) If protection against ultraviolet
be so constructed that the packaging is radiation is necessary, it must be pro-
not damaged by the framework and is vided by the addition of a pigment or
retained within the framework at all inhibiter such as carbon black to plas-
times. tic materials. These additives must be
(e) Large Packaging design types compatible with the contents and re-
must be constructed in such a way as main effective throughout the life of
to be bottom-lifted or top-lifted as the plastic Large Packaging body.
specified in §§ 178.970 and 178.975. Where use is made of carbon black, pig-
[75 FR 5397, Feb. 2, 2010, as amended at 75 FR ments or inhibitors, other than those
60339, Sept. 30, 2010] used in the manufacture of the tested
design type, retesting may be omitted
§ 178.920 Standards for metal Large if changes in the carbon black content,
Packagings. the pigment content or the inhibitor
(a) The provisions in this section content do not adversely affect the
apply to metal Large Packagings in- physical properties of the material of
tended to contain liquids and solids. construction.
Metal Large Packaging types are des- (2) Additives may be included in the
ignated: composition of the plastic material to
(1) 50A steel improve the resistance to aging or to
(2) 50B aluminum serve other purposes, provided they do
(3) 50N metal (other than steel or alu- not adversely affect the physical or
minum) chemical properties of the material of
(b) Each Large Packaging must be construction.
made of suitable ductile metal mate- (3) No used material other than pro-
rials. Welds must be made so as to duction residues or regrind from the

maintain design type integrity of the same manufacturing process may be
receptacle under conditions normally used in the manufacture of rigid plastic
incident to transportation. Low-tem- Large Packagings.
237
§ 178.930 49 CFR Ch. I (10–1–18 Edition)
(c) Rigid plastic Large Packagings: (2) Integral and detachable pallets. (i)
(1) May not have a volumetric capac- Any integral pallet base forming part
ity greater than 3,000 L (793 gallons); of a Large Packaging or any detach-
and able pallet must be suitable for me-
(2) May not have a volumetric capac- chanical handling with the Large
ity less than 450 L (119 gallons). Packaging filled to its maximum per-
missible gross mass.
§ 178.930 Standards for fiberboard (ii) The pallet or integral base must
Large Packagings. be designed to avoid protrusions caus-
ing damage to the fiberboard Large
(a) The provisions in this section
Packagings in handling.
apply to fiberboard Large Packagings
(iii) The body must be secured to any
intended to contain solids. Rigid fiber-
detached pallet to ensure stability in
board Large Packaging types are des-
handling and transport. Where a de-
ignated:
tachable pallet is used, its top surface
(1) 50G fiberboard must be free from protrusions that
(2) [Reserved] might damage the Large Packaging.
(b) Construction requirements for fiber- (3) Strengthening devices, such as
board Large Packagings. (1) Fiberboard timber supports to increase stacking
Large Packagings must be constructed performance may be used but must be
of strong, solid or double-faced cor- external to the liner.
rugated fiberboard (single or (4) The load-bearing surfaces of Large
multiwall) that is appropriate to the Packagings intended for stacking must
capacity of the Large Packagings and be designed to distribute the load in a
to their intended use. Water resistance stable manner.
of the outer surface must be such that (c) Fiberboard Large Packagings may
the increase in mass, as determined in not have a volumetric capacity greater
a test carried out over a period of 30 than 3,000 L (793 gallons) and not less
minutes by the Cobb method of deter- than 450 L (119 gallons).
mining water absorption, is not greater
[75 FR 5397, Feb. 2, 2010, as amended at 75 FR
than 155 grams per square meter (0.0316 60339, Sept. 30, 2010]
pounds per square foot)—see ISO 535 (E)
(IBR, see § 171.7 of this subchapter). Fi- § 178.935 Standards for wooden Large
berboard must have proper bending Packagings.
qualities. Fiberboard must be cut, (a) The provisions in this section
creased without cutting through any apply to wooden Large Packagings in-
thickness of fiberboard, and slotted so tended to contain solids. Wooden Large
as to permit assembly without crack- Packaging types are designated:
ing, surface breaks or undue bending. (1) 50C natural wood.
The fluting or corrugated fiberboard (2) 50D plywood.
must be firmly glued to the facings. (3) 50F reconstituted wood.
(i) The walls, including top and bot- (b) Construction requirements for
tom, must have a minimum puncture wooden Large Packagings are as fol-
resistance of 15 Joules (11 foot-pounds lows:
of energy) measured according to ISO (1) The strength of the materials used
3036 (IBR, see § 171.7 of this subchapter). and the method of construction must
(ii) Manufacturers’ joints in the be appropriate to the capacity and in-
outer packaging of Large Packagings tended use of the Large Packagings.
must be made with an appropriate (i) Natural wood used in the con-
overlap and be taped, glued, stitched struction of Large Packagings must be
with metal staples or fastened by other well-seasoned, commercially dry and
means at least equally effective. Where free from defects that would materially
joints are made by gluing or taping, a lessen the strength of any part of the
water resistant adhesive must be used. Large Packagings. Each Large Pack-
Metal staples must pass completely aging part must consist of uncut wood
through all pieces to be fastened and be or a piece equivalent in strength and

formed or protected so that any inner integrity. Large Packagings parts are
liner cannot be abraded or punctured equivalent to one piece when a suitable
by them. method of glued assembly is used (i.e.,
238
a Lindermann joint, tongue and groove § 178.940 Standards for flexible Large
joint, ship, lap or babbet joint; or butt Packagings.
joint with at least two corrugated (a) The provisions in this section
metal fasteners at each joint, or when apply to flexible Large Packagings in-
other methods at least equally effec- tended to contain liquids and solids.
tive are used). Flexible Large Packagings types are
(ii) Plywood used in construction designated:
must be at least 3-ply. Plywood must (1) 51H flexible plastics.
be made of well-seasoned rotary cut, (2) 51M flexible paper.
sliced or sawn veneer, commercially (b) Construction requirements for
dry and free from defects that would flexible Large Packagings are as fol-
materially lessen the strength of the lows:
Large Packagings. All adjacent piles (1) The strength of the material and
must be glued with water resistant ad- the construction of the flexible Large
hesive. Materials other than plywood Packagings must be appropriate to its
may be used for the construction of the capacity and its intended use.
Large Packaging. (2) All materials used in the con-
(iii) Reconstituted wood used in the struction of flexible Large Packagings
construction of Large Packagings must of types 51M must, after complete im-
be water resistant reconstituted wood mersion in water for not less than 24
such as hardboard, particle board or hours, retain at least 85 percent of the
other suitable type. tensile strength as measured originally
(iv) Wooden Large Packagings must on the material conditioned to equi-
be firmly nailed or secured to corner librium at 67 percent relative humidity
or less.
posts or ends or be assembled by simi-
(3) Seams must be stitched or formed
lar devices.
by heat sealing, gluing or any equiva-
(2) Integral and detachable pallets. (i) lent method. All stitched seam-ends
Any integral pallet base forming part must be secured.
of a Large Packaging, or any detach- (4) In addition to conformance with
able pallet must be suitable for me- the requirements of § 173.24 of this sub-
chanical handling of a Large Pack- chapter, flexible Large Packaging must
aging filled to its maximum permis- be resistant to aging and degradation
sible gross mass. caused by ultraviolet radiation.
(ii) The pallet or integral base must (5) For plastic flexible Large Pack-
be designed to avoid protrusion that agings, if necessary, protection against
may cause damage to the Large Pack- ultraviolet radiation must be provided
aging in handling. by the addition of pigments or inhibi-
(iii) The body must be secured to any tors such as carbon black. These addi-
detachable pallet to ensure stability in tives must be compatible with the con-
handling and transportation. Where a tents and remain effective throughout
detachable pallet is used, its top sur- the life of the Large Packaging. Where
face must be free from protrusions that use is made of carbon black, pigments
might damage the Large Packaging. or inhibitors other than those used in
(3) Strengthening devices, such as the manufacture of the tested design
timber supports to increase stacking type, retesting may be omitted if the
performance, may be used but must be carbon black content, the pigment con-
tent or the inhibitor content do not ad-
external to the liner.
versely affect the physical properties
(4) The load bearing surfaces of the of the material of construction.
Large Packaging must be designed to
(6) Additives may be included in the
distribute loads in a stable manner. composition of the material of the
(c) Wooden Large Packagings: Large Packaging to improve the resist-
(1) May not have a volumetric capac- ance to aging, provided they do not ad-
ity greater than 3,000 L (793 gallons);
versely affect the physical or chemical

and properties of the material.
(2) May not have a volumetric capac- (7) When flexible material Large
ity less than 450 L (119 gallons). Packagings are filled, the ratio of
239
§ 178.950 49 CFR Ch. I (10–1–18 Edition)
height to width must be no more than at the start of production of that pack-
2:1. aging.
(c) Flexible Large Packagings: (3) Periodic design requalification test is
(1) May not have a volumetric capac- the performance of the applicable tests
ity greater than 3,000 L (793 gallons); specified in paragraph (c)(2) of this sec-
(2) May not have a volumetric capac- tion on a Large Packaging design type,
ity less than 56 L (15 gallons); and to requalify the design for continued
(3) Must be designed and tested to a production at the frequency specified
capacity of not less than 50 kg (110 in paragraph (e) of this section.
pounds). (4) Production inspection is the inspec-
tion, which must initially be conducted
Subpart Q—Testing of Large on each newly manufactured Large
Packagings Packaging.
(5) Different Large Packaging design
SOURCE: 75 FR 5400, Feb. 2, 2010, unless oth- type is one which differs from a pre-
erwise noted. viously qualified Large Packaging de-
sign type in structural design, size, ma-
§ 178.950 Purpose and scope. terial of construction, wall thickness,
This subpart prescribes certain test- or manner of construction, but does
ing requirements for Large Packagings not include:
identified in subpart P of this part. (i) A packaging which differs in sur-
face treatment;
§ 178.955 General requirements.
(ii) A rigid plastic Large Packaging,
(a) General. The test procedures pre- which differs with regard to additives
scribed in this subpart are intended to used to comply with § 178.925(b) or
ensure that Large Packagings con- § 178.940(b);
taining hazardous materials can with- (iii) A packaging which differs only
stand normal conditions of transpor- in its lesser external dimensions (i.e.,
tation. These test procedures are con-
height, width, length) provided mate-
sidered minimum requirements. Each
rials of construction and material
packaging must be manufactured and
thickness or fabric weight remain the
assembled so as to be capable of suc-
same;
cessfully passing the prescribed tests
and to conform to the requirements of (6) Remanufactured Large Packaging is
§ 173.24 of this subchapter while in a metal or rigid Large Packaging that
transportation. is produced as a UN type from a non-
(b) Responsibility. The Large Pack- UN type or is converted from one UN
aging manufacturer is responsible for design type to another UN design type.
ensuring each Large Packaging is capa- Remanufactured Large Packagings are
ble of passing the prescribed tests. To subject to the same requirements of
the extent a Large Packaging’s assem- this subchapter that apply to new
bly function, including final closure, is Large Packagings of the same type.
performed by the person who offers a (7) Reused Large Packaging is a Large
hazardous material for transportation, Packaging intended to be refilled and
that person is responsible for per- has been examined and found free of de-
forming the function in accordance fects affecting its ability to withstand
with §§ 173.22 and 178.2 of this sub- the performance tests. See also
chapter. § 173.36(c) of this subchapter.
(c) Definitions. For the purpose of this (d) Design qualification testing. The
subpart: packaging manufacturer must achieve
(1) Large packaging design type refers successful test results for the design
to a Large Packaging which does not qualification testing at the start of
differ in structural design, size, mate- production of each new or different
rial of construction and packing. Large Packaging design type. Applica-
(2) Design qualification testing is the tion of the certification mark by the
performance of the drop, stacking, and manufacturer constitutes certification

bottom-lift or top-lift tests, as applica- that the Large Packaging design type
ble, prescribed in this subpart, for each passed the prescribed tests in this sub-
different Large Packaging design type, part.
240
(e) Periodic design requalification test- (iii) The inner packagings have the
ing. (1) Periodic design requalification same or smaller openings and the clo-
must be conducted on each qualified sure is of similar design (e.g., screw
Large Packaging design type if the cap, friction lid, etc.);
manufacturer is to maintain authoriza- (iv) Sufficient additional cushioning
tion for continued production. The material is used to take up void spaces
Large Packaging manufacturer must and to prevent significant movement of
achieve successful test results for the the inner packagings;
periodic design requalification at suffi- (v) Inner packagings are oriented
cient frequency to ensure each pack- within the outer packaging in the same
aging produced by the manufacturer is manner as in the tested package; and
capable of passing the design qualifica- (vi) The gross mass of the package
tion tests. Design requalification tests does not exceed that originally tested.
must be conducted at least once every (2) A lesser number of the tested
24 months. inner packagings, or of the alternative
(2) Changes in the frequency of design types of inner packagings identified in
requalification testing specified in paragraph (g)(1) of this section, may be
paragraph (e)(1) of this section are au- used provided sufficient cushioning is
thorized if approved by the Associate added to fill void space(s) and to pre-
Administrator. vent significant movement of the inner
(f) Test samples. The manufacturer packagings.
must conduct the design qualification (h) Approval of equivalent packagings.
and periodic tests prescribed in this A Large Packaging differing from
subpart using random samples of pack- standards in subpart P of this part, or
agings, in the numbers specified in the tested using methods other than those
appropriate test section. specified in this subpart, may be used if
(g) Selective testing. The selective approved by the Associate Adminis-
testing of Large Packagings, which dif- trator. The Large Packagings and test-
fer only in minor respects from a testing methods must be shown to have an
ed type is permitted as described in equivalent level of safety.
this section. For air transport, Large (i) Proof of compliance. In addition to
Packagings must comply with the periodic design requalification
§ 173.27(c)(1) and (c)(2) of this sub- testing intervals specified in paragraph
chapter. Variations are permitted in (e) of this section, the Associate Ad-
inner packagings of a tested Large ministrator, or a designated represent-
Packaging, without further testing of ative, may at any time require dem-
the package, provided an equivalent onstration of compliance by a manu-
level of performance is maintained and facturer, through testing in accordance
the methodology used to determine with this subpart, to ensure packagings
that the inner packaging, including meet the requirements of this subpart.
closure, maintains an equivalent level As required by the Associate Adminis-
of performance is documented in writ- trator, or a designated representative,
ing by the person certifying compli- the manufacturer must either:
ance with this paragraph and retained (1) Conduct performance tests or
in accordance with paragraph (l) of this have tests conducted by an inde-
section. Permitted variations are as pendent testing facility, in accordance
follows: with this subpart; or
(1) Inner packagings of equivalent or (2) Make a sample Large Packaging
smaller size may be used provided— available to the Associate Adminis-
(i) The inner packagings are of simi- trator, or a designated representative,
lar design to the tested inner pack- for testing in accordance with this sub-
agings (i.e., shape—round, rectangular, part.
etc.); (j) Record retention. Following each
(ii) The material of construction of design qualification test and each peri-
the inner packagings (glass, plastic, odic retest on a Large Packaging, a
metal, etc.) offers resistance to impact test report must be prepared.

and stacking forces equal to or greater (1) The test report must be main-
than that of the originally tested inner tained at each location where the pack-
packaging; aging is manufactured, certified, and a
241
§ 178.960 49 CFR Ch. I (10–1–18 Edition)
design qualification test or periodic

retest is conducted as follows:
formed.
fully performed.
(2) The test report must be made inner packagings. All closures must be
available to a user of a Large Pack- installed using proper techniques and
aging or a representative of the De- torques.
partment of Transportation upon re- (b) For the drop and stacking test,
quest. The test report, at a minimum, inner receptacles must be filled to not
must contain the following informa- less than 95 percent of maximum ca-
tion: pacity (see § 171.8 of this subchapter) in
(i) Name and address of test facility; the case of solids and not less than 98
(ii) Name and address of applicant percent of maximum in the case of liq-
(where appropriate); uids. Bags must be filled to the max-
(iii) A unique test report identifica- imum mass at which they may be used.
tion; For Large Packagings where the inner
(iv) Date of the test report; packagings are designed to carry liq-
(v) Manufacturer of the packaging; uids and solids, separate testing is re-
(vi) Description of the packaging de- quired for both liquid and solid con-
sign type (e.g., dimensions, materials, tents. The material to be transported
closures, thickness, etc.), including in the packagings may be replaced by a
methods of manufacture (e.g., blow non-hazardous material, except for
molding) and which may include draw- chemical compatibility testing or
ing(s) and/or photograph(s); where this would invalidate the results
(vii) Maximum capacity; of the tests.
(viii) Characteristics of test contents, (c) If the material to be transported
e.g., viscosity and relative density for is replaced for test purposes by a non-
liquids and particle size for solids; hazardous material, the material used
(ix) Mathematical calculations per- must be of the same or higher specific
formed to conduct and document test- gravity as the material to be carried,
ing (for example, drop height, test ca- and its other physical properties
pacity, outage requirements, etc.); (grain, size, viscosity) which might in-
(x) Test descriptions and results; and fluence the results of the required tests
(xi) Signature with the name and must correspond as closely as possible
title of signatory. to those of the hazardous material to
[75 FR 5400, Feb. 2, 2010, as amended at 75 FR be transported. It is permissible to use
60339, Sept. 30, 2010; 76 FR 3389, Jan. 19, 2011; additives, such as bags of lead shot, to
78 FR 14715, Mar. 7, 2013; 78 FR 65487, Oct. 31, achieve the requisite total package
2013; 81 FR 35545, June 2, 2016] mass, so long as they do not affect the
test results.
§ 178.960 Preparation of Large Pack- (d) Paper or fiberboard Large Pack-
agings for testing. agings must be conditioned for at least
(a) Except as otherwise provided in 24 hours immediately prior to testing
this subchapter, each Large Packaging in an atmosphere maintained—
(1) At 50 percent ±2 percent relative
and package must be closed in prepara-

tion for testing and tests must be car- humidity, and at a temperature of 23 °C
ried out in the same manner as if pre- ±2 °C (73 °F ±4 °F). Average values
pared for transportation, including should fall within these limits. Short-
242
term fluctuations and measurement (15.9 cubic feet) or less must be subject
limitations may cause individual meas- to an additional drop test.
urements to vary by up to ±5 percent (e) Drop height. (1) For all Large
relative humidity without significant Packagings, drop heights are specified
impairment of test reproducibility; as follows:
(2) At 65 percent ±2 percent relative (i) Packing group I: 1.8 m (5.9 feet)
humidity, and at a temperature of 20 °C (ii) Packing group II: 1.2 m (3.9 feet)
±2 °C (68 °F ±4 °F), or 27 °C ±2 °C (81 °F (iii) Packing group III: 0.8 m (2.6 feet)
±4 °F). Average values should fall with- (2) Drop tests are to be performed
in these limits. Short-term fluctua- with the solid or liquid to be trans-
tions and measurement limitations ported or with a non-hazardous mate-
may cause individual measurements to rial having essentially the same phys-
vary by up to ±5 percent relative hu- ical characteristics.
midity without significant impairment (3) The specific gravity and viscosity
of a substituted non-hazardous mate-
of test reproducibility; or
rial used in the drop test for liquids
(3) For testing at periodic intervals
must be similar to the hazardous mate-
only (i.e., other than initial design rial intended for transportation. Water
qualification testing), at ambient con- also may be used for the liquid drop
ditions. test under the following conditions:
(i) Where the substances to be carried
§ 178.965 Drop test.
have a specific gravity not exceeding
(a) General. The drop test must be 1.2, the drop heights must be those
conducted for the qualification of all specified in paragraph (e)(1) of this sec-
Large Packaging design types and per- tion for each Large Packaging design
formed periodically as specified in type; and
§ 178.955(e) of this subpart. (ii) Where the substances to be car-
(b) Special preparation for the drop test. ried have a specific gravity exceeding
Large Packagings must be filled in ac- 1.2, the drop heights must be as fol-
cordance with § 178.960. lows:
(c) Conditioning. Rigid plastic Large (A) Packing Group I: SG × 1.5 m (4.9
Packagings and Large Packagings with feet).
plastic inner receptacles must be con- (B) Packing Group II: SG × 1.0 m (3.3
ditioned for testing by reducing the feet).
temperature of the packaging and its (C) Packing Group III: SG × 0.67 m
contents to ¥18 °C (0 °F) or lower. Test (2.2 feet).
liquids must be kept in the liquid (f) Criteria for passing the test. For all
state, if necessary, by the addition of Large Packaging design types there
anti-freeze. Water/anti-freeze solutions may be no loss of the filling substance
with a minimum specific gravity of 0.95 from inner packaging(s) or article(s).
for testing at ¥18 °C (0 °F) or lower are Ruptures are not permitted in Large
considered acceptable test liquids, and Packaging for articles of Class 1 which
may be considered equivalent to water permit the spillage of loose explosive
for test purposes. Large Packagings substances or articles from the Large
conditioned in this way are not re- Packaging. Where a Large Packaging
quired to be conditioned in accordance undergoes a drop test, the sample
with § 178.960(d). passes the test if the entire contents
(d) Test method. (1) Samples of all are retained even if the closure is no
Large Packaging design types must be longer sift-proof.
dropped onto a rigid, non-resilient, [75 FR 5400, Feb. 2, 2010, as amended at 75 FR
smooth, flat and horizontal surface. 60339, Sept. 30, 2010]
The point of impact must be the most
vulnerable part of the base of the Large § 178.970 Bottom lift test.
Packaging being tested. Following the (a) General. The bottom lift test must
drop, the Large Packaging must be re- be conducted for the qualification of
stored to the upright position for ob- all Large Packagings design types de-
servation. signed to be lifted from the base.
(2) Large Packaging design types (b) Special preparation for the bottom
with a capacity of 0.45 cubic meters lift test. The Large Packaging must be
243
§ 178.975 49 CFR Ch. I (10–1–18 Edition)
loaded to 1.25 times its maximum per- (ii) Suspend the flexible Large Pack-
missible gross mass, the load being aging by its lifting devices.
evenly distributed. (iii) Apply a constant downward force
(c) Test method. All Large Packaging through a specially designed platen.
design types must be raised and low- The platen will be a minimum of 60
ered twice by a lift truck with the percent and a maximum of 80 percent
forks centrally positioned and spaced of the cross sectional surface area of
at three quarters of the dimension of the flexible Large Packaging.
the side of entry (unless the points of (iv) The combination of the mass of
entry are fixed). The forks must pene- the filled flexible Large Packaging and
trate to three quarters of the direction the force applied through the platen
of entry. must be a minimum of six times the
(d) Criteria for passing the test. For all maximum net mass of the flexible
Large Packagings design types de- Large Packaging. The test must be
signed to be lifted from the base, there conducted for a period of five minutes.
may be no permanent deformation (v) Other equally effective methods
which renders the Large Packaging un- of top lift testing and preparation may
safe for transport and there must be no be used with approval of the Associate
loss of contents. Administrator.
(d) Criterion for passing the test. For
§ 178.975 Top lift test. all Large Packagings design types de-
signed to be lifted from the top, there
(a) General. The top lift test must be
may be no permanent deformation
conducted for the qualification of all of
which renders the Large Packagings
Large Packagings design types to be
unsafe for transport and no loss of con-
lifted from the top or, for flexible
tents.
Large Packagings, from the side.
(b) Special preparation for the top lift § 178.980 Stacking test.
test. (1) Metal and rigid plastic Large
(a) General. The stacking test must
Packagings design types must be load-
be conducted for the qualification of
ed to twice its maximum permissible
all Large Packagings design types in-
gross mass.
tended to be stacked.
(2) Flexible Large Packaging design
(b) Special preparation for the stacking
types must be filled to six times the
test. (1) All Large Packagings except
maximum permissible gross mass, the
flexible Large Packaging design types
load being evenly distributed.
must be loaded to their maximum per-
(c) Test method. (1) A Large Pack- missible gross mass.
aging must be lifted in the manner for (2) Flexible Large Packagings must
which it is designed until clear of the be filled to not less than 95 percent of
floor and maintained in that position their capacity and to their maximum
for a period of five minutes. net mass, with the load being evenly
(2) Rigid plastic Large Packaging de- distributed.
sign types must be: (c) Test method. (1) All Large Pack-
(i) Lifted by each pair of diagonally agings must be placed on their base on
opposite lifting devices, so that the level, hard ground and subjected to a
hoisting forces are applied vertically uniformly distributed superimposed
for a period of five minutes; and test load for a period of at least five
(ii) Lifted by each pair of diagonally minutes (see paragraph (c)(5) of this
opposite lifting devices so that the section).
hoisting forces are applied towards the (2) Fiberboard and wooden Large
center at 45° to the vertical, for a pe- Packagings must be subjected to the
riod of five minutes. test for 24 hours.
(3) If not tested as indicated in para- (3) Rigid plastic Large Packagings
graph (c)(1) of this section, a flexible which bear the stacking load must be
Large Packaging design type must be subjected to the test for 28 days at 40
°C (104 °F).
tested as follows:
(i) Fill the flexible Large Packaging (4) For all Large Packagings, the
to 95% full with a material representa- load must be applied by one of the fol-
tive of the product to be shipped. lowing methods:
244
(i) One or more Large Packagings of 8.3 corresponds to the weight in pounds of 1.0
the same type loaded to their max- gallon of water.
imum permissible gross mass and 1.5 is a compensation factor that converts
the static load of the stacking test into
stacked on the test Large Packaging; a load suitable for dynamic compression
(ii) The calculated superimposed test testing.
load weight loaded on either a flat
plate or a reproduction of the base of (e) Criterion for passing the test. (1) For
the Large Packaging, which is stacked metal or rigid plastic Large Pack-
on the test Large Packaging; or agings, there may be no permanent de-
(5) Calculation of superimposed test formation which renders the Large
load. For all Large Packagings, the Packaging unsafe for transportation
load to be placed on the Large Pack- and no loss of contents.
aging must be 1.8 times the combined (2) For fiberboard or wooden Large
maximum permissible gross mass of Packagings, there may be no loss of
the number of similar Large Packaging contents and no permanent deforma-
that may be stacked on top of the tion that renders the whole Large
Large Packaging during transpor- Packaging, including the base pallet,
tation. unsafe for transportation.
(d) Periodic Retest. (1) The package (3) For flexible Large Packagings,
must be tested in accordance with there may be no deterioration which
§ 178.980(c) of this subpart; or renders the Large Packaging unsafe for
(2) The packaging may be tested transportation and no loss of contents.
using a dynamic compression testing (4) For the dynamic compression
machine. The test must be conducted test, a container passes the test if,
at room temperature on an empty, un- after application of the required load,
sealed packaging. The test sample there is no permanent deformation to
must be centered on the bottom platen the Large Packaging which renders the
of the testing machine. The top platen whole Large Packaging; including the
must be lowered until it comes in con- base pallet, unsafe for transportation;
tact with the test sample. Compression in no case may the maximum deflec-
must be applied end to end. The speed tion exceed one inch.
of the compression tester must be one- [75 FR 5400, Feb. 2, 2010, as amended at 75 FR
half inch plus or minus one-fourth inch 60339, Sept. 30, 2010; 78 FR 1097, Jan. 7, 2013]
per minute. An initial preload of 50
pounds must be applied to ensure a § 178.985 Vibration test.
definite contact between the test sam- (a) General. All rigid Large Pack-
ple and the platens. The distance be- aging and flexible Large Packaging de-
tween the platens at this time must be sign types must be capable of with-
recorded as zero deformation. The force standing the vibration test.
‘‘A’’ to then be applied must be cal- (b) Test method. (1) A sample Large
culated using the applicable formula: Packaging, selected at random, must
Liquids: A = (1.8)(n¥1) [w + (s × v × 8.3 be filled and closed as for shipment.
× .98)] × 1.5; Large Packagings intended for liquids
may be tested using water as the filling
or material for the vibration test.
(2) The sample Large Packaging must
Solids: A = (1.8)(n¥1) [w + (s × v × 8.3 ×
be placed on a vibrating platform that
.95)] × 1.5
has a vertical or rotary double-ampli-
Where: tude (peak-to-peak displacement) of
A = applied load in pounds. one inch. The Large Packaging must be
n = maximum number of Large Packagings constrained horizontally to prevent it
that may be stacked during transpor- from falling off the platform, but must
tation. be left free to move vertically and
w = maximum weight of one empty container bounce.
in pounds.
(3) The sample Large Packaging must
s = specific gravity (liquids) or density (sol-
ids) of the lading. be placed on a vibrating platform that

v = actual capacity of container (rated ca- has a vertical double-amplitude (peak-
pacity + outage) in gallons. to-peak displacement) of one inch. The
and: Large Packaging must be constrained
245
§ 178.1000 49 CFR Ch. I (10–1–18 Edition)
horizontally to prevent it from falling section. The following information is

off the platform, but must be left free required in the sequence presented:
to move vertically and bounce. (i) Except as provided in
(4) The test must be performed for § 178.503(e)(1)(ii), the United Nations
one hour at a frequency that causes the packaging symbol as illustrated in
package to be raised from the vibrating § 178.503(e)(1)(i).
platform to such a degree that a piece (ii) The code number designating the
of material of approximately 1.6-mm Flexible Bulk Container design type
(0.063-inch) in thickness (such as steel according to § 178.1005. The letter ‘‘W’’
strapping or paperboard) can be passed must follow the Flexible Bulk Con-
between the bottom of the Large Pack- tainer design type identification code
aging and the platform. Other methods on a Flexible Bulk Container when the
at least equally effective may be used Flexible Bulk Container differs from
(see § 178.801(i)). the requirements in subpart R of this
(c) Criterion for passing the test. A part, or is tested using methods other
Large Packaging passes the vibration than those specified in this subpart,
test if there is no rupture or leakage. and is approved by the Associate Ad-
[75 FR 5400, Feb. 2, 2010, as amended at 75 FR ministrator in accordance with
60339, Sept. 30, 2010] § 178.1035;
(iii) The capital letter Z identifying
Subpart R—Flexible Bulk Container that the Flexible Bulk Container meets
Standards Packing Group III performance stand-
ard under which the design type has
been successfully tested.
SOURCE: 78 FR 1097, Jan. 7, 2013, unless oth-
erwise noted. (iv) The month (designated numeri-
cally) and year (last two digits) of
§ 178.1000 Purpose and scope. manufacture;
(a) This subpart prescribes require- (v) The country authorizing the allo-
ments for Flexible Bulk Containers cation of the mark. The letters ‘‘USA’’
(FBCs) intended for the transportation indicate that the Flexible Bulk Con-
of hazardous materials. FBC standards tainer is manufactured and marked in
in this subpart are based on the UN the United States in compliance with
Model Regulations. the provisions of this subchapter.
(b) Terms used in this subpart are de- (vi) The name and address or symbol
fined in § 171.8 of this subchapter. of the manufacturer or the approval
§ 178.1005 Flexible Bulk Container part R and subpart S of this part. Sym-
identification code. bols, if used, must be registered with
The Flexible Bulk Container code the Associate Administrator.
designation is BK3. (vii) The stacking test load in kilo-
grams (kg). For Flexible Bulk Con-
§ 178.1010 Marking of Flexible Bulk tainers not designed for stacking the
Containers. figure ‘‘0’’ must be shown.
(a) The manufacturer must: (viii) The maximum permissible
(1) Mark every Flexible Bulk Con- gross mass in kg.
tainer in a durable and clearly visible (2) The following is an example of
manner. The marking may be applied symbols and required markings for a
in a single line or in multiple lines pro- Flexible Bulk container suitable for
vided the correct sequence is followed stacking; stacking load: 1,000 kg; max-
with the information required by this imum gross mass: 2,500 kg.
246
ER07JA13.002</GPH>
(b) [Reserved] of manufacture of the Flexible Bulk

Container.
§ 178.1015 General Flexible Bulk Con-
tainer standards.
Subpart S—Testing of Flexible Bulk
(a) Each Flexible Bulk Containers Containers
must be sift-proof and completely
closed during transport to prevent the
release of contents and waterproof. SOURCE: 78 FR 1098, Jan. 7, 2013, unless oth-
erwise noted.
(b) Parts of the Flexible Bulk Con-
tainer that are in direct contact with § 178.1030 Purpose and scope.
hazardous materials:
(1) Must not be affected or signifi- This subpart prescribes certain test-
cantly weakened by those hazardous ing requirements for Flexible Bulk
materials. Containers identified in subpart R of
(2) Must not cause a dangerous effect this part.
with the dangerous goods (e.g., cata-
§ 178.1035 General requirements.
lyzing a reaction or reacting with the
hazardous materials). (a) General. The test procedures pre-
(3) Must not allow permeation of the scribed in this subpart are intended to
hazardous materials that could con- ensure that Flexible Bulk Containers
stitute a danger under conditions nor- containing hazardous materials can
mally incident to transportation. withstand normal conditions of trans-
(c) Filling and discharge devices portation. These test procedures are
must be so constructed as to be pro- considered minimum requirements.
tected against damage during trans- Each packaging must be manufactured
port and handling. The filling and dis- and assembled so as to be capable of
charge devices must be capable of successfully passing the prescribed
being secured against unintended open- tests and to conform to the require-
ing. ments of § 173.24 of this subchapter
(d) Slings of the Flexible Bulk Con- while in transportation.
tainer, if fitted with such, must with- (b) Responsibility. The Flexible Bulk
stand pressure and dynamic forces Container manufacturer is responsible
which can be expected under conditions for ensuring each Flexible Bulk Con-
normally incident to transportation. tainers is capable of passing the pre-
(e) Handling devices must be strong scribed tests. To the extent a Flexible
enough to withstand repeated use. Bulk Container’s assembly function,
(f) A venting device must be fitted to including final closure, is performed by
Flexible Bulk Containers intended to the person who offers a hazardous ma-
transport hazardous materials that terial for transportation, that person is
may develop dangerous accumulation responsible for performing the function
of gases within the Flexible Bulk Con- in accordance with §§ 173.22 and 178.2 of
tainer. Any venting device must be de- this subchapter.
signed so that external foreign sub- (c) Definitions. For the purpose of this
stances or the ingress of water are pre- subpart:
vented from entering the Flexible Bulk (1) Flexible Bulk Container design type
Container through the venting device refers to a Flexible Bulk Container
under conditions normally incident to that does not differ in structural de-
transportation. sign, size, material of construction and
[78 FR 1097, Jan. 7, 2013, as amended at 82 FR packing.
15896, Mar. 30, 2017] (2) Design qualification testing is the
performance of the drop, topple, right-
§ 178.1020 Period of use for transpor- ing, tear, stacking, and top-lift tests
tation of hazardous materials in prescribed in this subpart, for each dif-
Flexible Bulk Containers. ferent Flexible Bulk Container design
The use of Flexible Bulk Containers type, at the start of production of that
for the transport of hazardous mate- packaging.
rials is permitted for a period of time (3) Periodic design requalification test is
not to exceed two years from the date the performance of the applicable tests
247
§ 178.1035 49 CFR Ch. I (10–1–18 Edition)
specified in paragraph (c)(2) of this sec- subpart using random samples of pack-
tion on a Flexible Bulk Container de- agings, in the numbers specified in the
sign type, to requalify the design for appropriate test section.
continued production at the frequency (g) Proof of compliance. In addition to
specified in paragraph (e) of this sec- the periodic design requalification
tion. testing intervals specified in paragraph
(4) Production inspection is the inspec- (e) of this section, the Associate Ad-
tion that must initially be conducted ministrator, or a designated represent-
on each newly manufactured Flexible ative, may at any time require dem-
Bulk Container. onstration of compliance by a manu-
(5) Different Flexible Bulk Container facturer, through testing in accordance
design type is one that differs from a with this subpart, to ensure packagings
previously qualified Flexible Bulk Con- meet the requirements of this subpart.
tainer design type in structural design, As required by the Associate Adminis-
size, material of construction, wall trator, or a designated representative,
thickness, or manner of construction, the manufacturer must either:
but does not include: (1) Conduct performance tests or
(i) A packaging that differs in surface have tests conducted by an inde-
treatment; pendent testing facility, in accordance
(ii) A packaging that differs only in with this subpart; or
its lesser external dimensions (i.e., (2) Make a sample Flexible Bulk Con-
height, width, length) provided mate- tainer available to the Associate Ad-
rials of construction and material ministrator, or a designated represent-
thickness or fabric weight remain the ative, for testing in accordance with
same; this subpart.
(d) Design qualification testing. The (h) Record retention. Following each
packaging manufacturer must achieve design qualification test and each peri-
successful test results for the design odic retest on a Flexible Bulk Con-
qualification testing at the start of tainer, a test report must be prepared.
production of each new or different The test report must be maintained at
Flexible Bulk Container design type. each location where the Flexible Bulk
Application of the certification mark Container is manufactured and each lo-
by the manufacturer constitutes cer- cation where the design qualification
tification that the Flexible Bulk Con- tests are conducted, for as long as the
tainer design type passed the pre- Flexible Bulk Container is produced
scribed tests in this subpart. and for at least two years thereafter,
(e) Periodic design requalification test- and at each location where the periodic
ing. (1) Periodic design requalification retests are conducted until such tests
must be conducted on each qualified are successfully performed again and a
Flexible Bulk Container design type if new test report produced. In addition, a
the manufacturer is to maintain au- copy of the test report must be main-
thorization for continued production. tained by a person certifying compli-
The Flexible Bulk Container manufac- ance with this part. The test report
turer must achieve successful test re- must be made available to a user of a
sults for the periodic design requali- Flexible Bulk Container or a represent-
fication at sufficient frequency to en- ative of the Department upon request.
sure each packaging produced by the The test report, at a minimum, must
manufacturer is capable of passing the contain the following information:
design qualification tests. Design re- (1) Name and address of test facility;
qualification tests must be conducted (2) Name and address of applicant
at least once every 24 months. (where appropriate);
(2) Changes in the frequency of design (3) A unique test report identifica-
requalification testing specified in tion;
paragraph (e)(1) of this section are au- (4) Date of the test report;
thorized if approved by the Associate (5) Manufacturer of the packaging;
Administrator. (6) Description of the flexible bulk

(f) Test samples. The manufacturer container design type (e.g., dimensions
must conduct the design qualification materials, closures, thickness, etc.), in-
and periodic tests prescribed in this cluding methods of manufacture (e.g.,
248
blow molding) and which may include (2) Following the drop, the Flexible
drawing(s) and/or photograph(s); Bulk Container must be restored to the
(7) Maximum capacity; upright position for observation.
(8) Characteristics of test contents (d) Drop height. (1) For all Flexible
(e.g., particle size for solids); Bulk Containers, drop heights are spec-
(9) Mathematical calculations per- ified as follows: Packing group III: 0.8
formed to conduct and document test- m (2.6 feet)
ing (e.g., drop height, test capacity, (2) Drop tests are to be performed
outage requirements, etc.); with the solid to be transported or with
(10) Test descriptions and results; and a non-hazardous material having essen-
(11) Signature with the name and tially the same physical characteris-
title of signatory. tics.
(e) Criteria for passing the test. For all
§ 178.1040 Preparation of Flexible Bulk
Containers for testing. Flexible Bulk Container design types
there may be no loss of the filling sub-
(a) Except as otherwise provided in stance. However a slight discharge
this subchapter, each Flexible Bulk (e.g., from closures or stitch holes)
Container must be closed in prepara- upon impact is not considered a failure
tion for testing and tests must be car- of the Flexible Bulk Container pro-
ried out in the same manner as if pre- vided that no further leakage occurs
pared for transportation. All closures after the container has been restored
must be installed using proper tech- to the upright position.
niques and torques.
(b) If the material to be transported § 178.1050 Top lift test.
is replaced for test purposes by a non-
hazardous material, the physical prop- (a) General. The top lift test must be
erties (grain, size, viscosity) of the re- conducted for the qualification of all of
placement material used that might Flexible Bulk Containers design types
influence the results of the required to be lifted from the top.
tests must correspond as closely as (b) Special preparation for the top lift
possible to those of the hazardous ma- test. Flexible Bulk Container design
terial to be transported. It is permis- types must be filled to six times the
sible to use additives, such as bags of maximum permissible gross mass, the
lead shot, to achieve the requisite total load being evenly distributed.
package mass, so long as they do not (c) Test method. (1) A Flexible Bulk
affect the test results. Container must be lifted in the manner
for which it is designed until clear of
§ 178.1045 Drop test. the floor and maintained in that posi-
(a) General. The drop test must be tion for a period of five minutes.
conducted for the qualification of all (2) If not tested as indicated in para-
Flexible Bulk Container design types graph (c)(1) of this section, a Flexible
and performed periodically as specified Bulk Container design type must be
in § 178.1035(e) of this subpart. tested as follows:
(b) Special preparation for the drop test. (i) Fill the Flexible Bulk Container
Flexible Bulk Containers must be filled to 95% full with a material representa-
to their maximum permissible gross tive of the product to be shipped.
mass. (ii) Suspend the Flexible Bulk Con-
(c) Test method. (1) A sample of all tainer by its lifting devices.
Flexible Bulk Container design types (iii) Apply a constant downward force
must be dropped onto a rigid, non-resil- through a specially designed platen.
ient, smooth, flat and horizontal sur- The platen will be a minimum of 60
face. This test surface must be large percent and a maximum of 80 percent
enough to be immovable during testing of the cross sectional surface area of
and sufficiently large enough to ensure the Flexible Bulk Container.
that the test Flexible Bulk Container (iv) The combination of the mass of
falls entirely upon the surface. The the filled Flexible Bulk Container and
test surface must be kept free from the force applied through the platen
local defects capable of influencing the must be a minimum of six times the
test results. maximum net mass of the Flexible
249
§ 178.1055 49 CFR Ch. I (10–1–18 Edition)
Bulk Container. The test must be con- permissible gross mass, the load being
ducted for a period of five minutes. evenly distributed.
(v) Other equally effective methods (c) Test method. Samples of all Flexi-
of top lift testing and preparation may ble Bulk Container design types must
be used with approval of the Associate be toppled onto any part of its top by
Administrator. lifting the side furthest from the drop
(d) Criteria for passing the test. For all edge upon a rigid, non-resilient,
Flexible Bulk Containers design types smooth, flat and horizontal surface.
designed to be lifted from the top, This test surface must be large enough
there may be no damage to the Flexi- to be immovable during testing and
ble Bulk Container or its lifting de- sufficiently large enough to ensure
vices that renders the Flexible Bulk that the test Flexible Bulk Container
Container unsafe for transport, and no falls entirely upon the surface. The
loss of contents. test surface must be kept free from
local defects capable of influencing the
§ 178.1055 Stacking test. test results.
(a) General. The stacking test must (d) Topple height. (1) For all Flexible
be conducted for the qualification of Bulk Containers, topple heights are
all Flexible Bulk Containers design specified as follows: Packing group III:
types. 0.8 m (2.6 feet).
(b) Special preparation for the stacking (e) Criterion for passing the test. For
test. All Flexible Bulk Containers de- all Flexible Bulk Container design
sign types must be loaded to their max- types there may be no loss of the fill-
imum permissible gross mass. ing substance. However a slight dis-
(c) Test method. (1) All Flexible Bulk charge (e.g., from closures or stitch
Containers must be placed on their holes) upon impact is not considered a
base on level, hard ground and sub- failure of the Flexible Bulk Container.
jected to a uniformly distributed super-
imposed test load that is four times the § 178.1065 Righting test.
design type maximum gross weight for
(a) General. The righting test must be
a period of at least twenty-four hours.
(2) For all Flexible Bulk Containers,
Flexible Bulk Containers design types
the load must be applied by one of the
designed to be lifted from the top or
following methods:
side.
(i) Four Flexible Bulk Containers of
the same type loaded to their max- (b) Special preparation for the righting
imum permissible gross mass and test. Flexible Bulk Container design
stacked on the test Flexible Bulk Con- types must be filled to not less than
tainer; 95% of their capacity and to their max-
(ii) The calculated superimposed test imum permissible gross mass, the load
load weight loaded on either a flat being evenly distributed.
plate or a reproduction of the base of (c) Test method. A sample Flexible
the Flexible Bulk Container, which is Bulk Container design type must be
stacked on the test Flexible Bulk Con- tested; the Flexible Bulk Container
tainer. should start lying on its side and then
(d) Criteria for passing the test. There must be lifted at a speed of at least
may be no deterioration that renders 0.1m/s (0.328 ft/s) to an upright position
the Flexible Bulk Container unsafe for clear of the floor, by no more than half
transportation and no loss of contents of the lifting devices.
during the test or after removal of the (d) Criterion for passing the test. For
test load. all Flexible Bulk Container design
types there must be no damage that
§ 178.1060 Topple test. renders the Flexible Bulk Container
(a) General. The topple test must be unsafe for transport or handling.
§ 178.1070 Tear test.
Flexible Bulk Containers design types.

(b) Special preparation for the topple (a) General. The tear test must be
test. Flexible Bulk Container design conducted for the qualification of all of
types must be filled to their maximum Flexible Bulk Containers design types.
250
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. A
(b) Special preparation for the tear test. (2) The Flexible Bulk Container after
Flexible Bulk Container design types being cut according to the provisions of
must be filled its maximum permis- § 178.1070(c)(1), must be subjected to a
sible gross mass, the load being evenly uniformly distributed superimposed
distributed. load equivalent to twice the maximum
(c) Test method. (1) A Flexible Bulk gross mass of the package. This load
Container design type must be placed must be applied for at least fifteen
on the ground and a 300 mm (11.9 in) minutes. Flexible Bulk Containers that
cut shall be made. This 300 mm (11.9 in) are designed to be lifted from the top
cut must: or the side must, after removal of the
(i) Completely penetrate all layers of superimposed load, be lifted clear of
the Flexible Bulk Container on a wall the floor and maintained in that posi-
with a wide face. tion for a period of fifteen minutes.
(ii) Be made at a 45° angle to the (d) Criterion for passing the test. For
principal axis of the Flexible Bulk Con- all Flexible Bulk Container design
tainer, halfway between the bottom types, the cut must not spread more
surface and the top level of the con- than an additional 25% of its original
tents. length.
APPENDIX A TO PART 178—SPECIFICATIONS FOR STEEL

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

Designation
Grade 1 1 Grade 2 1 2 Grade 3 2 4 5
Carbon .......................................... 0.10/0.20 ............................... 0.24 maximum ...................... 0.22 maximum.

Manganese ................................... 1.10/1.60 ............................... 0.50/1.00 ............................... 1.25 maximum.
Phosphorus, maximum ................. 0.04 ....................................... 0.04 ....................................... 0.045.6
Sulfur, maximum .......................... 0.05 ....................................... 0.05 ....................................... 0.05.
Silicon ........................................... 0.15/0.30 ............................... 0.30 maximum ......................
Copper, maximum ........................ 0.40 ....................................... ...............................................
Columbium ................................... ............................................... 0.01/0.04 ...............................
Heat treatment authorized ............ (3) .......................................... (3) .......................................... (3).
Maximum stress (p.s.i.) ................ 35,000 ................................... 35,000 ................................... 35,000.
1 Additionof other elements to obtain alloying effect is not authorized.
2 Ferritic
grain size 6 or finer according to ASTM E 112–96 (IBR, see § 171.7 of this subchapter).
3 Anysuitable heat treatment in excess of 1,100 °F., except that liquid quenching is not permitted.
4 Other alloying elements may be added and shall be reported.
5 For compositions with a maximum carbon content of 0.15 percent of ladle analysis, the maximum limit for manganese on
ladle analysis may be 1.40 percent.
6 Rephosphorized Grade 3 steels containing no more than 0.15 percent phosphorus are permitted if carbon content does not
exceed 0.15 percent and manganese does not exceed 1 percent.
CHECK ANALYSIS TOLERANCES

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

Carbon ...................................................................... To 0.15 inclusive .............................................. 0.02 0.03

Over 0.15 to 0.40 inclusive .............................. 0.03 0.04
Manganese ............................................................... To 0.60 inclusive .............................................. 0.03 0.03
Phosphorus 7 ............................................................. All ranges ......................................................... .................... 0.01
Sulfur ......................................................................... All ranges ......................................................... .................... 0.01
Silicon ........................................................................ To 0.30 inclusive .............................................. 0.02 0.03

Copper ...................................................................... To 1.00 inclusive .............................................. 0.03 0.03
Nickel ........................................................................ To 1.00 inclusive .............................................. 0.03 0.03
251
Pt. 178, App. B 49 CFR Ch. I (10–1–18 Edition)
CHECK ANALYSIS TOLERANCES—Continued

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


Chromium .................................................................. To 0.90 inclusive .............................................. 0.03 0.03
Molybdenum .............................................................. To 0.20 inclusive .............................................. 0.01 0.01
Zirconium .................................................................. All ranges ......................................................... 0.01 0.05
Columbium ................................................................ To 0.04 inclusive .............................................. 0.005 0.01
Aluminum .................................................................. Over 0.10 to 0.20 inclusive .............................. 0.04 0.04
[Amdt. 178–3, 34 FR 12283, July 25, 1969; 34 FR 12593, Aug. 1, 1969, as amended by Amdt. 178–
64, 45 FR 81573, Dec. 11, 1980; Amdt. 178–97, 55 FR 52728, Dec. 21, 1990; 68 FR 75758, Dec. 31, 2003]
APPENDIX B TO PART 178—ALTERNATIVE surface of all seams and welds must be coat-
LEAKPROOFNESS TEST METHODS ed with a solution of soap suds or a water
and oil mixture. The test must be conducted
In addition to the method prescribed in for a period of time sufficient to pressurize
§ 178.604 of this subchapter, the following the interior of the packaging to the specified
leakproofness test methods are authorized: air pressure and to determine if there is
(1) Helium test. The packaging must be leakage of air from the packaging. A pack-
filled with at least 1 L inert helium gas, air
aging passes the test if there is no leakage of
tight closed, and placed in a testing cham-
air from the packaging.
ber. The testing chamber must be evacuated
down to a pressure of 5 kPa which equals an (4) Solution over partial seams test. For other
over-pressure inside the packaging of 95 kPa. than design qualification testing, the fol-
The air in the testing chamber must be ana- lowing test may be used for metal drums:
lyzed for traces of helium gas by means of a The packaging must be restrained while an
mass spectrograph. The test must be con- internal air pressure of 48 kPa (7.0 psig) is
ducted for a period of time sufficient to evac- applied; the method of restraint may not af-
uate the chamber and to determine if there fect the results of the test. The packaging
is leakage into or out of the packaging. If he- must be coated with a soap solution over the
lium gas is detected, the leaking packaging entire side seam and a distance of not less
must be automatically separated from non- than eight inches on each side of the side
leaking drums and the leaking area deter- seam along the chime seam(s). The test must
mined according to the method prescribed in be conducted for a period of time sufficient
§ 178.604(d) of this subchapter. A packaging to pressurize the interior of the packaging to
passes the test if there is no leakage of he-
the specified air pressure and to determine if
lium.
there is leakage of air from the packaging. A
(2) Pressure differential test. The packaging
shall be restrained while either pressure or a packaging passes the test if there is no leak-
vacuum is applied internally. The packaging age of air from the packaging. Chime cuts
must be pressurized to the pressure required must be made on the initial drum at the be-
by § 178.604(e) of this subchapter for the ap- ginning of each production run and on the
propriate packing group. The method of re- initial drum after any adjustment to the
straint must not affect the results of the chime seamer. Chime cuts must be main-
test. The test must be conducted for a period tained on file in date order for not less than
of time sufficient to appropriately pressurize six months and be made available to a rep-
or evacuate the interior of the packaging resentative of the Department of Transpor-
and to determine if there is leakage into or tation on request.
out of the packaging. A packaging passes the
pressure differential test if there is no [Amdt. 178–97, 55 FR 52728, Dec. 21, 1990, as
change in measured internal pressure. amended at 56 FR 66287, Dec. 20, 1991; 57 FR
(3) Solution over seams. The packaging must 45466, Oct. 1, 1992]
be restrained while an internal air pressure
is applied; the method of restraint may not
affect the results of the test. The exterior
252
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. D
APPENDIX C TO PART 178—NOMINAL AND with other devices such as a remote tempera-
MINIMUM THICKNESSES OF STEEL ture sensor, metal fuse on the valve, or coat-
DRUMS AND JERRICANS ed wax, provided the device is tested and the
test report is retained for verification. Under
For each listed packaging capacity, the this alternative, it is permissible to record
following table compares the ISO 3574 (IBR, the highest temperature to which the cyl-
see § 171.7 of this subchapter) nominal thick- inder is subjected instead of temperature
ness with the corresponding ISO 3574 min- measurements in intervals of not more than
imum thickness. five (5) minutes.
2.3 Instrumentation. A calibrated recording
Cor- device or a computerized data acquisition
responding
ISO nomi- system with an appropriate range should be
Maximum capacity (L) ISO min-
nal (mm) imum provided to measure and record the outputs
(mm) of the thermocouples.
20 ................................................... 0.7 0.63 3. Test Specimen.
30 ................................................... 0.8 0.73 3.1 Specimen Configuration. Each outer
40 ................................................... 0.8 0.73 package material type and design must be
60 ................................................... 1.0 0.92 tested, including any features such as han-
120 ................................................. 1.0 0.92 dles, latches, fastening systems, etc., that
220 ................................................. 1.0 0.92
450 ................................................. 1.9 1.77
may compromise the ability of the outer
package to provide thermal protection.
3.2 Test Specimen Mounting. The tested
[Amdt. 178–106, 59 FR 67522, Dec. 29, 1994, as outer package must be supported at the four
amended at 68 FR 75758, Dec. 31, 2003] corners using fire brick or other suitable
means. The bottom surface of the outer
APPENDIX D TO PART 178—THERMAL package must be exposed to allow exposure
RESISTANCE TEST to heat.
4. Preparation for Testing.
1. Scope. This test method evaluates the 4.1 It is recommended that the cylinder be
thermal resistance capabilities of a com- closed at ambient temperature and config-
pressed oxygen generator and the outer ured as when filled with a valve and pressure
packaging for a cylinder of compressed oxy- relief device. The oxygen generator must be
gen or other oxidizing gas and an oxygen filled with an oxidizing agent and may be
generator. When exposed to a temperature of tested with or without packaging.
205 °C (400 °F) for a period of not less than
4.2 Place the package or generator onto
three hours, the outer surface of the cylinder
supporting bricks or a stand inside the test
may not exceed a temperature of 93 °C (199
oven in such a manner to ensure even tem-
°F) and the oxygen generator must not actu-
perature flow.
ate.
5. Test Procedure.
2. Apparatus.
2.1 Test Oven. The oven must be large 5.1 Close oven door and check for proper
enough in size to fully house the test outer reading on thermocouples.
package without clearance problems. The 5.2 Raise the temperature of the oven to a
test oven must be capable of maintaining a minimum temperature of 205 °C ±2 °C (400 °F
minimum steady state temperature of 205 °C ±5 °F). Maintain a minimum oven tempera-
(400 °F). ture of 205 °C ±2 °C (400 °F ±5 °F) for at least
2.2 Thermocouples. At least three three hours. Exposure time begins when the
thermocouples must be used to monitor the oven steady state temperature reaches a
temperature inside the oven and an addi- minimum of 205 °C ±2 °C (400 °F ±5 °F).
tional three thermocouples must be used to 5.3 At the conclusion of the three-hour pe-
monitor the temperature of the cylinder. riod, the outer package may be removed
The thermocouples must be 1⁄16 inch, ceramic from the oven and allowed to cool naturally.
packed, metal sheathed, type K (Chromel- 6. Recordkeeping.
Alumel), grounded junction with a nominal 6.1 Record a complete description of the
30 American wire gauge (AWG) size con- material being tested, including the manu-
ductor. The thermocouples measuring the facturer, size of cylinder, etc.
temperature inside the oven must be placed 6.2 Record any observations regarding the
at varying heights to ensure even tempera- behavior of the test specimen during expo-
ture and proper heat-soak conditions. For sure, such as smoke production,
the thermocouples measuring the tempera- delamination, resin ignition, and time of oc-
ture of the cylinder: (1) Two of them must be currence of each event.
placed on the outer cylinder side wall at ap- 6.3 Record the temperature and time his-
proximately 2 inches (5 cm) from the top and tory of the cylinder temperature during the
bottom shoulders of the cylinder; and (2) one entire test for each thermocouple location.
must be placed on the cylinder valve body Temperature measurements must be re-
near the pressure relief device. Alter- corded at intervals of not more than five (5)
natively, the thermocouples may be replaced minutes. Record the maximum temperatures
253
Pt. 178, App. E 49 CFR Ch. I (10–1–18 Edition)
achieved at all three thermocouple locations ample: An 80 degree nozzle nominally rated
and the corresponding time. at 2.25 GPH and operated at 85 pounds per
7. Requirements. square inch (PSI) gauge to deliver 2.03 GPH.
7.1 For a cylinder, the outer package (iii) Have a 12 inch (305 mm) burner exten-
must provide adequate protection such that sion installed at the end of the draft tube
the outer surface of the cylinder and valve with an opening 6 inches (152 mm) high and
does not exceed a temperature of 93 °C (199 11 inches (280 mm) wide.
°F) at any of the three points where the (iv) Have a burner fuel pressure regulator
thermocouples are located. that is adjusted to deliver a nominal 2.0 GPH
7.2 For an oxygen generator, the gener- of #2 Grade kerosene or equivalent.
ator must not actuate. Burner models which have been used suc-
cessfully in testing are the Lenox Model OB–
[72 FR 4457, Jan. 31, 2008, as amended at 72 32, Carlin Model 200 CRD and Park Model
FR 55099, Sept. 28, 2007] DPL.
(3) Calorimeter. (i) The calorimeter to be
APPENDIX E TO PART 178—FLAME used in testing must be a total heat flux Foil
PENETRATION RESISTANCE TEST Type Gardon Gage of an appropriate range
(approximately 0 to 15.0 British thermal unit
(a) Criteria for Acceptance. (1) At least three (BTU) per ft.2 sec., 0–17.0 watts/cm2). The cal-
specimens of the outer packaging materials orimeter must be mounted in a 6 inch by 12
must be tested; inch (152 by 305 mm) by 3⁄4 inch (19 mm) thick
(2) Each test must be conducted on a flat 16 insulating block which is attached to a steel
inch × 24 inch test specimen mounted in the angle bracket for placement in the test stand
horizontal ceiling position of the test appa- during burner calibration as shown in Figure
ratus to represent the outer packaging de- 2 of this part of this appendix.
sign; (ii) The insulating block must be mon-
(3) Testing must be conducted on all design itored for deterioration and the mounting
features (latches, seams, hinges, etc.) affect- shimmed as necessary to ensure that the cal-
ing the ability of the outer packaging to orimeter face is parallel to the exit plane of
safely prevent the passage of fire in the hori- the test burner cone.
zontal ceiling position; and (4) Thermocouples. The seven thermocouples
(4) There must be no flame penetration of to be used for testing must be 1⁄16 inch ce-
any specimen within 5 minutes after applica- ramic sheathed, type K, grounded
tion of the flame source and the maximum thermocouples with a nominal 30 American
allowable temperature at a point 4 inches wire gage (AWG) size conductor. The seven
above the test specimen, centered over the thermocouples must be attached to a steel
burner cone, must not exceed 205 °C (400 °F). angle bracket to form a thermocouple rake
(b) Summary of Method. This method pro- for placement in the test stand during burn-
vides a laboratory test procedure for meas- er calibration.
uring the capability of cargo compartment (5) Apparatus Arrangement. The test burner
lining materials to resist flame penetration must be mounted on a suitable stand to posi-
with a 2 gallon per hour (GPH) #2 Grade ker- tion the exit of the burner cone a distance of
osene or equivalent burner fire source. Ceil- 8 inches from the ceiling liner panel and 2
ing and sidewall liner panels may be tested inches from the sidewall liner panel. The
individually provided a baffle is used to sim- burner stand should have the capability of
ulate the missing panel. Any specimen that allowing the burner to be swung away from
passes the test as a ceiling liner panel may the test specimen during warm-up periods.
be used as a sidewall liner panel. (6) Instrumentation. A recording potentiom-
(c) Test Specimens. (1) The specimen to be eter or other suitable instrument with an ap-
tested must measure 16 ±1⁄8 inches (406 ±3 propriate range must be used to measure and
mm) by 24 + 1⁄8 inches (610 ±3 mm). record the outputs of the calorimeter and
(2) The specimens must be conditioned at the thermocouples.
70 °F. ±5 °F. (21 °C. ±2 °C.) and 55% ±5% hu- (7) Timing Device. A stopwatch or other de-
midity for at least 24 hours before testing. vice must be used to measure the time of
(d) Test Apparatus. The arrangement of the flame application and the time of flame pen-
test apparatus must include the components etration, if it occurs.
described in this section. Minor details of the (e) Preparation of Apparatus. Before calibra-
apparatus may vary, depending on the model tion, all equipment must be turned on and
of the burner used. allowed to stabilize, and the burner fuel flow
(1) Specimen Mounting Stand. The mounting must be adjusted as specified in paragraph
stand for the test specimens consists of steel (d)(2).
angles. (f) Calibration. To ensure the proper ther-
(2) Test Burner. The burner to be used in mal output of the burner the following test
tesing must— must be made:

(i) Be a modified gun type. (1) Remove the burner extension from the
(ii) Use a suitable nozzle and maintain fuel end of the draft tube. Turn on the blower
pressure to yield a 2 GPH fuel flow. For ex- portion of the burner without turning the
254
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. E
fuel or igniters on. Measure the air velocity above the horizontal (ceiling) test specimen.
using a hot wire anemometer in the center of The thermocouple should be centered over
the draft tube across the face of the opening. the burner cone.
Adjust the damper such that the air velocity (2) Mount the test specimen on the test
is in the range of 1550 to 1800 ft./min. If tabs stand shown in Figure 1 in either the hori-
are being used at the exit of the draft tube, zontal or vertical position. Mount the insu-
they must be removed prior to this measure- lating material in the other position.
ment. Reinstall the draft tube extension (3) Position the burner so that flames will
cone. not impinge on the specimen, turn the burn-
(2) Place the calorimeter on the test stand er on, and allow it to run for 2 minutes. Ro-
as shown in Figure 2 at a distance of 8 inches tate the burner to apply the flame to the
(203 mm) from the exit of the burner cone to specimen and simultaneously start the tim-
simulate the position of the horizontal test ing device.
specimen. (4) Expose the test specimen to the flame
(3) Turn on the burner, allow it to run for for 5 minutes and then turn off the burner.
2 minutes for warm-up, and adjust the damp- The test may be terminated earlier if flame
er to produce a calorimeter reading of 8.0 ±0.5 penetration is observed.
BTU per ft.2 sec. (9.1 ±0.6 Watts/cm2). (5) When testing ceiling liner panels,
(4) Replace the calorimeter with the ther- record the peak temperature measured 4
mocouple rake. inches above the sample.
(5) Turn on the burner and ensure that (6) Record the time at which flame pene-
each of the seven thermocouples reads 1700 tration occurs if applicable.
°F. ±100 °F. (927 °C. ±38 °C.) to ensure steady (h) Test Report. The test report must in-
state conditions have been achieved. If the clude the following:
temperature is out of this range, repeat steps (1) A complete description of the materials
2 through 5 until proper readings are ob- tested including type, manufacturer, thick-
tained. ness, and other appropriate data.
(6) Turn off the burner and remove the (2) Observations of the behavior of the test
thermocouple rake. specimens during flame exposure such as
(7) Repeat (1) to ensure that the burner is delamination, resin ignition, smoke, etc., in-
in the correct range. cluding the time of such occurrence.
(g) Test Procedure. (1) Mount a thermo- (3) The time at which flame penetration
couple of the same type as that used for cali- occurs, if applicable, for each of the three
bration at a distance of 4 inches (102 mm) specimens tested.
255
Pt. 178, App. E 49 CFR Ch. I (10–1–18 Edition)
256
ER11MR13.013</GPH>
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 178, App. E
257
ER11MR13.014</GPH>
[72 FR 55099, Sept. 28, 2007, as amended at 78 179.101 Individual specification require-
FR 15328, Mar. 11, 2013] ments applicable to pressure tank car
tanks.
179.101–1 Individual specification require-
PART 179—SPECIFICATIONS FOR ments.
TANK CARS 179.102 Special commodity requirements for
pressure tank car tanks.
Subpart A—Introduction, Approvals and 179.102–1 Carbon dioxide, refrigerated liquid.
Reports 179.102–2 Chlorine.
179.102–3 Materials poisonous by inhalation.
Sec. 179.102–4 Vinyl fluoride, stabilized.
179.1 General. 179.102–17 Hydrogen chloride, refrigerated
179.2 Definitions and abbreviations. liquid.
179.3 Procedure for securing approval. 179.103 Special requirements for class 114A
179.4 Changes in specifications for tank * * * tank car tanks.
cars. 179.103–1 Type.
179.5 Certificate of construction. 179.103–2 Manway cover.
179.6 Repairs and alterations. 179.103–3 Venting, loading and unloading
179.7 Quality assurance program. valves, measuring and sampling devices.
179.8 Limitation on actions by states, local 179.103–4 Safety relief devices and pressure
governments, and Indian tribes. regulators.
179.103–5 Bottom outlets.
Subpart B—General Design Requirements
Subpart D—Specifications for Non-Pressure
179.10 Tank mounting. Tank Car Tanks (Classes DOT-111AW,
179.11 Welding certification. 115AW, and 117AW)
179.12 Interior heater systems.
179.13 Tank car capacity and gross weight 179.200 General specifications applicable to
limitation. non-pressure tank car tanks (Class DOT–
179.14 Coupler vertical restraint system. 111, DOT–117).
179.15 Pressure relief devices. 179.200–1 Tank built under these specifica-
179.16 Tank-head puncture-resistance sys- tions must meet the applicable require-
tems. ments in this part.
179.200–3 Type.
179.18 Thermal protection systems.
179.200–4 Insulation.
179.20 Service equipment; protection sys-
179.200–6 Thickness of plates.
tems.
179.200–7 Materials.
179.22 Marking.
179.200–8 Tank heads.
179.24 Stamping.
179.200–9 Compartment tanks.
179.200–10 Welding.
Subpart C—Specifications for Pressure 179.200–11 Postweld heat treatment.
Tank Car Tanks (Classes DOT-105, 109, 179.200–13 Manway ring or flange, pressure
112, 114, and 120) relief device flange, bottom outlet nozzle
flange, bottom washout nozzle flange and
179.100 General specifications applicable to other attachments and openings.
pressure tank car tanks. 179.200–14 Expansion capacity.
179.100–1 Tanks built under these specifica- 179.200–15 Closures for manways.
tions shall comply with the requirements 179.200–16 Gauging devices, top loading and
of §§ 179.100, 179.101 and when applicable, unloading devices, venting and air inlet
§§ 179.102 and 179.103. devices.
179.100–3 Type. 179.200–17 Bottom outlets.
179.100–4 Insulation. 179.200–19 Reinforcements, when used, and
179.100–6 Thickness of plates. appurtenances not otherwise specified.
179.100–7 Materials. 179.200–21 Closures for openings.
179.100–8 Tank heads. 179.200–22 Test of tanks.
179.100–9 Welding. 179.200–23 Tests of pressure relief valves.
179.100–10 Postweld heat treatment. 179.200–24 Stamping.
179.100–12 Manway nozzle, cover and protec- 179.201 Individual specification require-
tive housing. ments applicable to non-pressure tank
179.100–13 Venting, loading and unloading car tanks.
valves, measuring and sampling devices. 179.201–1 Individual specification require-
179.100–14 Bottom outlets. ments.
179.100–16 Attachments. 179.201–2 [Reserved]
179.100–17 Closures for openings. 179.201–3 Lined tanks.

179.100–18 Tests of tanks. 179.201–4 Material.
179.100–19 Tests of safety relief valves. 179.201–5 Postweld heat treatment and cor-
179.100–20 Stamping. rosion resistance.
258
179.201–6 Manways and manway closures. 179.221–1 Individual specification require-
179.201–8 Sampling device and thermometer ments.
well.
179.201–9 Gauging device. Subpart E—Specifications for Multi-Unit
179.201–10 Water capacity marking. Tank Car Tanks (Classes DOT-106A
179.201–11 Insulation. and 110AW)
179.202 Individual specification require-
179.300 General specifications applicable to
ments applicable to DOT–117 tank car
multi-unit tank car tanks designed to be
tanks.
removed from car structure for filling
179.202–1 Applicability. and emptying (Classes DOT-106A and
179.202–2 [Reserved] 110AW).
179.202–3 Approval to operate at 286,000 179.300–1 Tanks built under these specifica-
gross rail load (GRL). tions shall meet the requirements of
179.202–4 Thickness of plates. §§ 179.300 and 179.301.
179.202–5 Tank head puncture resistance 179.300–3 Type and general requirements.
system. 179.300–4 Insulation.
179.202–6 Thermal protection system. 179.300–6 Thickness of plates.
179.202–7 Jackets. 179.300–7 Materials.
179.202–8 Bottom outlets. 179.300–8 Tank heads.
179.202–9 Top fittings protection. 179.300–9 Welding.
179.300–10 Postweld heat treatment.
179.300–12 Protection of fittings.
ments.
179.300–13 Venting, loading and unloading
179.202–12 Performance standard require- valves.
ments (DOT–117P). 179.300–14 Attachments not otherwise speci-
179.202–13 Retrofit standard requirements fied.
(DOT–117R). 179.300–15 Pressure relief devices.
179.203—179.202–22 [Reserved] 179.300–16 Tests of tanks.
179.220 General specifications applicable to 179.300–17 Tests of pressure relief devices.
nonpressure tank car tanks consisting of 179.300–18 Stamping.
an inner container supported within an 179.300–19 Inspection.
outer shell (class DOT-115). 179.300–20 Reports.
179.220–1 Tanks built under these specifica- 179.301 Individual specification require-
tions must meet the requirements of ments for multi-unit tank car tanks.
§§ 179.220 and 179.221. 179.302 [Reserved]
179.220–3 Type.
179.220–4 Insulation. Subpart F—Specification for Cryogenic Liq-
179.220–6 Thickness of plates. uid Tank Car Tanks and Seamless Steel
179.220–7 Materials. Tanks (Classes DOT-113 and 107A)
179.220–8 Tank heads.
179.400 General specification applicable to
179.220–9 Compartment tanks. cryogenic liquid tank car tanks.
179.220–10 Welding. 179.400–1 General.
179.220–11 Postweld heat treatment. 179.400–3 Type.
179.220–13 Inner container manway nozzle 179.400–4 Insulation system and perform-
and cover. ance standard.
179.220–14 Openings in the tanks. 179.400–5 Materials.
179.220–15 Support system for inner con- 179.400–6 Bursting and buckling pressure.
tainer. 179.400–7 Tank heads.
179.220–16 Expansion capacity. 179.400–8 Thickness of plates.
179.220–17 Gauging devices, top loading and 179.400–9 Stiffening rings.
unloading devices, venting and air inlet 179.400–10 Sump or siphon bowl.
devices. 179.400–11 Welding.
179.220–18 Bottom outlets. 179.400–12 Postweld heat treatment.
179.220–20 Reinforcements, when used, and 179.400–13 Support system for inner tank.
appurtenances not otherwise specified. 179.400–14 Cleaning of inner tank.
179.400–15 Radioscopy.
179.220–22 Closure for openings.
179.400–16 Access to inner tank.
179.220–23 Test of tanks. 179.400–17 Inner tank piping.
179.220–24 Tests of pressure relief valves. 179.400–18 Test of inner tank.
179.220–25 Stamping. 179.400–19 Valves and gages.
179.220–26 Stenciling. 179.400–20 Pressure relief devices.
179.221 Individual specification require- 179.400–21 Test of pressure relief valves.

ments applicable to tank car tanks con- 179.400–22 Protective housings.
sisting of an inner container supported 179.400–23 Operating instructions.
within an outer shell. 179.400–24 Stamping.
259
§ 179.1 49 CFR Ch. I (10–1–18 Edition)
179.400–25 Stenciling. sponsibility of the tank builder. Mark-
179.401 Individual specification require- ing the tank with the DOT specifica-
ments applicable to inner tanks for cryo- tion shall be understood to certify
genic liquid tank car tanks.
compliance by the builder that the
ments. functions performed by the builder, as
179.500 Specification DOT-107A * * * *, prescribed in this part, have been per-
seamless steel tank car tanks. formed in compliance with this part.
179.500–1 Tanks built under these specifica- (f) The tank builder should inform
tions shall meet the requirements of each person to whom that tank is
§ 179.500. transferred of any specification re-
179.500–3 Type and general requirements.
179.500–4 Thickness of wall. quirements which have not been met at
179.500–5 Material. time of transfer.
179.500–6 Heat treatment.
[Amdt. 179–17, 41 FR 38183, Sept. 9, 1976, as
179.500–7 Physical tests.
amended by Amdt. 179–50, 60 FR 49076, Sept.
179.500–8 Openings in tanks.
21, 1995; 68 FR 48571, Aug. 14, 2003]
179.500–10 Protective housing.
179.500–11 Loading and unloading valves.
179.500–12 Pressure relief devices. § 179.2 Definitions and abbreviations.
179.500–13 Fixtures. (a) The following apply in part 179:
179.500–14 Test of tanks. (1) AAR means Association of Amer-
179.500–15 Handling of tanks failing in tests.
179.500–16 Tests of pressure relief devices. ican Railroads.
179.500–17 Marking. (2) Approved means approval by the
179.500–18 Inspection and reports. AAR Tank Car Committee.
APPENDIX A TO PART 179—PROCEDURES FOR (3) ASTM means American Society
TANK-HEAD PUNCTURE-RESISTANCE TEST for Testing and Materials.
APPENDIX B TO PART 179—PROCEDURES FOR (4) [Reserved]
SIMULATED POOL AND TORCH-FIRE TEST-
(5) Definitions in part 173 of this
ING
chapter also apply.
AUTHORITY: 49 U.S.C. 5101–5128; 49 CFR 1.81 (6) F means degrees Fahrenheit.
and 1.97.
(7) NGT means National Gas Taper
SOURCE: 29 FR 18995, Dec. 29, 1964, unless Threads.
otherwise noted. Redesignated at 32 FR 5606, (8) NPT means an American Standard
Apr. 5, 1967. Taper Pipe Thread conforming to the
requirements of NBS Handbook H–28
Subpart A—Introduction, (IBR, see § 171.7 of this subchapter).
Approvals and Reports (9) [Reserved]
(10) Tank car facility means an entity
§ 179.1 General. that manufactures, repairs, inspects,
(a) This part prescribes the specifica- tests, qualifies, or maintains a tank
tions for tanks that are to be mounted car to ensure that the tank car con-
on or form part of a tank car and which forms to this part and subpart F of part
are to be marked with a DOT specifica- 180 of this subchapter, that alters the
tion. certificate of construction of the tank
(b) Except as provided in paragraph car, that ensures the continuing quali-
(c) of this section, tanks to which this fication of a tank car by performing a
part is applicable, must be built to the function prescribed in parts 179 or 180
specifications prescribed in this part. of this subchapter, or that makes any
(c) Tanks built to specifications pre- representation indicating compliance
dating those in this part may continue with one or more of the requirements
in use as provided in § 180.507 of this of parts 179 or 180 of this subchapter.
subchapter. (11) Tanks means tank car tanks.
(d) Any person who performs a func- (b) [Reserved]
tion prescribed in this part, shall per-
form that function in accordance with [29 FR 18995, Dec. 20, 1964. Redesignated at 32
this part. 179–10, 36 FR 21344, Nov. 6, 1971; Amdt. 179–50,
(e) When this part requires a tank to 60 FR 49076, Sept. 21, 1995; Amdt. 179–50, 61
be marked with a DOT specification FR 33255, June 26, 1996; 63 FR 52850, Oct. 1,
(for example, DOT-105A100W), compli- 1998; 66 FR 45186, 45390, Aug. 28, 2001; 68 fR
ance with that requirement is the re- 75759, Dec. 31, 2003]
260
§ 179.3 Procedure for securing ap- partment. The recommendation will be

proval. considered by the Department in deter-
(a) Application for approval of de- mining appropriate action.
signs, materials and construction, con- [29 FR 18995, Dec. 29, 1964. Redesignated at 32
version or alteration of tank car tanks FR 5606, Apr. 5, 1967 and amended by Amdt.
under these specifications, complete 179–41, 52 FR 36672, Sept. 30, 1987; 63 FR 52850,
with detailed prints, must be sub- Oct. 1, 1998; 70 FR 73166, Dec. 9, 2005]
mitted in prescribed form to the Exec-
utive Director—Tank Car Safety, AAR, § 179.5 Certificate of construction.
for consideration by its Tank Car Com-
(a) Before a tank car is placed in
mittee and other appropriate commit-
service, the party assembling the com-
tees. Approval or rejections of applica-
tions based on appropriate committee pleted car shall furnish a Certificate of
action will be issued by the executive Construction, Form AAR 4–2 to the
director. owner and the Executive Director—
(b) When, in the opinion of the Com- Tank Car Safety, AAR, certifying that
mittee, such tanks or equipment are in the tank, equipment, and car fully con-
compliance with the requirements of forms to all requirements of the speci-
this subchapter, the application will be fication.
approved. (b) When cars or tanks are covered in
(c) When such tanks or equipment one application and are identical in all
are not in compliance with the require- details are built in series, one certifi-
ments of this subchapter, the Com- cate will suffice for each series when
mittee may recommend service trials submitted to the Executive Director—
to determine the merits of a change in Tank Car Safety, AAR.
specifications. Such service trials may (c) If the owner elects to furnish serv-
be conducted only if the builder or ice equipment, the owner shall furnish
shipper applies for and obtains a spe-
the Executive Director—Tank Car
cial permit.
Safety, AAR, a report in prescribed
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 form, certifying that the service equip-
FR 5606, Apr. 5, 1967 and amended by Amdt. ment complies with all the require-
179–41, 52 FR 36672, Sept. 30, 1987; 63 FR 52850,
ments of the specifications.
Oct. 1, 1998; 68 FR 48571, Aug. 14, 2003; 70 FR
73166, Dec. 9, 2005] (d) When cars or tanks which are cov-
ered on one application and are iden-
§ 179.4 Changes in specifications for tical in all details are built in series,
tank cars. one certificate shall suffice for each se-
(a) Proposed changes in or additions ries when submitted to the Executive
to specifications for tanks must be sub- Director—Tank Car Safety, AAR. One
mitted to the Executive Director— copy of the Certificate of Construction
Tank Car Safety, AAR, for consider- must be furnished to the Executive Di-
ation by its Tank Car Committee. An rector—Tank Car Safety, AAR for each
application for construction of tanks car number of consecutively numbered
to any new specification may be sub- group or groups covered by the original
mitted with proposed specification. application.
Construction should not be started
until the specification has been ap- [Amdt. 179–10, 36 FR 21344, Nov. 6, 1971, as
proved or a special permit has been amended at 63 FR 52850, Oct. 1, 1998; 68 FR
issued. When proposing a new specifica- 48571, Aug. 14, 2003]
tion, the applicant shall furnish infor-
mation to justify a new specification. § 179.6 Repairs and alterations.
This data should include the properties For procedure to be followed in mak-
of the lading and the method of loading ing repairs or alterations, see appendix
and unloading. R of the AAR Specifications for Tank
(b) The Tank Car Committee will re- Cars (IBR, see § 171.7 of this sub-
view the proposed specifications at its chapter).

earliest convenience and report its rec-
ommendations through the Executive [68 FR 75759, Dec. 31, 2003]
Director—Tank Car Safety to the De-
261
§ 179.7 49 CFR Ch. I (10–1–18 Edition)
§ 179.7 Quality assurance program. the inspection and test technique and
(a) At a minimum, each tank car fa- minimum detectable crack length.
cility shall have a quality assurance (11) Procedures for the periodic cali-
program, approved by AAR, that— bration and measurement of inspection
(1) Ensures the finished product con- and test equipment.
forms to the requirements of the appli- (12) A system for the maintenance of
cable specification and regulations of records, inspections, tests, and the in-
this subchapter; terpretation of inspection and test re-
(2) Has the means to detect any non- sults.
conformity in the manufacturing, re- (c) Each tank car facility shall en-
pair, inspection, testing, and qualifica- sure that only personnel qualified for
tion or maintenance program of the each non-destructive inspection and
tank car; and test perform that particular operation.
(3) Prevents non-conformities from (d) Each tank car facility shall pro-
recurring. vide written procedures to its employ-
(b) At a minimum, the quality assur- ees to ensure that the work on the
ance program must have the following tank car conforms to the specification,
elements AAR approval, and owner’s acceptance
(1) Statement of authority and re- criteria.
sponsibility for those persons in charge (e) Each tank car facility shall train
of the quality assurance program. its employees in accordance with sub-
(2) An organizational chart showing part H of part 172 of this subchapter on
the interrelationship between man- the program and procedures specified
agers, engineers, purchasing, construc- in paragraph (b) of this section to en-
tion, inspection, testing, and quality sure quality.
control personnel. (f) No tank car facility may manufac-
(3) Procedures to ensure that the lat- ture, repair, inspect, test, qualify or
est applicable drawings, design calcula- maintain tank cars subject to require-
tions, specifications, and instructions ments of this subchapter, unless it is
are used in manufacture, inspection, operating in conformance with a qual-
testing, and repair. ity assurance program and written pro-
(4) Procedures to ensure that the fab- cedures required by paragraphs (a) and
rication and construction materials re- (b) of this section.
ceived are properly identified and docu- [Amdt. 179–50, 60 FR 49076, Sept. 21, 1995, as
mented. amended by Amdt. 179–50, 61 FR 33255, June
(5) A description of the manufac- 26, 1996; 68 FR 48571, Aug. 14, 2003; 68 FR 75759,
turing, repair, inspection, testing, and Dec. 31, 2003]
qualification or maintenance program,
including the acceptance criteria, so § 179.8 Limitation on actions by states,
that an inspector can identify the char- local governments, and Indian
tribes.
acteristics of the tank car and the ele-
ments to inspect, examine, and test at Sections 5125 and 20106 of Title 49,
each point. United States Code, limit the author-
(6) Monitoring and control of proc- ity of states, political subdivisions of
esses and product characteristics dur- states, and Indian tribes to impose re-
ing production. quirements on the transportation of
(7) Procedures for correction of hazardous materials in commerce. A
nonconformities. state, local, or Indian tribe require-
(8) Provisions indicating that the re- ment on the transportation of haz-
quirements of the AAR Specifications ardous materials by rail may be pre-
for Tank Cars (IBR, see § 171.7 of this empted under either 49 U.S.C. 5125 or
subchapter), apply. 20106, or both.
(9) Qualification requirements of per- (a) Section 171.1(f) of this subchapter
sonnel performing non-destructive in- describes the circumstances under
spections and tests. which 49 U.S.C. 5125 preempts a re-
(10) Procedures for evaluating the in- quirement of a state, political subdivi-
spection and test technique employed, sion of a state, or Indian tribe.
including the accessibility of the area (b) Under the Federal Railroad Safe-
and the sensitivity and reliability of ty Act (49 U.S.C. 20106), administered
262
by the Federal Railroad Administra- (a) For other than tank cars con-
tion (see 49 CFR parts 200–244), laws, taining poisonous-by-inhalation mate-
regulations and orders related to rail- rial, a tank car may be loaded to a
road safety, including security, shall be gross weight on rail of up to 286,000
nationally uniform to the extent prac- pounds (129,727 kg) upon approval by
ticable. A state may adopt, or continue the Associate Administrator for Safe-
in force, a law, regulation, or order ty, Federal Railroad Administration
covering the same subject matter as a (FRA). Tank cars must conform to the
DOT regulation or order applicable to conditions of the approval and must be
railroad safety and security (including operated only under controlled inter-
the requirements in this subpart) only change conditions agreed to by partici-
when an additional or more stringent pating railroads.
state law, regulation, or order is nec- (b) Tank cars containing poisonous-
essary to eliminate or reduce an essen- by-inhalation material meeting the ap-
tially local safety or security hazard; is plicable authorized tank car specifica-
not incompatible with a law, regulations listed in § 173.244(a)(2) or (3) or
tion, or order of the United States Gov- § 173.314(c) or (d) of this subchapter may
ernment; and does not unreasonably have a gross weight on rail of up to
burden interstate commerce. 286,000 pounds (129,727 kg). Tank cars
[74 FR 1801, Jan. 13, 2009] containing poisonous-by-inhalation
material not meeting the specifica-
Subpart B—General Design tions listed in § 173.244(a)(2) or (3) or
Requirements § 173.314(c) or (d) may be loaded to a
gross weight on rail of up to 286,000
§ 179.10 Tank mounting. pounds (129,727 kg) only upon approval
(a) The manner in which tanks are of the Associate Administrator for
attached to the car structure shall be Safety, Federal Railroad Administra-
approved. The use of rivets to secure tion (FRA). Any increase in weight
anchors to tanks prohibited. above 263,000 pounds may not be used
(b) [Reserved] to increase thequantity of the contents
of the tank car.
§ 179.11 Welding certification.
[74 FR 1802, Jan. 13, 2009, as amended at 75
(a) Welding procedures, welders and FR 27216, May 14, 2010; 77 FR 37985, June 25,
fabricators shall be approved. 2012; 81 FR 35545, June 2, 2016]
(b) [Reserved]
§ 179.14 Coupler vertical restraint sys-
§ 179.12 Interior heater systems. tem.
(a) Interior heater systems shall be of (a) Performance standard. Each tank
approved design and materials. If a car shall be equipped with couplers ca-
tank is divided into compartments, a pable of sustaining, without disengage-
separate system shall be provided for ment or material failure, vertical loads
each compartment. of at least 200,000 pounds (90,718.5 kg)
(b) Each interior heater system shall applied in upward and downward direc-
be hydrostatically tested at not less tions in combination with buff loads of
than 13.79 bar (200 psig) and shall hold 2,000 pounds (907.2 kg), when coupled to
the pressure for 10 minutes without cars which may or may not be equipped
leakage or evidence of distress. with couplers having this vertical re-
[Amdt. 179–52, 61 FR 28678, June 5, 1996, as straint capability.
amended by 66 FR 45390, Aug. 28, 2001] (b) Test verification. Except as pro-
vided in paragraph (d) of this section,
§ 179.13 Tank car capacity and gross compliance with the requirements of
weight limitation. paragraph (a) of this section shall be
Except as provided in this section, achieved by verification testing of the
tank cars, built after November 30, coupler vertical restraint system in ac-
1970, or any existing tank cars that are cordance with paragraph (c) of this sec-
converted, may not exceed 34,500 gal- tion.
lons (130,597 L) capacity or 263,000 (c) Coupler vertical restraint tests. A
pounds (119,295 kg) gross weight on rail. coupler vertical restraint system shall
263
§ 179.15 49 CFR Ch. I (10–1–18 Edition)
be tested under the following condi- § 179.15 Pressure relief devices.

tions: Except for DOT Class 106, 107, 110, and
(1) The test coupler shall be tested 113 tank cars, tanks must have a pres-
with a mating coupler (or simulated sure relief device, made of material
coupler) having only frictional vertical compatible with the lading, that con-
force resistance at the mating inter- forms to the following requirements:
face; or a mating coupler (or simulated (a) Performance standard. Each tank
coupler) having the capabilities de- must have a pressure relief device,
scribed in paragraph (a) of this section; made of materials compatible with the
(2) The testing apparatus shall simu- lading, having sufficient flow capacity
late the vertical coupler performance to prevent pressure build-up in the
at the mating interface and may not tank to no more than the flow rating
interfere with coupler failure or other- pressure of the pressure relief device in
wise inhibit failure due to force appli- fire conditions as defined in appendix A
cations and reactions; and of the AAR Specifications for Tank
(3) The test shall be conducted as fol- Cars (IBR, see § 171.7 of this sub-
lows: chapter).
(i) A minimum of 200,000 pounds (b) Settings for reclosing pressure relief
devices. (1) Except as provided in para-
(90,718.5 kg) vertical downward load
graph (b)(2) of this section, a reclosing
shall be applied continuously for at
pressure relief valve must have a min-
least 5 minutes to the test coupler head
imum start-to-discharge pressure equal
simultaneously with the application of
to the sum of the static head and gas
a nominal 2,000 pounds (907.2 kg) buff
padding pressure and the lading vapor
load; pressure at the following reference
(ii) The procedures prescribed in temperatures:
paragraph (c)(3)(i) of this section, shall (i) 46 °C (115 °F) for noninsulated
be repeated with a minimum vertical tanks;
upward load of 200,000 pounds (90,718.5 (ii) 43 °C (110 °F) for tanks having a
kg); and thermal protection system incor-
(iii) A minimum of three consecutive porating a metal jacket that provides
successful tests shall be performed for an overall thermal conductance at 15.5
each load combination prescribed in °C (60 °F) of no more than 10.22
paragraphs (c)(3) (i) and (ii) of this sec- kilojoules per hour per square meter
tion. A test is successful when a per degree Celsius (0.5 Btu per hour/per
vertical disengagement or material square foot/per degree F) temperature
failure does not occur during the appli- differential; and
cation of any of the loads prescribed in (iii) 41 °C (105 °F) for insulated tanks.
this paragraph. (2)(i) The start-to-discharge pressure
(d) Authorized couplers. As an alter- of a pressure relief device may not be
native to the test verifications in para- lower than 5.17 Bar (75 psig) or exceed
graph (c) of this section, the following 33 percent of the minimum tank burst
couplers are authorized: pressure.
(1) E double shelf couplers designated (ii) Tanks built prior to October 1,
by the Association of American Rail- 1997 having a minimum tank burst
roads’ Catalog Nos., SE60CHT, SE60CC, pressure of 34.47 Bar (500 psig) or less
SE60CHTE, SE60CE, SE60DC, SE60DE, may be equipped with a reclosing pres-
SE67CC, SE67CE, SE67BHT, SE67BC, sure relief valve having a start-to-dis-
SE67BHTE, SE67BE, SE68BHT, SE68BC, charge pressure of not less than 14.5
SE68BHTE, SE68BE, SE69AHTE, and percent of the minimum tank burst
SE69AE. pressure but no more than 33 percent of
(2) F double shelf couplers designated the minimum tank burst pressure.
by the Association of American Rail- (3) The vapor tight pressure of a re-
roads’ Catalog Nos., SF70CHT, SF70CC, closing pressure relief valve must be at
SF70CHTE, SF70CE, SF73AC, SF73AE, least 80 percent of the start-to-dis-
SF73AHT, SF73AHTE, SF79CHT, charge pressure.

(4) The flow rating pressure must be
SF79CC, SF79CHTE, and SF79CE.
110 percent of the start-to-discharge
[Amdt. 179–42, 54 FR 38797, Sept. 20, 1989] pressure for tanks having a minimum
264
tank burst pressure greater than 34.47 the discharge setting of the reclosing
Bar (500 psig) and from 110 percent to pressure relief device.
130 percent for tanks having a min- (f) Nonreclosing pressure relief device.
imum tank burst pressure less than or In addition to paragraphs (a), (b)(4), (c),
equal to 34.47 Bar (500 psig). and (d) of this section, a nonreclosing
(5) The tolerance for a reclosing pres- pressure relief device must conform to
sure relief valve is ±3 psi for valves the following requirements:
with a start-to-discharge pressure of (1) A non-reclosing pressure relief de-
6.89 Bar (100 psig) or less and ±3 percent vice must incorporate a rupture disc
for valves with a start-to-discharge designed to burst at a pressure equal to
pressure greater than 6.89 Bar (100 the greater of 100% of the tank test
psig). pressure, or 33% of the tank burst pres-
(c) Flow capacity of pressure relief de- sure.
vices. The total flow capacity of each (2) The approach channel and the dis-
reclosing and nonreclosing pressure re- charge channel may not reduce the re-
lief device must conform to appendix A quired minimum flow capacity of the
of the AAR Specifications for Tank pressure relief device.
Cars.
(3) The non-reclosing pressure relief
(d) Flow capacity tests. The manufac-
device must be designed to prevent
turer of any reclosing or nonreclosing
interchange with other fittings in-
pressure relief device must design and
stalled on the tank car, must have a
test the device in accordance with ap-
structure that encloses and clamps the
pendix A of the AAR Specifications for
rupture disc in position (preventing
Tank Cars.
any distortion or damage to the rup-
(e) Combination pressure relief systems.
ture disc when properly applied), and
A non-reclosing pressure relief device
must have a cover, with suitable means
may be used in series with a reclosing
of preventing misplacement, designed
pressure relief valve. The pressure re-
to direct any discharge of the lading
lief valve must be located outboard of
downward.
the non-reclosing pressure relief de-
(4) The non-reclosing pressure relief
vice.
device must be closed with a rupture
(1) When a breaking pin device is
disc that is compatible with the lading
used in combination with a reclosing
and manufactured in accordance with
pressure relief valve, the breaking pin
Appendix A of the AAR Specifications
must be designed to fail at the start-to-
for Tank Cars. The tolerance for a rup-
discharge pressure specified in para-
ture disc is + 0 to ¥15 percent of the
graph (b) of this section, and the re-
burst pressure marked on the disc.
closing pressure relief valve must be
designed to discharge at not greater (g) Location of relief devices. Each
than 95 percent of the start-to-dis- pressure relief device must commu-
charge pressure. nicate with the vapor space above the
(2) When a rupture disc is used in lading as near as practicable on the
combination with a reclosing pressure longitudinal center line and center of
relief valve, the rupture disc must be the tank.
designed to burst at the pressure speci- (h) Marking of pressure relief devices.
fied in paragraph (b) of this section, Each pressure relief device and rupture
and the reclosing pressure relief valve disc must be permanently marked in
must be designed to discharge at not accordance with the appendix A of the
greater than 95 percent of the pressure. AAR Specifications for Tank Cars.
A device must be installed to detect [Amdt. 179–52, 61 FR 28678, June 5, 1996, as
any accumulation of pressure between amended by Amdt. 179–52, 61 FR 50255, Sept.
the rupture disc and the reclosing pres- 25, 1996; 62 FR 51561, Oct. 1, 1997; 64 FR 51919,
sure relief valve. The detection device Sept. 27, 1999; 66 FR 45390, Aug. 28, 2001; 68 FR
must be a needle valve, trycock, or 75759, Dec. 31, 2003]
tell-tale indicator. The detection de-
§ 179.16 Tank-head puncture-resist-
vice must be closed during transpor-

tation. ance systems.
(3) The vapor tight pressure and the (a) Performance standard. When the
start-to-discharge tolerance is based on regulations in this subchapter require
265
§ 179.18 49 CFR Ch. I (10–1–18 Edition)
a tank-head puncture-resistance sys- lease of any lading within the tank car,
tem, the system shall be capable of sus- except release through the pressure re-
taining, without any loss of lading, lease device, when subjected to:
coupler-to-tank-head impacts at rel- (1) A pool fire for 100 minutes; and
ative car speeds of 29 km/hour (18 mph) (2) A torch fire for 30 minutes.
when: (b) Thermal analysis. (1) Compliance
(1) The weight of the impact car is at with the requirements of paragraph (a)
least 119,295 kg (263,000 pounds);
of this section shall be verified by ana-
(2) The impacted tank car is coupled
lyzing the fire effects on the entire sur-
to one or more backup cars that have a
total weight of at least 217,724 kg face of the tank car. The analysis must
(480,000 pounds) and the hand brake is consider the fire effects on and heat
applied on the last ‘‘backup’’ car; and flux through tank discontinuities, pro-
(3) The impacted tank car is pressur- tective housings, underframes, metal
ized to at least 6.9 Bar (100 psig). jackets, insulation, and thermal pro-
(b) Verification by testing. Compliance tection. A complete record of each
with the requirements of paragraph (a) analysis shall be made, retained, and
of this section shall be verified by full- upon request, made available for in-
scale testing according to appendix A spection and copying by an authorized
of this part. representative of the Department. The
(c) Alternative compliance by other procedures outlined in ‘‘Temperatures,
than testing. As an alternative to re- Pressures, and Liquid Levels of Tank
quirements prescribed in paragraph (b) Cars Engulfed in Fires,’’ DOT/FRA/
of this section, compliance with the re- OR&D–84/08.11, (1984), Federal Railroad
quirements of paragraph (a) of this sec- Administration, Washington, DC
tion may be met by installing full-head (available from the National Technical
protection (shields) or full tank-head Information Service, Springfield, VA)
jackets on each end of the tank car shall be deemed acceptable for ana-
conforming to the following: lyzing the fire effects on the entire sur-
(1) The full-head protection (shields)
face of the tank car.
or full tank-head jackets must be at
least 1.27 cm (0.5 inch) thick, shaped to (2) When the analysis shows the ther-
the contour of the tank head and made mal resistance of the tank car does not
from steel having a tensile strength conform to paragraph (a) of this sec-
greater than 379.21 N/mm2 (55,000 psi). tion, the thermal resistance of the
(2) The design and test requirements tank car must be increased by using a
of the full-head protection (shields) or system listed by the Department under
full tank-head jackets must meet the paragraph (c) of this section or by test-
impact test requirements in Section 5.3 ing a new or untried system and
of the AAR Specifications for Tank verifying it according to appendix B of
Cars (IBR, see § 171.7 of this sub- this part.
chapter). (c) Systems that no longer require test
(3) The workmanship must meet the verification. The Department maintains
requirements in Section C, Part II, a list of thermal protection systems
Chapter 5, of the AAR Specifications that comply with the requirements of
for Design, Fabrication, and Construc- appendix B of this part and that no
tion of Freight Cars (IBR, see § 171.7 of longer require test verification. Infor-
this subchapter). mation necessary to equip tank cars
[Amdt. 179–50, 60 FR 49077, Sept. 21, 1995, as with one of these systems is available
amended by Amdt. 179–50, 61 FR 33255, June in the PHMSA Records Center, Pipe-
26, 1996; 66 FR 45390, Aug. 28, 2001; 68 FR 75759, line and Hazardous Materials Safety
Dec. 31, 2003]
Administration, East Building, 1200
§ 179.18 Thermal protection systems. New Jersey Avenue, SE., Washington,
DC 20590–0001.
(a) Performance standard. When the
regulations in this subchapter require [Amdt. 179–50, 60 FR 49077, Sept. 21, 1995, as
thermal protection on a tank car, the amended by Amdt. 179–50, 61 FR 33256, June
tank car must have sufficient thermal 26, 1996; 66 FR 45390, Aug. 28, 2001; 70 FR 56099,
resistance so that there will be no re- Sept. 23, 2005; 72 FR 55696, Oct. 1, 2007]
266
§ 179.20 Service equipment; protection car. One identification plate must be

systems. installed on the right side (AR) of the
If an applicable tank car specifica- tank car, and the other must be in-
tion authorizes location of filling or stalled on the back end left side (BL)
discharge connections in the bottom body bolster webs so that each plate is
shell, the connections must be de- readily accessible for inspection. The
signed, constructed, and protected ac- plates must be at least 3⁄32 inch thick
cording to paragraphs E9.00 and E10.00 and manufactured from corrosion re-
of the AAR Specifications for Tank sistant metal. When the tank jacket
Cars (IBR, see § 171.7 of this sub- (flashing) covers the body bolster web
chapter). and identification plates, additional
identical plates must be installed on
[68 FR 75759, Dec. 31, 2003] the AR and BL corners of the tank in
a visible location. Tank cars built be-
§ 179.22 Marking.
fore July 25, 2012, may have the plate
In addition to any other marking re- instead of or in addition to the stamp-
quirement in this subchapter, the fol- ing.
lowing marking requirements apply: (2) Each plate must be stamped, em-
(a) Each tank car must be marked ac- bossed, or otherwise marked by an
cording to the requirements in appen- equally durable method in letters 3/16
dix C of the AAR Specifications for inch high with the following informa-
Tank Cars (IBR, see § 171.7 of this sub- tion (parenthetical abbreviations may
chapter). be used, and the AAR form reference is
(b) Each tank car that requires a to the applicable provisions of the AAR
tank-head puncture-resistance system Specifications for Tank Cars (IBR, see
must have the letter ‘‘S’’ substituted § 171.7 of this subchapter):
for the letter ‘‘A’’ in the specification (i) Tank Manufacturer (Tank MFG):
marking. Full name of the car builder as shown
(c) Each tank car that requires a on the certificate of construction (AAR
tank-head puncture-resistance system, form 4–2).
a thermal protection system, and a (ii) Tank Manufacturer’s Serial Number
metal jacket must have the letter ‘‘J’’ (SERIAL NO): For the specific car.
substituted for the letter ‘‘A’’ or ‘‘S’’ in (iii) AAR Number (AAR NO): The AAR
the specification marking. number from line 3 of AAR Form 4–2.
(d) Each tank car that requires a (iv) Tank Specification (SPECIFICA-
tank-head puncture-resistance system, TION): The specification to which the
a thermal protection system, and no tank was built from line 7 of AAR form
metal jacket must have the letter ‘‘T’’ 4–2.
substituted for the letter ‘‘A’’ or ‘‘S’’ in (v) Tank Shell Material/Head Material
the specification marking. (SHELL MATL/HEAD MATL): ASTM or
(e) Each tank car manufactured after AAR specification of the material used
March 16, 2009 to meet the require- in the construction of the tank shell
ments of § 173.244(a)(2) or (3) or and heads from lines 15 and 16 of AAR
§ 173.314(c) or (d) shall be marked with Form 4–2. For Class DOT–113W, DOT–
the letter ‘‘I’’ following the test pres- 115W, AAR–204W, and AAR–206W, the
sure instead of the letter ‘‘W’’. (Exam- materials used in the construction of
ple: DOT 105J600I). the outer tank shell and heads must be
[Amdt. 179–50, 60 FR 49077, Sept. 21, 1995, as listed. Only list the alloy (e.g., 5154) for
amended by Amdt. 179–50, 61 FR 33256, June aluminum tanks and the type (e.g.,
26, 1996; 68 FR 75759, Dec. 31, 2003; 74 FR 1802, 304L or 316L) for stainless steel tanks.
Jan. 13, 2009] (vi) Insulation Material (INSULATION
MATL): Generic names of the first and
§ 179.24 Stamping. second layer of any thermal protection/
(a)(1) After July 25, 2012, to certify insulation material applied.
compliance with federal requirements, (vii) Insulation Thickness (INSULA-
the tank manufacturer must install TION THICKNESS): In inches.

two identical permanent identification (viii) Underframe/Stub Sill Type (UF/SS
plates, one located on both inboard sur- DESIGN): The design from Line 32 of
faces of the body bolsters of the tank AAR Form 4–2.
267
§ 179.100 49 CFR Ch. I (10–1–18 Edition)
(ix) Date of Manufacture (DATE OF cific approval is granted for a facility’s

MFR): The month and year of tank equipment and controls.
manufacture. If the underframe has a
different built date than the tank, FR 5606, Apr. 5, 1967, and amended by Amdt.
show both dates. 179–10, 36 FR 21344, Nov. 6, 1971; 65 FR 58632,
(3) When a modification to the tank Sept. 29, 2000; 74 FR 1802, Jan. 13, 2009]
changes any of the information shown
in paragraph (a)(2) of this section, the § 179.100–4 Insulation.
car owner or the tank car facility mak- (a) If insulation is applied, the tank
ing the modification must install an shell and manway nozzle must be insu-
additional variable identification plate lated with an approved material. The
on the tank in accordance with para- entire insulation must be covered with
graph (a)(1) of this section showing the a metal jacket of a thickness not less
following information: than 11 gauge (0.1196 inch) nominal
(i) AAR Number (AAR NO): The AAR (Manufacturers’ Standard Gauge) and
number from line 3 of AAR Form 4–2 flashed around all openings so as to be
for the alteration or conversion. weather-tight. The exterior surface of a
(ii) All items of paragraph (a)(2) of carbon steel tank, and the inside sur-
this section that were modified, fol- face of a carbon steel jacket must be
lowed by the month and year of modi- given a protective coating.
fication. (b) If insulation is a specification re-
(b) [Reserved]. quirement, it shall be of sufficient
[77 FR 37985, June 25, 2012, as amended at 81
thickness so that the thermal conduct-
FR 35545, June 2, 2016] ance at 60 °F is not more than 0.075 Btu
per hour, per square foot, per degree F
temperature differential. If exterior
Subpart C—Specifications for heaters are attached to tank, the
Pressure Tank Car Tanks thickness of the insulation over each
(Classes DOT-105, 109, 112, heater element may be reduced to one-
114 and 120) half that required for the shell.
§ 179.100 General specifications appli- [29 FR 18995, Dec. 29, 1964. Redesignated at 32
cable to pressure tank car tanks. FR 5606, Apr. 5, 1967, and amended by Amdt.
179–10, 36 FR 21344, Nov. 6, 1971; Amdt. 179–50,
60 FR 49077, Sept. 21, 1995]
§ 179.100–1 Tanks built under these
specifications shall comply with the
requirements of §§ 179.100, 179.101 § 179.100–6 Thickness of plates.
and when applicable, §§ 179.102 and (a) The wall thickness after forming
179.103. of the tank shell and heads must not be
less than that specified in § 179.101, nor
§ 179.100–3 Type. that calculated by the following for-
(a) Tanks built under this specifica- mula:
tion shall be fusion-welded with heads
t = Pd / 2SE
designed convex outward. Except as
provided in § 179.103 they shall be cir- Where:
cular in cross section, shall be provided d = Inside diameter in inches;
with a manway nozzle on top of the E = 1.0 welded joint efficiency; except for
tank of sufficient size to permit access heads with seams = 0.9;
to the interior, a manway cover to pro- P = Minimum required bursting pressure in
vide for the mounting of all valves, p.s.i.;
measuring and sampling devices, and a S = Minimum tensile strength of plate mate-
protective housing. Other openings in rial in p.s.i., as prescribed in § 179.100–7;
the tank are prohibited, except as pro- t = Minimum thickness of plate in inches
after forming.
vided in part 173 of this chapter,
§§ 179.100–14, 179.101–1, 179.102 or § 179.103. (b) If plates are clad with material
(b) Head shields and shells of tanks having tensile strength properties at
built under this specification must be least equal to the base plate, the clad-
normalized. Tank car heads must be ding may be considered a part of the
normalized after forming unless spe- base plate when determining thickness.
268
If cladding material does not have ten- Minimum elon-

sile strength at least equal to the base Minimum ten- gation in 2
sile strength inches (per-
plate, the base plate alone shall meet Specifications (p.s.i.) 0 tem- cent) 0 tem-
the thickness requirement. per, welded per, welded
condition 3 4 condition (lon-
(c) When aluminum plate is used, the gitudinal)
minimum width of bottom sheet of
ASTM B 209, Alloy 5454 1 31,000 18
tank shall be 60 inches, measured on ASTM B 209, Alloy 5652 1 25,000 18
the arc, but in all cases the width shall
1 For fabrication, the parent plate material may be 0, H112,
be sufficient to bring the entire width or H32 temper, but design calculations must be based on
of the longitudinal welded joint, in- minimum tensile strength shown.
2 0 temper only.
cluding welds, above the bolster. 3 Weld filler metal 5556 must not be used.
4 Maximum stress to be used in calculations.
FR 5606, Apr. 5, 1967, and amended by Amdt. (c) High alloy steel plate. (1) High alloy
179–10, 36 FR 21344, Nov. 6, 1971]
steel plate must conform to the fol-
§ 179.100–7 Materials. lowing specifications:
(a) Steel plate: Steel plate materials Minimum tensile Minimum elon-
used to fabricate tank shell and gation in 2
strength (p.s.i.)
Specifications inches (percent)
manway nozzle must comply with one welded condi- weld metal (lon-
tion1
of the following specifications with the gitudinal)
indicated minimum tensile strength ASTM A 240/A 240M
and elongation in the welded condition. (incorporated by ref-
The maximum allowable carbon con- erence; see § 171.7 of
this subchapter), Type
tent must be 0.31 percent when the in- 304L ........................... 70,000 30
dividual specification allows carbon ASTM A 240/A 240M
greater than this amount. The plates (incorporated by ref-
may be clad with other approved mate- erence; see § 171.7 of
this subchapter), Type
rials. 316L ........................... 70,000 30
Minimum elon- 1 Maximum stresses to be used in calculations.
Minimum tensile gation in 2
strength (p.s.i.) inches (percent) (2)(i) High alloy steels used to fab-
Specifications welded condi- welded condi-
tion1 tion (longitu- ricate tank must be tested in accord-
dinal) ance with the following procedures in
AAR TC 128, Gr. B ....... 81,000 19 ASTM A 262, ‘‘Standard Practices for
ASTM A 302 2, Gr. B ..... 80,000 20 Detecting Susceptibility to Inter-
ASTM A 516 2 ................ 70,000 20 granular Attack in Austenitic Stain-
ASTM A 537 2, Class 1 70,000 23
less Steel’’ (IBR, see § 171.7 of this sub-
1 Maximum stresses to be used in calculations.
2 These specifications are incorporated by reference (IBR, chapter), and must exhibit corrosion
see § 171.7 of this subchapter). rates not exceeding the following: * * *
(b) Aluminum alloy plate: Aluminum Corrosion
Test procedures Material
alloy plate material used to fabricate rate i.p.m.
tank shell and manway nozzle must be Practice B ............... Types 304L and 316L .. 0.0040
suitable for fusion welding and must Practice C ............... Type 304L ..................... 0.0020
comply with one of the following speci-
fications (IBR, see § 171.7 of this sub- (ii) Type 304L and 316L test speci-
chapter) with its indicated minimum mens must be given a sensitizing treat-
tensile strength and elongation in the ment prior to testing.
welded condition. * * * (d) All attachments welded to tank
Minimum elon- shell must be of approved material
Minimum ten- gation in 2 which is suitable for welding to the
sile strength inches (per-
Specifications (p.s.i.) 0 tem- cent) 0 tem- tank.
per, welded per, welded
condition 3 4 condition (lon- [Amdt. 179–10, 36 FR 21344, Nov. 6, 1971, as
gitudinal) amended by Amdt. 179–32, 48 FR 27707, June
16, 1983; Amdt. 179–47, 58 FR 50237, Sept. 24,
ASTM B 209, Alloy 5052 1 25,000 18

1993; Amdt. 179–52, 61 FR 28679, June 5, 1996;
ASTM B 209, Alloy 5083 2 38,000 16
ASTM B 209, Alloy 5086 1 35,000 14 Amdt. 179–52, 61 FR 50255, Sept. 25, 1996; 66
ASTM B 209, Alloy 5154 1 30,000 18 FR 45186, Aug. 28, 2001; 67 FR 51660, Aug. 8,
ASTM B 209, Alloy 5254 1 30,000 18 2002; 68 FR 75759, Dec. 31, 2003]
269
§ 179.100–8 49 CFR Ch. I (10–1–18 Edition)
§ 179.100–8 Tank heads. sion resistance test as specified in

§ 179.100–7(c)(2).
(a) The tank head shape shall be an
ellipsoid of revolution in which the [Amdt. 179–10, 36 FR 21345, Nov. 6, 1971, as
major axis shall equal the diameter of amended by Amdt. 179–47, 58 FR 50238, Sept.
24, 1993; Amdt. 179–52, 61 FR 28679, June 5,
the shell adjacent to the head and the 1996; 67 FR 51660, Aug. 8, 2002; 68 FR 75758,
minor axis shall be one-half the major 75759, Dec. 31, 2003]
axis.
(b) Each tank head made from steel § 179.100–12 Manway nozzle, cover and
which is required to be ‘‘fine grain’’ by protective housing.
the material specification, which is hot (a) Manway nozzles must be of ap-
formed at a temperature exceeding 1700 proved design of forged or rolled steel
°F., must be normalized after forming for steel tanks or of fabricated alu-
by heating to a temperature between minum alloy for aluminum tanks, with
1550° and 1700 °F., by holding at that an access opening of at least 18 inches
temperature for at least 1 hour per inside diameter, or at least 14 inches by
inch of thickness (30-minute min- 18 inches around or oval. Each nozzle
imum), and then by cooling in air. If must be welded to the tank and the
the material specification requires opening reinforced in an approved man-
quenching and tempering, the treat- ner in compliance with the require-
ments of AAR Specifications for Tank
ment specified in that specification
Cars, appendix E, Figure E10 (IBR, see
must be used instead of the one speci-
§ 171.7 of this subchapter).
fied above. (b) Manway cover shall be machined
[29 FR 18995, Dec. 29, 1964. Redesignated, 32 to approved dimensions and be of
FR 5606, Apr. 5, 1967 and amended by Amdt. forged or rolled carbon or alloy steel,
179–12, 39 FR 15038, Apr. 30, 1974] rolled aluminum alloy or nickel when
required by the lading. Minimum
§ 179.100–9 Welding. thickness is listed in § 179.101. Manway
(a) All joints shall be fusion-welded cover shall be attached to manway noz-
in compliance with the requirements of zle by through or stud bolts not enter-
AAR Specifications for Tank Cars, ap- ing tank, except as provided in
pendix W (IBR, see § 171.7 of this sub- § 179.103–2(a).
chapter). Welding procedures, welders (c) Except as provided in § 179.103,
protective housing of cast, forged or
and fabricators shall be approved.
fabricated approved materials must be
(b) [Reserved] bolted to manway cover with not less
[29 FR 18995, Dec. 29, 1964, as amended at 65 than twenty 3⁄4-inch studs. The shear-
FR 58632, Sept. 29, 2000; 68 FR 75759, Dec. 31, ing value of the bolts attaching protec-
2003] tive housing to manway cover must
not exceed 70 percent of the shearing
§ 179.100–10 Postweld heat treatment. value of bolts attaching manway cover
(a) After welding is complete, steel to manway nozzle. Housing must have
tanks and all attachments welded steel sidewalls not less than three-
thereto must be postweld heat treated fourths inch in thickness and must be
as a unit in compliance with the re- equipped with a metal cover not less
quirements of AAR Specifications for than one-fourth inch in thickness that
can be securely closed. Housing cover
Tank Cars, appendix W (IBR, see § 171.7
must have suitable stop to prevent
cover striking loading and unloading
(b) For aluminum tanks, postweld connections and be hinged on one side
heat treatment is prohibited. only with approved riveted pin or rod
(c) Tank and welded attachments, with nuts and cotters. Openings in wall
fabricated from ASTM A 240/A 240M of housing must be equipped with screw
(IBR, see § 171.7 of this subchapter), plugs or other closures.
Type 304L or Type 316L materials do

not require postweld heat treatment, FR 5606, Apr. 5, 1967, and amended by Amdt.
but these materials do require a corro- 179–10, 36 FR 21345, Nov. 6, 1971; 68 FR 75760,
Dec. 31, 2003]
270
§ 179.100–13 Venting, loading and unin conjunction with the metal of the
loading valves, measuring and sam- tank shell. When the sump or siphon
pling devices. bowl is pressed in the bottom of the
(a) Venting, loading and unloading tank shell, the wall thickness of the
valves must be of approved design, pressed section must not be less than
made of metal not subject to rapid de- that specified for the shell. The section
terioration by the lading, and must of a circular cross section tank to
withstand the tank test pressure with- which a sump or siphon bowl is at-
out leakage. The valves shall be bolted tached need not comply with the out-
to seatings on the manway cover, ex- of-roundness requirement specified in
cept as provided in § 179.103. Valve out- AAR Specifications for Tank Cars, ap-
lets shall be closed with approved pendix W, W14.06 (IBR, see § 171.7 of this
screw plugs or other closures fastened subchapter). Any portion of a sump or
to prevent misplacement. siphon bowl not forming a part of cyl-
(b) The interior pipes of the loading inder of revolution must have walls of
and unloading valves shall be anchored such thickness and be so reinforced
and, except as prescribed in §§ 173.314(j),
that the stresses in the walls caused by
179.102 or 179.103, may be equipped with
a given internal pressure are no greater
excess flow valves of approved design.
than the circumferential stress that
(c) Gauging device, sampling valve
and thermometer well are not speci- would exist under the same internal
fication requirements. When used, they pressure in the wall of a tank of cir-
shall be of approved design, made of cular cross section designed in accord-
metal not subject to rapid deteriora- ance with § 179.100–6(a), but in no case
tion by the lading, and shall withstand shall the wall thickness be less than
the tank test pressure without leakage. that specified in § 179.101–1.
Interior pipes of the gauging device and [29 FR 18995, Dec. 29, 1964. Redesignated at 32
sampling valve, except as prescribed in FR 5606, Apr. 5, 1967, and amended by Amdt.
§§ 173.314(j), 179.102 or 179.103, may be 179–10, 36 FR 21345, Nov. 6, 1971; Amdt. 179–40,
equipped with excess flow valves of ap- 52 FR 13046, Apr. 20, 1987; Amdt. 179–42, 54 FR
proved design. Interior pipe of the ther- 38798, Sept. 20, 1989; 65 FR 58632, Sept. 29,
mometer well shall be anchored in an 2000; 68 FR 48571, Aug. 14, 2003; 68 FR 75760,
approved manner to prevent breakage Dec. 31, 2003]
due to vibration. The thermometer
well shall be closed by an approved § 179.100–14 Bottom outlets.
valve attached close to the manway (a) Bottom outlets for discharge of
cover, or other approved location, and lading is prohibited, except as provided
closed by a screw plug. Other approved in § 179.103–3. If indicated in § 179.101,
arrangements that permit testing ther- tank may be equipped with a bottom
mometer well for leaks without com- washout of approved construction. If
plete removal of the closure may be applied, bottom washout shall be in ac-
used. cordance with the following require-
(d) An excess flow valve as referred to ments;
in this specification, is a device which
(1) The extreme projection of the bot-
closes automatically against the out-
tom washout equipment may not be
ward flow of the contents of the tank
more than that allowed by appendix E
in case the external closure valve is
of the AAR Specifications for Tank
broken off or removed during transit.
Excess flow valves may be designed Cars (IBR, see § 171.7 of this sub-
with a by-pass to allow the equali- chapter).
zation of pressures. (2) Bottom washout shall be of cast,
(e) Bottom of tank shell may be forged or fabricated metal and shall be
equipped with a sump or siphon bowl, fusion-welded to the tank. It shall be of
or both, welded or pressed into the good weldable quality in conjunction
shell. Such sumps or siphon bowls, if with metal of tank.
applied, are not limited in size and (3) If the bottom washout nozzle ex-
must be made of cast, forged or fab- tends 6 inches or more from shell of
ricated metal. Each sump or siphon tank, a V-shaped breakage groove shall
bowl must be of good welding quality be cut (not cast) in the upper part of
271
§ 179.100–16 49 CFR Ch. I (10–1–18 Edition)
the outlet nozzle at a point imme- § 179.100–17 Closures for openings.

diately below the lowest part of the in- (a) Closures shall be of approved de-
side closure seat or plug. In no case sign and made of metal not subject to
may the nozzle wall thickness at the rapid deterioration by the lading.
root of the ‘‘V’’ be more than 1⁄4-inch.
Plugs, if used, shall be solid, with NPT
Where the nozzle is not a single piece,
threads, and shall be of a length which
provision shall be made for the equiva-
will screw at least six threads inside
lent of the breakage groove. The nozzle
the face of fitting or tank.
must be of a thickness to insure that
(b) [Reserved]
accidental breakage will occur at or
below the ‘‘V’’ groove or its equivalent. § 179.100–18 Tests of tanks.
On cars without continuous center
sills, the breakage groove or its equiva- (a) Each tank shall be tested by com-
lent may not be more than 15 inches pletely filling tank and manway nozzle
below the tank shell. On cars with con- with water or other liquid having simi-
tinuous center sills, the breakage lar viscosity, at a temperature which
groove or its equivalent must be above shall not exceed 100 °F during the test;
the bottom of the center sill construc- and applying the pressure prescribed in
tion. § 179.101. The tank shall hold the pre-
(4) The closure plug and seat shall be scribed pressure for at least 10 minutes
readily accessible or removable for re- without leakage or evidence of distress.
pairs. (b) Insulated tanks shall be tested be-
(5) The closure of the washout nozzle fore insulation is applied.
must be equipped with a 3⁄4-inch solid (c) Caulking of welded joints to stop
screw plug. Plug must be attached by leaks developed during the foregoing
at least a 1⁄4-inch chain. test is prohibited. Repairs in welded
(6) Joints between closures and their joints shall be made as prescribed in
seats may be gasketed with suitable AAR Specifications for Tank Cars, ap-
material. pendix W (IBR, see § 171.7 of this sub-
(b) [Reserved] chapter).
(d) Testing of exterior heaters is not
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 a specification requirement.
179–10, 36 FR 21345, Nov. 6, 1971; Amdt. 179–40, [29 FR 18995, Dec. 29, 1964. Redesignated at 32
52 FR 13046, Apr. 20, 1987; 66 FR 45186, Aug. 28, FR 5606, Apr. 5, 1967; 66 FR 45186, Aug. 28,
2001; 68 FR 75760, Dec. 31, 2003] 2001; 68 FR 75760, Dec. 31, 2003]
§ 179.100–16 Attachments. § 179.100–19 Tests of safety relief

valves.
(a) Reinforcing pads must be used be-
tween external brackets and shells if (a) Each valve shall be tested by air
the attachment welds exceed 6 linear or gas for compliance with § 179.15 be-
inches of 1⁄4-inch fillet or equivalent fore being put into service.
weld per bracket or bracket leg. When (b) [Reserved]
reinforcing pads are used, they must [29 FR 18995, Dec. 29, 1964. Redesignated at 32
not be less than one-fourth inch in FR 5606, Apr. 5, 1967, as amended at 62 FR
thickness, have each corner rounded to 51561, Oct. 1, 1997]
a 1-inch minimum radius, and be at-
tached to the tank by continuous fillet § 179.100–20 Stamping.
welds except for venting provisions. (a) To certify that the tank complies
The ultimate shear strength of the with all specification requirements,
bracket-to-reinforcing pad weld must each tank shall be plainly and perma-
not exceed 85 percent of the ultimate nently stamped in letters and figures
shear strength of the reinforcing pad- at least 3⁄8 inch high into the metal
to-tank weld. near the center of both outside heads
(b) Attachments not otherwise speci- as follows:
fied shall be applied by approved
Example of required
means. stamping
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 Specification ................................. DOT-105A100W
FR 5606, Apr. 5, 1967, and amended by Amdt. Material ......................................... ASTM A 516
179–10, 36 FR 21346, Nov. 6, 1971] Cladding material (if any) ............. ASTM A240–304
272
Example of required tification plates instead of or in addi-

stamping tion to the head stamping.
Tank builder’s initials .................... Clad
Date of original test ...................... ABC
Car assembler (if other than tank- 00–0000 FR 5606, Apr. 5, 1967, and amended by Amdt.
er builder). DEF 179–10, 36 FR 21346, Nov. 6, 1971; Amdt. 179–52,
61 FR 28679, June 5, 1996; 65 FR 50463, Aug. 18,
(b) After July 25, 2012, newly con- 2000; 77 FR 37985, June 25, 2012]
structed DOT tank cars must have
their DOT specification and other re- § 179.101 Individual specification re-
quired information stamped plainly quirements applicable to pressure
tank car tanks.
and permanently on stainless steel
identification plates in conformance EDITORIAL NOTE: At 66 FR 45186, Aug. 28,
with the applicable requirements pre- 2001, an amendment published amending a
scribed in § 179.24(a). Tank cars built table in § 179.101. No text or table appears in
before July 25, 2012, may have the iden- § 179.101.
§ 179.101–1 Individual specification requirements.

In addition to § 179.100, the individual specification requirements are as follows:
Minimum
Bursting Test Manway
DOT specifica- plate Bottom out- Bottom Reference
Insulation pressure pressure cover
tion thickness let washout (179.***)
(psig) (psig) thickness
(inches)
105A100ALW Yes ............. 500 5/8 100 22 1/2 No ............... No.

105A200ALW Yes ............. 500 5/8 200 22 1/2 No ............... No.
105A300ALW Yes ............. 750 5/8 300 22 5/8 No ............... No.
105A100W ..... Yes ............. 500 3 9/16 100 2 1/4 No ............... No.
105A200W ..... Yes ............. 500 3 9/16 200 2 1/4 No ............... No.
105A300W ..... Yes ............. 750 1 11/16 300 72 1/4 No ............... No.
105A400W ..... Yes ............. 1,000 1 11/16 400 72 1/4 No ............... No.
105A500W ..... Yes ............. 1,250 1 11/16 500 2 1/4 No ............... No ............ 102–1, 102–2
105A600W ..... Yes ............. 1,500 1 11/16 600 2 1/4 No ............... No ............ 102–4, 102–17
109A100ALW Optional ...... 500 5/8 100 22 1/2 No ............... Optional.
109A300W ..... Optional ...... 500 1 11/16 300 2 1/4 No ............... Optional.
112A200W ..... Optional 4 .... 500 3 5 9/16 200 2 1/4 No ............... No.
112A340W ..... Optional 4 .... 850 1 11/16 340 2 1/4 No ............... No.
112A400W ..... Optional 4 .... 1,000 1 11/16 400 2 1/4 No ............... No.
112A500W ..... Optional 4 .... 1,250 1 11/16 500 2 1/4 No ............... No.
114A340W ..... Optional 4 .... 850 1 11/16 340 6 Optional ...... Optional ... 103
114A400W ..... Optional 4 .... 1,000 1 11/16 400 6 Optional ...... Optional ... 103
120A200ALW Yes ............. 500 5/8 200 22 1/2 Optional ...... Optional ... 103
120A100W ..... Yes ............. 500 3 9/16 100 2 1/4 Optional ...... Optional ... 103
120A400W ..... Yes ............. 1,000 1 11/16 400 2 1/4 Optional ...... Optional ... 103
120A500W ..... Yes ............. 1,250 1 11/16 500 2 1/4 Optional ...... Optional ... 103
1 When steel of 65,000 to 81,000 p.s.i. minimum tensile strength is used, the thickness of plates shall be not less than 5⁄8 inch,
and when steel of 81,000 p.s.i. minimum tensile strength is used, the minimum thickness of plate shall be not less than 9⁄16 inch.
2 When approved material other than aluminum alloys are used, the thickness shall be not less than 21⁄4 inches.
3 When steel of 65,000 p.s.i. minimum tensile strength is used, minimum thickness of plates shall be not less than 1⁄2 inch.
4 Tank cars not equipped with a thermal protection or an insulation system used for the transportation of a Class 2 (com-
pressed gas) material must have at least the upper two-thirds of the exterior of the tank, including manway nozzle and all appur-
tenances in contact with this area, finished with a reflective coat of white paint.
5 For inside diameter of 87 inches or less, the thickness of plates shall be not less than 1⁄2 inch.
6 See AAR Specifications for Tank Cars, appendix E, E4.01 (IBR, see § 171.7 of this subchapter), and § 179.103–2.
7 When the use of nickel is required by the lading, the thickness shall not be less than two inches.
[Amdt. 179–52, 61 FR 28679, June 5, 1996, as amended at 66 FR 45390, Aug. 28, 2001; 68 FR 75760,
Dec. 31, 2003]
273
§ 179.102 49 CFR Ch. I (10–1–18 Edition)
§ 179.102 Special commodity require- this subchapter), Grade 70, or AAR

ments for pressure tank car tanks. Specification TC 128, Grade A or B.
(a) In addition to §§ 179.100 and 179.101 (2)–(3) [Reserved]
the following requirements are applica- (b) [Reserved]
ble: [Amdt. 179–7, 36 FR 14697, Aug. 10, 1971; Amdt.
(b) [Reserved] 179–10, 36 FR 21346, Nov. 6, 1971, as amended
by Amdt. 179–25, 44 FR 20433, Apr. 5, 1979;
§ 179.102–1 Carbon dioxide, refrig- Amdt. 179–40, 52 FR 13046, Apr. 20, 1987; Amdt.
erated liquid. 179–45, 55 FR 52728, Dec. 21, 1990; Amdt. 179–52,
61 FR 28680, June 5, 1996; 68 FR 75760, Dec. 31,
(a) Tank cars used to transport car- 2003]
bon dioxide, refrigerated liquid must
comply with the following special re- § 179.102–3 Materials poisonous by in-
quirements: halation.
(1) All plates for tank, manway noz- (a) Each tank car built after March
zle and anchorage of tanks must be 16, 2009 for the transportation of a ma-
made of carbon steel conforming to terial poisonous by inhalation must, in
ASTM A 516/A 516M (IBR, see § 171.7 of addition to the requirements pre-
this subchapter), Grades 55, 60, 65, or 70, scribed in § 179.100–12(c), enclose the
or AAR Specification TC 128–78, Grade service equipment within a protective
B. The ASTM A 516/A 516M plate must housing and cover.
also meet the Charpy V-Notch test re- (1) Tank cars must be equipped with
quirements of ASTM A 20/A 20M (see a top fitting protection system and
table 16) (IBR, see § 171.7 of this sub- nozzle capable of sustaining, without
chapter) in the longitudinal direction failure, a rollover accident at a speed
of rolling. The TC 128 plate must also of 9 miles per hour, in which the rolling
meet the Charpy V-Notch energy ab- protective housing strikes a stationary
sorption requirements of 15 ft.-lb. min- surface assumed to be flat, level and
imum average for 3 specimens, and 10 rigid and the speed is determined as a
ft.-lb. minimum for one specimen, at linear velocity, measured at the geo-
minus 50 °F in the longitudinal direc- metric center of the loaded tank car as
tion of rolling in accord with ASTM A a transverse vector. Failure is deemed
370 (IBR, see § 171.7 of this subchapter). to occur when the deformed protective
Production-welded test plates prepared housing contacts any of the service
as required by W4.00 of AAR Specifica- equipment or when the tank retention
tions for Tank Cars, appendix W (IBR, capability is compromised.
see § 171.7 of this subchapter), must in- (2) As an alternative to the tank car
clude impact test specimens of weld top fitting protection system require-
metal and heat-affected zone. As an al- ments in paragraph (a)(1) of this sec-
ternate, anchor legs may be fabricated tion, the tank car may be equipped
of stainless steel, ASTM A 240/A 240M with a system that prevents the release
Types 304, 304L, 316 or 316L, for which of product from any top fitting in the
impact tests are not required. case of an accident where any top fit-
(2)–(6) [Reserved] ting would be sheared off. The tank
(b) [Reserved] nozzle must meet the performance
[29 FR 18995, Dec. 29, 1964] standard in paragraph (a)(1) of this sec-
tion and only mechanically operated
EDITORIAL NOTE: For FEDERAL REGISTER ci- excess flow devices are authorized.
tations affecting § 179.102–1, see the List of (b) An application for approval of a
CFR Sections Affected, which appears in the
Finding Aids section of the printed volume
tank car built in accordance with
and at www.fdsys.gov. § 173.244(a)(3) or § 173.314(d) must include
a demonstration, through engineering
§ 179.102–2 Chlorine. analysis, that the tank jacket and sup-
(a) Each tank car used to transport port structure system, including any
chlorine must comply with all of the anchors and support devices, is capable
of withstanding a 6 mile per hour cou-
following:
(1) Tanks must be fabricated from pling without jacket shift such that re-
carbon steel complying with ASTM sults in damage to the nozzle.
Specification A 516 (IBR, see § 171.7 of [74 FR 1802, Jan. 13, 2009]
274
§ 179.102–4 Vinyl fluoride, stabilized. (f) A pressure gage may be installed.

Each tank used to transport vinyl (g) Aluminum, copper, silver, zinc, or
fluoride, stabilized, must comply with an alloy containing any of these metals
the following special requirements: may not be used in the tank construc-
(a) All plates for the tank must be tion, or in fittings in contact with the
fabricated of material listed in para- lading.
graph (a)(2) of this section, and appur- (h) The jacket must be stenciled, ad-
tenances must be fabricated of mate- jacent to the water capacity stencil,
rial listed in paragraph (a)(1) or (a)(2) MINIMUM OPERATING TEMPERA-
of this section. TURE l °F.
(1) Stainless steel, ASTM A 240/A (i) The tank car and insulation must
240M (IBR, see § 171.7 of this sub- be designed to prevent the vapor pres-
chapter), Type 304, 304L, 316 or 316L, in sure of the lading from increasing from
which case impact tests are not re- the pressure at the maximum allowable
quired; or filling density to the start-to-discharge
(2) Steel complying with ASTM Spec-
pressure of the reclosing pressure relief
ification A 516 (IBR, see § 171.7 of this
valve within 30 days, at an ambient
subchapter); Grade 70; ASTM Specifica- temperature of 90 °F.
tion A 537 (IBR, see § 171.7 of this sub-
chapter), Class 1; or AAR Specification [Amdt. 179–32, 48 FR 27707, June 16, 1983, as
TC 128, Grade B, in which case impact amended at 49 FR 24317, June 12, 1984; 49 FR
tests must be performed as follows: 42736, Oct. 24, 1984; Amdt. 179–45, 55 FR 52728,
Dec. 21, 1990; Amdt. 179–52, 61 FR 28680, June
(i) ASTM A 516/A 516M and A 537/A 5, 1996; 65 FR 58632, Sept. 29, 2000; 66 FR 33452,
537M material must meet the Charpy June 21, 2001; 66 FR 45186, 45390, Aug. 28, 2001;
V-Notch test requirements, in longitu- 67 FR 51660, Aug. 8, 2002; 68 FR 75758, 75760
dinal direction of rolling, of ASTM A Dec. 31, 2003]
20/A 20M (IBR, see § 171.7 of this sub-
chapter). § 179.102–17 Hydrogen chloride, refrig-
(ii) AAR Specification TC 128 mate- erated liquid.
rial must meet the Charpy V-Notch Each tank car used to transport hy-
test requirements, in longitudinal di- drogen chloride, refrigerated liquid
rection of rolling, of 15 ft.-lb. minimum must comply with the following special
average for 3 specimens, with a 10 ft.- requirements:
lb. minimum for any one specimen, at (a) The tank car must comply with
minus 50 °F or colder, in accordance Specification DOT-105J600W and be de-
with ASTM A 370 (IBR, see § 171.7 of signed for loading at minus 50 °F. or
this subchapter). colder.
(iii) Production welded test plates (b) All plates for the tank must be
must— fabricated of material listed in para-
(A) Be prepared in accordance with graph (b)(2) of this section, and appur-
AAR Specifications for Tank Cars, ap- tenances must be fabricated of mate-
pendix W, W4.00 (IBR, see § 171.7 of this rial listed in paragraph (b)(1) or (b)(2)
subchapter); of this section.
(B) Include impact specimens of weld (1) Stainless steel, ASTM A 240/A
metal and heat affected zone prepared 240M (IBR, see § 171.7 of this sub-
and tested in accordance with AAR chapter), Type 304, 304L, 316, or 316L, in
Specifications for Tank Cars, appendix which case impact tests are not re-
W, W9.00; and quired; or
(C) Meet the same impact require- (2) Steel conforming to ASTM A 516/
ments as the plate material. A 516M (IBR, see § 171.7 of this sub-
(b) Insulation must be of approved chapter), Grade 70; ASTM A 537/A 537M,
material. (IBR, see § 171.7 of this subchapter)
(c) Excess flow valves must be in- Class 1; or AAR Specification TC 128,
stalled under all liquid and vapor Grade B in which case impact tests
valves, except safety relief valves. must be performed as follows:
(d) A thermometer well may be in- (i) ASTM A 516/A 516M and A 537/A
stalled. 537M material must meet the Charpy
(e) Only an approved gaging device V-notch test requirements, in longitu-
may be installed. dinal direction of rolling, of ASTM A
275
§ 179.103 49 CFR Ch. I (10–1–18 Edition)
20/A 20M (IBR, see § 171.7 of this sub- MINIMUM OPERATING TEMPERATURE l
chapter). °F.
(ii) AAR Specification TC 128 mate- (l) The tank car and insulation must
rial must meet the Charpy V-notch be designed to prevent the pressure of
test requirements, in longitudinal di- the lading from increasing from the
rection of rolling of 15 ft.-lb. minimum pressure at the maximum allowable
average for 3 specimens, with a 10 ft.- filling density to the start-to-discharge
lb. minimum for any one specimen, at pressure of the pressure relief valve
minus 50 °F or colder, in accordance within 30 days, at an ambient tempera-
with ASTM A 370 (IBR, see § 171.7 of ture of 90° F.
this subchapter). (m) Except as provided in § 173.314(d),
(iii) Production welded test plates tank cars built on or after March 16,
must— 2009 used for the transportation of hy-
(A) Be prepared in accordance with drogen chloride, refrigerated liquid,
AAR Specifications for Tank Cars, ap- must meet the applicable authorized
pendix W, W4.00 (IBR, see § 171.7 of this tank car specification listed in
subchapter); § 173.314(c).
(B) include impact test specimens of
weld metal and heat affected zone pre- [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
pared and tested in accordance with amended at 48 FR 50441, Nov. 1, 1983; 49 FR
AAR Specifications for Tank Cars, ap- 24317, June 12, 1984; 49 FR 42736, Oct. 24, 1984;
Amdt. 179–45, 55 FR 52728, Dec. 21, 1990; 66 FR
pendix W, W9.00; and 45390, Aug. 28, 2001; 67 FR 51660, Aug. 8, 2002;
(C) meet the same impact require- 68 FR 75758, 75760, Dec. 31, 2003; 74 FR 1802,
ments as the plate material. Jan. 13, 2009]
(c) Insulation must be of approved
material. § 179.103 Special requirements for
(d) Pressure relief valves must be class 114A * * * tank car tanks.
trimmed with monel or other approved (a) In addition to the applicable re-
material and equipped with a rupture quirements of §§ 179.100 and 179.101 the
disc of silver, polytetrafluoroethylene following requirements shall be com-
coated monel, or tantalum. Each pres- plied with:
sure relief device shall have the space (b) [Reserved]
between the rupture disc and the valve
vented with a suitable auxiliary valve. § 179.103–1 Type.
The discharge from each pressure relief
(a) Tanks built under this section
valve must be directed outside the pro-
may be of any approved cross section.
tective housing.
(e) Loading and unloading valves (b) Any portion of the tank shell not
must be trimmed with Hastelloy B or circular in cross section shall have
C, monel, or other approved material, walls of such thickness and be so rein-
and identified as ‘‘Vapor’’ or ‘‘Liquid’’. forced that the stresses in the walls
Excess flow valves must be installed caused by a given internal pressure are
under all liquid and vapor valves, ex- no greater than the circumferential
cept safety relief valves. stresses which would exist under the
(f) A thermometer well may be in- same internal pressure in the wall of a
stalled. tank of circular cross section designed
(g) Only an approved gaging device in accordance with paragraphs § 179.100–
may be installed. 6 (a) and (b), but in no case shall the
(h) A sump must be installed in the wall thickness be less than that speci-
bottom of the tank under the liquid fied in § 179.101.
pipes. (c) [Reserved]
(i) All gaskets must be made of, or (d) Valves and fittings need not be
coated with, polytetrafluoroethylene mounted on the manway cover.
or other approved material. (e) One opening may be provided in
(j) The tank car tank may be each head for use in purging the tank
interior.
equipped with exterior cooling coils on

top of the tank car shell. [29 FR 18995, Dec. 29, 1964. Redesignated at 32
(k) The jacket must be stenciled, ad- FR 5606, Apr. 5, 1967, and amended by Amdt.
jacent to the water capacity stencil, 179–50, 60 FR 49077, Sept. 21, 1995]
276
§ 179.103–2 Manway cover. § 179.103–4 Safety relief devices and

pressure regulators.
(a) The manway cover must be an ap-
proved design. (a) Safety relief devices and pressure
(b) If no valves or measuring and regulators must be located on top of
sampling devices are mounted on the tank near the center of the car on
manway cover, no protective housing is a nozzle, mounting plate or recess in
required. the shell. Through or stud bolts, if
used, must not enter the tank.
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 (b) Metal guard of approved design
FR 5606, Apr. 5, 1967, and amended by Amdt. must be provided to protect safety re-
179–50, 60 FR 49077, Sept. 21, 1995]
lief devices and pressure regulators
from damage.
§ 179.103–3 Venting, loading and un-
loading valves, measuring and sam- [Amdt. 179–10, 36 FR 21348, Nov. 6, 1971]
pling devices.
(a) Venting, loading and unloading § 179.103–5 Bottom outlets.
valves, measuring and sampling de- (a) In addition to or in place of the
vices, when used, shall be attached to a venting, loading and unloading valves,
nozzle or nozzles on the tank shell or measuring and sampling devices as pre-
heads. scribed in § 179.103–3, tanks may be
(b) These valves and appurtenances equipped with approved bottom outlet
must be grouped in one location and, valves. If applied, bottom outlet valves
except as provided in § 179.103–5, must must meet the following requirements:
be equipped with a protective housing (1) On cars with center sills, a ball
with cover, or may be recessed into valve may be welded to the outside bot-
tank shell with cover. An additional tom of the tank or mounted on a pad or
set grouped in another location may be nozzle with a tongue and groove or
provided. Protective housing with male and female flange attachment,
cover, when used, must have steel side- but in no case shall the breakage
walls not less than three-fourths inch groove or equivalent extend below the
in thickness and a metal cover not less bottom flange of the center sill. On
than one-fourth inch in thickness that cars without continuous center sills, a
ball valve may be welded to the outside
can be securely closed. Underframe
bottom of the tank or mounted with a
sills are an acceptable alternate to the
tongue and groove or male and female
protective housing cover, provided the
flange attachment on a pad attached to
arrangement is of approved design. For the outside bottom of the tank. The
fittings recessed into tank shell, pro- mounting pad must have a maximum
tective cover must be metal and not thickness of 21⁄2 inches measured on the
less than one-fourth inch in thickness. longitudinal centerline of the tank.
(c) When tank car is used to trans- The valve operating mechanism must
port liquefied flammable gases, the in- be provided with a suitable locking ar-
terior pipes of the loading, unloading, rangement to insure positive closure
and sampling valves must be equipped during transit.
with excess flow valves of approved de- (2) When internal bottom outlet
sign except when quick closing internal valve is used in liquefied flammable
valves of approved design are used. gas service, the outlet of the valve
When the interior pipe of the gaging must be equipped with an excess flow
device provides a means for the passage valve of approved design, except when a
of lading from the interior to the exte- quick-closing internal valve of ap-
rior of the tank, it must be equipped proved design is used. Protective hous-
with an excess flow valve of approved ing is not required.
design or with an orifice not exceeding (3) Bottom outlet must be equipped
0.060 inch. with a liquid tight closure at its lower
end.
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 (b) Bottom outlet equipment must be
of approved design and must meet the
179–10, 36 FR 21348, Nov. 6, 1971]
following requirements:
277
§ 179.200 49 CFR Ch. I (10–1–18 Edition)
(1) The extreme projection of the bot- clude an in-line auxiliary valve, either
tom outlet equipment may not be more integral with the quick-coupling device
than allowed by appendix E of the AAR or located between the primary bottom
Specifications for Tank Cars (IBR, see outlet valve and the quick-coupling de-
§ 171.7 of this subchapter). All bottom vice. The quick-coupling device closure
outlet reducers and closures and their dust cap or outlet nozzle shall be fitted
attachments shall be secured to the car with a minimum 1-inch NPT closure
by at least 3⁄8 inch chain, or its equiva- (see Fig. E17.8 and E17.9).
lent, except that bottom outlet closure (3) The valve operating mechanism
plugs may be attached by 1⁄4 inch chain. must be provided with a suitable lock-
When the bottom outlet closure is of ing arrangement to insure positive clo-
the combination cap and valve type, sure during transit.
the pipe connection to the valve shall (4) If the outlet nozzle extends 6
be closed by a plug, cap, or approved inches or more from shell of tank, a V-
quick coupling device. The bottom out- shaped breakage groove shall be cut
let equipment should include only the (not cast) in the upper part to the out-
valve, reducers and closures that are let nozzle at a point immediately below
necessary for the attachment of un- the lowest part of value closest to the
loading fixtures. The permanent at- tank. In no case may the nozzle wall
tachment of supplementary exterior thickness at the roof of the ‘‘V’’ be
fittings must be approved by the AAR more than 1⁄4-inch. On cars without
Committee on Tank Cars. continuous center sills, the breakage
(2) To provide for the attachment of groove or its equivalent may not be
unloading connections, the discharge more than 15 inches below the tank
end of the bottom outlet nozzle or re- shell. On cars with continuous center
ducer, the valve body of the exterior sills, the breakage groove or its equiva-
valve, or some fixed attachment there- lent must be above the bottom of the
to, shall be provided with one of the center sill construction.
following arrangements or an approved (5) The valve body must be of a thick-
modification thereof. (See appendix E. ness which will insure that accidental
Fig. E17 of the AAR Specifications for breakage of the outlet nozzle will occur
Tank Cars for illustrations of some of at or below the ‘‘V’’ groove, or its
the possible arrangements.) equivalent, and will not cause distor-
(i) A bolted flange closure arrange- tion of the valve seat or valve.
ment including a minimum 1-inch NPT [Amdt. 179–10, 36 FR 21348, Nov. 6, 1971, as
pipe plug (see Fig. E17.1) or including amended by Amdt. 179–40, 52 FR 13046, Apr.
an auxiliary valve with a threaded clo- 20, 1987; Amdt. 179–41, 52 FR 36672, Sept. 30,
sure. 1987; Amdt. 179–50, 60 FR 49077, Sept. 21, 1995;
Amdt. 179–52, 61 FR 28680, June 5, 1996; Amdt.
(ii) A threaded cap closure arrange-
179–53, 61 FR 51342, Oct. 1, 1996; 66 FR 45186,
ment including a minimum 1-inch NPT Aug. 28, 2001; 68 FR 75761, Dec. 31, 2003]
pipe plug (see Fig. E17.2) or including
an auxiliary valve with a threaded clo-
sure.
Subpart D—Specifications for Non-
(iii) A quick-coupling device using a Pressure Tank Car Tanks
threaded plug closure of at least 1-inch (Classes DOT-111AW, 115AW,
NPT or having a threaded cap closure and 117AW)
with a minimum 1-inch NPT pipe plug
(see Fig. E17.3 through E17.5). A min- § 179.200 General specifications appli-
cable to non-pressure tank car
imum 1-inch auxiliary test valve with a tanks (Class DOT–111, DOT–117).
threaded closure may be substituted
for the 1-inch pipe plug (see Fig E17.6). § 179.200–1 Tank built under these
If the threaded cap closure does not specifications must meet the appli-
have a pipe plug or integral auxiliary cable requirements in this part.
test valve, a minimum 1-inch NPT pipe
plug shall be installed in the outlet § 179.200–3 Type.
nozzle above the closure (see Fig. Tank built under these specifications
E17.7). must be circular in cross section, with
(iv) A two-piece quick-coupling deformed heads designed convex outward.
vice using a clamped dust cap must in- When specified in § 179.201–1, the tank
278
must have at least one manway or one (b) The wall thickness after forming
expansion dome with manway, and of 3:1 ellipsoidal heads must be not less
such other external projections as are than specified in § 179.201–1, nor that
prescribed herein. When the tank is di- calculated by the following formula:
vided into compartments, each com-
partment must be treated as a separate
tank.
[Amdt. 179–10, 36 FR 21348, Nov. 6, 1971]
Where:
§ 179.200–4 Insulation. d = Inside diameter in inches;
E = 0.9 Welded joint efficiency; except E = 1.0
(a) If insulation is applied, the tank for seamless heads;
shell and expansion dome when used P = Minimum required bursting pressure in
must be insulated with an approved psig;
material. The entire insulation must S = Minimum tensile strength of plate mate-
be covered with a metal jacket of a rial in p.s.i. as prescribed in § 179.200–7;
thickness not less than 11 gauge (0.1196 t = Minimum thickness of plate in inches
inch) nominal (Manufacturer’s Stand- after forming.
ard Gauge) and flashed around all open- (c) The wall thickness after forming
ings so as to be weather tight. The ex- of a flanged and dished head must be
terior surface of a carbon steel tank not less than specified in § 179.201–1, nor
and the inside surface of a carbon steel that calculated by the following for-
jacket must be given a protection coat- mula:
ing.
(b) If insulation is a specification re-
quirement, it shall be of sufficient
thickness so that the thermal conduct-
ance at 60 °F is not more than 0.225 Btu Where:
per hour, per square foot, per degree F E = 0.9 Welded joint efficiency; except E = 1.0
temperature differential, unless other- for seamless heads;
wise provided in § 179.201–1. If exterior L = Main inside radius to which head is
heaters are attached to tank, the dished, measured on concave side in
inches;
thickness of the insulation over each
P = Minimum required bursting pressure in
heater element may be reduced to one- psig;
half that required for the shell. S = Minimum tensile strength of plate mate-
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 rial in p.s.i. as prescribed in § 179.200–7;
FR 5606, Apr. 5, 1967, and amended by Amdt. t = Minimum thickness of plate in inches
179–10, 36 FR 21349, Nov. 6, 1971; Amdt. 179–50, after forming.
60 FR 49078, Sept. 21, 1995] (d) If plates are clad with material
having tensile strength properties at
§ 179.200–6 Thickness of plates.
least equal to the base plate, the clad-
(a) The wall thickness after forming ding may be considered a part of the
of the tank shell, dome shell, and of 2:1 base plate when determining thickness.
ellipsoidal heads must be not less than If cladding material does not have ten-
specified in § 179.201–1, nor that cal- sile strength at least equal to the base
culated by the following formula: plate, the base plate alone must meet
the thickness requirements.
(e) For a tank constructed of longitu-
dinal sections, the minimum width of
bottom sheet of the tank must be 60
Where: inches measured on the arc, but in all
EC13NO91.034</MATH>
d = Inside diameter in inches; cases the width must be sufficient to

E = 0.9 Welded joint efficiency; except E = 1.0 bring the entire width of the longitu-
for seamless heads; dinal welded joint, including welds,
P = Minimum required bursting pressure in
above the bolster.
psig;
S = Minimum tensile strength of plate mate- (f) For a tank built of one piece cy-
EC13NO91.033</MATH>
rial in p.s.i. as prescribed in § 179.200–7; lindrical sections, the thickness speci-

t = Minimum thickness of plate in inches fied for bottom sheet must apply to the
after forming. entire cylindrical section.
279
EC13NO91.032</MATH>
§ 179.200–7 49 CFR Ch. I (10–1–18 Edition)
(g) See § 179.200–9 for thickness re- Minimum

Minimum ten- elongation in
quirements for a compartmented tank. sile strength 2 inches
Specifications (p.s.i.) weld- (percent)
[Amdt. 179–10, 36 FR 21349, Nov. 6, 1971, as ed condition 1 weld metal
amended at 66 FR 45390, Aug. 28, 2001] (longitudinal)
ASTM A 240/A 240M (incor-

§ 179.200–7 Materials. porated by reference; see
§ 171.7 of this subchapter),
(a) Plate material used to fabricate Type 304 ............................ 75,000 30
the tank and, when used, expansion ASTM A 240/A 240M (incor-
dome or manway nozzle material, must porated by reference; see
meet one of the following specifica- Type 304L .......................... 70,000 30
tions with the indicated minimum ten- ASTM A 240/A 240M (incor-
sile strength and elongation in the porated by reference; see
welded condition. Type 316 ............................ 75,000 30
(b) Carbon steel plate: The maximum ASTM A 240/A 240M (incor-
allowable carbon content must be 0.31 porated by reference; see
percent when the individual specifica- Type 316L .......................... 70,000 30
tion allows carbon content greater 1 Maximum stresses to be used in calculations.
than this amount. The plates may be 2 High alloy steel materials used to fabricate tank and ex-
clad with other approved materials: pansion dome, when used, must be tested in accordance with
Practice A of ASTM Specification A 262 titled, ‘‘Standard
Practices for Detecting Susceptibility to Intergranular Attack in
Minimum elon- Austenitic Stainless Steels’’ (IBR; see § 171.7 of this sub-
Minimum ten- gation in 2 chapter). If the specimen does not pass Practice A, Practice B
sile strength inches (per- or C must be used and the corrosion rates may not exceed
Specifications (p.s.i.) welded cent) weld the following:
condition 1 metal (longitu-
dinal)
Corrosion
Test procedure Material rate i.p.m.
AAR TC 128, Gr. B ........... 81,000 19
ASTM A 516 2 .................... 70,000 20 Practice B ................... Types 304, 304L, 316, 0.0040
1 Minimum
and 316L.
stresses to be used in calculations.
2 This specification is incorporated by reference (IBR, see Practice C ................... Type 304L .................. .0020
§ 171.7 of this subchapter). Type 304L and Type 316L test specimens must be given a
sensitizing treatment prior to testing. (A typical sensitizing
(c) Aluminum alloy plate: Aluminum treatment is 1 hour at 1250 F.)
alloy plate must be suitable for weld- (e) Nickel plate: Nickel plate must
ing and comply with one of the fol- comply with the following specifica-
lowing specifications (IBR, see § 171.7 of tion (IBR, see § 171.7 of this sub-
this subchapter): chapter):
Minimum Minimum
Minimum ten- elongation in Minimum elongation
sile strength 2 inches tensile in 2 inches
Specifications (p.s.i.) weld- (percent) 0 strength
Specifications (percent)
ed condi- temper weld (psi) weld- weld metal
tion 3 4 metal (longi- ed condi- (longitu-
tudinal) tion 1 dinal)
ASTM B 209, Alloy 5052 1 ..... 25,000 18 ASTM B 162 2 ................................ 40,000 20
ASTM B 209, Alloy 5083 2 ..... 38,000 16
ASTM B 209, Alloy 5086 1 ..... 35,000 14
(f) Manganese-molybdenum steel plate:
ASTM B 209, Alloy 5154 1 ..... 30,000 18
ASTM B 209, Alloy 5254 1 ..... 30,000 18
Manganese-molybdenum steel plate
ASTM B 209, Alloy 5454 1 ..... 31,000 18 must be suitable for fusion welding and
ASTM B 209, Alloy 5652 1 ..... 25,000 18 comply with the following specifica-
1 For fabrication, the parent plate material may be 0, H112,
tion (IBR, see § 171.7 of this sub-
or H32 temper, but design calculations must be based on chapter):
minimum tensile strength shown.
2 0 temper only.
Minimum
Minimum
3 Weld filler metal 5556 must not be used. elongation
tensile
4 Maximum stresses to be used in calculations. in 2 inches
strength
(p.s.i.) weld metal
(d) High alloy steel plate: High alloy welded (longitu-
condition 1
steel plate must comply with one of dinal)
the following specifications: ASTM A 302, Gr. B ....................... 80,000 20
280
(g) All parts and items of construc- inch and not more than 11⁄2-inch solid
tion in contact with the lading must be pipe plugs having NPT threads.
made of material compatible with (b) When the tank is divided into
plate material and not subject to rapid compartments by constructing each
deterioration by the lading, or be coat- compartment as a separate tank, these
ed or lined with suitable corrosion re- tanks shall be joined together by a cyl-
sistant material. inder made of plate, having a thickness
(h) All external projections that may not less than that required for the tank
be in contact with the lading and all shell and applied to the outside surface
castings, forgings, or fabrications used of tank head flanges. The cylinder shall
for fittings or attachments to tank and fit the straight flange portion of the
expansion dome, when used, in contact compartment tank head tightly. The
with lading must be made of material cylinder shall contact the head flange
to an approved specification. See AAR for a distance of at least two times the
Specifications for Tank Cars, appendix plate thickness, or a minimum of 1
M, M4.05 (IBR, see § 171.7 of this sub- inch, whichever is greater. The cyl-
chapter) for approved material speci- inder shall be joined to the head flange
fications for castings for fittings.
by a full fillet weld. Distance from
[Amdt. 179–10, 36 FR 21349, Nov. 9, 1971; 36 FR head seam to cylinder shall not be less
21893, Nov. 17, 1971, as amended by Amdt.179– than 11⁄2 inches or three times the plate
28, 46 FR 49906, Oct. 8, 1981; Amdt. 179–40, 52 thickness, whichever is greater. Voids
FR 13046, Apr. 20, 1987; Amdt. 179–52, 61 FR
28680, June 5, 1996; 66 FR 45186, Aug. 28, 2001;
created by the space between heads of
67 FR 51660, Aug. 8, 2002; 68 FR 75761, Dec. 31, tanks joined together to form a com-
2003; 70 FR 34076, June 13, 2005] partment tank shall be provided with a
tapped drain hole at their lowest point
§ 179.200–8 Tank heads. and a tapped hole at top of tank. The
(a) All external tank heads must be top hole shall be closed and the bottom
an ellipsoid of revolution in which the hole may be closed with solid pipe
major axis must equal the diameter of plugs not less than 3⁄4 inch nor more
the shell and the minor axis must be than 11⁄2 inches having NPT threads.
one-half the major axis. [29 FR 18995, Dec. 29, 1964. Redesignated at 32
(b) Internal compartment tank heads FR 5606, Apr. 5, 1967, and amended by Amdt.
may be 2:1 ellipsoidal, 3:1 ellipsoidal, or 179–10, 36 FR 21350, Nov. 6, 1971; 66 FR 45186,
flanged and dished to thicknesses as Aug. 28, 2001; 68 FR 75761, Dec. 31, 2003]
specified in § 179.200–6. Flanged and
dished heads must have main inside ra- § 179.200–10 Welding.
dius not exceeding 10 feet, and inside (a) All joints shall be fusion-welded
knuckle radius must not be less than in compliance with the requirements of
33⁄4 inches for steel, alloy steel, or nick- AAR Specifications for Tank Cars, ap-
el tanks, and not less than 5 inches for pendix W (IBR, see § 171.7 of this sub-
aluminum alloy tanks. chapter). Welding procedures, welders
[Amdt. 179–10, 36 FR 21350, Nov. 6, 1971] and fabricators shall be approved.
(b) Welding is not permitted on or to
§ 179.200–9 Compartment tanks. ductile iron or malleable iron fittings.
(a) When a tank is divided into com-
partments, by inserting interior heads, FR 5606, Apr. 5, 1967, and amended by Amdt.
interior heads must be inserted in ac- 179–10, 36 FR 21350, Nov. 6, 1971; 68 FR 75761,
cordance with AAR Specifications for Dec. 31, 2003]
Tank Cars, appendix E, E7.00 (IBR, see
§ 171.7 of this subchapter), and must § 179.200–11 Postweld heat treatment.
comply with the requirements specified
When specified in § 179.201–1, after
in § 179.201–1. Voids between compart-
welding is complete, postweld heat
ment heads must be provided with at
treatment must be in compliance with
least one tapped drain hole at their
the requirements of AAR Specifica-
lowest point, and a tapped hole at the

tions for Tank Cars, appendix W (IBR,
top of the tank. The top hole must be
see § 171.7 of this subchapter).
closed, and the bottom hole may be
closed, with not less than three-fourths [68 FR 75761, Dec. 31, 2003]
281
§ 179.200–13 49 CFR Ch. I (10–1–18 Edition)
§ 179.200–13 Manway ring or flange, Figure E 10C of the AAR Specifications

pressure relief device flange, bot- for Tank Cars or by the use of rein-
tom outlet nozzle flange, bottom forcing as outlined in Appendix E, E3.04
washout nozzle flange and other at- and Figures E10K and E10L. When the
tachments and openings.
opening in the tank shell is less than
(a) These attachments shall be fusion the inside diameter of the dome, and
welded to the tank and reinforced in an the dome pocket is not closed off in an
approved manner in compliance with approved manner, dome pocket drain
the requirements of appendix E, figure holes shall be provided in the tank
10, of the AAR Specifications for Tank shell with nipples projecting inside the
Cars (IBR, see § 171.7 of this sub-
tank at least 1 inch.
chapter).
(b) The opening in the manway ring (d) The dome head shall be of ap-
must be at least 16 inches in diameter proved contour and shall be designed
except that acid resistant lined for pressure on concave side.
manways must be at least 18 inches in (e) Aluminum alloy domes: (1) The
diameter before lining. dome shell thickness shall be cal-
(c) The manway ring or flange, shall culated by the formula in § 179.200–6(a).
be made of cast, forged or fabricated (2) The dome head may be an ellip-
metal. The metal of the dome, tank, or soid of revolution in which the major
nozzle must be compatible with the axis shall be equal to the diameter of
manway ring or flange, so that they the dome shell and the minor axis shall
may be welded together. be one-half the major axis. The thick-
(d) The openings for the manway or ness in this case shall be determined by
other fittings shall be reinforced in an using formula in § 179.200–6(a).
approved manner. (3) The dome head, if dished, must be
[Amdt. 179–40, 52 FR 13047, Apr. 20, 1987, as dished to a radius not exceeding 96
amended at 68 FR 75761, Dec. 31, 2003] inches. Thickness of dished dome head
must be calculated by the formula in
§ 179.200–14 Expansion capacity. § 179.200–6(c).
(a) Tanks shall have expansion capac- (4) Tank shell shall be reinforced by
ity as prescribed in this subchapter. the addition of a plate equal to or
This capacity shall be provided in the greater than shell in thickness and the
tank for Class DOT-111A cars, or in a cross sectional area shall exceed metal
dome for Class DOT-103 and 104 type removed for dome opening, or tank
cars. shell shall be reinforced by a seamless
(b) For tank cars having an expan- saddle plate equal to or greater than
sion dome, the expansion capacity is shell in thickness and butt welded to
the total capacity of the tank and tank shell. The reinforcing saddle plate
dome combined. The capacity of the shall be provided with a fluid opening
dome shall be measured from the inside having a vertical flange of the diame-
top of shell of tank to the inside top of
ter of the dome for butt welding shell
dome or bottom of any vent pipe pro-
of dome to the flange. The reinforcing
jecting inside of dome, except that
saddle plate shall extend about the
when a pressure relief device is applied
dome a distance measured along shell
to side of dome, the effective capacity
of tank at least equal to the extension
of the dome shall be measured from top
at top of tank. Other approved designs
of the pressure relief device opening in-
side of dome to inside top of shell of may be used.
tank. [29 FR 18995, Dec. 29, 1964. Redesignated at 32
(c) The opening in the tank shell FR 5606, Apr. 5, 1967, and amended by Amdt.
within the dome shall be at least 29 179–10, 36 FR 21350, Nov. 6, 1971; Amdt. 179–28,
inches in diameter. When the opening 46 FR 49906, Oct. 8, 1981; Amdt. 179–52, 61 FR
in the tank shell exceeds 30 inches in 28680, June 5, 1996; 66 FR 45186, 45390, Aug. 28,
diameter, the opening shall be rein- 2001; 68 FR 48571, Aug. 14, 2003]
forced in an approved manner. This ad-

§ 179.200–15 Closures for manways.
ditional reinforcement may be accom-
plished by the use of a dome opening of (a) Manway covers must be of ap-
the flued-type as shown in appendix E, proved type.
282
(b) Manway covers shall be designed and enclosed within a housing. Other
to provide a secure closure of the approved devices may be used in lieu of
manway. outage scale or telltale pipe.
(c) Manway covers must be of ap- (e) Bottom of tank shell may be
proved cast, forged, or fabricated met- equipped with a sump or siphon bowl,
als. Malleable iron, if used, must com- or both, welded or pressed into the
ply with ASTM A 47 (IBR, see § 171.7 of shell. Such sumps or siphon bowls, if
this subchapter), Grade 35018. Cast iron applied are not limited in size and
manway covers must not be used. must be made of cast, forged, or fab-
(d) All joints between manway covers ricated metal. Each sump or siphon
and their seats shall be made tight bowl must be of good welding quality
against leakage of vapor and liquid by in conjunction with the metal of the
use of gaskets of suitable material. tank shell. When sump or siphon bowl
(e) For other manway cover require- is pressed in the bottom of the tank
ments see § 179.201–1. shell, the wall thickness of the pressed
section must not be less than that
specified for the shell. The section of a
179–10, 36 FR 21350, Nov. 6, 1971; Amdt. 179–37, circular cross section tank to which a
50 FR 11066, Mar. 19, 1985; 68 FR 75762, Dec. 31, sump or siphon bowl is attached need
2003] not comply with the out-of-roundness
requirement specified in appendix W,
§ 179.200–16 Gauging devices, top load- W14.06, of the AAR Specifications for
ing and unloading devices, venting Tank Cars. Any portion of a sump or si-
and air inlet devices. phon bowl not forming a part of a cyl-
(a) When installed, these devices inder of revolution must have walls of
shall be of an approved design which such thickness and be so reinforced
will prevent interchange with any that the stresses in the walls caused by
other fixture, and be tightly closed. a given internal pressure are not great-
Unloading pipes shall be securely an- er than the circumferential stress
chored within the tank. Each tank or which would exist under the same in-
compartment may be equipped with ternal pressure in the wall of a tank of
one separate air connection. circular cross section designed in ac-
(b) When the characteristics of the cordance with § 179.200–6 (a) and (d). In
commodity for which the car is author- no case shall the wall thickness be less
ized are such that these devices must than that specified in § 179.201–1.
be equipped with valves or fittings to (f) When top loading and discharge
permit the loading and unloading of devices, or venting and air inlet de-
the contents, these devices, including vices are installed with exposed piping
valves, shall be of an approved design, to a removed location, shutoff valves
and be provided with a protective hous- must be applied directly to reinforcing
ing except when plug or ball type pads or nozzles at their communication
valves with operating handles removed through the tank shell, and must be
are used. Provision shall be made for enclosed in a protective housing with
closing pipe connections of valves. provision for a seal. The piping must
(c) A tank may be equipped with a include breakage grooves, and suitable
vacuum relief valve of an approved de- bracing. Relief valves must be applied
sign. Protective housing is not re- to liquid lines for protection in case
quired. lading is trapped. Provision must be
(d) When using a visual gauging de- made to insure closure of the valves
vice on a car with a hinged manway while the car is in transit.
cover, an outage scale visible through (g) Protective housing, when re-
the manway opening shall be provided. quired, must be fabricated of approved
If loading devices are applied to permit material and have cover and sidewalls
tank loading with cover closed, a tell- not less than 0.119 inch in thickness.
tale pipe may be provided. Telltale pipe
shall be capable of determining that re- FR 5606, Apr. 5, 1967, and amended by Amdt.
quired outage is provided. Pipe shall be 179–10, 36 FR 21350, Nov. 6, 1971; Amdt. 179–52,
equipped with 1⁄4 inch minimum NPT 61 FR 28680, June 5, 1996; 69 FR 54047, Sept. 7,
control valve mounted outside tank 2004]
283
§ 179.200–17 49 CFR Ch. I (10–1–18 Edition)
§ 179.200–17 Bottom outlets. valves, must be of cast, fabricated, or

(a) If indicated in § 179.201–1, tank forged metal. If welded to tank, they
may be equipped with bottom outlet. must be of good weldable quality in
Bottom outlet, if applied, must comply conjunction with metal of tank.
with the following requirements: (6) To provide for the attachment of
(1) The extreme projection of the bot- unloading connections, the discharge
tom outlet equipment may not be more end of the bottom outlet nozzle or re-
than that allowed by appendix E of the ducer, the valve body of the exterior
AAR Specifications for Tank Cars valve, or some fixed attachment there-
(IBR, see § 171.7 of this subchapter). All to, shall be provided with one of the
bottom outlet reducers and closures following arrangements or an approved
and their attachments shall be secured modification thereof. (See appendix E.
to the car by at least 3⁄8-inch chain, or Fig. E17 of the AAR Specifications for
its equivalent, except that the bottom Tank Cars for illustrations of some of
outlet closure plugs may be attached the possible arrangements.)
by 1⁄4-inch chain. When the bottom out- (i) A bolted flange closure arrange-
let closure is of the combination cap ment including a minimum 1-inch NPT
and valve type, the pipe connection to pipe plug (see Fig. E17.1) or including
the valve shall be closed by a plug, cap, an auxiliary valve with a threaded clo-
or approved quick coupling device. The sure.
bottom outlet equipment should in- (ii) A threaded cap closure arrange-
clude only the valve, reducers and clo- ment including a minimum 1-inch NPT
sures that are necessary for the attach- pipe plug (see Fig. E17.2) or including
ment of unloading fixtures. The perma- an auxiliary valve with a threaded clo-
nent attachment of supplementary ex- sure.
terior fittings shall be approved by the (iii) A quick-coupling device using a
AAR Committee on Tank Cars. threaded plug closure of at least 1-inch
(2) Bottom outlet must be of ap- NPT or having a threaded cap closure
proved construction, and be provided with a minimum 1-inch NPT pipe plug
with a liquid-tight closure at its lower (see Fig. E17.3 through E17.5). A min-
end. imum 1-inch auxiliary test valve with a
(3) On cars with center sills, a ball threaded closure may be substituted
valve may be welded to the outside bot- for the 1-inch pipe plug (see Fig. E17.6).
tom of the tank or mounted on a pad or If the threaded cap closure does not
nozzle with a tongue and groove or have a pipe plug or integral auxiliary
male and female flange attachment. In test valve, a minimum 1-inch NPT pipe
no case shall the breakage groove or plug shall be installed in the outlet
equivalent extend below the bottom nozzle above the closure (see Fig.
flange of the center sill. On cars with- E17.7).
out continuous center sills, a ball valve (iv) A two-piece quick-coupling de-
may be welded to the outside bottom of vice using a clamped dust cap must in-
the tank or mounted with a tongue and clude an in-line auxiliary valve, either
groove or male and female flange at- integral with the quick-coupling device
tachment on a pad attached to the out- or located between the primary bottom
side bottom of the tank. The mounting outlet valve and the quick-coupling de-
pad must have a maximum thickness of vice. The quick-coupling device closure
21⁄2 inches measured on the longitu- dust cap or outlet nozzle shall be fitted
dinal centerline of the tank. The valve with a minimum 1-inch NPT closure
operating mechanism must be provided (see Fig. E17.8 and E17.9).
with a suitable locking arrangement to (7) If the outlet nozzle extends 6
insure positive closure during transit. inches or more from the shell of the
(4) The valve operating mechanism tank, a V-shaped breakage groove shall
for valves applied to the interior of the be cut (not cast) in the upper part of
tank, and outlet nozzle construction, the outlet nozzle at a point imme-
must insure against the unseating of diately below the lowest part of valve
the valve due to stresses or shocks in- closest to the tank. In no case may the
cident to transportation. nozzle wall thickness at the root of the
(5) Bottom outlet nozzle of interior ‘‘V’’ be more than 1⁄4 inch. The outlet
valves and the valve body of exterior nozzle on interior valves or the valve
284
body on exterior valves may be steam tank, a V-shaped breakage groove shall
jacketed, in which case the breakage be cut (not cast) in the upper part of
groove or its equivalent must be below the nozzle at a point immediately
the steam chamber but above the bot- below the lowest part of the inside clo-
tom of center sill construction. If the sure seat or plug. In no case may the
outlet nozzle is not a single piece, or if nozzle wall thickness at the root of the
exterior valves are applied, provisions ‘‘V’’ be more than 1⁄4 inch. Where the
shall be made for the equivalent of the nozzle is not a single piece, provisions
breakage groove. On cars without con- shall be made for the equivalent of the
tinuous center sills, the breakage breakage groove. The nozzle must be of
groove or its equivalent must be no a thickness to insure that accidental
more than 15 inches below the tank breakage will occur at or below the
shell. On cars with continuous center ‘‘V’’ groove or its equivalent. On cars
sills, the breakage groove or its equiva- without continuous center sills, the
lent must be above the bottom of the
breakage groove or its equivalent may
center sill construction.
not be more than 15 inches below the
(8) The flange on the outlet nozzle or
outer shell. On cars with continuous
the valve body of exterior valves must
be of a thickness which will prevent center sills, the breakage groove or its
distortion of the valve seat or valve by equivalent must be above the bottom
any change in contour of the shell re- of the center sill construction.
sulting from expansion of lading, or (4) The closure plug and seat must be
other causes, and which will insure readily accessible or removable for re-
that accidental breakage of the outlet pairs, including grinding.
nozzle will occur at or below the ‘‘V’’ (5) The closure of the washout nozzle
groove, or its equivalent. must be equipped with a 3⁄4-inch solid
(9) The valve must have no wings or screw plug. Plug must be attached by
stem projecting below the ‘‘V’’ groove at least a 1⁄4-inch chain.
or its equivalent. The valve and seat (6) Joints between closures and their
must be readily accessible or remov- seats may be gasketed with suitable
able for repairs, including grinding. material.
(10) The valve operating mechanism
on interior valves must have means for [29 FR 18995, Dec. 29, 1964. Redesignated at 32
compensating for variation in the
179–10, 36 FR 21351, Nov. 6, 1971; Amdt. 179–40,
vertical diameter of the tank produced 52 FR 13047, Apr. 20, 1987; 68 FR 75762, Dec. 31,
by expansion, weight of the liquid con- 2003]
tents, or other causes, and may operate
from the interior of the tank, but in § 179.200–19 Reinforcements, when
the event the rod is carried through used, and appurtenances not other-
the dome, or tank shell, leakage must wise specified.
be prevented by packing in stuffing box
(a) All attachments to tank and
or other suitable seals and a cap.
dome shall be applied by approved
(b) If indicated in § 179.201–1, tank
means. Rivets if used shall be caulked
may be equipped with bottom washout
of approved construction. If applied, inside and outside.
bottom washout shall be in accordance (b) Reinforcing pads must be used be-
with the following requirements: tween external brackets and shells if
(1) The extreme projection of the bot- the attachment welds exceed 6 lineal
tom washout equipment may not be inches of 1⁄4-inch fillet or equivalent
more than that allowed by appendix E weld per bracket or bracket leg. When
of the AAR Specifications for Tank reinforcing pads are used, they must
Cars. not be less than one-fourth inch in
(2) Bottom washout shall be of cast, thickness, have each corner rounded to
forged or fabricated metal. If welded to a 1 inch minimum radius, and be at-
tank, they shall be of good weldable tached to the tank by continuous fillet
quality in conjunction with metal of welds except for venting provisions.

tank. The ultimate shear strength of the
(3) If the washout nozzle extends 6 bracket to reinforcing pad weld must
inches or more from the shell of the not exceed 85 percent of the ultimate
285
§ 179.200–21 49 CFR Ch. I (10–1–18 Edition)
shear strength of the reinforcing pad to (b) [Reserved]

tank weld.
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967, as amended at 62 FR
FR 5606, Apr. 5, 1967, and amended by Amdt. 51561, Oct. 1, 1997]
179–10, 36 FR 21351, Nov. 6, 1971]
§ 179.200–24 Stamping.
§ 179.200–21 Closures for openings.
(a) To certify that the tank complies
(a) All plugs shall be solid, with NPT
with all specification requirements,
threads, and shall be of a length which
will screw at least 6 threads inside the each tank shall be plainly and perma-
face of fitting or tank. Plugs, when in- nently stamped in letters and figures
serted from the outside of tank heads, at least 3⁄8 inch high into the metal
shall have the letter ‘‘S’’ at least 3⁄8 near the center of both outside heads
inch in size stamped with steel stamp as follows:
or cast on the outside surface to indi-
Example of required
cate the plug is solid. stamping
(b) [Reserved]
Specification ................................. DOT-111A
§ 179.200–22 Test of tanks. Material ......................................... ASTM A 516–GR 70
Cladding material (if any) ............. ASTM A240–304 Clad
(a) Each tank shall be tested by com- Tank builder’s initials .................... ABC
pletely filling the tank and dome or Date of original test ...................... 00–0000
nozzles with water, or other liquid hav- Car assembler (if other than tank DEF
ing similar viscosity, of a temperature builder).
which shall not exceed 100 °F. during
the test; and applying the pressure pre- (b) On Class DOT-111 tank cars, the
scribed in § 179.201–1. Tank shall hold last numeral of the specification num-
the prescribed pressure for at least 10 ber may be omitted from the stamping;
minutes without leakage or evidence of for example, DOT-111A100W.
distress. All rivets and closures, except (c) After July 25, 2012, newly con-
safety relief valves or safety vents, structed DOT tank cars must have
shall be in place when test is made. their DOT specification and other re-
(b) Insulated tanks shall be tested be- quired information stamped plainly
fore insulation is applied. and permanently on stainless steel
(c) Rubber-lined tanks shall be tested identification plates in conformance
before rubber lining is applied.
with the applicable requirements pre-
(d) Caulking of welded joints to stop
scribed in § 179.24(a). Tank cars built
leaks developed during the foregoing
tests is prohibited. Repairs in welded before July 25, 2012, may have the iden-
joints shall be made as prescribed in tification plates instead of or in addi-
AAR Specifications for Tank Cars, ap- tion to the head stamping.
pendix W (IBR, see § 171.7 of this sub- [29 FR 18995, Dec. 29, 1964. Redesignated at 32
chapter). FR 5606, Apr. 5, 1967, and amended by Amdt.
[29 FR 18995, Dec. 29, 1964, as amended at 68 179–10, 36 FR 21351, Nov. 6, 1971; Amdt. 179–52,
FR 75762, Dec. 31, 2003] 61 FR 28680, June 5, 1996; 68 FR 48571, Aug. 14,
2003; 77 FR 37985, June 25, 2012]
§ 179.200–23 Tests of pressure relief
valves. § 179.201 Individual specification re-
quirements applicable to non-pres-
(a) Each valve shall be tested by air
sure tank car tanks.
or gas for compliance with § 179.15 be-
fore being put into service.

286
Minimum
Bursting Test
DOT Specifica- plate Bottom Bottom References
Insulation pressure pressure
tion 1 thickness outlet washout (179.201 - ***)
(psig) (psig)
(inches)
111A60ALW1 ... Optional .......... 240 12 ⁄ 60 Optional .......... Optional .......... 6(a).
111A60ALW2 ... Optional .......... 240 12 ⁄ 60 No ................... Optional.
111A60W1 ....... Optional .......... 240 ⁄
7 16 60 Optional .......... Optional .......... 6(a).
111A60W2 ....... Optional .......... 240 ⁄
7 16 60 No ................... Optional.
111A60W5 ....... Optional .......... 240 ⁄
7 16 60 No ................... No ................... 3, 6(b).
111A60W6 ....... Optional .......... 240 7⁄16 60 Optional .......... Optional .......... 4, 5, 6(a), 6(c).
111A60W7 ....... Optional .......... 240 7⁄16 60 No ................... No ................... 4, 5, 6(a).
111A100ALW1 Optional .......... 500 5⁄8 100 Optional .......... Optional .......... 6(a).
111A100ALW2 Optional .......... 500 5⁄8 100 No ................... Optional.
111A100W1 ..... Optional .......... 500 7⁄16 100 Optional .......... Optional .......... 6(a).
111A100W2 ..... Optional .......... 500 7⁄16 100 No ................... Optional.
111A100W3 ..... Yes ................. 500 7⁄16 100 Optional .......... Optional .......... 6(a).
111A100W4 ..... Yes (see 500 7⁄16 100 No ................... No ................... 6(a), 8, 10.
179.201–11).
111A100W5 ..... Optional .......... 500 ⁄
7 16 100 No ................... No ................... 3.
111A100W6 ..... Optional .......... 500 ⁄
7 16 100 Optional .......... Optional .......... 4, 5, 6(a) and 6(c).
111A100W7 ..... Optional .......... 500 ⁄
7 16 100 No ................... No ................... 4, 5, 6(c).
1 Tanks marked ‘‘ALW’’ are constructed from aluminum alloy plate; ‘‘AN’’ nickel plate; ‘‘CW,’’ ‘‘DW,’’ ‘‘EW,’’ ‘‘W6,’’ and ‘‘W7’’
high alloy steel or manganese-molybdenum steel plate; and those marked ‘‘BW’’ or ‘‘W5’’ must have an interior lining that con-
forms to § 179.201–3.
[Amdt. 179–52, 61 FR 28680, June 5, 1996, as amended by 66 FR 45390, Aug. 28, 2001; 68 FR 48571,
Aug. 14, 2003]
§ 179.201–2 [Reserved] oxidation, moisture, and all foreign

matter during the lining operation.
§ 179.201–3 Lined tanks. (3) Other approved lining materials
(a) Rubber-lined tanks. (1) Each tank may be used provided the material is
or each compartment thereof must be resistant to the corrosive or solvent ac-
lined with acid-resistant rubber or tion of the lading in the liquid or gas
other approved rubber compound vul- phase and is suitable for the service
canized or bonded directly to the metal temperatures.
tank, to provide a nonporous laminated (b) Before a tank car tank is lined
lining, at least 5⁄32-inch thick, except with rubber, or other rubber compound,
overall rivets and seams formed by riv- a report certifying that the tank and
eted attachments in the lining must be its equipment have been brought into
double thickness. The rubber lining compliance with spec. DOT-111A60W5
must overlap at least 11⁄2 inches at all or 111A100W5 must be furnished by car
edges which must be straight and be owner to the party who is to apply the
beveled to an angle of approximately lining. A copy of this report in ap-
45°, or butted edges of lining must be
proved form, certifying that tank has
sealed with a 3-inch minimum strip of
been lined in compliance with all re-
lining having 45° beveled edges.
quirements of one of the above speci-
(2) As an alternate method, the lining
may be joined with a skived butt seam fications, must be furnished by party
then capped with a separate strip of lining tank to car owner. Reports of
lining 3 inches wide having 45° beveled the latest lining application must be
edges. An additional rubber reinforcing retained by the car owner until the
pad at least 41⁄2 feet square and at least next relining has been accomplished
1⁄2-inch thick must be applied by vul- and recorded.
canizing to the lining on bottom of (c) All rivet heads on inside of tank
tank directly under the manway open- must be buttonhead, or similar shape,
ing. The edges of the rubber pad must and of uniform size. The under surface
be beveled to an angle of approxi- of heads must be driven tight against
mately 45°. An opening in this pad for the plate. All plates, castings and rivet
sump is permitted. No lining must be heads on the inside of the tank must be
under tension when applied except due calked. All projecting edges of plates,
to conformation over rivet heads. Inte- castings and rivet heads on the inside
rior of tank must be free from scale, of the tank must be rounded and free
287
§ 179.201–4 49 CFR Ch. I (10–1–18 Edition)
from fins and other irregular projec- 7(d), Footnote 2. Tanks and attach-
tions. Castings must be free from po- ments welded directly thereto, fab-
rosity. ricated from ASTM A 240/A 240M Type
(d) All surfaces of attachments or fit- 304L or Type 316L materials are not re-
tings and their closures exposed to the quired to be postweld heat treated.
lading must be covered with at least 1⁄8- (b) Tanks and attachments welded di-
inch acid resistant material. Attach- rectly thereto, fabricated from ASTM
ments made of metal not affected by A 240/A 240M Type 304L and Type 316
the lading need not be covered with materials must be tested to dem-
rubber or other acid resistant material. onstrate that they possess the corro-
(e) Hard rubber or polyvinyl chloride sion resistance specified in § 179.200–
may be used for pressure retaining 7(d), Footnote 2.
parts of safety vents provided the ma- [68 FR 75762, Dec. 31, 2003]
terial is resistant to the corrosive or
solvent action of the lading in the liq- § 179.201–6 Manways and manway clo-
uid or gas phase and is suitable for the sures.
service temperatures. (a) The manway cover for spec. DOT
(f) Polyvinyl chloride lined tanks. 104W, 111A60–ALW1, 111A60W1,
Tank car tanks or each compartment 111A100ALW1, 111A–100W1, 111A100W3,
thereof may be lined with elastomeric or 111A100W6 must be designed to make
polyvinyl chloride having a minimum it impossible to remove the cover while
lining thickness of three thirty-seconds the interior of the tank is subjected to
inch. pressure.
(g) Polyurethane lined tanks. Tank (b) The manway cover for spec. DOT
car tanks or each compartment thereof 11A60W5, or 111A100W5 must be made of
may be lined with elastomeric poly- a suitable metal. The top, bottom and
urethane having a minimum lining edge of manway cover must be acid re-
thickness of one-sixteenth inch. sistant material covered as prescribed
in § 179.201–3. Through-bolt holes must
[Amdt. 179–10, 36 FR 21352, Nov. 6, 1971, as
amended at 66 FR 45186, Aug. 28, 2001; 68 FR be lined with acid resistant material at
48571, Aug. 14, 2003] least one-eighth inch in thickness.
Cover made of metal not affected by
§ 179.201–4 Material. the lading need not be acid resistant
material covered.
All fittings, tubes, and castings and
(c) The manway ring and cover for
all projections and their closures, ex-
specifications DOT-103CW, 103DW,
cept for protective housing, must also
103EW, 111360W7, or 11A100W6 must be
meet the requirements specified in
made of the metal and have the same
ASTM A 262 (IBR, see § 171.7 of this sub-
inspection procedures specified in AAR
chapter), except that when preparing
Specifications for Tank Cars, appendix
the specimen for testing the carburized
M, M3.03 (IBR, see § 171.7 of this sub-
surface may be finished by grinding or
chapter).
machining.
[Amdt. 179–10, 36 FR 21353, Nov. 6, 1971; 66 FR
[68 FR 75762, Dec. 31, 2003] 45186, Aug. 28, 2001; 68 FR 48571, Aug. 14, 2003;
68 FR 75762, Dec. 31, 2003]
§ 179.201–5 Postweld heat treatment
and corrosion resistance. § 179.201–8 Sampling device and ther-
(a) Tanks and attachments welded di- mometer well.
rectly thereto must be postweld heat (a) Sampling valve and thermometer
treated as a unit at the proper tem- well are not specification require-
perature except as indicated below. ments. When used, they must be of ap-
Tanks and attachments welded directly proved design, made of metal not sub-
thereto fabricated from ASTM A 240/A ject to rapid deterioration by lading,
240M (IBR, see § 171.7 of this sub- and must withstand a pressure of 100
chapter) Type 430A, Type 304 and Type psig without leakage. Interior pipes of
316 materials must be postweld heat the sampling valve must be equipped
treated as a unit and must be tested to with excess flow valves of an approved
demonstrate that they possess the cor- design. Interior pipe of thermometer
rosion resistance specified in § 179.200– well must be closed by an approved
288
valve attached close to fitting where it ing requirements prescribed in

passes through the tank and closed by § 179.24(a) instead of into the metal of
a screw plug. Other approved arrange- the tank or immediately below the
ments that permit testing thermom- stamped marks specified in § 179.200–
eter well for leaks without complete 24(a).
removal of the closure may be used.
(b) [Reserved]
FR 5606, Apr. 5, 1967. Amended at 77 FR 37985,
[Amdt. 179–10, 36 FR 21348, Nov. 6, 1971, as June 25, 2012]
amended at 66 FR 45390, Aug. 28, 2001]
§ 179.201–11 Insulation.
§ 179.201–9 Gauging device.
(a) Insulation shall be of sufficient
A gauging device of an approved de- thickness so that the thermal conduct-
sign must be applied to permit deter- ance at 60 °F. is not more than 0.075
mining the liquid level of the lading. Btu per hour, per square foot, per de-
The gauging device must be made of gree F. temperature differential.
materials not subject to rapid deterio- (b) [Reserved]
ration by the lading. When the interior
pipe of the gauging device provides a § 179.202 Individual specification re-
means for passage of the lading from quirements applicable to DOT–117
the interior to the exterior of the tank, tank car tanks.
it must be equipped with an excess flow
valve of an approved design. If the § 179.202–1 Applicability.
opening for passage of lading through Each tank built under these speci-
the gauging device is not more than fications must conform to the general
0.060 inch diameter an excess flow valve requirements of § 179.200 and the pre-
is not required. The gauging device scriptive standards in §§ 179.202–1
must be provided with a protective through 179.202–11, or the performance
housing. standard requirements of § 179.202–12.
[Amdt. 179–10, 36 FR 21353, Nov. 6, 1971]
[80 FR 26749, May 8, 2015]
§ 179.201–10 Water capacity marking.
§ 179.202–2 [Reserved]
(a) Water capacity of the tank in
pounds stamped plainly and perma- § 179.202–3 Approval to operate at
nently in letters and figures at least 3⁄8 286,000 gross rail load (GRL).
inch high into the metal of the tank
A tank car may be loaded to a gross
immediately below the stamped marks
weight on rail of up to 286,000 pounds
specified in § 179.200–24(a). This mark
(129,727 kg) upon approval by the Asso-
shall also be stenciled on the jacket
ciate Administrator for Safety, Federal
immediately below the dome platform
Railroad Administration (FRA). See
and directly behind or within 3 feet of
§ 179.13.
the right or left side of the ladder, or
ladders, if there is a ladder on each side [80 FR 26749, May 8, 2015]
of the tank, in letters and figures at
least 11⁄2 inches high as follows: § 179.202–4 Thickness of plates.
WATER CAPACITY
The wall thickness after the forming
of the tank shell and heads must be, at
000000 Pounds a minimum, 9/16 of an inch AAR TC–128
Grade B, normalized steel, in accord-
(b) After July 25, 2012, authorized ance with § 179.200–7(b).
DOT non-pressure tank cars that com-
ply with this section and are equipped [80 FR 26749, May 8, 2015]
with stainless steel identification
plates may have the water capacity of § 179.202–5 Tank head puncture resist-
the tank in pounds prescribed in the ance system.
first sentence of paragraph (a) of this The DOT–117 specification tank car
section stamped plainly and perma- must have a tank head puncture resist-
nently on their identification plate in ance system in conformance with
conformance with the applicable mark- § 179.16(c). The full height head shields
289
§ 179.202–6 49 CFR Ch. I (10–1–18 Edition)
must have a minimum thickness of 1⁄2 of a carbon steel tank and the inside
inch. surface of a carbon steel jacket.
[80 FR 26749, May 8, 2015] [80 FR 26749, May 8, 2015]
§ 179.202–6 Thermal protection system. § 179.202–8 Bottom outlets.

The DOT Specification 117 tank car If the tank car is equipped with a
must have a thermal protection sys- bottom outlet, the handle must be re-
tem. The thermal protection system moved prior to train movement or be
must: designed with protection safety sys-
(a) Conform to § 179.18 of this part; tem(s) to prevent unintended actuation
(b) Be equipped with a thermal pro- during train accident scenarios.
tection blanket with at least 1⁄2-inch-
thick material that meets § 179.18(c) of [80 FR 26749, May 8, 2015]
this part; and
(c) Include a reclosing pressure relief § 179.202–9 Top fittings protection.
device in accordance with § 173.31 of The tank car tank must be equipped
this subchapter. with top fittings protection conforming
to AAR Specifications for Tank Cars,
[81 FR 53957, Aug. 15, 2016]
appendix E paragraph 10.2.1 (IBR, see
§ 179.202–7 Jackets. § 171.7 of this subchapter).
The entire thermal protection sys- [80 FR 26749, May 8, 2015]
tem must be covered with a metal
jacket of a thickness not less than 11 § 179.202–11 Individual specification
gauge A1011 steel or equivalent; and requirements.
flashed around all openings so as to be In addition to § 179.200, the individual
weather tight. A protective coating specification requirements are as fol-
must be applied to the exterior surface lows:
Bursting Minimum plate Test pressure
DOT specification Insulation pressure thickness Bottom outlet
(psig)
(psig) (Inches)
117A100W ........................... Optional ............................... 500 9/16 100 Optional.
[80 FR 26749, May 8, 2015] 12-inch indenter with a weight of

286,000 pounds.
§ 179.202–12 Performance standard re- (2) Minimum head impact speed: 18
quirements (DOT–117P).
mph when impacted at the center of
(a) Approval. Design, testing, and the head by a rigid 12-inch by 12-inch
modeling results must be reviewed and indenter with a weight of 286,000
approved by the Associate Adminis- pounds.
trator for Railroad Safety/Chief Safety (d) Thermal protection systems. The
Officer, Federal Railroad Administra- tank car must be equipped with a ther-
tion (FRA), 1200 New Jersey Ave. SE., mal protection system. The thermal
Washington, DC 20590. protection system must be equivalent
(b) Approval to operate at 286,000 gross to the performance standard prescribed
rail load (GRL). In addition to the rein § 179.18 and include a reclosing pres-
quirements of paragraph (a) of this sec- sure relief device in accordance with
tion, a tank car may be loaded to a
§ 173.31 of this subchapter.
gross weight on rail of up to 286,000
(e) Bottom outlet. If the tank car is
pounds (129,727 kg) upon approval by
the Associate Administrator for Safe- equipped with a bottom outlet, the
ty, Federal Railroad Administration handle must be removed prior to train
(FRA). See § 179.13. movement or be designed with protec-
tion safety system(s) to prevent unin-
(c) Puncture resistance. (1) Minimum

side impact speed: 12 mph when im- tended actuation during train accident
pacted at the longitudinal and vertical scenarios.
center of the shell by a rigid 12-inch by
290
(f) Top fittings protection. The tank side surface of a carbon steel jacket
car tank must be equipped with top fit- must be given a protective coating.
tings protection conforming to AAR (g) Bottom outlets. If the tank car is
Specifications for Tank Cars, appendix equipped with a bottom outlet, the
E paragraph 10.2.1 (IBR, see § 171.7 of handle must be removed prior to train
this subchapter). movement or be designed with protec-
[80 FR 26749, May 8, 2015, as amended at 81 tion safety system(s) to prevent unin-
FR 53957, Aug. 15, 2016; 83 FR 48401, Sept. 25, tended actuation during train accident
2018] scenarios.
(h) Top fittings protection—(1) Protec-
§ 179.202–13 Retrofit standard require- tive housing. Except as provided in
ments (DOT–117R). §§ 179.202–13(h)(2) and (3) of this para-
(a) Applicability. Each tank retrofit graph, top fittings on DOT Specifica-
under these specifications must con- tion 117R tank cars must be located in-
form to the general requirements of side a protective housing not less than
§ 179.200 and the prescriptive standards 12-inch in thickness and constructed of
in § 179.202–13, or the performance a material having a tensile strength
standard requirements of § 179.202–12. not less than 65 kpsi and must conform
(b) Approval to operate at 286,000 gross to all of the following conditions:
rail load (GRL). A tank car may be (i) The protective housing must have
loaded to a gross weight on rail of up a height exceeding the tallest valve or
to 286,000 pounds (129,727 kg) upon ap- fitting which requires protection and
proval by the Associate Administrator the height of a valve or fitting within
for Safety, Federal Railroad Adminis- the protective housing must be kept to
tration (FRA). See § 179.13. the minimum size compatible to allow
(c) Thickness of plates. The wall thick- for proper operation.
ness after forming of the tank shell and (ii) The protective housing or cover
heads must be, at a minimum, 7/16 of may not reduce the flow capacity of a
an inch, and constructed with steel au- pressure relief device below the min-
thorized by the HMR at the time of imum required.
construction. (iii) The protective housing must pro-
(d) Tank head puncture resistance sys- vide a means of drainage with a min-
tem. The DOT–117R specification tank imum flow area equivalent to six (6) 1-
car must have a tank head puncture re- inch diameter weep holes.
sistance system in conformance with (iv) When connected to the nozzle or
§ 179.16(c). The full height head shields fitting cover plate, and subject to a
must have a minimum thickness of 1⁄2 horizontal force applied perpendicular
inch. to and uniformly over the projected
(e) Thermal protection system. (1) The plane of the protective housing, the
DOT Specification 117R tank car must tensile connection strength of the pro-
have a thermal protection system. The tective housing must be designed to
thermal protection system must con- be—
form to § 179.18 of this part and include (A) no greater than 70 percent of the
a reclosing pressure relief device in ac- nozzle to tank tensile connection
cordance with § 173.31 of this sub- strength;
chapter. (B) no greater than 70 percent of the
(2) A non-jacketed tank car modified cover plate to nozzle connection
to the DOT Specification 117R must be strength; and
equipped with a thermal protection (C) no less than either 40 percent of
blanket with at least 1⁄2-inch-thick ma- the nozzle to tank tensile connection
terial that meets § 179.18(c) of this part. strength or the shear strength of twen-
(f) Jackets. The entire thermal protec- ty (20) 12-inch bolts.
tion system must be covered with a (2) Pressure relief devices. (i) The pres-
metal jacket of a thickness not less sure relief device(s) must be located in-
than 11 gauge A1011 steel or equivalent; side the protective housing, unless
and flashed around all openings so as space does not allow for placement
to be weather tight. The exterior sur- within a housing. If multiple pressure
face of a carbon steel tank and the in- relief devices are installed, no more
291
§§ 179.203—179.202–22 49 CFR Ch. I (10–1–18 Edition)
than one (1) may be located outside of § 179.220–4 Insulation.

a protective housing.
The annular space between the inner
(ii) The height of a pressure relief de- container and the outer shell must con-
vice located outside of a protective tain an approved insulation material.
housing in accordance with paragraph
(h)(2)(i) of this section may not exceed [Amdt. 179–9, 36 FR 21340, Nov. 6, 1971]
the tank car jacket by more than 12
inches. § 179.220–6 Thickness of plates.
(iii) The highest point of a closure of (a) The wall thickness, after forming
any unused pressure relief device noz- of the inner container shell and 2:1 el-
zle may not exceed the tank car jacket lipsoidal heads must be not less than
by more than six (6) inches. specified in § 179.221–1, or not less than
(3) Alternative. As an alternative to that calculated by the following for-
the protective housing requirements in mula:
paragraph (h)(1) of this section, the
tank car may be equipped with a sys-
tem that prevents the release of con-
tents from any top fitting under acci-
dent conditions where any top fitting Where:
may be sheared off. d = Inside diameter in inches;
E = 0.9 welded joint efficiency; except E = 1.0
[80 FR 26749, May 8, 2015, as amended at 81 for seamless heads;
FR 53957, Aug. 15, 2016; 83 FR 48401, Sept. 25, P = Minimum required bursting pressure in
2018] psig;
S = Minimum tensile strength of plate mate-
§§ 179.203—179.202–22 [Reserved] rial in p.s.i. as prescribed in AAR Speci-
fications for Tank Cars, appendix M,
§ 179.220 General specifications appli- Table M1;
cable to nonpressure tank car tanks t = Minimum thickness of plate in inches
consisting of an inner container after forming.
supported within an outer shell
(class DOT-115). (b) The wall thickness after forming
of the inner container heads, if flanged
§ 179.220–1 Tanks built under these and dished, must be not less than speci-
specifications must meet the re- fied in § 179.221–1, or not less than that
quirements of §§ 179.220 and
calculated by the following formula:
179.221.
§ 179.220–3 Type.
(a) Tanks built under these specifica-
tions must consist of an inner con- Where:
tainer, a support system for the inner E = 0.9 welded joint efficiency; except E = 1.0
container, and an outer shell. for seamless heads;
(b) The inner container must be a fu- L = Main inside radius to which head is
sion welded tank of circular cross sec- dished, measured on concave side in
tion with formed heads designed con- inches;
vex outward and must have a manway P = Minimum required bursting pressure in
psig;
on top of the tank as prescribed herein.
S = Minimum tensile strength of plate mate-
When the inner container is divided
rial in psi as prescribed in AAR Speci-
into compartments, each compartment fications for Tank Cars, appendix M,
must be considered a separate con- Table M1 (IBR, see § 171.7 of this sub-
tainer. chapter);
(c) The outer shell must be a fusion t = Minimum thickness of plate in inches
welded tank with formed heads de- after forming.
signed convex outward.
(c) The wall thickness after forming

EC13NO91.036</MATH>
[Amdt. 179–9, 36 FR 21340, Nov. 6, 1971] of the cylindrical section and heads of
the outer shell must be not less than
seven-sixteenths of an inch.
292
EC13NO91.035</MATH>
(d) See § 179.220–9 for plate thickness Minimum Minimum

requirements for inner container when elongation
tensile in 2 inches
divided into compartments. strength
(p.s.i.) weld metal
welded
[Amdt. 179–9, 36 FR 21340, Nov. 6, 1971, as (longitu-
condition1 dinal)
75762, Dec. 31, 2003] ASTM A 240/A 240M (incor-
porated by reference; see
§ 179.220–7 Materials. § 171.7 of this subchapter),
Type 304 .................................... 75,000 30
(a) The plate material used to fab- ASTM A 240/A 240M (incor-
ricate the inner container and nozzles porated by reference; see
must meet one of the following speci- § 171.7 of this subchapter),
Type 304L .................................. 70,000 30
fications and with the indicated min- ASTM A 240/A 240M (incor-
imum tensile strength and elongation porated by reference; see
in the welded condition. § 171.7 of this subchapter),
Type 316 .................................... 74,000 30
(b) Carbon steel plate: The maximum
ASTM A 240/A 240M (incor-
allowable carbon content must be 0.31 porated by reference; see
percent when the individual specifica- § 171.7 of this subchapter),
tion allows carbon content greater Type 316L .................................. 70,000 30
than this amount. The plates may be 1 Maximum stresses to be used in calculations.
clad with other approved materials.
(e) Manganese-molybdenum steel
Minimum Minimum plate: Manganese-molybdenum steel
elongation
tensile in 2 inches plate must be suitable for fusion weld-
strength
Specifications (p.s.i.) (percent) ing and must comply with the fol-
weld metal
welded lowing specification (IBR, see § 171.7 of
(longitu-
condition 1 dinal) this subchapter):
AAR TC 128, Gr. B ....................... 81,000 19 Minimum
ASTM A 516 2, Gr. 70 ................... 70,000 20 Minimum elongation
tensile in 2 inches
1 Maximum stresses to be used in calculations. strength
2 This specification is incorporated by reference (IBR, see (p.s.i.) weld metal
§ 171.7 of this subchapter). welded (longitu-
condition 1 dinal)
(c) Aluminum alloy plate: Aluminum
alloy plate must be suitable for weld- ASTM A 302, Gr. B ....................... 80,000 20
ing and comply with one of the fol- 1 Maximum stresses to be used in calculations.
lowing specifications (IBR, see § 171.7 of
this subchapter): * * * (f) Plate materials used to fabricate
the outer shell and heads must be those
Minimum Minimum listed in paragraphs (b), (c), (d), or (e)
elongation
tensile in 2 inches of this section. The maximum allow-
strength
Specifications (p.s.i.) (percent) able carbon content must be 0.31 per-
weld metal
welded cent when the individual specification
(longitu-
condition3 4 dinal) allows carbon content greater than
ASTM B 209, Alloy 5052 1 ............. 25,000 18 this amount. The plates may be clad
ASTM B 209, Alloy 5083 2 ............. 38,000 16 with other approved materials.
ASTM B 209, Alloy 5086 1 ............. 35,000 14 (g) All appurtenances on the inner
ASTM B 209, Alloy 5154 1 ............. 30,000 18 container in contact with the lading
ASTM B 209, Alloy 5254 1 ............. 30,000 18
ASTM B 209, Alloy 5454 1 ............. 31,000 18
must be made of approved material
ASTM B 209, Alloy 5652 1 ............. 25,000 18 compatible with the plate material of
1 For fabrication, the parent plate material may be 0 H112,
the inner container. These appur-
or H32 temper, but design calculations must be based on the tenances must not be subject to rapid
minimum tensile strength shown. deterioration by the lading, or must be
2 0 temper only.
3 Weld filler metal 5556 must not be used. coated or lined with suitable corrosion
resistant material. See AAR Specifica-
tions for Tank Cars, appendix M, M4.05
(d) High alloy steel plate: High alloy

steel plate must comply with one of
the following specifications (IBR, see
§ 171.7 of this subchapter):
293
§ 179.220–8 49 CFR Ch. I (10–1–18 Edition)
for approved material specifications for must be not less than 11⁄2 inches or
castings for fittings. three times the plate thickness, which-
[Amdt. 179–9, 36 FR 21340, Nov. 6, 1971, as
ever is greater.
amended by Amdt. 179–28, 46 FR 49906, Oct. 8, [Amdt. 179–9, 36 FR 21341, Nov. 6, 1971]
1981; Amdt. 179–40, 52 FR 13048, Apr. 20, 1987;
Amdt. 179–52, 61 FR 28681, June 5, 1996; 66 FR § 179.220–10 Welding.
45186, Aug. 28, 2001; 67 FR 51660, Aug. 8, 2002;
68 FR 75762, Dec. 31, 2003] (a) All joints must be fusion welded
in compliance with AAR Specifications
§ 179.220–8 Tank heads. for Tank Cars, appendix W (IBR, see
(a) Tank heads of the inner con- § 171.7 of this subchapter). Welding pro-
tainer, inner container compartments cedures, welders, and fabricators shall
and outer shell must be of approved be approved.
contour, and may be flanged and dished (b) Radioscopy of the outer shell is
or ellipsoidal for pressure on concave not a specification requirement.
side. (c) Welding is not permitted on or to
(b) Flanged and dished heads must ductile iron or malleable iron fittings.
have main inside radius not exceeding [Amdt. 179–9, 36 FR 21341, Nov. 6, 1971, as
10 feet and inside knuckle radius must amended at 68 FR 75762, Dec. 31, 2003]
be not less than 33⁄4 inches for steel and
alloy steel tanks nor less than 5 inches § 179.220–11 Postweld heat treatment.
for aluminum alloy tanks. (a) Postweld heat treatment of the
(c) Ellipsoidal heads must be an ellip- inner container is not a specification
soid of revolution in which the major requirement.
axis must equal the diameter of the (b) Postweld heat treatment of the
shell and the minor axis must be one- cylindrical portions of the outer shell
half the major axis. to which the anchorage or draft sills
[Amdt. 179–9, 36 FR 21341, Nov. 6, 1971] are attached must comply with AAR
Specifications for Tank Cars, appendix
§ 179.220–9 Compartment tanks. W (IBR, see § 171.7 of this subchapter).
(a) The inner container may be di- (c) When cold formed heads are used
vided into compartments by inserting on the outer shell they must be heat
interior heads, or by fabricating each treated before welding to shell if
compartment as a separate container postweld heat treatment is not prac-
and joining with a cylinder, or by fabri- ticable due to assembly procedures.
cating each compartment as a separate [Amdt. 179–9, 36 FR 21341, Nov. 6, 1971, as
tank without a joining cylinder. Each amended at 68 FR 75762, Dec. 31, 2003]
compartment must be capable of with-
standing, without evidence of yielding § 179.220–13 Inner container manway
or leakage, the required test pressure nozzle and cover.
applied in each compartment sepa- (a) Inner container manway nozzle
rately, or in any combination of com- must be of approved design with access
partments. opening at least 18 inches inside diame-
(b) When the inner container is di- ter, or at least 14 inches by 18 inches
vided into compartments by fabri- obround or oval.
cating each compartment as a separate (b) Manway covers must be of ap-
container and joining with a cylinder, proved type. Design must provide a se-
the cylinder must have a plate thick- cure closure of the manway and must
ness not less than that required for the make it impossible to remove the cover
inner container shell and must be ap- while the tank interior is under pres-
plied to the outside surface of the sure.
straight flange portion of the container (c) All joints between manway covers
head. The cylinder must fit the and their seats must be made tight
straight flange tightly for a distance of against leakage of vapor and liquid by
at least two times the plate thickness, use of suitable gaskets.
or 1 inch, whichever is greater and (d) Manway covers must be cast,

must be joined to the straight flange forged, or fabricated metal complying
by a full fillet weld. Distance from fil- with subsection § 179.220–7(g) of this
let weld seam to container head seam section.
294
(e) A seal must be provided between § 179.220–16 Expansion capacity.

the inner container manway nozzle and Expansion capacity must be provided
the opening in the outer shell. in the shell of the inner container as
[Amdt. 179–9, 36 FR 21341, Nov. 6, 1971] prescribed in § 179.221–1.
[Amdt. 179–9, 36 FR 21341, Nov. 6, 1971]
§ 179.220–14 Openings in the tanks.
Openings in the inner container and § 179.220–17 Gauging devices, top load-
the outer shell must be reinforced in ing and unloading devices, venting
compliance with AAR Specifications and air inlet devices.
for Tank Cars, appendix E (IBR, see (a) When installed, each device must
§ 171.7 of this subchapter). In deter- be of approved design which will pre-
mining the required reinforcement vent interchange with any other fix-
area for openings in the outer shell, t ture and must be tightly closed. Each
shall be one-fourth inch. unloading pipe must be securely an-
chored within the inner container.
[68 FR 75763, Dec. 31, 2003] Each inner container or compartment
thereof may be equipped with one sepa-
§ 179.220–15 Support system for inner rate air connection.
container.
(b) When the characteristics of the
(a) The inner container must be sup- commodity for which the car is author-
ported within the outer shell by a sup- ized require these devices to be
port system of adequate strength and equipped with valves or fittings to per-
ductility at its operating temperature mit the loading and unloading of the
to support the inner container when contents, these devices including
filled with liquid lading to any level. valves, shall be provided with a protec-
The support system must be designed tive housing except when plug or ball-
to support, without yielding, impact type valves with operating handles re-
loads producing accelerations of the moved are used. Provision must be
following magnitudes and directions made for closing pipe connections of
when the inner container is loaded so valves.
that the car is at its rail load limit, (c) Inner container may be equipped
and the car is equipped with a conven- with a vacuum relief valve of approved
tional AAR Specification M–901 draft design. Protective housing is not re-
gear. quired.
Longitudinal...............................................7G (d) When a gauging device is required
Transverse ..................................................3G in § 179.221–1, an outage scale visible
Vertical ......................................................3G through the manway opening must be
(b) The longitudinal acceleration provided. If loading devices are applied
may be reduced to 3G where a cush- to permit tank loading with cover
ioning device of approved design, which closed, a telltale pipe may be provided.
has been tested to demonstrate its abil- The telltail pipe must be capable of de-
ity to limit body forces to 400,000 termining that required outage is pro-
pounds maximum at a 10 miles per vided. The pipe must be equipped with
1⁄4-inch maximum, NPT control valve
hour impact, is used between the cou-
mounted outside tank and enclosed
pler and the tank structure. The sup-
within a protective housing. Other ap-
port system must be of approved design
proved devices may be used in place of
and the inner container must be ther-
an outage scale or a telltale pipe.
mally isolated from the outer shell to
(e) The bottom of the tank shell may
the best practical extent. The inner
be equipped with a sump or siphon
container and outer shell must be per-
bowl, or both, welded or pressed into
manently bonded to each other elec- the shell. These sumps or siphon bowls,
trically either by the support system if applied, are not limited in size and
used, piping, or by a separate electrical must be made of cast, forged, or fab-
connection of approved design.
ricated metal. Each sump or siphon

[Amdt. 179–9, 36 FR 21341, Nov. 6, 1971, as bowl must be of good welding quality
amended by Amdt. 179–28, 46 FR 49906, Oct. 8, in conjunction with the metal of the
1981] tank shell. When the sump or siphon
295
§ 179.220–18 49 CFR Ch. I (10–1–18 Edition)
bowl is pressed in the bottom of the (2) Each bottom outlet must be pro-
tank shell, the wall thickness of the vided with a liquid tight closure at its
pressed section must not be less than lower end.
that specified for the shell. The section (3) The valve and its operating mech-
of a circular cross section tank to anism must be applied to the outside
which a sump or siphon bowl is at- bottom of the inner container. The
tached need not comply with the out- valve operating mechanism must be
of-roundness requirement specified in provided with a suitable locking ar-
appendix W, W14.06 of the AAR Speci- rangement to insure positive closure
fications for Tank Cars. Any portion of during transportation.
a sump or siphon bowl not forming a (4) Valve outlet nozzle and valve body
part of a cylinder of revolution must must be of cast, fabricated or forged
have walls of such thickness and must metal. If welded to inner container,
be so reinforced that the stresses in the they must be of good weldable quality
walls caused by a given internal pres- in conjunction with metal of tank.
sure are not greater than the circum- (5) To provide for the attachment of
ferential stress which would exist unloading connections, the bottom of
under the same internal pressure in the the main portion of the outlet nozzle or
wall of a tank of circular cross section valve body, or some fixed attachment
designed in accordance with §§ 179.220– thereto, must be provided with thread-
6(a) and 179.220–9. In no case shall the ed cap closure arrangement or bolted
wall thickness be less than that speci- flange closure arrangement having
fied in § 179.221–1. minimum 1-inch threaded pipe plug.
(f) Protective housing, when re- (6) If outlet nozzle and its closure ex-
quired, must be of approved material tends below the bottom of the outer
and must have cover and sidewalls not shell, a V-shaped breakage groove shall
less than 0.119 inch in thickness. be cut (not cast) in the upper part of
[Amdt. 179–9, 36 FR 21341, Nov. 6, 1971, as the outlet nozzle at a point imme-
amended at 69 FR 54047, Sept. 7, 2004] diately below the lowest part of the
valve closest to the tank. In no case
§ 179.220–18 Bottom outlets. may the nozzle wall thickness at the
(a) The inner container may be root of the ‘‘V’’ be more than 1⁄4-inch.
equipped with a bottom outlet of ap- The outlet nozzle or the valve body
proved design and an opening provided may be steam jacketed, in which case
in the outer shell of its access. If ap- the breakage groove or its equivalent
plied, the bottom outlet must comply must be below the steam chamber but
with the following requirements: above the bottom of the center sill con-
(1) The extreme projection of the bot- struction. If the outlet nozzle is not a
tom outlet equipment may not be more single piece or its exterior valves are
than that allowed by appendix E of the applied, provision shall be made for the
AAR Specifications for Tank Cars equivalent of the breakage groove. On
(IBR, see § 171.7 of this subchapter). All cars without continuous center sills,
bottom outlet reducers and closures the breakage groove or its equivalent
and their attachments shall be secured may not be more than 15 inches below
to car by at at least 3⁄8-inch chain, or the outer shell. On cars with contin-
its equivalent, except that bottom out- uous center sills, the breakage groove
let closure plugs may be attached by or its equivalent must be above the
1⁄4-inch chain. When the bottom outlet bottom of the center sill construction.
closure is of the combination cap and (7) The valve body must be of a thick-
valve type, the pipe connection to the ness which will prevent distortion of
valve shall be closed by a plug, or cap. the valve seat or valve by any change
The bottom outlet equipment should in contour of the shell resulting from
include only the valve, reducers and expansion of lading, or other causes,
closures that are necessary for the at- and which will insure that accidental
tachment of unloading fixtures. The breakage of the outlet nozzle will occur
permanent attachment of supple- at or below the ‘‘V’’ groove, or its

mentary exterior fittings shall be ap- equivalent.
proved by the AAR Committee on Tank (8) The valve must have no wings or
Cars. stem projection below the ‘‘V’’ groove
296
or its equivalent. The valve and seat § 179.220–20 Reinforcements, when

must be readily accessible or remov- used, and appurtenances not other-
able for repairs, including grinding. wise specified.
(b) Inner container may be equipped All attachments to inner container
with bottom washout of approved de- and outer shell must be applied by ap-
sign. If applied, bottom washout must proved means.
comply with the following require-
[Amdt. 179–9, 36 FR 21342, Nov. 6, 1971]
ments:
(1) The extreme projection of the bot- § 179.220–22 Closure for openings.
tom washout equipment may not be
more than that allowed by appendix E (a) All plugs must be solid, with NPT
of the AAR Specifications for Tank threads, and must be of a length which
Cars. will screw at least six threads inside
(2) Bottom washout must be of cast, the face of fitting or tank. Plugs, when
forged or fabricated metals. If it is inserted from the outside of the outer
shell tank heads, must have the letter
welded to the inner container, it must
‘‘S’’ at least three-eighths inch in size
be of good weldable quality in conjunc-
stamped with steel stamp or cast on
tion with metal of tank.
the outside surface to indicate the plug
(3) If washout nozzle extends below is solid.
the bottom of the outer shell, a V-
(b) Openings in the outer shell used
shaped breakage groove shall be cut
during construction for installation
(not cast) in the upper part of the noz- must be closed in an approved manner.
zle at a point immediately below the
lowest part of the inside closure seat or [Amdt. 179–9, 36 FR 21343, Nov. 6, 1971]
plug. In no case may the nozzle wall
thickness at the root of the ‘‘V’’ be § 179.220–23 Test of tanks.
more than 1⁄4-inch. Where the nozzle is (a) Each inner container or compart-
not a single piece, provisions shall be ment must be tested hydrostatically to
made for the equivalent of the break- the pressure specified in § 179.221–1. The
age groove. The nozzle must be of a temperature of the pressurizing me-
thickness to insure that accidental dium must not exceed 100 °F. during
breakage will occur at or below the the test. The container must hold the
‘‘V’’ groove or its equivalent. On cars prescribed pressure for at least 10 min-
without a continuous center sill, the utes without leakage or evidence of
breakage groove or its equivalent may distress. Safety relief devices must not
not be more than 15 inches below the be in place when the test is made.
outer shell. On cars with continuous (b) The inner container must be pres-
center sills, the breakage groove or its sure tested before installation within
equivalent must be above the bottom the outer shell. Items which, because of
of the center sill construction. assembly sequence, must be welded to
(4) The closure plug and seat must be inner container after its installation
readily accessible or removable for re- within outer shell must have their at-
pairs. tachment welds thoroughly inspected
by a nondestructive dye penetrant
(5) The closure of the washout nozzle
method or its equivalent.
must be equipped with a 3⁄4-inch solid
(c) Pressure testing of outer shell is
screw plug. Plug must be attached by
not a specification requirement.
at least a 1⁄4-inch chain.
(6) Joints between closures and their [Amdt. 179–9, 36 FR 21343, Nov. 6, 1971]
seats may be gasketed with suitable
material. § 179.220–24 Tests of pressure relief
valves.
[Amdt. 179–9, 36 FR 21342, Nov. 6, 1971, as
amended by Amdt. 179–40, 52 FR 13048, Apr.
Each safety relief valve must be test-
ed by air or gas for compliance with
20, 1987; 68 FR 75763, Dec. 31, 2003]

§ 179.15 before being put into service.
[Amdt. 179–9, 36 FR 21343, Nov. 6, 1971, as
amended at 62 FR 51561, Oct. 1, 1997]
297
§ 179.220–25 49 CFR Ch. I (10–1–18 Edition)
§ 179.220–25 Stamping. scribed in § 179.24(a). Tank cars built

(a) To certify that the tank complies before July 25, 2012, may have the iden-
with all specification requirements, tification plates instead of or in addi-
each outer shell must be plainly and tion to the head stamping.
permanently stamped in letters and [Amdt. 179–9, 36 FR 21343, Nov. 6, 1971, as
figures at least 3⁄8-inch high into the amended at 77 FR 37986, June 25, 2012]
metal near the center of both outside
heads as follows: § 179.220–26 Stenciling.
Examples of required (a) The outer shell, or the jacket if
stamping the outer shell is insulated, must be
Specifications ................................ DOT-115A60W6. stenciled in compliance with AAR
Inner container: Specifications for Tank Cars, appendix
Material .................................. ASTM A240–316L.
Shell thickness ...................... Shell 0.167 in.
C (IBR, see § 171.7 of this subchapter).
Head thickness ...................... Head 0.150 in. (b) Stenciling must be applied on
Tank builders initials .............. ABC. both sides of the outer shell or jacket
Date of original test ............... 00–0000.
Outer shell: near the center in letters and figures at
Material .................................. ASTM A285–C. least 11⁄2 inches high to indicate the
Tank builders initials .............. WYZ. safe upper temperature limit, if appli-
Car assembler (if other than inner DEF.
container or outer shell build- cable, for the inner tank, insulation,
ers). and the support system.
[Amdt. 179–9, 36 FR 21343, Nov. 6, 1971, as
(b) After July 25, 2012, newly con-
amended at 68 FR 75763, Dec. 31, 2003]
structed DOT tank cars must have
their DOT specification and other re- § 179.221 Individual specification re-
quired information stamped plainly quirements applicable to tank car
and permanently on stainless steel tanks consisting of an inner con-
identification plates in conformance tainer supported within an outer
with the applicable requirements pre- shell.

Minimum
Bursting Test
plate Bottom Bottom Reference
DOT specification Insulation pressure pressure
thickness outlet washout (179.221–***)
(psig) (psig)
(inches)
115A60ALW ............ Yes ................. 240 3 16⁄ 60 Optional. Optional.

115A60W1 .............. Yes ................. 240 18 ⁄ 60 Optional .......... Optional .......... 1
115A60W6 .............. Yes ................. 240 18 ⁄ 60 Optional .......... Optional .......... 1
[Amdt. 170–52, 61 FR 28681, June 5, 1996, as amended at 62 FR 51561, Oct. 1, 1997; 66 FR 45390,
Aug. 28, 2001]
298
Subpart E—Specifications for that specified in § 179.301 and shall be

Multi-Unit Tank Car Tanks such that at the tank test pressure the
maximum fiber stress in the wall of the
(Classes DOT-106A and tank will not exceed 15,750 p.s.i. as cal-
110AW) culated by the following formula:
§ 179.300 General specifications appli- s=[p(1.3D2 + 0.4d2] / (D2¥d2)
cable to multi-unit tank car tanks
designed to be removed from car where:
structure for filling and emptying d = inside diameter in inches;
(Classes DOT-106A and 110AW). D = outside diameter in inches;
p = tank test pressure in psig;
§ 179.300–1 Tanks built under these s = wall stress in psig
specifications shall meet the re-
quirements of §§ 179.300 and (c) If plates are clad with material
179.301. having tensile strength at least equal
to the base plate, the cladding may be
§ 179.300–3 Type and general require- considered a part of the base plate
ments. when determining the thickness. If
(a) Tanks built under this specifica- cladding material does not have tensile
tion shall be cylindrical, circular in strength at least equal to the base
cross section, and shall have heads of plate, the base plate alone shall meet
approved design. All openings shall be the thickness requirements.
located in the heads.
[29 FR 18995, Dec. 29, 1964, as amended by
(b) Each tank shall have a water ca-
Order 71, 31 FR 9083, July 1, 1966. Redesig-
pacity of at least 1500 pounds and not nated at 32 FR 5606, Apr. 5, 1967; 66 FR 45186,
more than 2600 pounds. 45390, Aug. 28, 2001]
(c) For tanks made in foreign coun-
tries, a chemical analysis of materials § 179.300–7 Materials.
and all tests as specified shall be car- (a) Steel plate material used to fab-
ried out within the limits of the United ricate tanks must conform with the
States under the supervision of a com- following specifications with the indi-
petent and impartial inspector. cated minimum tensile strength and
§ 179.300–4 Insulation. elongation in the welded condition.
However, the maximum allowable car-
(a) Tanks shall not be insulated. bon content for carbon steel must not
(b) [Reserved] exceed 0.31 percent, although the indi-
§ 179.300–6 Thickness of plates. vidual ASTM specification may allow
for a greater amount of carbon. The
(a) For class DOT-110A tanks, the plates may be clad with other approved
wall thickness after forming of the cy- materials:
lindrical portion of the tank must not
be less than that specified in § 179.301 Elongation
Tensile in 2 inches
nor that calculated by the following strength (percent)
formula: Specifications 2 (psi) welded welded con-
condition 1 dition 1 (lon-
(minimum) gitudinal)
(minimum)
ASTM A 240/A 240M type 304 75,000 25

ASTM A 240/A 240M type 304L 70,000 25
Where: ASTM A 240/A 240M type 316 75,000 25
d = inside diameter in inches; ASTM A 240/A 240M type 316L 70,000 25
E = 1.0 welded joint efficiency; ASTM A 240/A 240M type 321 75,000 25
P = minimum required bursting pressure in ASTM A 285 Gr. A .................... 45,000 29
ASTM A 285 Gr. B .................... 50,000 20
psig;
ASTM A 285 Gr. C .................... 55,000 20
S = minimum tensile strength of plate mate- ASTM A 515/A 515M Gr. 65 ..... 65,000 20
rial in p.s.i. as prescribed in § 179.300–7; ASTM A 515/A 515M Gr. 70 ..... 70,000 20
t = minimum thickness of plate material in ASTM A 516/A 516M Gr. 70 ..... 70,000 20
inches after forming.

2 These specifications are incorporated by reference (IBR,
(b) For class DOT-106A tanks, the
see § 171.7 of this subchapter.)
wall thickness of the cylindrical por-
tion of the tank shall not be less than (b) [Reserved]
299
EC13NO91.037</MATH>
§ 179.300–8 49 CFR Ch. I (10–1–18 Edition)
(c) All plates must have their heat pendix W, except that circumferential
number and the name or brand of the welds in tanks less than 36 inches in-
manufacturer legibly stamped on them side diameter need not be radiotaped.
at the rolling mill. (c) Forge-welded joints shall be thor-
oughly hammered or rolled to insure
[Amdt. 179–10, 36 FR 21355, Nov. 6, 1971, as
amended by Amdt. 179–42, 54 FR 38798, Sept. sound welds. The flanges of the heads
20, 1989; Amdt. 179–43, 55 FR 27642, July 5, shall be forge lapwelded to the shell
1990; Amdt. 179–52, 61 FR 28682, June 5, 1996; and then crimped inwardly toward the
Amdt. 179–52, 61 FR 50255, Sept. 25, 1996; center line at least one inch on the ra-
Amdt. 179–53, 61 FR 51342, Oct. 1, 1996; 68 FR dius. Welding and crimping must be ac-
75763, Dec. 31, 2003] complished in one heat.
§ 179.300–8 Tank heads. [29 FR 18995, Dec. 29, 1964. Redesignated at 32
FR 5606, Apr. 5, 1967, as amended by Amdt.
(a) Class DOT-110A tanks shall have 179–10, 36 FR 21355, Nov. 6, 1971; 68 FR 75763,
fusion-welded heads formed concave to Dec. 31, 2003]
pressure. Heads for fusion welding shall
be an ellipsoid of revolution 2:1 ratio of § 179.300–10 Postweld heat treatment.
major to minor axis. They shall be one After welding is complete, steel
piece, hot formed in one heat so as to tanks and all attachments welded
provide a straight flange at least 11⁄2 thereto, must be postweld heat treated
inches long. The thickness shall not be as a unit in compliance with the re-
less than that calculated by the fol- quirements of AAR Specifications for
lowing formula: Tank Cars, appendix W (IBR, see § 171.7
[68 FR 75763, Dec. 31, 2003]
where symbols are as defined in § 179.300–6(a). § 179.300–12 Protection of fittings.

(b) Class DOT-106A tanks must have (a) Tanks shall be of such design as
forged-welded heads, formed convex to will afford maximum protection to any
pressure. Heads for forge welding must fittings or attachment to the head in-
be torispherical with an inside radius cluding the housing referred to in
not greater than the inside diameter of § 179.300–12(b). Tank ends shall slope or
the shell. They must be one piece, hot curve inward toward the axis so that
formed in one heat so as to provide a the diameter at each end is at least 2
straight flange at least 4 inches long. inches less than the maximum diame-
They must have snug drive fit into the ter.
shell for forge welding. The wall thick- (b) Loading and unloading valves
ness after forming must be sufficient to shall be protected by a detachable pro-
meet the test requirements of § 179.300– tective housing of approved design
16 and to provide for adequate thread- which shall not project beyond the end
ing of openings. of the tank and shall be securely fas-
tened to the tank head. Pressure relief
FR 5606, Apr. 5, 1967, and amended by Amdt. devices shall not be covered by the
179–10, 36 FR 21355, Nov. 6, 1971] housing.
[29 FR 18995, Dec. 29, 1964, as amended at 68
§ 179.300–9 Welding. FR 57634, Oct. 6, 2003]
(a) Longitudinal joints must be fu-
sion welded. Head-to-shell joints must § 179.300–13 Venting, loading and un-
be forge welded on class DOT-106A loading valves.
tanks and fusion welded on class DOT- (a) Valves shall be of approved type,
110A tanks. Welding procedures, weld- made of metal not subject to rapid de-
ers and fabricators must be approved in terioration by lading, and shall with-
accordance with AAR Specifications stand tank test pressure without leak-
for Tank Cars, appendix W (IBR, see age. The valves shall be screwed di-
§ 171.7 of this subchapter). rectly into or attached by other ap-

(b) Fusion-welded joints must be in proved methods to one tank head. Pro-
compliance with the requirements of vision shall be made for closing outlet
AAR Specifications for Tank Cars, ap- connections of the valves.
300
EC13NO91.038</MATH>
(b) Threads for openings must be Na- shall burst at a pressure not exceeding
tional Gas Taper Threads (NGT) tapped that specified in § 179.301.
to gauge, clean cut, even and without (d) Fusible plugs shall function at a
checks. Taper threads must comply temperature not exceeding 175 °F. and
with § 178.61(h)(3)(i) and (h)(3)(ii). shall be vapor-tight at a temperature
Threads for the clean-out/inspection of not less than 130 °F.
ports of DOT Specification 110A multi- [29 FR 18995, Dec. 29, 1964, as amended at 64
unit tank car tanks may be straight FR 51920, Sept. 27, 1999; 66 FR 45390, Aug. 28,
threads instead of taper threads. The 2001; 68 FR 75763, Dec. 31, 2003]
straight threads must meet the re-
quirements of § 178.61(h)(3)(i) and § 179.300–16 Tests of tanks.
(h)(3)(iii). Hex plugs may be secured to (a) After postweld heat treatment,
threaded boss ports using stainless tanks shall be subjected to hydrostatic
steel safety wire that must not fail expansion test in a water jacket, or by
during its intended use. other approved methods. No tank shall
have been subjected previously to in-
ternal pressure within 100 pounds of
FR 5606, Apr. 5, 1967. Amended at 77 FR 37986,
June 25, 2012] the test pressure. Each tank shall be
tested to the pressure prescribed in
§ 179.300–14 Attachments not other- § 179.301. Pressure shall be maintained
wise specified. for 30 seconds and sufficiently longer to
insure complete expansion of tank.
Siphon pipes and their couplings on Pressure gage shall permit reading to
the inside of the tank head and lugs on accuracy of one percent. Expansion
the outside of the tank head for attach- gage shall permit reading of total ex-
ing the valve protective housing must pansion to accuracy of one percent. Ex-
be fusion-welded in place prior to pansion shall be recorded in cubic cm.
postweld heat treatment. All other fix- (1) No leaks shall appear and perma-
tures and appurtenances, except as spe- nent volumetric expansion shall not
cifically provided for, are prohibited. exceed 10 percent of total volumetric
[Amdt. 179–10, 36 FR 21355, Nov. 6, 1971] expansion at test pressure.
(2) [Reserved]
§ 179.300–15 Pressure relief devices. (b) After all fittings have been in-
stalled, each tank shall be subjected to
(a) Unless prohibited in part 173 of interior air pressure test of at least 100
this subchapter, tanks shall be psig under conditions favorable to de-
equipped with one or more relief detection of any leakage. No leaks shall
vices of approved type, made of metal appear.
not subject to rapid deterioration by (c) Repairs of leaks detected in man-
the lading and screwed directly into ufacture or in foregoing tests shall be
tank heads or attached to tank heads made by the same process as employed
by other approved methods. The total in manufacture of tank. Caulking, sol-
discharge capacity shall be sufficient dering, or similar repairing is prohib-
to prevent building up pressure in tank ited.
in excess of 82.5 percent of the tank
test pressure. When relief devices of [29 FR 18995, Dec. 29, 1964. Redesignated at 32
the fusible plug type are used, the re-
179–10, 36 FR 21355, Nov. 6, 1971; 66 FR 45390,
quired discharge capacity shall be Aug. 28, 2001]
available in each head. See AAR Speci-
fications for Tank Cars, appendix A § 179.300–17 Tests of pressure relief de-
(IBR, see § 171.7 of this subchapter), for vices.
the formula for calculating discharge (a) Each valve shall be tested by air
capacity. or gas before being put into service.
(b) Threads for openings shall be Na- The valve shall open and be vapor-tight
tional Gas Taper Threads (NGT) tapped at the pressure prescribed in § 179.301.
to gage, clean cut, even and without (b) Rupture disks of non-reclosing
checks. pressure relief devices must be tested
(c) Pressure relief devices shall be set and qualified as prescribed in appendix
for start-to-discharge and rupture discs A, Paragraph 5, of the AAR Manual of
301
§ 179.300–18 49 CFR Ch. I (10–1–18 Edition)
Standards and Recommended Prac- § 179.300–19 Inspection.

tices, Section C—Part III, AAR Speci-
(a) Tank shall be inspected within
fications for Tank Cars (IBR, see § 171.7
of this subchapter). the United States and Canada by a
(c) For pressure relief devices of the competent and impartial inspector as
fusible plug type, a sample of the plug approved by the Associate Adminis-
used shall function at the temperatures trator of Safety, FRA. For tanks made
prescribed in § 179.300–15. outside the United States or Canada,
(d) The start-to-discharge and vapor- the specified inspection shall be made
tight pressures shall not be affected by within the United States.
any auxiliary closure or other com- (b) The inspector shall carefully in-
bination. spect all plates from which tanks are
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 to be made and secure records certi-
FR 5606, Apr. 5, 1967, and amended by Amdt. fying that plates comply with the spec-
179–10, 36 FR 21355, Nov. 6, 1971; 66 FR 45390, ification. Plates which do not comply
Aug. 28, 2001; 68 FR 48572, Aug. 14, 2003; 68 FR with § 179.300–7 shall be rejected.
75763, Dec. 31, 2003]
(c) The inspector shall make such in-
§ 179.300–18 Stamping. spection as may be necessary to see
that all the requirements of this speci-
(a) To certify that the tank complies
fication, including markings, are fully
with all specification requirements,
each tank shall be plainly and perma- complied with; shall see that the fin-
nently stamped in letters and figures 3⁄8 ished tanks are properly stress relieved
inch high into the metal of valve end and tested.
chime as follows: (d) The inspector shall stamp his offi-
(1) DOT Specification number. cial mark on each accepted tank as re-
(2) Material and cladding material if quired in § 179.300–18, and render the re-
any (immediately below the specifica- port required in § 179.300–20.
tion number).
[29 FR 18995, Dec. 29, 1964, as amended at 72
(3) Owner’s or builder’s identifying
FR 55696, Oct. 1, 2007]
symbol and serial number (imme-
diately below the material identifica- § 179.300–20 Reports.
tion). The symbol shall be registered
with the Bureau of Explosives, duplica- (a) Before a tank is placed in service,
tions are not authorized. the inspector shall furnish to the build-
(4) Inspector’s official mark (imme- er, tank owner, Bureau of Explosives
diately below the owner’s or builder’s and the Secretary, Mechanical Divi-
symbol). sion, Association of American Rail-
(5) Date of original tank test (month roads, a report in approved form certi-
and year, such as 1–64 for January fying that the tank and its equipment
1964). This should be so placed that comply with all the requirements of
dates of subsequent tests may easily be this specification.
added thereto. (b) For builder’s Certificate of Con-
(6) Water capacity—0000 pounds.
struction, see § 179.5 (b), (c), and (d).
(b) A copy of the above stamping in
letters and figures of the prescribed [29 FR 18995, Dec. 29, 1964. Redesignated at 32
size stamped on a brass plate secured FR 5606, Apr. 5, 1967, and amended by Amdt.
to one of the tank heads is authorized. 179–10, 36 FR 21355, Nov. 5, 1971]
§ 179.301 Individual specification requirements for multi-unit tank car tanks.

(a) In addition to § 179.300 the individual specification requirements are as fol-
lows:
DOT specification 106A500–X 106A800–X 110A500–W 110A600–W 110A800–W 110A1000–W
Minimum required bursting pressure,

psig ................................................ (1) (1) 1250 1500 2000 2500
Minimum thickness shell, inches ...... ⁄
13 32 11 16⁄ 11⁄32 3⁄8 15⁄32 19⁄32
Test pressure, psig (see § 179.300–

16) ................................................. 500 800 500 600 800 1000
302
DOT specification 106A500–X 106A800–X 110A500–W 110A600–W 110A800–W 110A1000–W
Safety relief devices, psig (see

§ 179.300–15) ................................ .................... .................... .................... .................... .................... ........................
Start-to-discharge, or burst max-
imum, p.s.i. .................................... 375 600 375 450 600 700
Vapor-tight, minimum psig ................ 300 480 300 360 480 650
1 None specified.
(b) [Reserved]
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 FR 5606, Apr. 5, 1967, and amended by Amdt.
179–10, 36 FR 21355, Nov. 6, 1971; Amdt. 179–40, 52 FR 13049, Apr. 20, 1987; 65 FR 58632, Sept. 29,
2000; 66 FR 45390, Aug. 28, 2001]
§ 179.302 [Reserved] relief devices, controls, gages and

valves, as prescribed herein.
Subpart F—Specification for Cryo- [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
genic Liquid Tank Car Tanks amended at 68 FR 75763, Dec. 31, 2003]
and Seamless Steel Tanks § 179.400–4 Insulation system and per-
(Classes DOT-113 and 107A) formance standard.
(a) For the purposes of this specifica-
SOURCE: Amdt. 179–32, 48 FR 27708, June 16, tion—
1983, unless otherwise noted. (1) Standard Heat Transfer Rate
(SHTR), expressed in Btu/day/lb of
§ 179.400 General specification appli- water capacity, means the rate of heat
cable to cryogenic liquid tank car transfer used for determining the satis-
tanks.
factory performance of the insulation
§ 179.400–1 General. system of a cryogenic tank car tank in
cryogenic liquid service (see § 179.401–1
A tank built to this specification table).
must comply with §§ 179.400 and 179.401. (2) Test cryogenic liquid means the
cryogenic liquid, which may be dif-
§ 179.400–3 Type. ferent from the lading intended to be
(a) A tank built to this specification shipped in the tank, being used during
must— the performance tests of the insulation
(1) Consist of an inner tank of cir- system.
cular cross section supported essen- (3) Normal evaporation rate (NER), ex-
tially concentric within an outer jack- pressed in lbs. (of the cryogenic liquid)/
et of circular cross section, with the day, means the rate of evaporation, de-
termined by test of a test cryogenic
out of roundness of both the inner tank
liquid in a tank maintained at a pres-
and outer jacket limited in accordance
sure of approximately one atmosphere,
with Paragraph UG–80 in Section VIII
absolute. This determination of the
of the ASME Code (IBR, see § 171.7 of NER is the NER test.
this subchapter); (4) Stabilization period means the
(2) Have the annular space evacuated elapsed time after a tank car tank is
after filling the annular space with an filled with the test cryogenic liquid
approved insulating material; until the NER has stabilized, or 24
(3) Have the inner tank heads de- hours has passed, whichever is greater.
signed concave to pressure; and (5) Calculated heat transfer rate. The
(4) Have the outer jacket heads de- calculated heat transfer rate (CHTR) is
signed convex to pressure. determined by the use of test data ob-
(b) The tank must be equipped with tained during the NER test in the for-
piping systems for vapor venting and mula:
transfer of lading, and with pressure q = [N(D h)(90-tl)] / [V(8.32828)(ts-tf)]
303
§ 179.400–5 49 CFR Ch. I (10–1–18 Edition)
Where: (f) The outer jacket must be provided
q = CHTR, in Btu/day/lb., of water capacity; with fittings to permit effective evacu-
N = NER, determined by NER test, in lbs./ ation of the annular space between the
day; outer jacket and the inner tank.
Dh = latent heat of vaporization of the test
cryogenic liquid at the NER test pressure
(g) A device to measure the absolute
of approximately one atmosphere, abso- pressure in the annular space must be
lute, in Btu/lb.; provided. The device must be portable
90 = ambient temperature at 90 °F.; with an easily accessible connection or
V = gross water volume at 60 °F. of the inner permanently positioned where it is
tank, in gallons; readily visible to the operator.
tl = equilibrium temperature of intended lad-
ing at maximum shipping pressure, in [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
°F.; amended at 49 FR 24318, June 12, 1984; 66 FR
8.32828 = constant for converting gallons of 45186, Aug. 28, 2001]
water at 60 °F. to lbs. of water at 60 °F.,
in lbs./gallon; § 179.400–5 Materials.
ts = average temperature of outer jacket, de-
termined by averaging jacket tempera- (a) Stainless steel of ASTM A 240/A
tures at various locations on the jacket 240M (IBR, see § 171.7 of this sub-
at regular intervals during the NER test, chapter), Type 304 or 304L must be used
in °F.; for the inner tank and its appur-
tf = equilibrium temperature of the test tenances, as specified in AAR Speci-
cryogenic liquid at the NER test pressure
of approximately, one atmosphere, abso-
fications for Tank Cars, appendix M
lute, in °F. (IBR, see § 171.7 of this subchapter), and
must be—
(b) DOT-113A60W tank cars must— (1) In the annealed condition prior to
(1) Be filled with hydrogen, cryogenic
fabrication, forming and fusion weld-
liquid to the maximum permitted fill
ing;
density specified in § 173.319(d)(2) table
of this subchapter prior to performing (2) Suitable for use at the tempera-
the NER test; and ture of the lading; and
(2) Have a CHTR equal to or less than (3) Compatible with the lading.
the SHTR specified in § 179.401–1 table (b) Any steel casting, steel forging,
for a DOT-113A60W tank car. steel structural shape or carbon steel
(c) DOT-113C120W tank cars must— plate used to fabricate the outer jacket
(1) Be filled with ethylene, cryogenic or heads must be as specified in AAR
liquid to the maximum permitted fill Specifications for Tank Cars, appendix
density specified in § 173.319(d)(2) table M.
of this subchapter prior to performing (c) Impact tests must be—
the NER test, or be filled with nitro- (1) Conducted in accordance with
gen, cryogenic liquid to 90 percent of AAR Specifications for Tank Cars, ap-
the volumetric capacity of the inner pendix W, W9.01;
tank prior to performing the NER test; (2) Performed on longitudinal speci-
and mens of the material;
(2) Have a CHTR equal to or less than (3) Conducted at the tank design
75 percent of the SHTR specified in service temperature or colder; and
§ 179.401–1 table for a DOT-113C120W (4) Performed on test plate welds and
tank car. materials used for inner tanks and ap-
(d) Insulating materials must be appurtenances and which will be sub-
proved.
jected to cryogenic temperatures.
(e) If the insulation consists of a pow-
(d) Impact test values must be equal
der having a tendency to settle, the en-
tire top of the cylindrical portion of to or greater than those specified in
the inner tank must be insulated with AAR Specifications for Tank Cars, ap-
a layer of glass fiber insulation at least pendix W. The report of impact tests
one-inch nominal thickness, or equiva- must include the test values and lat-
eral expansion data.
lent, suitably held in position and cov-

ering an area extending 25 degrees to [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
each side of the top center line of the amended at 67 FR 51660, Aug. 8, 2002; 68 FR
inner tank. 75763, Dec. 31, 2003]
304
§ 179.400–6 Bursting and buckling specified in § 179.401–1, or that cal-

pressure. culated by the following formula,
(a) [Reserved] whichever is greater:
(b) The outer jacket of the required t = 1.83 Pd / 2SE
evacuated insulation system must be
designed in accordance with § 179.400– Where:
8(d) and in addition must comply with t = minimum thickness of plate, after form-
the design loads specified in Section 6.2 ing, in inches;
of the AAR Specifications for Tank P = minimum required bursting pressure in
Cars (IBR, see § 171.7 of this sub- psig;
d = inside diameter, in inches;
chapter). The designs and calculations
S = minimum tensile strength of the plate
must provide for the loadings trans- material, as prescribed in AAR Specifica-
ferred to the outer jacket through the tions for Tank Cars, Appendix M, Table
support system. M1, in psi;
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as E = 0.9, a factor representing the efficiency
amended by Amdt. 179–51, 61 FR 18934, Apr. of welded joints, except that for seamless
29, 1996; 65 FR 58632, Sept. 29, 2000; 68 FR heads, E = 1.0.
75763, Dec. 31, 2003] (c) The minimum wall thickness,
§ 179.400–7 Tank heads. after forming, of a flanged and dished
head for the inner tank must be that
(a) Tank heads of the inner tank and specified in § 179.401–1, or that cal-
outer jacket must be flanged and culated by the following formula,
dished, or ellipsoidal. whichever is greater:
(b) Flanged and dished heads must
have— t = [PL(3 + √(L/r))] / (8SE)
(1) A main inside dish radius not Where:
greater than the outside diameter of
t = minimum thickness of plate, after form-
the straight flange; ing, in inches;
(2) An inside knuckle radius of not P = minimum required bursting pressure in
less than 6 percent of the outside di- psig;
ameter of the straight flange; and L = main inside radius of dished head, in
(3) An inside knuckle radius of at inches;
least three times the head thickness. r = inside knuckle radius, in inches;
S = minimum tensile strength of plate mate-
§ 179.400–8 Thickness of plates. rial, as prescribed in AAR Specifications
(a) The minimum wall thickness, for Tank Cars, appendix M, table M1, in
after forming, of the inner shell and psi;
E = 0.9, a factor representing the efficiency
any 2:1 ellipsoidal head for the inner
of welded joints, except that for seamless
tank must be that specified in § 179.401– heads, E = 1.0.
1, or that calculated by the following
formula, whichever is greater: (d) The minimum wall thickness,
after forming, of the outer jacket shell
t = Pd / 2SE may not be less than 7⁄16 inch. The min-
Where: imum wall thickness, after forming, of
t = minimum thickness of plate, after form- the outer jacket heads may not be less
ing, in inches; than 1⁄2 inch and they must be made
P = minimum required bursting pressure in from steel specified in § 179.16(c). The
psig; annular space is to be evacuated, and
d = inside diameter, in inches;
S = minimum tensile strength of the plate
the cylindrical portion of the outer
material, as prescribed in AAR Specifica- jacket between heads, or between stiff-
tions for Tank Cars, appendix M, Table ening rings if used, must be designed to
M1 (IBR, see § 171.7 of this subchapter), in withstand an external pressure of 37.5
psi; psig (critical collapsing pressure), as
E = 0.9, a factor representing the efficiency determined by the following formula:
of welded joints, except that for seamless
heads, E = 1.0. Pc = [2.6E(t/D)2.5] / [(L/D) ¥ 0.45(t/D)0.5]
(b) The minimum wall thickness, Where:

after forming, of any 3:1 ellipsoidal Pc = Critical collapsing pressure (37.5 psig
head for the inner tank must be that minimum) in psig;
305
§ 179.400–9 49 CFR Ch. I (10–1–18 Edition)
E = modulus of elasticity of jacket material, plate which may be considered effec-
in psi; tive is 4W.) The closed section between
t = minimum thickness of jacket material, an external ring and the outer jacket
after forming, in inches;
must be provided with a drain opening.
D = outside diameter of jacket, in inches;
L = distance between stiffening ring centers
(d) The stiffening ring must have a
in inches. (The heads may be considered moment of inertia large enough to sup-
as stiffening rings located 1⁄3 of the head port the critical collapsing pressure, as
depth from the head tangent line.) determined by either of the following
[Amdt. 179–32, 48 FR 27708, June 16, 1983; 49
formulas:
FR 42736, Oct. 24, 1984; 64 FR 51920, Sept. 27, I = [0.035D3 LPc] / E,
1999, as amended at 66 FR 45390, Aug. 28, 2001;
68 FR 75763, Dec. 31, 2003] or
§ 179.400–9 Stiffening rings. I′ = [0.046D3 LPc] / E

(a) If stiffening rings are used in de- Where:
signing the cylindrical portion of the I = required moment of inertia of stiffening
outer jacket for external pressure, they ring about the centroidal axis parallel to
the vessel axis, in inches to the fourth
must be attached to the jacket by power;
means of fillet welds. Outside stiff- I′ = required moment of inertia of combined
ening ring attachment welds must be section of stiffening ring and effective
continuous on each side of the ring. In- width of jacket plate about the cen-
side stiffening ring attachment welds troidal axis parallel to the vessel axis, in
may be intermittent welds on each side inches to the fourth power;
of the ring with the total length of D = outside diameter of the outer jacket, in
inches;
weld on each side not less than one- L = one-half of the distance from the center-
third of the circumference of the tank. line of the stiffening ring to the next line
The maximum space between welds of support on one side, plus one-half of
may not exceed eight times the outer the distance from the centerline to the
jacket wall thickness. next line of support on the other side of
(b) A portion of the outer jacket may stiffening ring. Both distances are meas-
be included when calculating the mo- ured parallel to the axis of the vessel, in
inches. (A line of support is:
ment of inertia of the ring. The effec-
tive width of jacket plate on each side (1) A stiffening ring which meets the re-
quirements of this paragraph, or
of the attachment of the stiffening ring (2) A circumferential line of a head at
is given by the following formula: one-third the depth of the head from
W = 0.78(Rt)0.5 the tangent line);
Pc = critical collapsing pressure (37.5 psig
Where: minimum) in psig;
W = width of jacket effective on each side of E = modulus of elasticity of stiffening ring
the stiffening ring, in inches; material, in psi.
R = outside radius of the outer jacket, in
inches; (e) Where loads are applied to the
t = plate thickness of the outer jacket, after outer jacket or to stiffening rings from
forming, in inches. the system used to support the inner
tank within the outer jacket, addi-
(c) Where a stiffening ring is used tional stiffening rings, or an increased
that consists of a closed section having moment of inertia of the stiffening
two webs attached to the outer jacket, rings designed for the external pres-
the jacket plate between the webs may sure, must be provided to carry the
be included up to the limit of twice the support loads.
value of ‘‘W’’, as defined in paragraph
(b) of this section. The outer flange of [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
the closed section, if not a steel struc- amended at 66 FR 45391, Aug. 28, 2001]
tural shape, is subject to the same lim-
§ 179.400–10 Sump or siphon bowl.
itations with ‘‘W’’ based on the ‘‘R’’
and ‘‘t’’ values of the flange. Where two A sump or siphon bowl may be in the
separate members such as two angles, bottom of the inner tank shell if—
are located less than ‘‘2W’’ apart they (a) It is formed directly into the
may be treated as a single stiffening inner tank shell, or is formed and weld-
ring member. (The maximum length of ed to the inner tank shell and is of
306
weldable quality metal that is compat- shell if postweld heat treatment is not
ible with the inner tank shell; practical due to assembly procedures.
(b) The stress in any orientation
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as
under any condition does not exceed
amended at 68 FR 75763, Dec. 31, 2003]
the circumferential stress in the inner
tank shell; and § 179.400–13 Support system for inner
(c) The wall thickness is not less tank.
than that specified in § 179.401–1.
(a) The inner tank must be supported
§ 179.400–11 Welding. within the outer jacket by a support
system of approved design. The system
(a) Except for closure of openings and
a maximum of two circumferential and its areas of attachment to the
closing joints in the cylindrical portion outer jacket must have adequate
of the outer jacket, each joint of an strength and ductility at operating
inner tank and the outer jacket must temperatures to support the inner tank
be a fusion double welded butt joint. when filled with the lading to any level
(b) The closure for openings and the incident to transportation.
circumferential closing joints in the (b) The support system must be de-
cylindrical portion of the outer jacket, signed to support, without yielding,
including head to shell joints, may be a impact loads producing accelerations
single welded butt joint using a back- of the following magnitudes and direc-
ing strip on the inside of the joint. tions when the inner tank is fully load-
(c) Each joint must be welded in ac- ed and the car is equipped with a con-
cordance with the requirements of ventional draft gear:
AAR Specifications for Tank Cars, ap- Longitudinal ...........................................7‘‘g’’
pendix W (IBR, see § 171.7 of this sub- Transverse ...............................................3‘‘g’’
chapter). Vertical ...................................................3‘‘g’’
(d) Each welding procedure, welder, The longitudinal acceleration may be
and fabricator must be approved. reduced to 3‘‘g’’ where a cushioning de-
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as vice of approved design, which has been
amended at 68 FR 75763, Dec. 31, 2003] tested to demonstrate its ability to
limit body forces to 400,000 pounds
§ 179.400–12 Postweld heat treatment. maximum at 10 miles per hour, is used
(a) Postweld heat treatment of the between the coupler and the tank
inner tank is not required. structure.
(b) The cylindrical portion of the (c) The inner tank and outer jacket
outer jacket, with the exception of the must be permanently bonded to each
circumferential closing seams, must be other electrically, by either the sup-
postweld heat treated as prescribed in port system, piping, or a separate elec-
AAR Specifications for Tank Cars, ap- trical connection of approved design.
pendix W (IBR, see § 171.7 of this sub-
chapter). Any item to be welded to this § 179.400–14 Cleaning of inner tank.
portion of the outer jacket must be at-
The interior of the inner tank and all
tached before postweld heat treatment.
connecting lines must be thoroughly
Welds securing the following need not
cleaned and dried prior to use. Proper
be postweld heat treated when it is not
practical due to final assembly proce- precautions must be taken to avoid
dures: contamination of the system after
(1) the inner tank support system to cleaning.
the outer jacket,
§ 179.400–15 Radioscopy.
(2) connections at piping penetra-
tions, Each longitudinal and circumferen-
(3) closures for access openings, and tial joint of the inner tank, and each
(4) circumferential closing joints of longitudinal and circumferential dou-
head to shell joints. ble welded butt joint of the outer jack-
(c) When cold formed heads are used et, must be examined along its entire
on the outer jacket they must be heat length in accordance with the require-
treated before welding to the jacket ments of AAR Specifications for Tank
307
§ 179.400–16 49 CFR Ch. I (10–1–18 Edition)
Cars, appendix W (IBR, see § 171.7 of tank. The vapor phase line must have a
this subchapter). manually operated shut-off valve lo-
[68 FR 75763, Dec. 31, 2003] cated as close as practicable to the
outer jacket, plus a secondary closure
§ 179.400–16 Access to inner tank. that is liquid and gas tight. This sec-
(a) The inner tank must be provided ondary closure must permit any
with a means of access having a min- trapped pressure to bleed off before the
imum inside diameter of 16 inches. Re- closure can be removed completely.
inforcement of the access opening must (3) Vapor phase blowdown line. A blow-
be made of the same material used in down line must be provided. It must be
the inner tank. The access closure attached to the vapor phase line speci-
must be of an approved material and fied in paragraph (a)(2) of this section,
design. upstream of the shut-off valve in that
(b) If a welded closure is used, it line. A by-pass line with a manually
must be designed to allow it to be re- operated shut-off valve must be pro-
opened by grinding or chipping and to vided to permit reduction of the inner
be closed again by rewelding, pref- tank pressure when the vapor phase
erably without a need for new parts. A line is connected to a closed system.
cutting torch may not be used. The discharge from this line must be
outside the housing and must be di-
§ 179.400–17 Inner tank piping. rected upward and away from oper-
(a) Product lines. The piping system ating personnel.
for vapor and liquid phase transfer and (b) Any pressure building system pro-
venting must be made for material vided for the purpose of pressurizing
compatible with the product and hav- the vapor space of the inner tank to fa-
ing satisfactory properties at the lad- cilitate unloading the liquid lading
ing temperature. The outlets of all must be approved.
vapor phase and liquid phase lines
must be located so that accidental dis- [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
charge from these lines will not im- amended at 66 FR 45391, Aug. 28, 2001]
pinge on any metal of the outer jacket,
car structures, trucks or safety appli- § 179.400–18 Test of inner tank.
ances. Suitable provison must be made (a) After all items to be welded to the
to allow for thermal expansion and inner tank have been welded in place,
contraction. the inner tank must be pressure tested
(1) Loading and unloading line. A liq- at the test pressure prescribed in
uid phase transfer line must be pro- § 179.401–1. The temperature of the pres-
vided and it must have a manually op- surizing medium may not exceed 38 °C
erated shut-off valve located as close (100 °F) during the test. The inner tank
as practicable to the outer jacket, plus must hold the prescribed pressure for a
a secondary closure that is liquid and period of not less than ten minutes
gas tight. This secondary closure must without leakage or distortion. In a
permit any trapped pressure to bleed pneumatic test, due regard for the pro-
off before the closure can be removed tection of all personnel should be taken
completely. A vapor trap must be in- because of the potential hazard in-
corporated in the line and located as volved. After a hydrostatic test the
close as practicable to the inner tank. container and piping must be emptied
On a DOT-113A60W tank car, any load- of all water and purged of all water
ing and unloading line must be vacuum vapor.
jacketed between the outer jacket and
(b) Caulking of welded joints to stop
the shut-off valve and the shut-off
valve must also be vacuum jacketed. leaks developed during the test is pro-
(2) Vapor phase line. A vapor phase hibited. Repairs to welded joints must
line must connect to the inner tank be made as prescribed in AAR Speci-
and must be of sufficient size to permit fications for Tank Cars, appendix W
(IBR, see § 171.7 of this subchapter).
the pressure relief devices specified in

§ 179.400–20 and connected to this line to [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
operate at their design capacity with- amended at 68 FR 75763, Dec. 31, 2003; 73 FR
out excessive pressure build-up in the 57008, Oct. 1, 2008]
308
§ 179.400–19 Valves and gages. tion of the tank assembly and piping
(a) Valves. Manually operated shut- system. The discharge from these de-
off valves and control valves must be vices must be directed away from oper-
provided wherever needed for control of ating personnel, principal load bearing
vapor phase pressure, vapor phase vent- members of the outer jacket, car struc-
ing, liquid transfer and liquid flow ture, trucks and safety appliances.
rates. All valves must be made from Vent or weep holes in pressure relief
approved materials compatible with devices are prohibited. All main pres-
the lading and having satisfactory sure relief devices must discharge to
properties at the lading temperature. the outside of the protective housings
(1) Liquid control valves must be of in which they are located, except that
extended stem design. this requirement does not apply to
(2) Packing, if used, must be satisfac- pressure relief valves installed to pro-
tory for use in contact with the lading tect isolated sections of lines between
and of approved materials that will ef- the final valve and end closure.
fectively seal the valve stem without (b) Materials. Materials used in pres-
causing difficulty of operation. sure relief devices must be suitable for
(3) Each control valve and shut-off use at the temperature of the lading
valve must be readily operable. These and otherwise compatible with the lad-
valves must be mounted so that their ing in both the liquid and vapor phases.
operation will not transmit excessive (c) Inner tank. Pressure relief devices
forces to the piping system. for the inner tank must be attached to
(b) Gages. Gages, except portable vapor phase piping and mounted so as
units, must be securely mounted with- to remain at ambient temperature
in suitable protective housings. A liq- prior to operation. The inner tank
uid level gage and a vapor phase pres- must be equipped with one or more
sure gage must be provided as follows: pressure relief valves and one or more
(1) Liquid level gage. (i) A gage of ap- safety vents (except as noted in para-
proved design to indicate the quantity graph (c)(3)(iv) of this section), and in-
of liquefied lading within the inner stalled without an intervening shut-off
tank, mounted where it will be readily valve (except as noted in paragraph
visible to an operator during transfer (c)(3)(iii) of this section). Additional re-
operations or storage, or a portable quirements are as follows:
gage with a readily accessible connec- (1) Safety vent. The safety vent shall
tion, or function at the pressure specified in
(ii) A fixed length dip tube, with a § 179.401–1. The safety vent must be flow
manually operated shut-off valve lo- rated in accordance with the applicable
cated as close as practicable to the provisions of AAR Specifications for
outer jacket. The dip tube must indi- Tank Cars, appendix A (IBR, see § 171.7
cate the maximum liquid level for the of this subchapter), and provide suffi-
allowable filling density. The inner end cient capacity to meet the require-
of the dip tube must be located on the ments of AAR Specifications for Tank
longitudinal centerline of the inner Cars, appendix A, A8.07(a).
tank and within four feet of the trans- (2) Pressure relief valve. The pressure
verse centerline of the inner tank. relief valve must:
(2) Vapor phase pressure gage. A vapor (i) be set to start-to-discharge at the
phase pressure gage of approved design, pressure specified in § 179.401–1, and
with a manually operated shut-off (ii) meet the requirements of AAR
valve located as close as practicable to Specifications for Tank Cars, appendix
the outer jacket. The gage must indi- A, A8.07(b).
cate the vapor pressure within the (3) Installation of safety vent and pres-
inner tank and must be mounted where sure relief valve—(i) Inlet piping. (A) The
it will be readily visible to an operator. opening through all piping and fittings
An additional fitting for use of a test between the inner tank and its pres-
gage must be provided. sure relief devices must have a cross-
sectional area at least equal to that of

§ 179.400–20 Pressure relief devices. the pressure relief device inlet, and the
(a) The tank must be provided with flow characteristics of this upstream
pressure relief devices for the protec- system must be such that the pressure
309
§ 179.400–20 49 CFR Ch. I (10–1–18 Edition)
drop will not adversely affect the re- (4) Evaporation control. The routine
lieving capacity or the proper oper- release of vaporized lading may be con-
ation of the pressure relief device. trolled with a pressure controlling and
(B) When the required relief capacity mixing device, except that a pressure
is met by the use of multiple pressure controlling and mixing device is re-
relief device placed on one connection, quired on each DOT-113A60W car. Any
the inlet internal cross-sectional area pressure controlling and mixing device
of this connection must be sufficient to must—
provide the required flow capacity for (i) Be set to start-to-discharge at a
the proper operation of the pressure re- pressure not greater than that speci-
lief device system. fied in § 179.401–1;
(ii) Outlet piping. (A) The opening (ii) Have sufficient capacity to limit
through the discharge lines must have the pressure within the inner tank to
a cross-sectional area at least equal to that pressure specified in § 179.401–1,
that of the pressure relief device outlet when the discharge is equal to twice
and may not reduce the relieving ca- the normal venting rate during trans-
pacity below that required to properly
portation, with normal vacuum and the
protect the inner tank.
outer shell at 130 °F; and
(B) When the required relieving ca-
(iii) Prevent the discharge of a gas
pacity is met by use of multiple pres-
mixture exceeding 50% of the lower
sure relief devices placed on a common
discharge manifold, the manifold out- flammability limit to the atmosphere
let internal cross-sectional area must under normal conditions of storage or
be at least equal to the combined out- transportation.
let areas of the pressure relief devices. (5) Safety interlock. If a safety inter-
(iii) Duplicate pressure relief devices lock is provided for the purpose of al-
may be used when an approved 3-way lowing transfer of lading at a pressure
selector valve is installed to provide higher than the pressure control valve
for relief through either duplicate pres- setting but less than the pressure relief
sure relief device. The 3-way valve valve setting, the design must be such
must be included in the mounting pre- that the safety interlock will not affect
scribed by AAR Specifications for Tank the discharge path of the pressure re-
Cars, appendix A, A6.02(g), when con- lief value or safety vent at any time.
ducting the flow capacity test on the The safety interlock must automati-
safety vent prescribed by AAR Speci- cally provide an unrestricted discharge
fications for Tank Cars, appendix A, path for the pressure control device at
A6.01. Flow capacity tests must be per- all times when the tank car is in trans-
formed with the 3-way valve at both of port service.
the extreme positions as well as at the (d) Outer jacket. The outer jacket
mid-position and the flow capacity must be provided with a suitable sys-
must be in accordance with AAR Speci- tem to prevent buildup of annular
fications for Tank Cars, appendix A, space pressure in excess of 16 psig or
A8.07(a). the external pressure for which the
(iv) An alternate pressure relief inner tank was designed, whichever is
valve, set as required in § 179.401–1, may less. The total relief area provided by
be used in lieu of the safety vent, pro- the system must be a minimum of 25
vided it meets the flow capacity pre-
square inches, and means must be pro-
scribed in AAR Specifications for Tank
vided to prevent clogging of any sys-
Cars, appendix A at a flow rating pres-
sure of 110 percent of its start-to-dis- tem opening, as well as to ensure ade-
charge pressure. Installation must— quate communication to all areas of
(A) Prevent moisture accumulation the insulation space. If a safety vent is
at the seat by providing drainage away a part of the system, it must be de-
from that area, signed to prevent distortion of the rup-
ture disc when the annular space is
(B) Permit periodic drainage of the

vent piping, and evacuated.
(C) Prevent accumulation of foreign (e) Piping system. Where a piping cir-
material in the vent system. cuit can be isolated by closing a valve,
310
means for pressure relief must be pro- § 179.400–24 Stamping.

vided. (a) A tank that complies with all
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as specification requirements must have
amended at 66 FR 45391, Aug. 28, 2001; 68 FR the following information plainly and
75763, Dec. 31, 2003] permanently stamped into the metal
near the center of the head of the outer
§ 179.400–21 Test of pressure relief jacket at the ‘‘B’’ end of the car, in let-
valves. ters and figures at least 3⁄8-inch high, in
Each valve must be tested with air or the following order:
gas for compliance with § 179.401–1 be- Example of re-
fore being put into service. quired stamping
Specification ............................................ DOT-113A60W.

§ 179.400–22 Protective housings. Design service temperature .................... Minus 423 °F.
Inner tank ................................................. Inner Tank.
Each valve, gage, closure and pres- Material ............................................. ASTM A240–304.
sure relief device, with the exception of Shell thickness ................................. Shell 3⁄16 inch.
secondary relief valves for the protec- Head thickness ................................. Head 3⁄16 inch.
Inside diameter ................................. ID 107 inch.
tion of isolated piping, must be en- Inner tank builder’s initials ................ ABC.
closed within a protective housing. The Date of original test (month and 00–0000GHK.
protective housing must be adequate to year) and initials of person con-
ducting original test.
protect the enclosed components from Water capacity .................................. 00000 lbs.
direct solar radiation, mud, sand, ad- Outer jacket ............................................. Outer jacket.
verse environmental exposure and me- Material ............................................. ASTM A515–70.
Outer jacket builder’s initials ............ DEF.
chanical damage incident to normal Car assembler’s initials (if other than XYZ.
operation of the tank car. It must be inner tank or outer jacket builder).
designed to provide reasonable access
to the enclosed components for oper- (b) Any stamping on the shell or
ation, inspection and maintenance and heads of the inner tank is prohibited.
so that vapor concentrations cannot (c) In lieu of the stamping required
build up to a dangerous level inside the by paragraph (a) of this section, the
housing in the event of valve leakage specified markings may be incor-
or pressure relief valve operation. All porated on a data plate of corrosion-re-
equipment within the protective hous- sistant metal, fillet welded in place on
ing must be operable by personnel the head of the outer jacket at the ‘‘B’’
wearing heavy gloves and must incor- end of the car.
porate provisions for locks or seals. A § 179.400–25 Stenciling.
protective housing and its cover must
be constructed of metal not less than Each tank car must be stenciled in
0.119 inch thick. compliance with the provisions of the
AAR Specifications for Tank Cars, ap-
§ 179.400–23 Operating instructions. pendix C (IBR, see § 171.7 of this sub-
chapter). The stenciling must also in-
All valves and gages must be clearly clude the following:
identified with corrosion-resistant (a) The date on which the rupture
nameplates. A plate of corrosion-resist- disc was last replaced and the initials
ant material bearing precautionary in- of the person making the replacement,
structions for the safe operation of the on the outer jacket in letters and fig-
equipment during storage and transfer ures at least 11⁄2 inches high.
operations must be securely mounted (b) The design service temperature
so as to be readily visible to an oper- and maximum lading weight, in letters
ator. The instruction plate must be and figures at least 11⁄2 inches high ad-
mounted in each housing containing jacent to the hazardous material sten-
operating equipment and controls for cil.
product handling. These instructions (c) The water capacity, in pounds net
must include a diagram of the tank and at 60 °F., with the tank at its coldest
its piping system with the various operating temperature, after deduction
gages, control valves and pressure re- for the volume above the inlet to the
lief devices clearly identified and lo- pressure relief device or pressure con-
cated. trol valve, structural members, baffles,
311
§ 179.401 49 CFR Ch. I (10–1–18 Edition)
piping, and other appurtenances inside DOT specification 113A60W 113C120W

the tank, in letters and figures at least
Alternate pressure re- ........................... 72.
11⁄2 inches high. lief valve vapor tight
(d) Both sides of the tank car, in let- pressure, min. psig.
ters at least 11⁄2 inches high, with the Alternate pressure re- ........................... 100.
lief valve flow rating
statement ‘‘Do Not Hump or Cut Off pressure, max. psig.
While in Motion.’’ Pressure control valve 17 ...................... Not required.
(e) The outer jacket, below the tank Start-to-vent, max.
classification stencil, in letters at least psig (see § 179.400–
20(c)(4)).
11⁄2 inches high, with the statement, Relief device dis- § 179.400–20 ..... 179.400–20.
‘‘vacuum jacketed.’’ charge restrictions.
Transfer line insulation § 179.400–17 ..... Not required.
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as
75763, Dec. 31, 2003] [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
amended at 49 FR 24318, June 12, 1984; 65 FR
§ 179.401 Individual specification re- 58632, Sept. 29, 2000; 66 FR 45390, Aug. 28, 2001]
quirements applicable to inner
tanks for cryogenic liquid tank car § 179.500 Specification DOT-107A * * *
tanks. * seamless steel tank car tanks.
§ 179.401–1 Individual specification re- § 179.500–1 Tanks built under these
quirements. specifications shall meet the re-
In addition to § 179.400, the individual quirements of § 179.500.
specification requirements for the
§ 179.500–3 Type and general require-
inner tank and its appurtenances are ments.
as follows:
(a) Tanks built under this specifica-
DOT specification 113A60W 113C120W tion shall be hollow forged or drawn in
Design service tem- ¥423 ................. ¥260. one piece. Forged tanks shall be ma-
perature, °F. chined inside and outside before ends
Material ....................... § 179.400–5 ....... § 179.400–5. are necked-down and, after necking-
Impact test (weld and § 179.400–5(c) .. § 179.400–5(c). down, the ends shall be machined to
plate material).
Impact test values ...... § 179.400–5(d) .. § 179.400–5(d). size on the ends and outside diameter.
Standard heat transfer Machining not necessary on inside or
rate. outside of seamless steel tubing, but
(Btu per day per lb. 0.097 ................. 0.4121. required on ends after necking-down.
of water capacity,
max.) (see (b) For tanks made in foreign coun-
§ 179.400–4). tries, chemical analysis of material
Bursting pressure, 240 .................... 300. and all tests as specified must be car-
min. psig.
Minimum plate thick- ⁄
3 16 ..................... ⁄ .
3 16 ried out within the limits of the United
ness shell, inches States under supervision of a com-
(see § 179.400–7(a)). petent and disinterested inspector; in
Minimum head thick- ⁄
3 16 ..................... ⁄ .
3 16
addition to which, provisions in
ness, inches (see
§ 179.400–8 (a), (b), § 179.500–18 (b) and (c) shall be carried
and (c)). out at the point of manufacture by a
Test pressure, psig 60 ...................... 120. recognized inspection bureau with prin-
(see § 179.400–16).
Safety vent bursting 60 ...................... 120.
cipal office in the United States.
pressure, max. psig. (c) The term ‘‘marked end’’ and
Pressure relief valve 30 ...................... 75. ‘‘marked test pressure’’ used through-
start-to-discharge out this specification are defined as
pressure, psig (±3
psi). follows:
Pressure relief valve 24 ...................... 60. (1) ‘‘Marked end’’ is that end of the
vapor tight pressure, tank on which marks prescribed in
min. psig.
Pressure relief valve 40 ...................... 85.
§ 179.500–17 are stamped.
flow rating pressure, (2) ‘‘Marked test pressure’’ is that
max. psig. pressure in psig which is indicated by

Alternate pressure re- ........................... 90. the figures substituted for the **** in
lief valve start to-dis-
charge pressure, the marking DOT-107A **** stamped on
psig (±3 psi). the marked end of tank.
312
(d) The gas pressure at 130 °F in the tions prescribed in paragraph (b) of this
tank shall not exceed 7⁄10 of the marked section.
test pressure of the tank. [29 FR 18995, Dec. 29, 1964. Redesignated at 32
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as FR 5606, Apr. 5, 1967, and amended by Amdt.
amended at 66 FR 45186, 45391, Aug. 28, 2001] 179–31, 47 FR 43067, Sept. 30, 1982; 66 FR 45391,
Aug. 28, 2001]
§ 179.500–4 Thickness of wall. § 179.500–5 Material.
(a) Minimum thickness of wall of (a) Tanks shall be made from open-
each finished tank shall be such that at hearth or electric steel of uniform
a pressure equal to 7⁄10 of the marked quality. Material shall be free from
test pressure of the tank, the cal- seams, cracks, laminations, or other
culated fiber stress in psi at inner wall defects injurious to finished tank. If
of tank multiplied by 3.0 will not ex- not free from such defects, the surface
ceed the tensile strength of any speci- may be machined or ground to elimi-
men taken from the tank and tested as nate these defects. Forgings and seam-
prescribed in § 179.500–7(b). Minimum less tubing for bodies of tanks shall be
wall thickness shall be 1⁄4 inch. stamped with heat numbers.
(b) Calculations to determine the (b) Steel (see Note 1) must conform
maximum marked test pressure per- to the following requirements as to
mitted to be marked on the tank shall chemical composition:
be made by the formula: Class I Class II Class III
Designation (percent) (percent) (percent)
P = [10S(D2 ¥ d2)] / [7(D2 + d2)]
Carbon, maximum ......... 0.50 0.50 0.53
Where: Manganese, maximum .. 1.65 1.65 1.85
Phosphorus, maximum .. .05 .05 .05
P = Maximum marked test pressure per- Sulphur, maximum ........ .06 .05 .05
mitted; Silicon, maximum .......... .35 .30 .37
Molybdenum, maximum ................ .25 .30
S = U / 3.0 Chromium, maximum .... ................ .30 .30
Sum of manganese and
Where: carbon not over .......... 2.10 2.10 ................
U = Tensile strength of that specimen which Note 1:Alternate steel containing other alloying elements
shows the lower tensile strength of the may be used if approved.
two specimens taken from the tank and
(1) For instructions as to the obtain-
tested as prescribed in § 179.500–7(b).
ing and checking of chemical analysis,
3 = Factor of safety.
see § 179.500–18(b)(3).
(D2 ¥ d2/(D2 + d2) = The smaller value ob- (2) [Reserved]
tained for this factor by the operations
specified in § 179.500–4(c). § 179.500–6 Heat treatment.
(c) Measure at one end, in a plane (a) Each necked-down tank shall be
perpendicular to the longitudinal axis uniformly heat treated. Heat treat-
of the tank and at least 18 inches from ment shall consist of annealing or nor-
that end before necking-down: malizing and tempering for Class I,
Class II and Class III steel or oil
d = Maximum inside diameter (inches) for quenching and tempering for Class III
the location under consideration; to be steel. Tempering temperatures shall
determined by direct measurement to an not be less than 1000 °F. Heat treat-
accuracy of 0.05 inch. ment of alternate steels shall be ap-
t = Minimum thickness of wall for the loca- proved. All scale shall be removed from
tion under consideration; to be deter-
outside of tank to an extent sufficient
mined by direct measurement to an accu-
racy of 0.001 inch. to allow proper inspection.
Take D = d + 2t. (b) To check uniformity of heat
Calculate the value of (D2¥d2)/(D2 + d2) treatment, Brinnel hardness tests shall
be made at 18 inch intervals on the en-
(1) Make similar measurements and tire longitudinal axis. The hardness
calculation for a corresponding loca- shall not vary more than 35 points in
tion at the other end of the tank. the length of the tank. No hardness
(2) Use the smaller result obtained, tests need be taken within 12 inches
from the foregoing, in making calcula- from point of head to shell tangency.
313
§ 179.500–7 49 CFR Ch. I (10–1–18 Edition)
(c) A magnetic particle inspection stress (psi) /30,000,000 (psi) + 0.005 (inches per
shall be performed after heat treat- inch)
ment on all tanks subjected to a
shall be recorded as the elastic limit.
quench and temper treatment to detect
the presence of quenching cracks. (1) Elongation shall be at least 18 per-
Cracks shall be removed to sound cent and reduction of area at least 35
metal by grinding and the surface ex- percent.
posed shall be blended smoothly into NOTE 1: Upon approval, the ratio of elastic
the surrounding area. A wall thickness limit to ultimate strength may be raised to
check shall then be made of the af- permit use of special alloy steels of definite
fected area by ultrasonic equipment or composition that will give equal or better
other suitable means acceptable to the physical properties than steels herein speci-
inspector and if the remaining wall fied.
thickness is less than the minimum re- (2) [Reserved]
corded thickness as determined by
§ 179.500–4(b) it shall be used for making [Amdt. 179–8, 36 FR 18470, Sept. 15, 1971, as
the calculation prescribed in paragraph amended at 66 FR 45391, Aug. 28, 2001]
(b) of this section.
§ 179.500–8 Openings in tanks.
§ 179.500–7 Physical tests. (a) Each end shall be closed by a
(a) Physical tests shall be made on cover made of forged steel. Covers shall
two test specimens 0.505 inch in diame- be secured to ends of tank by through
ter within 2-inch gauge length, taken bolts or studs not entering interior of
180 degrees apart, one from each ring tank. Covers shall be of a thickness
section cut from each end of each sufficient to meet test requirements of
forged or drawn tube before necking- § 179.500–12 and to compensate for the
down, or one from each prolongation at openings closed by attachments pre-
each end of each necked-down tank. scribed herein.
These test specimen ring sections or (1) It is also provided that each end
prolongations shall be heat treated, may be closed by internal threading to
with the necked-down tank which they accommodate an approved fitting. The
represent. The width of the test speci- internal threads as well as the threads
men ring section must be at least its on fittings for these openings shall be
wall thickness. Only when diameters clean cut, even, without checks, and
and wall thickness will not permit re- tapped to gauge. Taper threads are re-
moval of 0.505 by 2-inch tensile test quired and shall be of a length not less
bar, laid in the transverse direction, than as specified for American Stand-
may test bar cut in the longitudinal di- ard taper pipe threads. External
rection be substituted. When the thick- threading of an approved type shall be
ness will not permit obtaining a 0.505 permissible on the internal threaded
specimen, then the largest diameter ends.
specimen obtainable in the longitu-
(b) Joints between covers and ends
dinal direction shall be used. Speci-
and between cover and attachments
mens shall have bright surface and a
reduced section. When 0.505 specimen is shall be of approved form and made
not used the gauge length shall be a tight against vapor or liquid leakage
ratio of 4 to 1 length to diameter. by means of a confined gasket of suit-
(b) Elastic limit as determined by ex- able material.
tensometer, shall not exceed 70 percent
§ 179.500–10 Protective housing.
of tensile strength for class I steel or 85
percent of tensile strength for class II (a) Safety devices, and loading and
and class III steel. Determination shall unloading valves on tanks shall be pro-
be made at cross head speed of not tected from accidental damage by ap-
more than 0.125 inch per minute with proved metal housing, arranged so it
an extensometer reading to 0.0002 inch. may be readily opened to permit in-
The extensometer shall be read at inspection and adjustment of safety re-
crements of stress not exceeding 5,000 lief devices and valves, and securely
psi. The stress at which the strain first locked in closed position. Housing shall
exceeds be provided with opening having an
314
opening equal to twice the total dis- § 179.500–14 Test of tanks.

charge area of pressure relief device en-
(a) After heat-treatment, tanks shall
closed.
be subjected to hydrostatic tests in a
(b) [Reserved]
water jacket, or by other accurate
[29 FR 18995, Dec. 29, 1964. Redesignated at 32 method, operated so as to obtain reli-
FR 5606, Apr. 5, 1967, and amended at 66 FR able data. No tank shall have been sub-
45390, Aug. 28, 2001; 67 FR 61016, Sept. 27, 2002] jected previously to internal pressure
§ 179.500–11 Loading and unloading greater than 90 percent of the marked
valves. test pressure. Each tank shall be tested
to a pressure at least equal to the
(a) Loading and unloading valve or marked test pressure of the tank. Pres-
valves shall be mounted on the cover or sure shall be maintained for 30 seconds,
threaded into the marked end of tank. and sufficiently longer to insure com-
These valves shall be of approved type, plete expansion of tank. Pressure
made of metal not subject to rapid de- gauge shall permit reading to accuracy
terioration by lading or in service, and of one percent. Expansion gauge shall
shall withstand without leakage a pres-
permit reading of total expansion to
sure equal to the marked test pressure
accuracy of one percent. Expansion
of tank. Provision shall be made for
shall be recorded in cubic cm.
closing service outlet of valves.
(b) No leaks shall appear and perma-
(b) [Reserved]
nent volumetric expansion shall not
§ 179.500–12 Pressure relief devices. exceed 10 percent of the total volu-
metric expansion at test pressure.
(a) Tank shall be equipped with one
or more pressure relief devices of ap- § 179.500–15 Handling of tanks failing
proved type and discharge area, mount- in tests.
ed on the cover or threaded into the
(a) Tanks rejected for failure in any
non-marked end of the tank. If fittings
of the tests prescribed may be reheat-
are mounted on a cover, they shall be
treated, and will be acceptable if subse-
of the flanged type, made of metal not
quent to reheat-treatment they are
subject to rapid deterioration by lading
or in service. Total flow capacity shall subjected to and pass all of the tests.
be such that, with tank filled with air (b) [Reserved]
at pressure equal to 70 percent of the § 179.500–16 Tests of pressure relief de-
marked test pressure of tank, flow ca- vices.
pacity will be sufficient to reduce air
pressure to 30 percent of the marked (a) Pressure relief valves shall be
test pressure within 3 minutes after tested by air or gas before being put
pressure relief device opens. into service. Valve shall open at pres-
(b) Pressure relief devices shall open sure not exceeding the marked test
at a pressure not exceeding the marked pressure of tank and shall be vapor-
test pressure of tank and not less than tight at 80 percent of the marked test
7⁄10 of marked test pressure. (For toler- pressure. These limiting pressures shall
ance for pressure relief valves, see not be affected by any auxiliary clo-
§ 179.500–16(a).) sure or other combination.
(c) Cars used for the transportation (b) For pressure relief devices that
of flammable gases shall have the safe- incorporate a rupture disc, samples of
ty devices equipped with an approved the discs used shall burst at a pressure
ignition device. not exceeding the marked test pressure
of tank and not less than 7⁄10 of marked
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as test pressure.
57634, Oct. 6, 2003] [Amdt. 179–32, 48 FR 27708, June 16, 1983, as
amended at 66 FR 45391, Aug. 28, 2001]
§ 179.500–13 Fixtures.
(a) Attachments, other than those § 179.500–17 Marking.
mounted on tank covers or serving as (a) Each tank shall be plainly and
threaded closures for the ends of the permanently marked, thus certifying
tank, are prohibited. that tank complies with all require-
(b) [Reserved] ments of this specification. These
315
§ 179.500–18 49 CFR Ch. I (10–1–18 Edition)
marks shall be stamped into the metal tanks, and shall verify proper applica-
of necked-down section of tank at tion of heat number to such material
marked end, in letters and figures at by occasional inspections at steel man-
least 1⁄4 inch high, as follows: ufacturer’s plant.
(1) Spec. DOT-107A * * * *, the * * * * (3) Inspector shall obtain certified
to be replaced by figures indicating chemical analysis of each heat of mate-
marked test pressure of the tank. This rial.
pressure shall not exceed the cal- (4) Inspector shall make inspection of
culated maximum marked test pres- inside surface of tanks before necking-
sure permitted, as determined by the down, to insure that no seams, cracks,
formula in § 179.500–4(b). laminations, or other defects exist.
(2) Serial number immediately below (5) Inspector shall fully verify com-
the stamped mark specified in para- pliance with specification, verify heat
graph (a)(1) of this section. treatment of tank as proper; obtain
(3) Inspector’s official mark imme- samples for all tests and check chem-
diately below the stamped mark speci- ical analyses; witness all tests; and re-
fied in paragraph (a)(1) of this section. port minimum thickness of tank wall,
(4) Name, mark (other than trade- maximum inside diameter, and cal-
mark), or initials of company or person culated value of D, for each end of each
for whose use tank is being made, tank as prescribed in § 179.500–4(c).
which shall be recorded with the Bu- (6) Inspector shall stamp his official
reau of Explosives. mark on each accepted tank imme-
(5) Date (such as 1–01, for January diately below serial number, and make
2001) of tank test, so placed that dates certified report (see paragraph (c) of
of subsequent tests may easily be this section) to builder, to company or
added. person for whose use tanks are being
(6) Date (such as 1–01, for January made, to builder of car structure on
2001) of latest test of pressure relief de- which tanks are to be mounted, to the
vice or of the rupture disc, required Bureau of Explosives, and to the Sec-
only when tank is used for transpor- retary, Mechanical Division, Associa-
tation of flammable gases. tion of American Railroads.
(b) [Reserved] (c) Inspector’s report required herein
[29 FR 18995, Dec. 29, 1964, as amended by shall be in the following form:
Amdt. 179–52, 61 FR 28682, June 5, 1996; 66 FR (Place) lllllllllllllll
45391, Aug. 28, 2001] (Date) llllllllllllllll
§ 179.500–18 Inspection and reports. STEEL TANKS

(a) Before a tank car is placed in It is hereby certified that drawings were
service, the party assembling the com- submitted for these tanks under AAR Appli-
pleted car shall furnish to car owner, cation for Approval llllll and approved
Bureau of Explosives, and the Sec- by the AAR Committee on Tank Cars under
date of llllll.
retary, Mechanical Division, Associa- Built for llllllllllll Company
tion of American Railroads, a report in Location at lllllllllllllllll
proper form certifying that tanks and Built by llllllllllll Company
their equipment comply with all the Location at lllllllllllllllll
requirements of this specification and Consigned to lllllllll Company
including information as to serial num- Location at lllllllllllllllll
bers, dates of tests, and ownership Quantity llllllllllllllllll
Length (inches) lllllllllllllll
marks on tanks mounted on car struc- Outside diameter (inches) llllllllll
ture. Marks stamped into tank as required in
(b) Purchaser of tanks shall provide § 179.500–17 are:
for inspection by a competent inspec-
tor as follows: DOT-107A* * * *
(1) Inspector shall carefully inspect NOTE 1: The marked test pressure sub-
all material and reject that not com- stituted for the * * * * on each tank is shown
plying with § 179.500–5. on Record of General Data on Tanks at-

(2) Inspector shall stamp his official tached hereto.
mark on each forging or seamless tube Serial numbers ll to ll inclusive
accepted by him for use in making Inspector’s mark llllllllllllll
316
Owner’s mark llllllllllllllll Transportation Specification No.
Test date llllllllllllllllll 107A* * * *.
Water capacity (see Record of Hydrostatic (Signed) lllllllllllllll
Tests). (Inspector)
Tare weights (yes or no) (see Record of Hy- (Place) lllllllllllllll
drostatic Tests). (Date) llllllllllllllll
These tanks were made by process of llll
Steel used was identified as indicated by RECORD OF CHEMICAL ANALYSIS OF STEEL FOR
the attached list showing the serial number TANKS
of each tank, followed by the heat number. Numbered llll to llll inclusive
Steel used was verified as to chemical Size l inches outside diameter by l inches
analysis and record thereof is attached here- long
to. Heat numbers were stamped into metal. Built by llllllllllll Company
All material was inspected and each tank For lllllllllllllll Company
was inspected both before and after closing
in ends; all material accepted was found free Tanks rep- Chemical analysis
from seams, cracks, laminations, and other resented
Heat No. (serial
defects which might prove injurious to Nos.) C Mn P S Si Ni Cr Mo
strength of tank. Processes of manufacture
and heat-treatment of tanks were witnessed
and found to be efficient and satisfactory.
Before necking-down ends, each tank was
measured at each location prescribed in These analyses were made by
§ 179.500–4(c) and minimum wall thickness in (Signed) lllllllllllll
inches at each location was recorded; max- (Place) lllllllllllll
imum inside diameter in inches at each loca- (Date) llllllllllllll
tion was recorded; value of D in inches at
each location was calculated and recorded; RECORD OF CHEMICAL ANALYSIS OF STEEL IN
maximum fiber stress in wall at location TANKS
showing larger value for Numbered llll to llll inclusive
(D2 + d2)/(D2¥d2) Size ll inches outside by ll inches long
was calculated for 7⁄10 the marked test pres- Built by llllllllllll Company
sure and recorded. Calculations were made For lllllllllllllll Company
by the formula: Tanks
S=[0.7P(D2¥d2)/(D2 + d2)] rep- Elon- Reduc-
resent- Elastic Tensile gation tion of
Hydrostatic tests, tensile test of material, Heat ed by limit strength (percent area
No.
and other tests as prescribed in this speci- test (se- (psi) (psi) in 2 (per-
rial inches) cent)
fication, were made in the presence of the in- Nos.)
spector, and all material and tanks accepted
were found to be in compliance with the re-
quirements of this specification. Records
thereof are attached hereto.
I hereby certify that all of these tanks (Signed) lllllllllllll
proved satisfactory in every way and comply (Place) lllllllllllll
with the requirements of Department of (Date) llllllllllllll
RECORD OF HYDROSTATIC TESTS ON TANKS

Numbered ........................................................... to ......................................................................... inclusive
Size ..................................................................... inches outside by ................................................ ................ inches long
Built by ...................................................................................................................................................................... Company
For ............................................................................................................................................................................ Company
Percent ratio of
Permanent ex- Capacity in
Serial Nos. of Actual test pres- Total expansion permanent ex- Tare weight
pansion (cubic (pounds) 2 pounds of water
tanks sure (psig) (cubic cm) pansion to total at 60 °F
cm) expansion 1
1 If tests are made by method involving measurement of amount of liquid forced into tank by test pressure, then the basic data
on which calculations are made, such as pump factors, temperature of liquid, coefficient of compressibility of liquid, etc., must
also be given.
2 Do not include protective housing, but state whether with or without valves.
317
Pt. 179, App. A 49 CFR Ch. I (10–1–18 Edition)
(Signed) llllllllllllllllll (Date) lllllllllllllllllll
(Place) llllllllllllllllll
RECORD OF GENERAL DATA ON TANKS

Numbered ........................................................... to ......................................................................... inclusive
Built by ...................................................................................................................................................................... Company
For ............................................................................................................................................................................ Company
Data obtained as prescribed in § 179.500–4(c)

(S) Cal-
Marked end of tank Other end of tank Larger culated Marked Minimum
value of fiber test pres- tensile
(D) Cal- (t) Min- (d) Max- (D) cal- the fac- stress in sure in strength
(t) Min. (d) Max.
Serial thick- inside culated imum imum in- culated tor D2 + psi at 7⁄10 psig of mate-
value of D thick- side di- value of D d2/ marked stamped rial in psi
No. of ness of diameter in ness of ameter in D2¥d2 test pres- in tank recorded
tank wall in in inches=d + wall in in inches=d + sure
inches inches 2t inches inches 2t
(Signed) llllllllllllllllll
[Amdt. 179–32, 48 FR 27708, June 16, 1983, as amended by 66 FR 45391, Aug. 28, 2001]
APPENDIX A TO PART 179—PROCEDURES above the top of the sill; the other test must
FOR TANK-HEAD PUNCTURE-RESIST- be conducted with the coupler height at 79
ANCE TEST cm (31 inches), plus-or-minus 2.5 cm (1 inch),
above the top of the sill. If the combined
1. This test procedure is designed to verify thickness of the tank head and any addi-
the integrity of new or untried tank-head tional shielding material is less than the
puncture-resistance systems and to test for combined thickness on the vertical center-
system survivability after coupler-to-tank- line of the car, a third test must be con-
head impacts at relative speeds of 29 km/ ducted with the coupler positioned so as to
hour (18 mph). Tank-head puncture-resist-
strike the thinnest point of the tank head.
ance is a function of one or more of the fol-
lowing: Head thickness, jacket thickness, in- 3. One of the following test conditions
sulation thickness, and material of construc- must be applied:
tion.
Minimum ve-
2. Tank-head puncture-resistance test. A Minimum weight of locity of impact
tank-head puncture-resistance system must attached ram cars in Restrictions
in km/hour
kg (pounds)
be tested under the following conditions: (mph)
a. The ram car used must weigh at least
119,295 (263,000) ... 29 (18) ........... One ram car only.
119,295 kg (263,000 pounds), be equipped with a
155,582 (343,000) ... 25.5 (16) ........ One ram car or one
coupler, and duplicate the condition of a con-
car plus one rigidly
ventional draft sill including the draft yoke attached car.
and draft gear. The coupler must protrude 311,164 (686,000) ... 22.5 (14) ........ One ram car plus
from the end of the ram car so that it is the one or more rigidly
leading location of perpendicular contact attached cars.
with the impacted test car.
b. The impacted test car must be loaded 4. A test is successful if there is no visible
with water at six percent outage with inter- leak from the standing tank car for at least
nal pressure of at least 6.9 Bar (100 psig) and one hour after impact.
coupled to one or more ‘‘backup’’ cars which
have a total weight of 217,724 kg (480,000 [Amdt. 179–50, 60 FR 49078, Sept. 21, 1995, as
pounds) with hand brakes applied on the last amended by Amdt. 179–50, 61 FR 33256, June
‘‘backup’’ car. 26, 1996; 66 FR 45390, Aug. 28, 2001]
c. At least two separate tests must be con-
ducted with the coupler on the vertical cen-

terline of the ram car. One test must be con-
ducted with the coupler at a height of 53.3
cm (21 inches), plus-or-minus 2.5 cm (1 inch),
318
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 179, App. B
APPENDIX B TO PART 179—PROCEDURES (4) The entire surface of the thermal pro-
FOR SIMULATED POOL AND TORCH- tection system must be exposed to the simu-
FIRE TESTING lated pool fire.
(5) A pool-fire simulation test must run for
1. This test procedure is designed to meas- a minimum of 100 minutes. The thermal pro-
ure the thermal effects of new or untried tection system must retard the heat flow to
thermal protection systems and to test for the plate so that none of the thermocouples
system survivability when exposed to a 100- on the non-protected side of the plate indi-
minute pool fire and a 30-minute torch fire. cate a plate temperature in excess of 427 °C
2. Simulated pool fire test. (800 °F).
a. A pool-fire environment must be simu- (6) A minimum of three consecutive suc-
lated in the following manner: cessful simulation fire tests must be per-
(1) The source of the simulated pool fire formed for each thermal protection system.
must be hydrocarbon fuel with a flame tem- 3. Simulated torch fire test.
perature of 871 °C plus or minus 55.6 °C (1600 a. A torch-fire environment must be simu-
°F plus-or-minus 100 °F) throughout the du- lated in the following manner:
ration of the test. (1) The source of the simulated torch must
(2) A square bare plate with thermal prop- be a hydrocarbon fuel with a flame tempera-
erties equivalent to the material of construc- ture of 1,204 °C plus-or-minus 55.6 °C (2,200 °F
tion of the tank car must be used. The plate plus or minus 100 °F), throughout the dura-
dimensions must be not less than one foot by tion of the test. Furthermore, torch veloci-
one foot by nominal 1.6 cm (0.625 inch) thick. ties must be 64.4 km/h ±16 km/h (40 mph ±10
The bare plate must be instrumented with mph) throughout the duration of the test.
not less than nine thermocouples to record (2) A square bare plate with thermal prop-
the thermal response of the bare plate. The erties equivalent to the material of construc-
thermocouples must be attached to the sur- tion of the tank car must be used. The plate
face not exposed to the simulated pool fire dimensions must be at least four feet by four
and must be divided into nine equal squares feet by nominal 1.6 cm (0.625 inch) thick. The
with a thermocouple placed in the center of bare plate must be instrumented with not
each square. less than nine thermocouples to record the
(3) The pool-fire simulator must be con- thermal response of the plate. The
structed in a manner that results in total thermocouples must be attached to the sur-
flame engulfment of the front surface of the face not exposed to the simulated torch and
bare plate. The apex of the flame must be di- must be divided into nine equal squares with
rected at the center of the plate. a thermocouple placed in the center of each
(4) The bare plate holder must be con- square.
structed in such a manner that the only heat
(3) The bare plate holder must be con-
transfer to the back side of the bare plate is
structed in such a manner that the only heat
by heat conduction through the plate and
transfer to the back side of the plate is by
not by other heat paths.
heat conduction through the plate and not
(5) Before the bare plate is exposed to the
by other heat paths. The apex of the flame
simulated pool fire, none of the temperature
must be directed at the center of the plate.
recording devices may indicate a plate tem-
perature in excess of 37.8 °C (100 °F) nor less (4) Before exposure to the simulated torch,
than 0 °C (32 °F). none of the temperature recording devices
may indicate a plate temperature in excess
(6) A minimum of two thermocouple de-
of 37.8 °C (100 °F) or less than 0 °C (32 °F).
vices must indicate 427 °C (800 °F) after 13
minutes, plus-or-minus one minute, of simu- (5) A minimum of two thermocouples must
lated pool-fire exposure. indicate 427 °C (800 °F) in four minutes, plus-
b. A thermal protection system must be or-minus 30 seconds, of torch simulation ex-
tested in the simulated pool-fire environ- posure.
ment described in paragraph 2a of this ap- b. A thermal protection system must be
pendix in the following manner: tested in the simulated torch-fire environ-
(1) The thermal protection system must ment described in paragraph 3a of this ap-
cover one side of a bare plate as described in pendix in the following manner:
paragraph 2a(2) of this appendix. (1) The thermal protection system must
(2) The non-protected side of the bare plate cover one side of the bare plate identical to
must be instrumented with not less than that used to simulate a torch fire under
nine thermocouples placed as described in paragraph 3a(2) of this appendix.
paragraph 2a(2) of this appendix to record (2) The back of the bare plate must be in-
the thermal response of the plate. strumented with not less than nine
(3) Before exposure to the pool-fire simula- thermocouples placed as described in para-
tion, none of the thermocouples on the ther- graph 3a(2) of this appendix to record the
mal protection system configuration may in- thermal response of the material.
dicate a plate temperature in excess of 37.8 (3) Before exposure to the simulated torch,
°C (100 °F) nor less than 0 °C (32 °F). none of the thermocouples on the back side
319
of the thermal protection system configura- Subpart E—Qualification and Maintenance
tion may indicate a plate temperature in ex- of Cargo Tanks
cess of 37.8 °C (100 °F) nor less than 0 °C (32
°F). 180.401 Applicability.
(4) The entire outside surface of the ther- 180.403 Definitions.
mal protection system must be exposed to 180.405 Qualification of cargo tanks.
the simulated torch-fire environment. 180.407 Requirements for test and inspection
(5) A torch-simulation test must be run for of specification cargo tanks.
a minimum of 30 minutes. The thermal pro- 180.409 Minimum qualifications for inspec-
tection system must retard the heat flow to tors and testers.
the plate so that none of the thermocouples 180.411 Acceptable results of tests and in-
on the backside of the bare plate indicate a spections.
plate temperature in excess of 427 °C (800 °F). 180.413 Repair, modification, stretching, re-
(6) A minimum of two consecutive success- barrelling, or mounting of specification
ful torch-simulation tests must be performed cargo tanks.
for each thermal protection system. 180.415 Test and inspection markings.
180.416 Discharge system inspection and
[Amdt. 179–50, 60 FR 49078, Sept. 21, 1995, as maintenance program for cargo tanks
amended at 75 FR 53597, Sept. 1, 2010; 77 FR transporting liquefied compressed gases.
60945, Oct. 5, 2012] 180.417 Reporting and record retention re-
quirements.
PART 180—CONTINUING QUALI- Subpart F—Qualification and Maintenance
FICATION AND MAINTENANCE of Tank Cars
OF PACKAGINGS
180.501 Applicability.
180.503 Definitions.
Subpart A—General 180.505 Quality assurance program.
Sec. 180.507 Qualification of tank cars.
180.509 Requirements for inspection and test
of specification tank cars.
180.511 Acceptable results of inspections and
180.3 General requirements. tests.
180.513 Repairs, alterations, conversions,
Subpart B [Reserved] and modifications.
180.515 Markings.
Subpart C—Qualification, Maintenance 180.517 Reporting and record retention re-
and Use of Cylinders quirements.
180.519 Periodic retest and inspection of
180.201 Applicability. tank cars other than single-unit tank car
180.203 Definitions. tanks.
180.205 General requirements for requali-
fication of specification cylinders. Subpart G—Qualification and
180.207 Requirements for requalification of Maintenance of Portable Tanks
UN pressure receptacles.
180.209 Requirements for requalification of 180.601 Applicability.
specification cylinders. 180.603 Qualification of portable tanks.
180.211 Repair, rebuilding and reheat treat- 180.605 Requirements for periodic testing,
ment of DOT-4 series specification cyl- inspection and repair of portable tanks.
inders. APPENDIX A TO PART 180—INTERNAL SELF-
180.212 Repair of seamless DOT 3-series CLOSING STOP VALVE EMERGENCY CLO-
specification cylinders and seamless UN SURE TEST FOR LIQUEFIED COMPRESSED
pressure receptacles. GASES
180.213 Requalification markings. APPENDIX B TO PART 180—ACCEPTABLE INTER-
180.215 Reporting and record retention re- NAL SELF-CLOSING STOP VALVE LEAKAGE
quirements. TESTS FOR CARGO TANKS TRANSPORTING
180.217 Requalification requirements for LIQUEFIED COMPRESSED GASES
MEGCs. APPENDIX C TO PART 180—EDDY CURRENT EX-
AMINATION WITH VISUAL INSPECTION FOR
Subpart D—Qualification and Maintenance DOT 3AL CYLINDERS MANUFACTURED OF
ALUMINUM ALLOY 6351–T6
of IBCs APPENDIX D TO PART 180—HAZARDOUS MATE-
180.350 Applicability and definitions. RIALS CORROSIVE TO TANKS OR SERVICE

180.351 Qualification of IBCs. EQUIPMENT
180.352 Requirements for retest and inspec- AUTHORITY: 49 U.S.C. 5101–5128; 49 CFR 1.81
tion of IBCs. and 1.97.
320
SOURCE: Amdt. 180–2, 54 FR 25032, June 12, (3) Test dates displayed in associa-
1989, unless otherwise noted. tion with specification, registration,
approval, or exemption markings indi-
Subpart A—General cating conformance to a test or retest
requirement of this subchapter, an ap-
§ 180.1 Purpose and scope.
proval issued thereunder, or a special
This part prescribes requirements permit issued under subchapter A of
pertaining to the maintenance, recon- this chapter;
ditioning, repair, inspection and test- (4) Documents indicating conform-
ing of packagings, and any other func- ance to the testing, inspection, mainte-
tion having an effect on the continuing
nance or other continuing qualification
qualification and use of a packaging
under the requirements of this sub- requirements of this part; and
chapter. (5) Sales literature, including adver-
tising, indicating that the packaging
§ 180.2 Applicability. or container represented therein con-
(a) Any person who performs a func- forms to requirements contained in
tion prescribed in this part shall per- subchapter A or C of this chapter.
form that function in accordance with [Amdt. 180–2, 54 FR 25032, June 12, 1989, as
this part. amended by Amdt. 180–3, 58 FR 33306, June
(b) Any person who performs a func- 16, 1993; 70 FR 73166, Dec. 9, 2005]
tion prescribed in this part is consid-
ered subject to the regulations of this
subchapter when that person— Subpart B [Reserved]
(1) Makes any representation indi-
cating compliance with one or more of Subpart C—Qualification, Mainte-
the requirements of this part; or nance and Use of Cylinders
(2) Reintroduces into commerce a
packaging that bears markings indi- SOURCE: 67 FR 51660, Aug. 8, 2002, unless
cating compliance with this part. otherwise noted.
[Amdt. 180–2, 54 FR 25032, June 12, 1989, as
amended by Amdt. 180–2, 56 FR 27877, June § 180.201 Applicability.
17, 1991]
This subpart prescribes require-
§ 180.3 General requirements. ments, in addition to those contained
in parts 107, 171, 172, 173, and 178 of this
(a) No person may represent, mark,
certify, sell, or offer a packaging or chapter, for the continuing qualifica-
container as meeting the requirements tion, maintenance, or periodic requali-
of this part, or a special permit per- fication of DOT specification and ex-
taining to this part issued under sub- emption cylinders and UN pressure re-
chapter A of this chapter, whether or ceptacles.
not the packaging or container is in- [71 FR 33894, June 12, 2006]
tended to be used for the transpor-
tation of a hazardous material, unless § 180.203 Definitions.
it is marked, maintained, recondi-
tioned, repaired, or retested, as appro- As used in this section, the word
priate, in accordance with this part, an ‘‘cylinder’’ includes UN pressure recep-
approval issued thereunder, or a special tacles. In addition to the definitions
permit issued under subchapter A of contained in § 171.8 of this subchapter,
this chapter. the following definitions apply to this
(b) The representations, markings, subpart:
and certifications subject to the prohi- Commercially free of corrosive compo-
bitions of paragraph (a) of this section nents means a hazardous material hav-
include: ing a dew point at or below minus 46.7
(1) Identifications that include the °C (minus 52 °F) at 101kPa (1 atmos-
letters ‘‘DOT’’, ‘‘MC’’, ‘‘ICC’’, or ‘‘UN’’; phere) and free of components that will
(2) Special permit, approval, and reg- adversely react with the cylinder (e.g.
istration numbers that include the let- chemical stress corrosion).
ters ‘‘DOT’’;
321
§ 180.205 49 CFR Ch. I (10–1–18 Edition)
Condemn means a determination that Test pressure means the pressure used
a cylinder is unserviceable for the con- for the requalification of a cylinder.
tinued transportation of hazardous ma- Total expansion means the total in-
terials in commerce and that the cyl- crease in a cylinder’s volume due to ap-
inder may not be restored by repair, re- plication of the test pressure.
building, requalification, or any other Visual inspection means an internal or
procedure. external visual examination, or both,
Defect means an imperfection requir- performed as part of the cylinder re-
ing removal of a cylinder from service. qualification process.
Elastic expansion means a temporary Volumetric expansion test means a
increase in a cylinder’s volume, due to pressure test to determine the total
application of pressure, that is lost and permanent expansion of a cylinder
when pressure is released (elastic ex- at a given pressure. The volumetric ex-
pansion = total expansion minus per- pansion test is conducted using the
manent expansion). water jacket or direct expansion meth-
Filled or charged means an introduc- ods:
tion or presence of a hazardous mate- (1) Water jacket method means a volu-
rial in a cylinder. metric expansion test to determine a
Non-corrosive service means a haz- cylinder’s total and permanent expan-
ardous material that, in the presence sion by measuring the difference be-
of moisture, is not corrosive to the ma- tween the volume of water the cylinder
terials of construction of a cylinder externally displaces at test pressure
(including valve, pressure relief device, and the volume of water the cylinder
etc.). externally displaces at ambient pres-
Over-heated means a condition in sure.
which the temperature of any portion (2) Direct expansion method means a
of an aluminum cylinder has reached volumetric expansion test to calculate
176 °C (350 °F) or higher, or in which the a cylinder’s total and permanent ex-
temperature of any portion of a steel pansion by measuring the amount of
or nickel cylinder has reached 343 °C water forced into a cylinder at test
(650 °F) or higher. pressure, adjusted for the compress-
Permanent expansion means a perma- ibility of water, as a means of deter-
nent increase in a cylinder’s volume mining the expansion.
after the test pressure is released. [67 FR 51660, Aug. 8, 2002, as amended at 71
Proof pressure test means a pressure FR 33894, June 12, 2006]
test by interior pressurization without
the determination of a cylinder’s ex- § 180.205 General requirements for re-
pansion. qualification of specification cyl-
Rebuild means the replacement of a inders.
pressure part (e.g. a wall, head, or pres- (a) General. Each cylinder used for
sure fitting) by welding. the transportation of hazardous mate-
Rejected cylinder means a cylinder rials must be an authorized packaging.
that cannot be used for the transpor- To qualify as an authorized packaging,
tation of a hazardous material in com- each cylinder must conform to this
merce without repair, rebuilding, and subpart, the applicable requirements
requalification. specified in part 173 of this subchapter,
Repair means a procedure for correc- and the applicable requirements of sub-
tion of a rejected cylinder that may in- part C of part 178 of this subchapter.
volve welding. (b) Persons performing requalification
Requalification means the completion functions. No person may represent
of a visual inspection and/or the test(s) that a repair or requalification of a
required to be performed on a cylinder cylinder has been performed in accord-
to determine its suitability for contin- ance with the requirements in this sub-
ued service. chapter unless that person holds a cur-
Requalification identification number or rent approval issued under the proce-

RIN means a code assigned by DOT to dural requirements prescribed in sub-
uniquely identify a cylinder requali- part I of part 107 of this chapter. No
fication, repair, or rebuilding facility. person may mark a cylinder with a
322
RIN and a requalification date or oth- (1) Each cylinder that is requalified
erwise represent that a DOT specifica- in accordance with the requirements
tion or special permit cylinder has specified in this section must be
been requalified unless all applicable marked in accordance with § 180.213 or
requirements of this subpart have been the requirements of the Transport Can-
met. A person who requalifies cylinders ada TDG Regulations, or in the case of
must maintain the records prescribed a TC cylinder requalified in the United
in § 180.215 at each location at which it States by a DOT RIN holder, in accord-
inspects, tests, or marks cylinders. ance with the requirements of the
(c) Periodic requalification of cylinders. Transport Canada TDG Regulations ex-
Each cylinder bearing a DOT, CRC, cept that registration with Transport
BTC, or CTC specification marking Canada is not required and cylinders
must be requalified and marked as must be marked with the requalifiers
specified in the Requalification Table DOT issued requalifier identification
in this subpart or requalified and number.
marked by a facility registered by (2) Each cylinder that fails requali-
Transport Canada in accordance with fication must be:
the Transport Canada TDG Regula- (i) Rejected and may be repaired or
tions (IBR, see § 171.7 of this sub- rebuilt in accordance with § 180.211 or
chapter). Each cylinder bearing both a § 180.212, as appropriate; or
TC specification marking and also (ii) Condemned in accordance with
marked with a corresponding DOT paragraph (i) of this section.
specification marking must be requali- (3) For DOT specification cylinders,
fied and marked as specified in the Re- the marked service pressure may be
qualification Table in this subpart or changed upon approval of the Associate
requalified and marked by a facility Administrator and in accordance with
registered by Transport Canada in ac- written procedures specified in the ap-
cordance with the Transport Canada proval.
TDG Regulations (IBR, see § 171.7 of (4) For a specification 3, 3A, 3AA,
this subchapter). Each cylinder bearing 3AL, 3AX, 3AAX, 3B, 3BN, or 3T cyl-
a DOT special permit number must be inder filled with gases in other than Di-
requalified and marked in conformance vision 2.2, from the first requalification
with this section and the terms of the due on or after December 31, 2003, the
applicable special permit. Each cyl- burst pressure of a CG–1, CG–4, or CG–
inder bearing only a TC mark must be 5 pressure relief device must be at test
requalified and marked as specified in pressure with a tolerance of plus zero
the Transport Canada TDG Regula- to minus 10%. An additional 5% toler-
tions (IBR, see § 171.7 of this sub- ance is allowed when a combined rup-
chapter), except that registration with ture disc is placed inside a holder. This
Transport Canada is not required and requirement does not apply if a CG–2,
cylinders must be marked with the re- CG–3 or CG–9 thermally activated relief
qualifiers DOT issued requalifier iden- device or a CG–7 reclosing pressure
tification number. No cylinder may be valve is used on the cylinder.
filled with a hazardous material and of- (d) Conditions requiring test and inspec-
fered for transportation in commerce tion of cylinders. Without regard to any
unless that cylinder has been success- other periodic requalification require-
fully requalified and marked in accord- ments, a cylinder must be tested and
ance with this subpart. A cylinder may inspected in accordance with this sec-
be requalified at any time during or be- tion prior to further use if—
fore the month and year that the re- (1) The cylinder shows evidence of
qualification is due. However, a cyl- dents, corrosion, cracked or abraded
inder filled before the requalification areas, leakage, thermal damage, or any
becomes due may remain in service other condition that might render it
until it is emptied. A cylinder with a unsafe for use in transportation;
specified service life may not be re- (2) The cylinder has been in an acci-
filled and offered for transportation dent and has been damaged to an ex-
after its authorized service life has extent that may adversely affect its lad-
pired. ing retention capability;
323
§ 180.205 49 CFR Ch. I (10–1–18 Edition)
(3) The cylinder shows evidence of or apparatus (SCUBA), self-contained

is known to have been over-heated; or breathing apparatus (SCBA), or oxygen
(4) The Associate Administrator de- service must be inspected for sustained
termines that the cylinder may be in load cracking in accordance with Ap-
an unsafe condition. pendix C of this part at the first sched-
(e) Cylinders containing Class 8 (corro- uled 5-year requalification period after
sive) liquids. A cylinder previously con- January 1, 2007, and every five years
taining a Class 8 (corrosive) liquid may thereafter.
not be used to transport a Class 2 ma- (g) Pressure test. (1) Unless otherwise
terial in commerce unless the cylinder provided, each cylinder required to be
is— retested under this subpart must be re-
(1) Visually inspected, internally and tested by means suitable for measuring
externally, in accordance with para- the expansion of the cylinder under
graph (f) of this section and the inspec- pressure. Bands and other removable
tion is recorded as prescribed in attachments must be loosened or re-
§ 180.215; moved before testing so that the cyl-
(2) Requalified in accordance with inder is free to expand in all directions.
this section, regardless of the date of (2) The pressure indicating device of
the previous requalification; the testing apparatus must permit
(3) Marked in accordance with reading of pressures to within 1% of
§ 180.213; and the minimum prescribed test pressure
(4) Decontaminated to remove all sig- of each cylinder tested, except that for
nificant residue or impregnation of the an analog device, interpolation to 1⁄2 of
Class 8 material. the marked gauge divisions is accept-
(f) Visual inspection. Except as other- able. The expansion-indicating device
wise provided in this subpart, each of the testing apparatus must also per-
time a cylinder is pressure tested, it mit incremental reading of the cyl-
must be given an internal and external inder expansion to 1% of the total ex-
visual inspection. pansion of each cylinder tested or 0.1
(1) The visual inspection must be per- cc, whichever is larger. Midpoint visual
formed in accordance with the fol- interpolation is permitted.
lowing CGA Pamphlets: C–6 for steel (3) Each day before retesting, the re-
and nickel cylinders (IBR, see § 171.7 of tester shall confirm, by using a cali-
this subchapter); C–6.1 for seamless brated cylinder or other method au-
aluminum cylinders (IBR, see § 171.7 of thorized in writing by the Associate
this subchapter); C–6.2 for fiber rein- Administrator, that:
forced composite special permit cyl- (i) The pressure-indicating device, as
inders (IBR, see § 171.7 of this subpart of the retest apparatus, is accu-
chapter); C–6.3 for low pressure alu- rate within ±1.0% of the prescribed test
minum cylinders (IBR, see § 171.7 of pressure of any cylinder tested that
this subchapter); C–8 for DOT 3HT cyl- day. The pressure indicating device,
inders (IBR, see § 171.7 of this sub- itself, must be certified as having an
chapter); and C–13 for DOT 8 series cyl- accuracy of ±0.5%, or better, of its full
inders (IBR, see § 171.7 of this sub- range, and must permit readings of
chapter). pressure from 90%-110% of the min-
(2) For each cylinder with a coating imum prescribed test pressure of the
or attachments that would inhibit in- cylinder to be tested. The accuracy of
spection of the cylinder, the coating or the pressure indicating device within
attachments must be removed before the test system can be demonstrated at
performing the visual inspection. any point within 500 psig of the actual
(3) Each cylinder subject to visual in- test pressure for test pressures at or
spection must be approved, rejected, or above 3000 psig, or 10% of the actual
condemned according to the criteria in test pressure for test pressures below
the applicable CGA pamphlet. 3000 psig.
(4) In addition to other requirements (ii) The expansion-indicating device,
prescribed in this paragraph (f), each as part of the retest apparatus, gives a
specification cylinder manufactured of stable reading of expansion and is accu-
aluminum alloy 6351–T6 and used in rate to ±1.0% of the total expansion of
self-contained underwater breathing any cylinder tested or 0.1 cc, whichever
324
is larger. The expansion-indicating de- (2) The requalifier must notify the
vice itself must have an accuracy of cylinder owner, in writing, that the
±0.5%, or better, of its full scale. cylinder has been rejected.
(4) The test equipment must be (3) Unless the cylinder is requalified
verified to be accurate within ±1.0% of in conformance with requirements in
the calibrated cylinder’s pressure and § 180.211, it may not be filled with a
corresponding expansion values. This hazardous material and offered for
may be accomplished by bringing the transportation in commerce where use
pressure to a value shown on the cali- of a specification packaging is re-
bration certificate for the calibrated quired.
cylinder used and verifying that the re- (4) A rejected cylinder with a service
sulting total expansion is within ±1.0% pressure of less than 900 psig may be
requalified and marked if the cylinder
of the total expansion shown on the
is repaired or rebuilt and subsequently
calibration certificate. Alternatively,
inspected and tested in conformance
calibration may be demonstrated by
with—
bringing the total expansion to a
(i) The visual inspection require-
known value on the calibration certifi- ments of paragraph (f) of this section;
cate for the calibrated cylinder used (ii) Part 178 of this subchapter and
and verifying that the resulting pres- this part;
sure is within ±1.0% of the pressure (iii) Any special permit covering the
shown on the calibration certificate. manufacture, requalification, and/or
The calibrated cylinder must show no use of that cylinder; and
permanent expansion. The retester (iv) Any approval required under
must demonstrate calibration in con- § 180.211.
formance with this paragraph (g) to an (i) Cylinder condemnation. (1) A cyl-
authorized inspector on any day that it inder must be condemned when—
retests cylinders. A retester must (i) The cylinder meets a condition for
maintain calibrated cylinder certifi- condemnation under the visual inspec-
cates in conformance with tion requirements of paragraph (f) of
§ 180.215(b)(4). this section.
(5) Minimum test pressure must be (ii) The cylinder leaks through its
maintained for at least 30 seconds, and wall.
as long as necessary for complete ex- (iii) Evidence of cracking exists to
pansion of the cylinder. A system the extent that the cylinder is likely to
check may be performed at or below be weakened appreciably.
90% of test pressure prior to the retest. (iv) For a DOT specification cylinder,
In the case of a malfunction of the test other than a DOT 4E aluminum cyl-
equipment, the test may be repeated at inder or a special permit cylinder, per-
a pressure increased by 10% or 100 psig, manent expansion exceeds 10 percent of
whichever is less. This paragraph (g) total expansion.
(v) For a DOT 3HT cylinder—
does not authorize retest of a cylinder
(A) The pressure test yields an elas-
otherwise required to be condemned
tic expansion exceeding the marked re-
under paragraph (i) of this section.
jection elastic expansion (REE) value.
(6) Training materials may be used (B) The cylinder shows evidence of
for training persons who requalify cyl- denting or bulging.
inders using the volumetric expansion (C) The cylinder bears a manufacture
test method. or an original test date older than
(h) Cylinder rejection. A cylinder must twenty-four years or after 4380 pressur-
be rejected when, after a visual inspec- izations, whichever occurs first. If a
tion, it meets a condition for rejection cylinder is refilled, on average, more
under the visual inspection require- than once every other day, an accurate
ments of paragraph (f) of this section. record of the number of rechargings
(1) Except as provided in paragraphs must be maintained by the cylinder
(h)(3) and (h)(4) of this section, a cyl- owner or the owner’s agent.
inder that is rejected may not be (vi) For a DOT 4E aluminum cyl-
marked as meeting the requirements of inder, permanent expansion exceeds 12
this section. percent of total expansion.
325
§ 180.207 49 CFR Ch. I (10–1–18 Edition)
(vii) For a DOT special permit cyl- hazardous materials must conform to
inder, permanent expansion exceeds the requirements prescribed in para-
the limit in the applicable special per- graphs (a), (b) and (d) in § 180.205.
mit, or the cylinder meets another cri- (2) No pressure receptacle due for re-
terion for condemnation in the applica- qualification may be filled with a haz-
ble special permit. ardous material and offered for trans-
(viii) For an aluminum or an alu- portation in commerce unless that
minum-lined composite special permit pressure receptacle has been success-
cylinder, the cylinder is known to have
fully requalified and marked in accord-
been or shows evidence of having been
over-heated. ance with this subpart. A pressure re-
(2) When a cylinder must be con- ceptacle may be requalified at any
demned, the requalifier must— time during or before the month and
(i) Stamp a series of X’s over the year that the requalification is due.
DOT specification number and the However, a pressure receptacle filled
marked pressure or stamp ‘‘CON- before the requalification becomes due
DEMNED’’ on the shoulder, top head, may remain in service until it is
or neck using a steel stamp; emptied.
(ii) For composite cylinders, securely (3) No person may requalify a UN
affix to the cylinder a label with the composite pressure receptacle for con-
word ‘‘CONDEMNED’’ overcoated with tinued use beyond its 15-years author-
epoxy near, but not obscuring, the ized service life. A pressure receptacle
original cylinder manufacturer’s label; with a specified service life may not be
or refilled and offered for transportation
(iii) As an alternative to the stamp- after its authorized service life has ex-
ing or labeling as described in this
pired unless approval has been obtained
paragraph (i)(2), at the direction of the
in writing from the Associate Adminis-
owner, the requalifier may render the
cylinder incapable of holding pressure. trator.
(3) No person may remove or oblit- (b) Periodic requalification of UN pres-
erate the ‘‘CONDEMNED’’ marking. In sure receptacles. (1) Each pressure recep-
addition, the requalifier must notify tacle that is successfully requalified in
the cylinder owner, in writing, that the accordance with the requirements spec-
cylinder is condemned and may not be ified in this section must be marked in
filled with hazardous material and of- accordance with § 180.213. The requali-
fered for transportation in commerce fication results must be recorded in ac-
where use of a specification packaging cordance § 180.215.
is required. (2) Each pressure receptacle that fails
[67 FR 51660, Aug. 8, 2002, as amended at 68 requalification must be rejected or
FR 24662, May 8, 2003; 68 FR 75764, Dec. 31, condemned in accordance with the ap-
2003; 70 FR 34077, June 13, 2005; 70 FR 73166, plicable ISO requalification standard.
Dec. 9, 2005; 71 FR 51128, Aug. 29, 2006; 73 FR (c) Requalification interval. Each UN
4720, Jan. 28, 2008; 75 FR 53597, Sept. 1, 2010;
82 FR 15896, Mar. 30, 2017] pressure receptacle that becomes due
for periodic requalification must be re-
§ 180.207 Requirements for requalifica- qualified at the interval specified in
tion of UN pressure receptacles. the following table:
(a) General. (1) Each UN pressure re-
ceptacle used for the transportation of
TABLE 1—REQUALIFICATION INTERVALS OF UN PRESSURE RECEPTACLES
Interval (years) UN pressure receptacles/hazardous materials
10 ................... Pressure receptacles for all hazardous materials except as noted below (also for dissolved acetylene, see
paragraph (d)(3) of this section):
5 ..................... Composite pressure receptacles.
5 ..................... Metal hydride storage systems
5 ..................... Pressure receptacles used for:

All Division 2.3 materials.
UN1013, Carbon dioxide.
326
TABLE 1—REQUALIFICATION INTERVALS OF UN PRESSURE RECEPTACLES—Continued

Interval (years) UN pressure receptacles/hazardous materials
UN1043, Fertilizer ammoniating solution with free ammonia.

UN1051, Hydrogen cyanide, stabilized containing less than 3% water.
UN1052, Hydrogen fluoride, anhydrous.
UN1745, Bromine pentafluoride.
UN1746, Bromine trifluoride.
UN2073, Ammonia solution.
UN2495, Iodine pentafluoride.
UN2983, Ethylene Oxide and Propylene oxide mixture, not more than 30% ethylene oxide.
5 ..................... Pressure receptacles used for adsorbed gases.
(d) Requalification procedures. Each be requalified in accordance with ISO

UN pressure receptacle that becomes 10462:2013(E) (IBR, see § 171.7 of this sub-
due for requalification must be requali- chapter). Until December 31, 2018 re-
fied at the interval prescribed in para- qualification may be done in accord-
graph (c) of this section and in accordance with ISO 10462(E) (IBR, see § 171.7
ance with the procedures contained in of this subchapter). The porous mass
the following standard, as applicable. and the shell must be requalified no
When a pressure test is performed on a sooner than 3 years, 6 months, from the
UN pressure receptacle, the test must date of manufacture. Thereafter, subse-
be a water jacket volumetric expansion quent requalifications of the porous
test suitable for the determination of mass and shell must be performed at
the cylinder expansion or a hydraulic least once every ten years.
proof pressure test. The test equipment (4) Composite UN cylinders: Each
must conform to the accuracy require- composite cylinder must be inspected
ments in § 180.205(g). Alternative meth- and tested in accordance with ISO 11623
ods (e.g., acoustic emission) or requali- (IBR, see § 171.7 of this subchapter).
fication procedures may be performed (5) UN cylinders for adsorbed gases:
if prior approval has been obtained in Each UN cylinder for adsorbed gases
writing from the Associate Adminis- must be inspected and tested in accord-
trator. ance with § 173.302c and ISO 11513:2011
(1) Seamless steel: Each seamless (IBR, see § 171.7 of this subchapter).
steel UN pressure receptacle, including [71 FR 33894, June 12, 2006, as amended at 71
MEGC’s pressure receptacles, must be FR 54397, Sept. 14, 2006; 76 FR 3389, Jan. 19,
requalified in accordance with ISO 6406 2011; 80 FR 1168, Jan. 8, 2015; 82 FR 15897, Mar.
(IBR, see § 171.7 of this subchapter). 30, 2017]
However, UN cylinders with a tensile
strength greater than or equal to 950 § 180.209 Requirements for requalifica-
MPa must be requalified by ultrasonic tion of specification cylinders.
examination in accordance with ISO (a) Periodic qualification of cylinders.
6406. Each specification cylinder that be-
(2) Seamless UN aluminum: Each comes due for periodic requalification,
seamless aluminum UN pressure recep- as specified in the following table,
tacle must be requalified in accordance must be requalified and marked in con-
with ISO 10461 (IBR, see § 171.7 of this formance with the requirements of this
subchapter). subpart. Requalification records must
(3) Dissolved acetylene UN cylinders: be maintained in accordance with
Each dissolved acetylene cylinder must § 180.215. Table 1 follows:
TABLE 1—REQUALIFICATION OF CYLINDERS 1
Specification under which Minimum test pressure Requalification period
cylinder was made (psig) 2 (years)
DOT 3 ....................................................... 3000 psig ................................................. 5.

DOT 3A, 3AA ........................................... 5/3 times service pressure, except non- 5, 10, or 12 (see § 180.209(b), (e), (f),
corrosive service (see § 180.209(g)). (h), and (j).
DOT 3AL .................................................. 5/3 times service pressure ....................... 5, 10 or 12 (see § 180.209(e), (j) and
§ 180.209(m) 3).
DOT 3AX, 3AAX ...................................... 5/3 times service pressure ....................... 5, 10 (see § 180.209(e).
327
§ 180.209 49 CFR Ch. I (10–1–18 Edition)
TABLE 1—REQUALIFICATION OF CYLINDERS 1—Continued

Specification under which Minimum test pressure Requalification period
cylinder was made (psig) 2 (years)
3B, 3BN .................................................... 2 times service pressure (see 5 or 10 (see § 180.209(e), (f)).
§ 180.209(g)).
3E ............................................................. Test not required.
3HT ........................................................... 5/3 times service pressure ....................... 3 (see §§ 180.209(k) and 180.213(c)).
3T ............................................................. 5/3 times service pressure ....................... 5.
4AA480 ..................................................... 2 times service pressure (see 5 or 10 (see § 180.209(e) or (h)).
§ 180.209(g)).
4B, 4BA, 4BW, 4B–240ET ....................... 2 times service pressure, except non- 5, 10, or 12 (see § 180.209(e), (f), and
corrosive service (see § 180.209(g)). (j)).
4D, 4DA, 4DS .......................................... 2 times service ......................................... 5.
DOT 4E .................................................... 2 times service pressure, except non- 5 or 10 (see § 180.209(e)).
corrosive (see § 180.209(g)).
4L ............................................................. Test not required.
8, 8AL ....................................................... .................................................................. 10 or 20 (see § 180.209(i)).
Exemption or special permit cylinder ....... See current exemption or special permit See current exemption or special permit.
Foreign cylinder (see § 173.301(j) of this As marked on cylinder, but not less than 5 (see §§ 180.209(l) and 180.213(d)(2)).
subchapter for restrictions on use). 5/3 of any service or working pressure
marking.
1 Any cylinder not exceeding 2 inches outside diameter and less than 2 feet in length is excepted from volumetric expansion
test.
2 For cylinders not marked with a service pressure, see § 173.301a(b) of this subchapter.
3 This provision does not apply to cylinders used for carbon dioxide, fire extinguisher or other industrial gas service.
(b) DOT 3A or 3AA cylinders. (1) A cyl- (v) The cylinder is not used for un-
inder conforming to specification DOT derwater breathing.
3A or 3AA with a water capacity of 56.7 (vi) Each cylinder is stamped with a
kg (125 lb) or less that is removed from five-pointed star at least one-fourth of
any cluster, bank, group, rack, or vehi- an inch high immediately following the
cle each time it is filled, may be retest date.
qualified every ten years instead of (2) If, since the last required requali-
every five years, provided the cylinder fication, a cylinder has not been used
conforms to all of the following condi- exclusively for the gases specifically
tions: identified in paragraph (b)(1)(ii) of this
(i) The cylinder was manufactured section, but currently conforms with
after December 31, 1945. all other provisions of paragraph (b)(1)
of this section, it may be requalified
(ii) The cylinder is used exclusively
every 10 years instead of every five
for air; argon; cyclopropane; ethylene;
years, provided it is first requalified
helium; hydrogen; krypton; neon; ni-
and examined as prescribed by
trogen; nitrous oxide; oxygen; sulfur
§ 173.302a(b) (2), (3) and (4) of this sub-
hexafluoride; xenon; chlorinated hydro-
chapter.
carbons, fluorinated hydrocarbons, liq- (3) Except as specified in paragraph
uefied hydrocarbons, and mixtures (b)(2) of this section, if a cylinder,
thereof that are commercially free marked with a star, is filled with a
from corroding components; permitted compressed gas other than as specified
mixtures of these gases (see § 173.301(d) in paragraph (b)(1)(ii) of this section,
of this subchapter); and permitted mix- the star following the most recent test
tures of these gases with up to 30 per- date must be obliterated. The cylinder
cent by volume of carbon dioxide, pro- must be requalified five years from the
vided the gas has a dew point at or marked test date, or prior to the first
below minus (52 °F) at 1 atmosphere. filling with a compressed gas, if the re-
(iii) Before each refill, the cylinder is quired five-year requalification period
removed from any cluster, bank, group, has passed.
rack or vehicle and passes the hammer (c) DOT 4-series cylinders. A DOT 4-se-
test specified in CGA Pamphlet C–6 ries cylinder, except a 4L cylinder, that
(IBR, see § 171.7 of this subchapter). at any time shows evidence of a leak or
(iv) The cylinder is dried imme- of internal or external corrosion, dent-
diately after hydrostatic testing to re- ing, bulging or rough usage to the ex-
move all traces of water. tent that it is likely to be weakened
328
appreciably, or that has lost five per- nents, and protected externally by a
cent or more of its official tare weight suitable corrosion resistant coating
must be requalified before being re- (such as galvanizing or painting) and
filled and offered for transportation. internally by a suitable corrosion re-
(Refer to CGA Pamphlet C–6 or C–6.3, sistant lining (such as galvanizing)
as applicable, regarding cylinder weak- may be tested every 10 years instead of
ening.) After testing, the actual tare every five years, provided a visual in-
weight must be recorded as the new ternal and external examination of the
tare weight. cylinder is conducted every five years
(d) Cylinders 5.44 kg (12 lb) or less with in accordance with CGA Pamphlet C–6.
service pressures of 300 psig or less. A cyl- The cylinder must be examined at each
inder of 5.44 (12 lb) or less water capac- filling, and rejected if a dent, corroded
ity authorized for service pressure of area, leak or other condition indicates
300 psig or less must be given a com- possible weakness.
plete external visual inspection at the (g) Visual inspections. A cylinder con-
time periodic requalification becomes forming to a specification listed in the
due. External visual inspection must be table in this paragraph and used exclu-
in accordance with CGA Pamphlet C–6
sively in the service indicated may, in-
or C–6.1 (IBR, see § 171.7 of this sub-
stead of a periodic hydrostatic test, be
chapter). The cylinder may be proof
given a complete external visual in-
pressure tested. The test is successful
spection at the time periodic requali-
if the cylinder, when examined under
test pressure, does not display a defect fication becomes due. External visual
described in § 180.205(i)(1) (ii) or (iii). inspection must be in accordance with
Upon successful completion of the test CGA Pamphlet C–6 or C–6.3, as applica-
and inspection, the cylinder must be ble (IBR, see § 171.7 of this subchapter).
marked in accordance with § 180.213. When this inspection is used instead of
(e) Proof pressure test. A cylinder hydrostatic pressure testing, subse-
made in conformance with DOT Speci- quent inspections are required at five-
fications 4B, 4BA, 4BW, or 4E protected year intervals after the first inspec-
externally by a suitable corrosion-re- tion. After May 31, 2004, inspections
sistant coating and used exclusively for must be made only by persons holding
non-corrosive gas that is commercially a current RIN and the results recorded
free from corroding components may and maintained in accordance with
be requalified by volumetric expansion § 180.215. Records must include: date of
testing or proof pressure testing every inspection (month and year); DOT spec-
10 years instead of every 5 years. When ification number; cylinder identifica-
subjected to a proof pressure test, the tion (registered symbol and serial num-
cylinder must be carefully examined ber, date of manufacture, and owner);
under test pressure and removed from type of cylinder protective coating (in-
service if a leak or defect is found. cluding statement as to need of refin-
(f) Poisonous materials. A cylinder ishing or recoating); conditions
conforming to specification DOT 3A, checked (e.g., leakage, corrosion, goug-
3AA, 3B, 4BA, or 4BW having a service es, dents or digs in shell or heads, bro-
pressure of 300 psig or less and used ex- ken or damaged footring or protective
clusively for methyl bromide, liquid; ring or fire damage); disposition of cyl-
mixtures of methyl bromide and ethyl- inder (returned to service, returned to
ene dibromide, liquid; mixtures of cylinder manufacturer for repairs or
methyl bromide and chlorpicrin, liquid; condemned). A cylinder passing re-
mixtures of methyl bromide and petro- qualification by the external visual in-
leum solvents, liquid; or methyl bro- spection must be marked in accordance
mide and nonflammable, nonliquefied with § 180.213. Specification cylinders
compressed gas mixtures, liquid; com- must be in exclusive service as shown
mercially free of corroding compo- in the following table:
Cylinders conforming to— Used exclusively for—
DOT 3A, DOT 3AA, DOT 3A480X, DOT 4AA480 ...................... Anhydrous ammonia of at least 99.95% purity.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT Butadiene, inhibited, that is commercially free from corroding
4BA, DOT 4BW. components.
329
§ 180.209 49 CFR Ch. I (10–1–18 Edition)
Cylinders conforming to— Used exclusively for—
DOT 3A, DOT 3A480X, DOT 3AA, DOT 3B, DOT 4AA480, Cyclopropane that is commercially free from corroding compo-
DOT 4B, DOT 4BA, DOT 4BW. nents.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 4B, DOT 4BA, DOT Chlorinated hydrocarbons and mixtures thereof that are com-
4BW, DOT 4E. mercially free from corroding components.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 4B, DOT 4BA, DOT Fluorinated hydrocarbons and mixtures thereof that are com-
4BW, DOT 4E. mercially free from corroding components.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT Liquefied hydrocarbon gas that is commercially free from cor-
4BA, DOT 4BW, DOT 4E. roding components.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT Liquefied petroleum gas that meets the detail requirements lim-
4BA, DOT 4BW, DOT 4E. its in Table 1 of ASTM 1835, Standard Specification for Liq-
uefied Petroleum (LP) Gases (incorporated by reference;
see § 171.7 of this subchapter) or an equivalent standard
containing the same limits.
DOT 3A, DOT 3AA, DOT 3B, DOT 4B, DOT 4BA, DOT 4BW, Methylacetylene-propadiene, stabilized, that is commercially
DOT 4E. free from corroding components.
DOT 3A, DOT 3AA, DOT 3B, DOT 4B, DOT 4BA, DOT 4BW .. Anhydrous mono, di,trimethylamines that are commercially free
from corroding components.
DOT 4B240, DOT 4BW240 ......................................................... Ethyleneimine, stabilized.
DOT 4BW .................................................................................... Alkali metal alloys, liquid, n.o.s., Alkali metal dispersions or Al-
kaline earth metal dispersions, Potassium, Potassium So-
dium alloys and Sodium that are commercially free of cor-
roding components.
(h) Cylinders containing anhydrous am- (i) Requalification of DOT-8 series cyl-
monia. A cylinder conforming to speci- inders. (1) Each owner of a DOT-8 series
fication DOT 3A, 3A480X, or 4AA480 cylinder used to transport acetylene
used exclusively for anhydrous ammo- must have the cylinder shell and the
nia, commercially free from corroding porous filler requalified in accordance
components, and protected externally with CGA Pamphlet C–13 (IBR, see
by a suitable corrosion-resistant coat- § 171.7 of this subchapter). Requalifica-
ing (such as paint) may be requalified tion must be performed in accordance
every 10 years instead of every five with the following schedule:
years.
Shell (visual inspection) requalification Porous filler requalification
Date of cylinder manu-
facture Initial Subsequent Intial Subsequent
Before January 1, 1991 Before January 1, 2001 10 years ....................... Before January 1, 2011 Not required.
On or after January 1, 10 years 1 ..................... 10 years ....................... 5 to 20 years 2 ............. Not required.
1991.
1 Years from the date of cylinder manufacture.
2 No sooner than 5 years, and no later than 20 years from the date of manufacture.
(2) Unless requalified and marked in as a fire extinguisher and meeting the
accordance with CGA Pamphlet C–13 requirements of § 173.309(a) of this sub-
before October 1, 1994, an acetylene cyl- chapter may be requalified in accord-
inder must be requalified by a person ance with this paragraph (j).
who holds a current RIN. (1) A DOT 4B, 4BA, 4B240ET or 4BW
(3) If a cylinder valve is replaced, a cylinder may be tested as follows:
cylinder valve of the same weight must (i) For a cylinder with a water capac-
be used or the tare weight of the cyl- ity of 5.44 kg (12 lb) or less, by volu-
inder must be adjusted to compensate metric expansion test using the water
for valve weight differential. jacket method or by proof pressure
(4) The person performing a visual in- test. A requalification must be per-
spection or requalification must record formed by the end of 12 years after the
the results as specified in § 180.215. original test date and at 12-year inter-
(5) The person performing a visual in- vals thereafter.
spection or requalification must mark (ii) For a cylinder having a water ca-
the cylinder as specified in § 180.213. pacity over 5.44 kg (12 lb)—
(j) Cylinder used as a fire extinguisher. (A) By proof pressure test. A requali-
Only a DOT specification cylinder used fication must be performed by the end
330
of 12 years after the original test date (1) It has been inspected, tested and
and at 7-year intervals; or marked (with only the month and year
(B) By volumetric expansion test using of test) in conformance with the proce-
the water jacket method. A requalifica- dures and requirements of this subpart
tion must be performed 12 years after or the Associate Administrator has au-
the original test date and at 12-year in- thorized the filling company to fill for-
tervals thereafter. eign cylinders under an alternative
(2) A DOT 3A, 3AA, or 3AL cylinder method of qualification; and
must be requalified by volumetric ex- (2) It is offered for transportation in
pansion test using the water jacket conformance with the requirements of
method. A requalification must be per- § 171.12(a)(4) or § 171.23(a)(4) of this sub-
formed 12 years after the original test chapter.
date and at 12-year intervals there- (m) DOT–3AL cylinders manufactured
after. of 6351–T6 aluminum alloy. In addition
(k) 3HT cylinders. In addition to the to the periodic requalification and
other requirements of this section, a marking described in § 180.205, each cyl-
cylinder marked DOT-3HT must be re- inder manufactured of aluminum alloy
qualified in accordance with CGA C–8 6351–T6 used in self-contained under-
(IBR, see § 171.7 of this subchapter). water breathing apparatus (SCUBA),
(l) Requalification of foreign cylinders self-contained breathing apparatus
filled for export. A cylinder manufac- (SCBA), or oxygen service must be re-
tured outside the United States, other qualified and inspected for sustained
than as provided in §§ 171.12(a) and load cracking in accordance with the
171.23(a) of this subchapter, that has non-destructive examination method
not been manufactured, inspected, test- described in the following table. Each
ed and marked in accordance with part cylinder with sustained load cracking
178 of this subchapter may be filled that has expanded into the neck
with compressed gas in the United threads must be condemned in accord-
States, and shipped solely for export if ance with § 180.205(i). This provision
it meets the following requirements, in does not apply to cylinders used for
addition to other requirements of this carbon dioxide, fire extinguisher or
subchapter: other industrial gas service.
REQUALIFICATION AND INSPECTION OF DOT–3AL CYLINDERS MADE OF ALUMINUM ALLOY 6351–T6
Requalifica-
Sustained Load Cracking Con-
Requalification requirement Examination procedure 1 tion period
demnation Criteria 2 (years)
Eddy current examination combined Eddy current—In accordance with Any crack in the neck or shoulder 5
with visual inspection. Appendix C of this part. of 2 thread lengths or more.
Visual inspection—In accordance
with CGA Pamphlet C–6.1 (IBR;
see § 171.7 of this subchapter).
1 The requalifier performing eddy current must be familiar with the eddy current equipment and must standardize (calibrate) the
system in accordance with the requirements provided in Appendix C to this part.
2 The eddy current must be applied from the inside of the cylinder’s neck to detect any sustained load cracking that has ex-
panded into the neck threads.
[67 FR 51660, Aug. 8, 2002, as amended at 68 § 180.211 Repair, rebuilding and re-
FR 24662, May 8, 2003; 68 FR 55544, Sept. 26, heat treatment of DOT-4 series
2003; 68 FR 48572, Aug. 14, 2003; 68 FR 75764, specification cylinders.
Dec. 31, 2003; 70 FR 73166, Dec. 9, 2005; 71 FR
51128, Aug. 29, 2005; 72 FR 55696, Oct. 1, 2007; (a) General requirements for repair and
74 FR 53189, Oct. 16, 2009; 81 FR 3685, Jan. 21, rebuilding. Any repair or rebuilding of a
2016; 81 FR 35545, June 2, 2016] DOT–4 series cylinder must be per-
EDITORIAL NOTE: At 71 FR 54397, Sept. 14, formed by a person holding an approval
2006, § 180.209 was amended in (a)(1) table 1; as specified in § 107.805 of this chapter
however, because of the inaccurate amend- or by a registered facility in Canada in

atory language, the amendment could not be accordance with the Transport Canada
incorporated. TDG Regulations (IBR, see § 171.7 of
this subchapter). A person performing
331
§ 180.211 49 CFR Ch. I (10–1–18 Edition)
a rebuild function is considered a man- (c) Additional repair requirements for

ufacturer subject to the requirements 4L cylinders. (1) Repairs to a DOT 4L
of § 178.2(a)(2) and subpart C of part 178 cylinder must be performed in accord-
of this subchapter. The person per- ance with paragraphs (a) and (b) of this
forming a repair, rebuild, or reheat section and are limited to the fol-
treatment must record the test results lowing:
as specified in § 180.215. Each cylinder (i) The removal of either end of the
that is successfully repaired or rebuilt insulation jacket to permit access to
must be marked in accordance with the cylinder, piping system, or neck
§ 180.213. tube.
(b) General repair requirements. Each (ii) The replacement of the neck
repair of a DOT 4-series cylinder must tube. At least a 13 mm (0.51 inch) piece
be made in accordance with the fol- of the original neck tube must be pro-
lowing conditions: truding above the cylinder’s top end.
(1) The repair and the inspection of The original weld attaching the neck
the work performed must be made in tube to the cylinder must be sound and
accordance with the requirements of the replacement neck tube must be
the cylinder specification. welded to this remaining piece of the
(2) The person performing the repair original neck tube.
must use the procedure, equipment, (iii) The replacement of material
and filler metal or brazing material as such as, but not limited to, the insu-
authorized by the approval issued lating material and the piping system
under § 107.805 of this chapter. within the insulation space is author-
(3) Welding and brazing must be per- ized. The replacement material must
formed on an area free from contami- be equivalent to that used at the time
nants. of original manufacture.
(4) A weld defect, such as porosity in (iv) Other welding procedures that
a pressure retaining seam, must be are permitted by CGA Pamphlet C–3
completely removed before re-welding. (IBR, see § 171.7 of this subchapter), and
Puddling may be used to remove a weld not excluded by the definition of ‘‘re-
defect only by the tungsten inert gas build,’’ are authorized.
shielded arc process. (2) After repair, the cylinder must
(5) After removal of a non-pressure be—
attachment and before its replacement, (i) Pressure tested in accordance with
the cylinder must be given a visual in- the specifications under which the cyl-
spection in accordance with § 180.205(f). inder was originally manufactured;
(6) Reheat treatment of DOT 4B, 4BA (ii) Leak tested before and after as-
or 4BW specification cylinders after re- sembly of the insulation jacket using a
placement of non-pressure attachments mass spectrometer detection system;
is not required when the total weld ma- and
terial does not exceed 20.3 cm (8 (iii) Tested for heat conductivity re-
inches). Individual welds must be at quirements.
least 7.6 cm (3 inches) apart. (d) General rebuilding requirements. (1)
(7) After repair of a DOT 4B, 4BA or The rebuilding of a DOT 4-series cyl-
4BW cylinder, the weld area must be inder must be made in accordance with
leak tested at the service pressure of the following requirements:
the cylinder. (i) The person rebuilding the cylinder
(8) Repair of weld defects must be must use the procedures and equipment
free of cracks. as authorized by the approval issued
(9) When a non-pressure attachment under § 107.805 of this chapter.
with the original cylinder specification (ii) After removal of a non-pressure
markings is replaced, all markings component and before replacement of
must be transferred to the attachment any non-pressure component, the cyl-
on the repaired cylinder. inder must be visually inspected in ac-
(10) Walls, heads or bottoms of cyl- cordance with CGA Pamphlet C–6 (IBR,
inders with defects or leaks in base see § 171.7 of this subchapter).

metal may not be repaired, but may be (iii) The rebuilder may rebuild a DOT
replaced as provided for in paragraph 4B, 4BA or 4BW cylinder having a
(d) of this section. water capacity of 9.07 kg (20 lb) or
332
greater by replacing a head of the cyl- formed in accordance with paragraph

inder using a circumferential joint. (d) of this section. Rebuilding of a DOT
When this weld joint is located at other 4L cylinder is:
than an original welded joint, a nota- (i) Substituting or adding material in
tion of this modification must be the insulation space not identical to
shown on the Manufacturer’s Report of that used in the original manufacture
Rebuilding in § 180.215(c)(2). The weld of that cylinder;
joint must be on the cylindrical section (ii) Making a weld repair not to ex-
of the cylinder. ceed 150 mm (5.9 inches) in length on
(iv) Any welding and the inspection
the longitudinal seam of the cylinder
of the rebuilt cylinder must be in ac-
or 300 mm (11.8 inches) in length on a
cordance with the requirements of the
applicable cylinder specification and circumferential weld joint of the cyl-
the following requirements: inder; or
(A) Rebuilding of any cylinder in- (iii) Replacing the outer jacket.
volving a joint subject to internal pres- (2) Reheat treatment of cylinders is
sure may only be performed by fusion prohibited.
welding; (3) After rebuilding, each inner con-
(B) Welding must be performed on an tainment vessel must be proof pressure
area free from contaminants; and tested at 2 times its service pressure.
(C) A weld defect, such as porosity in Each completed assembly must be
a pressure retaining seam, must be leak-tested using a mass spectrometer
completely removed before re-welding. detection system.
Puddling may be used to remove a weld (f) Reheat treatment. (1) Prior to re-
defect only by using the tungsten inert heat treatment, each cylinder must be
gas shielded arc process. given a visual inspection, internally
(2) Any rebuilt cylinder must be— and externally, in accordance with
(i) Heat treated in accordance with § 180.205(f).
paragraph (f) of this section;
(2) Cylinders must be segregated in
(ii) Subjected to a volumetric expan-
sion test on each cylinder. The results lots for reheat treatment. The reheat
of the tests must conform to the appli- treatment and visual inspection must
cable cylinder specification; be performed in accordance with the
(iii) Inspected and have test data re- specification for the cylinders except
viewed to determine conformance with as provided in paragraph (f)(4) of this
the applicable cylinder specification; section.
and (3) After reheat treatment, each cyl-
(iv) Made of material conforming to inder in the lot must be subjected to a
the specification. Determination of volumetric expansion test and meet
conformance shall include chemical the acceptance criteria in the applica-
analysis, verification, inspection and ble specification or be scrapped.
tensile testing of the replaced part. (4) After all welding and heat treat-
Tensile tests must be performed on the ment, a test of the new weld must be
replaced part after heat treatment by performed as required by the original
lots defined in the applicable specifica- specification. The test results must be
tion. recorded in accordance with § 180.215.
(3) For each rebuilt cylinder, an in- (g) Repair, rebuilding and reheat treat-
spector’s report must be prepared to in- ment in Canada. Repair, rebuilding, or
clude the information listed in
reheat treatment of a DOT–4 series
§ 180.215(c).
specification cylinder performed by a
(4) Rebuilding a cylinder with brazed
seams is prohibited. registered facility in Canada in accord-
(5) When an end with the original cyl- ance with the Transport Canada TDG
inder specification markings is re- Regulations (IBR, see § 171.7 of this sub-
placed, all markings must be trans- chapter) is authorized.
ferred to the rebuilt cylinder. [67 FR 51660, Aug. 8, 2002, as amended at 68

(e) Additional rebuilding requirements FR 24664, May 8, 2003; 68 FR 75764, Dec. 31,
for DOT 4L cylinders. (1) The rebuilding 2003; 71 FR 54398, Sept. 14, 2006; 82 FR 15897,
of a DOT 4L cylinder must be per- Mar. 30, 2017]
333
§ 180.212 49 CFR Ch. I (10–1–18 Edition)
§ 180.212 Repair of seamless DOT 3-se- spection agency. Upon completion of

ries specification cylinders and the re-threading, the threads must be
seamless UN pressure receptacles. gauged in accordance with Federal
(a) General requirements for repair of Standard H–28 or an equivalent stand-
DOT 3-series cylinders and UN pressure ard containing the same specification
receptacles. (1) No person may repair a limits. The re-threaded cylinder must
DOT 3-series cylinder or a seamless UN be stamped clearly and legibly with the
pressure receptacle unless— words ‘‘RETHREAD’’ on the shoulder,
(i) The repair facility holds an ap- top head, or neck. No DOT specifica-
proval issued under the provisions in tion cylinder or UN cylinder may be re-
§ 107.805 of this chapter; and threaded more than one time without
(ii) Except as provided in paragraph approval of the Associate Adminis-
(b) of this section, the repair and the trator.
inspection is performed under the pro-
visions of an approval issued under sub- [71 FR 33895, June 12, 2006, as amended at 71
part H of part 107 of this chapter or by FR 54398, Sept. 14, 2006; 72 FR 55697, Oct. 1,
2007; 82 FR 15897, Mar. 30, 2017]
a facility registered by Transport Can-
ada in accordance with the Transport § 180.213 Requalification markings.
Canada TDG Regulations (IBR; see
§ 171.7 of this subchapter) and conform (a) General. Each cylinder or UN pres-
to the applicable cylinder specification sure receptacle requalified in accord-
or ISO standard contained in part 178 ance with this subpart with acceptable
of this subchapter. results must be marked as specified in
(2) The person performing the repair this section. Required specification
must prepare a report containing, at a markings may not be altered or re-
minimum, the results prescribed in moved.
§ 180.215. (b) Placement of markings. Each cyl-
(b) Repairs not requiring prior ap- inder must be plainly and permanently
proval. Approval is not required for the marked on the metal of the cylinder as
following specific repairs: permitted by the applicable specifica-
(1) The removal and replacement of a tion. Unless authorized by the cylinder
neck ring or foot ring on a DOT 3A, specification, marking on the cylinder
3AA or 3B cylinder or a UN pressure re- sidewall is prohibited.
ceptacle that does not affect a pressure (1) Requalification and required spec-
part of the cylinder when the repair is ification markings must be legible so
performed by a repair facility or a cyl- as to be readily visible at all times. Il-
inder manufacturer of these types of legible specification markings may be
cylinders. The repair may be made by remarked on the cylinder as provided
welding or brazing in conformance with by the original specification. Requali-
the original specification. After re-
fication markings may be placed on
moval and before replacement, the cyl-
any portion of the upper end of the cyl-
inder must be visually inspected and
inder excluding the sidewall, as pro-
any defective cylinder must be re-
vided in this section. Requalification
jected. The heat treatment, testing and
and required specification markings
inspection of the repair must be per-
formed under the supervision of an in- that are illegible may be reproduced on
spector and must be performed in ac- a metal plate and attached as provided
cordance with the original specifica- by the original specification.
tion. (2) Previous requalification markings
(2) External re-threading of DOT may not be obliterated, except that,
3AX, 3AAX or 3T specification cyl- when the space originally provided for
inders or a UN pressure receptacle requalification dates becomes filled,
mounted in a MEGC; or the internal re- additional dates may be added as fol-
threading of a DOT–3 series cylinder or lows:
a seamless UN pressure receptacle (i) All preceding requalification dates
when performed by a cylinder manufac- may be removed by peening provided

turer of these types of cylinders. The that—
repair work must be performed under (A) Permission is obtained from the
the supervision of an independent in- cylinder owner;
334
(B) The minimum wall thickness is A1

maintained in accordance with manu-
facturing specifications for the cyl- 9 06 X
inder; and 32
(C) The original manufacturing test
Where:
date is not removed.
(ii) When the cylinder is fitted with a ‘‘9’’ is the month of requalification
‘‘A123’’ is the RIN
footring, additional dates may be ‘‘06’’ is the year of requalification, and
marked on the external surface of the ‘‘X’’ represents the symbols described in
footring. paragraphs (f)(2) through (f)(8) of this
(c) Requalification marking method. section.
The depth of requalification markings
(1) Upon written request, variation
may not be greater than specified in
from the marking requirement may be
the applicable specification. The mark- approved by the Associate Adminis-
ings must be made by stamping, en- trator.
graving, scribing, or applying a label (2) Exception. A cylinder subject to
embedded in epoxy that will remain the requirements of § 171.23(a)(4) of this
legible and durable throughout the life subchapter may not be marked with a
of the cylinder, or by other methods RIN.
that produce a legible, durable mark. (e) Size of markings. The size of the
(1) A cylinder used as a fire extin- markings must be at least 6.35 mm (1⁄4
guisher (§ 180.209(j)) may be marked by in.) high, except RIN characters must
using a pressure sensitive label. be at least 3.18 mm (1⁄8 in.) high.
(2) For a DOT 3HT cylinder, the test (f) Marking illustrations. Examples of
date and RIN must be applied by low- required requalification markings for
stress steel stamps to a depth no great- DOT specification and special permit
er than that prescribed at the time of cylinders are illustrated as follows:
manufacture. Stamping on the sidewall (1) For designation of the 5-year volu-
is not authorized. metric expansion test, 10-year volu-
(3) For a composite cylinder, the re- metric expansion test for UN cylinders
qualification markings must be applied and cylinders conforming to § 180.209(f)
on a pressure sensitive label, securely and (h), or 12-year volumetric expan-
affixed in a manner prescribed by the sion test for fire extinguishers con-
cylinder manufacturer, near the origi- forming to § 173.309(a) of this sub-
nal manufacturer’s label. Stamping of chapter and cylinders conforming to
the composite surface is not author- § 180.209(e) and (g), the marking is as il-
ized. lustrated in paragraph (d) of this sec-
(d) Requalification markings. Each cyl- tion.
inder successfully passing requalifica- (2) For designation of the 10-year vol-
tion must be marked with the RIN set umetric expansion test for cylinders
in a square pattern, between the month conforming to § 180.209(b), the marking
and year of the requalification date. is as illustrated in paragraph (d) of this
The first character of the RIN must ap- section, except that the ‘‘X’’ is re-
pear in the upper left corner of the placed with a five-point star.
square pattern; the second in the upper (3) For designation of special filling
right; the third in the lower right; and limits up to 10% in excess of the
the fourth in the lower left. Example: marked service pressure for cylinders
A cylinder requalified in September conforming to § 173.302a(b) of this sub-
2006, and approved by a person who has chapter, the marking is as illustrated
been issued RIN ‘‘A123’’, would be in paragraph (d) of this section, except
marked plainly and permanently into that the ‘‘X’’ is replaced with a plus
the metal of the cylinder in accordance sign ‘‘ + ’’.
with location requirements of the cyl- (4) For designation of the proof pres-
inder specification or on a metal plate sure test, the marking is as illustrated
permanently secured to the cylinder in in paragraph (d) of this section, except
accordance with paragraph (b) of this that the ‘‘X’’ is replaced with the letter
section. An example of the markings ‘‘S’’.
prescribed in this paragraph (d) is as (5) For designation of the 5-year ex-
follows: ternal visual inspection for cylinders
335
§ 180.215 49 CFR Ch. I (10–1–18 Edition)
conforming to § 180.209(g), the marking corporated by reference in § 171.7 of this

is as illustrated in paragraph (d) of this subchapter applicable to the requali-
section, except that the ‘‘X’’ is re- fier’s activities. This information must
placed with the letter ‘‘E’’. be the same as contained in the edition
(6) For designation of DOT 8 series incorporated by reference in § 171.7 of
cylinder shell requalification only, the this subchapter.
marking is as illustrated in paragraph (b) Requalification records. Daily
(d) of this section, except that the ‘‘X’’ records of visual inspection, pressure
is replaced with the letter ‘‘S’’. test, and ultrasonic examination if per-
(7) For designation of DOT 8 series mitted under a special permit, as appli-
and UN cylinder shell and porous filler cable, must be maintained by the per-
requalification, the marking is as illus- son who performs the requalification
trated in paragraph (d) of this section, until either the expiration of the re-
except that the ‘‘X’’ is replaced with qualification period or until the cyl-
the letters ‘‘FS.’’ inder is again requalified, whichever
(8) For designation of a non- occurs first. A single date may be used
destructive examination combined for each test sheet, provided each test
with a visual inspection, the marking on the sheet was conducted on that
is as illustrated in paragraph (d) of this date. Ditto marks or a solid vertical
section, except that the ‘‘X’’ is re- line may be used to indicate repetition
placed with the type of test performed, of the preceding entry for the following
for example the letters ‘‘AE’’ for acous- entries only: date; actual dimensions;
tic emission or ‘‘UE’’ for ultrasonic ex- manufacturer’s name or symbol, if
amination. present; owner’s name or symbol, if
(9) For designation of the eddy cur- present; and test operator. Blank
rent examination combined with a vis- spaces may not be used to indicate rep-
ual inspection, the marking is as illus- etition of a prior entry. The records
trated in paragraph (d) of this section, must include the following informa-
except the ‘‘X’’ is replaced with the let- tion:
ters ‘‘VE.’’ (1) Calibration test records. For each
test to demonstrate calibration, the
[67 FR 51660, Aug. 8, 2002, as amended at 70
FR 73166, Dec. 9, 2005; 71 FR 33896, June 12, date; serial number of the calibrated
2006; 71 FR 51128, Aug. 29, 2006; 71 FR 78635, cylinder; calibration test pressure;
Dec. 29, 2006; 75 FR 53597, Sept. 1, 2010; 80 FR total, elastic and permanent expan-
72929, Nov. 23, 2015; 81 FR 3686, Jan. 21, 2016] sions; and legible identification of test
operator. The test operator must be
§ 180.215 Reporting and record reten- able to demonstrate that the results of
tion requirements. the daily calibration verification cor-
(a) Facility records. A person who re- respond to the hydrostatic tests per-
qualifies, repairs or rebuilds cylinders formed on that day. The daily
must maintain the following records verification of calibration(s) may be re-
where the requalification is performed: corded on the same sheets as, and with,
(1) Current RIN issuance letter; test records for that date.
(2) If the RIN has expired and renewal (2) Pressure test and visual inspection
is pending, a copy of the renewal re- records. The date of requalification; se-
quest; rial number; DOT specification or spe-
(3) Copies of notifications to Asso- cial permit number; marked pressure;
ciate Administrator required under actual dimensions; manufacturer’s
§ 107.805 of this chapter; name or symbol; owner’s name or sym-
(4) Current copies of those portions of bol, if present; result of visual inspec-
this subchapter applicable to its cyl- tion; actual test pressure; total, elastic
inder requalification and marking ac- and permanent expansions; percent
tivities at that location; permanent expansion; disposition, with
(5) Current copies of all special per- reason for any repeated test, rejection
mits governing exemption cylinders re- or condemnation; and legible identi-
qualified or marked by the requalifier fication of test operator. For each cyl-
at that location; and inder marked pursuant to
(6) The information contained in each § 173.302a(b)(5) of this subchapter, the
applicable CGA or ASTM standard in- test sheet must indicate the method by
336
which any average or maximum wall pressure, total expansion, permanent

stress was computed. Records must be expansion, elastic expansion, percent
kept for all completed, as well as un- permanent expansion (permanent ex-
successful tests. The entry for a second pansion may not exceed ten percent
test after a failure to hold test pressure (10%) of total expansion), and volu-
must indicate the date of the earlier metric capacity (volumetric capacity
test. of a rebuilt cylinder must be within
(3) Wall stress. Calculations of aver- ±3% of the calculated capacity);
age and maximum wall stress pursuant (viii) Each report must include the
to § 173.302a(b)(3) of this subchapter, if following certification statement: ‘‘I
performed. certify that this rebuilt cylinder is ac-
(4) Calibration certificates. The most curately represented by the data above
recent certificate of calibration must and conforms to all of the require-
be maintained for each calibrated cyl- ments in Subchapter C of Chapter I of
inder. Title 49 of the Code of Federal Regula-
(c) Repair, rebuilding or reheat treat- tions.’’. The certification must be
ment records. (1) Records covering weld- signed by the rebuild technician and
ing or brazing repairs, rebuilding or re- principal, officer, or partner of the re-
heat treating shall be retained for a build facility.
minimum of fifteen years by the ap- [67 FR 51660, Aug. 8, 2002, as amended at 68
proved facility. FR 24664, May 8, 2003; 70 FR 73166, Dec. 9,
(2) A record of rebuilding, in accord- 2005; 71 FR 54398, Sept. 14, 2006; 72 FR 55697,
ance with § 180.211(d), must be com- Oct. 1, 2007]
pleted for each cylinder rebuilt. The
record must be clear, legible, and con- § 180.217 Requalification requirements
tain the following information: for MEGCs.
(i) Name and address of test facility, (a) Periodic inspections. Each MEGC
date of test report, and name of origi- must be given an initial visual inspec-
nal manufacturer; tion and test in accordance with
(ii) Marks stamped on cylinder to in- § 178.75(i) of this subchapter before
clude specification number, service being put into service for the first
pressure, serial number, symbol of time. After the initial inspection, a
manufacturer, inspector’s mark, and MEGC must be inspected at least once
other marks, if any; every five years.
(iii) Cylinder outside diameter and (1) The 5-year periodic inspection
length in inches; must include an external examination
(iv) Rebuild process (welded, brazed, of the structure, the pressure recep-
type seams, etc.); tacles and the service equipment, as
(v) Description of assembly and any follows:
attachments replaced (e.g., neckrings, (i) The pressure receptacles are in-
footrings); spected externally for pitting, corro-
(vi) Chemical analysis of material for sion, abrasions, dents, distortions, de-
the cylinder, including seat and Code fects in welds or any other conditions,
No., type of analysis (ladle, check), including leakage, that might render
chemical components (Carbon (C), the MEGC unsafe for transport.
Phosphorous (P), Sulfur (S), Silicon (ii) The piping, valves, and gaskets
(Si), Manganese (Mn), Nickel (Ni), are inspected for corroded areas, de-
Chromium (Cr), Molybdenum (Mo), fects, and other conditions, including
Copper (Cu), Aluminum (Al), Zinc leakage, that might render the MEGC
(Zn)), material manufacturer, name of unsafe for filling, discharge or trans-
person performing the analysis, results port.
of physical tests of material for cyl- (iii) Missing or loose bolts or nuts on
inder (yield strength (psi), tensile any flanged connection or blank flange
strength (psi), elongation percentage are replaced or tightened.
(inches), reduction in area percentage, (iv) All emergency devices and valves
weld bend, tensile bend, name of in- are free from corrosion, distortion and
spector); any damage or defect that could pre-
(vii) Results of proof pressure test on vent their normal operation. Remote
cylinder, including test method, test closure devices and self-closing stop
337
§ 180.350 49 CFR Ch. I (10–1–18 Edition)
valves must be operated to dem- marked in English, with the year and
onstrate proper operation. month, and the type of the most recent
(v) Required markings on the MEGC periodic requalification performed
are legible in accordance with the ap- (e.g., 2004–05 AE/UE, where ‘‘AE’’ rep-
plicable requirements. resents acoustic emission and ‘‘UE’’
(vi) The framework, the supports and represents ultrasonic examination) fol-
the arrangements for lifting the MEGC lowed by the stamp of the approval
are in satisfactory condition. agency who performed or witnessed the
(2) The MEGC’s pressure receptacles most recent test.
and piping must be periodically re- (f) Records. The owner of each MEGC
qualified as prescribed in § 180.207(c), at or the owner’s authorized agent must
the interval specified in Table 1 in retain a written record of the date and
§ 180.207. results of all repairs and required in-
(b) Exceptional inspection and test. If a spections and tests. The report must
MEGC shows evidence of damaged or contain the name and address of the
corroded areas, leakage, or other condi- person performing the inspection or
tions that indicate a deficiency that test. The periodic test and inspection
could affect the integrity of the MEGC, records must be retained until the next
an exceptional inspection and test inspection or test is completed. Repair
must be performed, regardless of the records and the initial exceptional in-
last periodic inspection and test. The spection and test records must be re-
extent of the exceptional inspection tained during the period the MEGC is
and test will depend on the amount of in service and for one year thereafter.
damage or deterioration of the MEGC. These records must be made available
As a minimum, an exceptional inspec- for inspection by a representative of
tion of a MEGC must include inspec- the Department on request.
tion as specified in paragraph (a)(1) of
[71 FR 33896, June 12, 2006]
this section.
(c) Correction of unsafe condition.
When evidence of any unsafe condition Subpart D—Qualification and
is discovered, the MEGC may not be re- Maintenance of IBCs
turned to service until the unsafe con-
dition has been corrected and the § 180.350 Applicability and definitions.
MEGC has been requalified in accord- This subpart prescribes require-
ance with the applicable tests and in- ments, in addition to those contained
spection. in parts 107, 171, 172, 173 and 178 of this
(d) Repairs and modifications to subchapter, applicable to any person
MEGCs. No person may perform a responsible for the continuing quali-
modification to an approved MEGC fication, maintenance, or periodic re-
that may affect conformance to the ap- testing of an IBC. The following defini-
plicable ISO standard or safe use, and tions apply:
that involve a change to the design (a) Remanufactured IBCs are metal,
type or affect its ability to retain the rigid plastic or composite IBCs pro-
hazardous material in transportation. duced as a UN type from a non-UN
Before making any modification type, or are converted from one UN de-
changes to an approved MEGC, the sign type to another UN design type.
owner must obtain approval from the Remanufactured IBCs are subject to
Associate Administrator as prescribed the same requirements of this sub-
in § 178.74 of this subchapter. The repair chapter that apply to new IBCs of the
of a MEGC’s structural equipment is same type (also see § 178.801(c)(1) of this
authorized provided such repairs are subchapter for design type definition).
made in accordance with the require- (b) Repaired IBCs are metal, rigid
ments prescribed for its approved de- plastic or composite IBCs that, as a re-
sign and construction. Any repair to sult of impact or for any other cause
the pressure receptacles of a MEGC (such as corrosion, embrittlement or
must meet the requirements of other evidence of reduced strength as

§ 180.212. compared to the design type), are re-
(e) Requalification markings. Each stored so as to conform to the design
MEGC must be durably and legibly type and to be able to withstand the
338
design type tests. For the purposes of § 180.352 Requirements for retest and
this subchapter, the replacement of the inspection of IBCs.
rigid inner receptacle of a composite (a) General. Each IBC constructed in
IBC with one from the original manu- accordance with a UN standard for
facturer is considered a repair. Routine which a test or inspection specified in
maintenance of IBCs (see definition in paragraphs (b)(1), (b)(2) and (b)(3) of
paragraph (c) of this section) is not this section is required may not be
considered repair. The bodies of rigid filled and offered for transportation or
plastic IBCs and the inner receptacles transported until the test or inspection
of composite IBCs are not repairable. has been successfully completed. This
(c) Routine maintenance of IBCs is paragraph does not apply to any IBC
the routine performance on: filled prior to the test or inspection
(1) Metal, rigid plastic or composite due date. The requirements in this sec-
IBCs of operations such as: tion do not apply to DOT 56 and 57
(i) Cleaning; portable tanks.
(ii) Removal and reinstallation or re- (b) Test and inspections for metal, rigid
placement of body closures (including plastic, and composite IBCs. Each IBC is
associated gaskets), or of service equip- subject to the following test and in-
ment conforming to the original manu- spections:
facturer’s specifications provided that (1) Each IBC intended to contain sol-
the leaktightness of the IBC is verified; ids that are loaded or discharged under
or pressure or intended to contain liquids
(iii) Restoration of structural equip- must be tested in accordance with the
ment not directly performing a haz- leakproofness test prescribed in
ardous material containment or dis- § 178.813 of this subchapter prior to its
charge pressure retention function so first use in transportation and every
as to conform to the design type (for 2.5 years thereafter, starting from the
example, the straightening of legs or date of manufacture or the date of a re-
lifting attachments), provided the con-
pair conforming to paragraph (d)(1) of
tainment function of the IBC is not af-
this section. For this test, the IBC is
fected.
not required to have its closures fitted.
(2) Plastics or textile flexible IBCs of
(2) An external visual inspection
operations, such as:
must be conducted initially after pro-
(i) Cleaning; or
duction and every 2.5 years starting
(ii) Replacement of non-integral com-
from the date of manufacture or the
ponents, such as non-integral liners
and closure ties, with components con- date of a repair conforming to para-
forming to the original manufacturer’s graph (d)(1) of this section to ensure
specification; provided that these oper- that:
ations do not adversely affect the con- (i) The IBC is marked in accordance
tainment function of the flexible IBC with requirements in § 178.703 of this
or alter the design type. subchapter. Missing or damaged mark-
ings, or markings difficult to read
[68 FR 45042, July 31, 2003, as amended at 69 must be restored or returned to origi-
FR 76186, Dec. 20, 2004; 76 FR 3389, Jan. 19, nal condition.
2011] (ii) Service equipment is fully func-
§ 180.351 Qualification of IBCs. tional and free from damage which
may cause failure. Missing, broken, or
(a) General. Each IBC used for the damaged parts must be repaired or re-
transportation of hazardous materials placed.
must be an authorized packaging. (iii) The IBC is capable of with-
(b) IBC specifications. To qualify as an standing the applicable design quali-
authorized packaging, each IBC must fication tests. The IBC must be exter-
conform to this subpart, the applicable nally inspected for cracks, warpage,
requirements specified in part 173 of corrosion or any other damage which
this subchapter, and the applicable re- might render the IBC unsafe for trans-
quirements of subparts N and O of part
portation. An IBC found with such de-

178 of this subchapter. fects must be removed from service or
[Amdt. 180–5, 59 FR 38079, July 26, 1994, as repaired in accordance with paragraph
amended at 66 FR 45391, Aug. 28, 2001] (d) of this section. The inner receptacle
339
§ 180.352 49 CFR Ch. I (10–1–18 Edition)
of a composite IBC must be removed (B) Seams are free from defects in
from the outer IBC body for inspection stitching, heat sealing or gluing which
unless the inner receptacle is bonded to would render the IBC unsafe for trans-
the outer body or unless the outer body portation of hazardous materials. All
is constructed in such a way (e.g., a stitched seam-ends must be secure.
welded or riveted cage) that removal of (C) Fabric used to construct the IBC
the inner receptacle is not possible is free from cuts, tears and punctures.
without impairing the integrity of the Additionally, fabric must be free from
outer body. Defective inner receptacles scoring which may render the IBC un-
must be replaced in accordance with safe for transport.
paragraph (d) of this section or the en- (ii) Each fiberboard IBC must be in-
tire IBC must be removed from service. spected to ensure that:
For metal IBCs, thermal insulation (A) Fluting or corrugated fiberboard
must be removed to the extent nec- is firmly glued to facings.
essary for proper examination of the (B) Seams are creased and free from
IBC body. scoring, cuts, and scratches.
(3) Each metal, rigid plastic and com- (C) Joints are appropriately over-
posite IBC must be internally inspected lapped and glued, stitched, taped or
at least every five years to ensure that stapled as prescribed by the design.
the IBC is free from damage and to en- Where staples are used, the joints must
sure that the IBC is capable of with- be inspected for protruding staple-ends
standing the applicable design quali- which could puncture or abrade the
fication tests. inner liner. All such ends must be pro-
(i) The IBC must be internally in- tected before the IBC is authorized for
spected for cracks, warpage, and corro- hazardous materials service.
sion or any other defect that might (iii) Each wooden IBC must be in-
render the IBC unsafe for transpor- spected to ensure that:
tation. An IBC found with such defects (A) End joints are secured in the
must be removed from hazardous mate- manner prescribed by the design.
rials service until restored to the origi- (B) IBC walls are free from defects in
nal design type of the IBC. wood. Inner protrusions which could
(ii) Metal IBCs must be inspected to puncture or abrade the liner must be
ensure the minimum wall thickness recovered.
quirements in § 178.705(c)(1)(iv) of this (d) Requirements applicable to repair of
subchapter are met. Metal IBCs not IBCs. (1) Except for flexible and fiber-
conforming to minimum wall thickness board IBCs and the bodies of rigid plas-
requirements must be removed from tic and composite IBCs, damaged IBCs
hazardous materials service. may be repaired and the inner recep-
(c) Visual inspection for flexible, fiber- tacles of composite packagings may be
board, or wooden IBCs. Each IBC must replaced and returned to service pro-
be visually inspected prior to first use vided:
and permitted reuse, by the person who (i) The repaired IBC conforms to the
places hazardous materials in the IBC, original design type, is capable of with-
to ensure that: standing the applicable design quali-
(1) The IBC is marked in accordance fication tests, and is retested and in-
with requirements in § 178.703 of this spected in accordance with the applica-
subchapter. Additional marking al- ble requirements of this section;
lowed for each design type may be (ii) An IBC intended to contain liq-
present. Required markings that are uids or solids that are loaded or dis-
missing, damaged or difficult to read charged under pressure is subjected to
must be restored or returned to origi- a leakproofness test as specified in
nal condition. § 178.813 of this subchapter and is
(2) Proper construction and design marked with the date of the test; and
specifications have been met. (iii) The IBC is subjected to the inter-
(i) Each flexible IBC must be in- nal and external inspection require-
spected to ensure that: ments as specified in paragraph (b) of

(A) Lifting straps if used, are se- this section.
curely fastened to the IBC in accord- (iv) The person performing the tests
ance with the design type. and inspections after the repair must
340
durably mark the IBC near the (f) Retest date. The date of the most
manfacturer’s UN design type marking recent periodic retest must be marked
to show the following: as provided in § 178.703(b) of this sub-
(A) The country in which the tests chapter.
and inspections were performed; (g) Record retention. (1) The owner or
(B) The name or authorized symbol of lessee of the IBC must keep records of
the person performing the tests and in- periodic retests, initial and periodic in-
spections; and spections, and tests performed on the
(C) The date (month, year) of the IBC if it has been repaired or remanu-
tests and inspections. factured.
(v) Retests and inspections performed (2) Records must include design types
in accordance with paragraphs (d)(1)(i) and packaging specifications, test and
and (ii) of this section may be used to inspection dates, name and address of
satisfy the requirements for the 2.5 and test and inspection facilities, names or
five year periodic tests and inspections name of any persons conducting test or
required by paragraph (b) of this sec- inspections, and test or inspection spe-
tion, as applicable. cifics and results.
(2) Except for flexible and fiberboard (3) Records must be kept for each
IBCs, the structural equipment of an packaging at each location where peri-
IBC may be repaired and returned to odic tests are conducted, until such
service provided: tests are successfully performed again
(i) The repaired IBC conforms to the or for at least 2.5 years from the date
original design type and is capable of of the last test. These records must be
withstanding the applicable design made available for inspection by a rep-
qualification tests; and resentative of the Department on re-
quest.
(ii) The IBC is subjected to the inter-
nal and external inspection require- [Amdt. 180–5, 59 FR 38079, July 26, 1994, as
ments as specified in paragraph (b) of amended at 64 FR 10782, Mar. 5, 1999; 65 FR
this section. 58632, Sept. 29, 2000; 66 FR 45186, 45391, Aug.
28, 2001; 68 FR 45042, July 31, 2003; 69 FR 76186,
(3) Service equipment may be re-
Dec. 20, 2004; 70 FR 34399, June 14, 2005; 70 FR
placed provided: 56099, Sept. 23, 2005; 71 FR 78635, Dec. 29, 2006]
(i) The repaired IBC conforms to the
original design type and is capable of
withstanding the applicable design Subpart E—Qualification and
qualification tests; Maintenance of Cargo Tanks
(ii) The IBC is subjected to the exter- § 180.401 Applicability.
nal visual inspection requirements as
specified in paragraph (b) of this sec- This subpart prescribes require-
tion; and ments, in addition to those contained
(iii) The proper functioning and leak in parts 107, 171, 172, 173 and 178 of this
tightness of the service equipment, if subchapter, applicable to any person
applicable, is verified. responsible for the continuing quali-
(e) Requirements applicable to routine fication, maintenance or periodic test-
maintenance of IBCs. Except for routine ing of a cargo tank.
maintenance of metal, rigid plastics [Amdt. 180–2, 54 FR 25032, June 12, 1989, as
and composite IBCs performed by the amended at 55 FR 37065, Sept. 7, 1990]
owner of the IBC, whose State and
name or authorized symbol is durably § 180.403 Definitions.
marked on the IBC, the party per- In addition to the definitions con-
forming the routine maintenance shall tained in §§ 171.8, 178.320(a) and 178.345–
durably mark the IBC near the manu- 1 of this subchapter, the following defi-
facturer’s UN design type marking to nitions apply to this subpart:
show the following: Corroded or abraded means any visible
(1) The country in which the routine reduction in the material thickness of
maintenance was carried out; and the cargo tank wall or valve due to pit-
(2) The name or authorized symbol of ting, flaking, gouging, or chemical re-
the party performing the routine main- action to the material surface that ef-
tenance. fects the safety or serviceability of the
341
§ 180.405 49 CFR Ch. I (10–1–18 Edition)
cargo tank. The term does not include (1) A change to motor vehicle equip-
cosmetic or minor surface degradation ment such as lights, truck or tractor
that does not effect the safety or serv- power train components, steering and
iceability of the cargo tank brake systems, and suspension parts,
Corrosive to the tank or valve means and changes to appurtenances, such as
that the lading has been shown through fender attachments, lighting brackets,
experience or test data to reduce the ladder brackets; and
thickness of the material of construc- (2) Replacement of components such
tion of the tank wall or valve. as valves, vents, and fittings with a
Delivery hose assembly means a liquid component of a similar design and of
delivery hose and its attached cou- the same size.
plings. (3) Replacement of an appurtenance
Modification means any change to the by welding to a mounting pad.
original design and construction of a Replacement of a barrel means to re-
cargo tank or a cargo tank motor vehi- place the existing tank on a motor ve-
cle that affects its structural integrity hicle chassis with an unused (new)
or lading retention capability includ- tank. For the definition of tank, see
ing changes to equipment certified as § 178.320, § 178.345, or § 178.338–1 of this
part of an emergency discharge control subchapter, as applicable.
system required by § 173.315(n)(2) of this Stretching means any change in
subchapter. Any modification that in- length, width or diameter of the cargo
volves welding on the cargo tank wall tank, or any change to a cargo tank
must also meet all requirements for motor vehicle’s undercarriage that
‘‘Repair’’ as defined in this section. Ex- may affect the cargo tank’s structural
cluded from this category are the fol- integrity.
lowing: [Amdt. 180–2, 54 FR 25032, June 12, 1989, as
(1) A change to motor vehicle equip- amended at 55 FR 37065, Sept. 7, 1990; Amdt.
ment such as lights, truck or tractor 180–3, 57 FR 45466, Oct. 1, 1992; Amdt. 180–7, 59
power train components, steering and FR 55177, Nov. 3, 1994; 60 FR 17402, Apr. 5,
1995; Amdt. 180–10, 61 FR 51342, Oct. 1, 1996; 63
brake systems, and suspension parts,
FR 52850, Oct. 1, 1998; 64 FR 28050, May 24,
and changes to appurtenances, such as 1999; 68 FR 19286, Apr. 18, 2003; 69 FR 54047,
fender attachments, lighting brackets, Sept. 7, 2004]
ladder brackets; and
(2) Replacement of components such § 180.405 Qualification of cargo tanks.
as valves, vents, and fittings with a (a) General. Unless otherwise pro-
component of a similar design and of vided in this subpart, each cargo tank
the same size. used for the transportation of haz-
Owner means the person who owns a ardous material must be an authorized
cargo tank motor vehicle used for the packaging.
transportation of hazardous materials, (b) Cargo tank specifications. (1) To
or that person’s authorized agent. qualify as an authorized packaging,
Piping system means any component each cargo tank must conform to this
of a cargo tank delivery system, other subpart, the applicable requirements
than a delivery hose assembly, that specified in part 173 of this subchapter
contains product during loading or un- for the specific lading, and where a
loading. DOT specification cargo tank is re-
Rebarrelling means replacing more quired, an applicable specification in
than 50 percent of the combined shell effect on the date initial construction
and head material of a cargo tank. began: MC 300, MC 301, MC 302, MC 303,
Repair means any welding on a cargo MC 304, MC 305, MC 306, MC 307, MC 310,
tank wall done to return a cargo tank MC 311, MC 312, MC 330, MC 331, MC 338,
or a cargo tank motor vehicle to its DOT 406, DOT 407, or DOT 412 (§§ 178.337,
original design and construction speci- 178.338, 178.345, 178.346, 178.347, 178.348 of
fication, or to a condition prescribed this subchapter). However, except as
for a later equivalent specification in provided in paragraphs (b)(2), (d), (e),

effect at the time of the repair. Ex- (f)(5), and (f)(6) of this section, no cargo
cluded from this category are the fol- tank may be marked or certified after
lowing: August 31, 1995, to the applicable MC
342
306, MC 307, MC 312, MC 331, or MC 338 (ii) The cargo tank was marked or
specification in effect on December 30, certified before the date listed in table
1990. 2, column 2, as follows:
(2) Exception. A cargo tank originally
manufactured to the MC 306, MC 307, or TABLE 2
MC 312 specification may be recertified
Column 1 Column 2
to the original specification provided:
(i) Records are available verifying MC 306, MC 307, MC 312 ............................ Sept. 1, 1995
the cargo tank was originally manufac-
tured to the specification; (2) A cargo tank of a specification
(ii) If the cargo tank was stretched, listed in paragraph (c)(1) of this section
rebarrelled, or modified, records are may have its pressure relief devices
available verifying that the stretching, and outlets modified as follows:
rebarrelling, or modification was per- (i) A Specification MC 300, MC 301,
formed in accordance with the Na- MC 302, MC 303, or MC 305 cargo tank,
tional Board Inspection Code and this to conform with a Specification MC 306
part; or DOT 406 cargo tank (See §§ 178.346–3
(iii) A Design Certifying Engineer or and 178.346–4 of this subchapter).
Registered Inspector verifies the cargo (ii) A Specification MC 306 cargo
tank conforms to all applicable re- tank to conform to a Specification
quirements of the original specifica- DOT 406 cargo tank (See §§ 178.346–3 and
tion and furnishes to the owner written 178.346–4 of this subchapter).
documentation that verifies the tank (iii) A Specification MC 304 cargo
conforms to the original structural de- tank, to conform with a Specification
sign requirements in effect at the time MC 307 or DOT 407 cargo tank (See
the tank was originally constructed; §§ 178.347–4 and 178.345–11 of this sub-
(iv) The cargo tank meets all applica- chapter).
ble tests and inspections required by (iv) A Specification MC 307 cargo
§ 180.407(c); and tank, to conform with a Specification
(v) The cargo tank is recertified to DOT 407 cargo tank (See §§ 178.347–4 and
the original specification in accordance 178.345–11 of this subchapter).
with the reporting and record retention (v) A Specification MC 310 or MC 311
provisions of § 180.417. The certification cargo tank, to conform with a Speci-
documents required by § 180.417(a)(3) fication MC 312 or DOT 412 cargo tank
must include both the date the cargo (See §§ 178.348–4 and 178.345–11 of this
tank was originally certified to the subchapter).
specification and the date it was recer- (vi) A Specification MC 312 cargo
tified. The specification plate on the tank, to conform with a Specification
cargo tank or the cargo tank motor ve- DOT 412 cargo tank (See §§ 178.348–4 and
hicle must display the date the cargo 178.345–11 of this subchapter).
tank was originally certified to the (vii) A Specification MC 330 cargo
specification. tank, to conform with a Specification
(c) Cargo tank specifications no longer MC 331 cargo tank, except as specifi-
authorized for construction. (1) A cargo cally required by § 173.315 of this sub-
tank made to a specification listed in chapter (see §§ 178.337–8 and 178.337–9 of
column 1 of table 1 or table 2 of this this subchapter).
paragraph (c)(1) may be used when au- (d) MC 338 cargo tank. The owner of a
thorized in this part, provided— cargo tank that conforms to and was
(i) The cargo tank initial construc- used under the terms of an exemption
tion began on or before the date listed issued before October 1, 1984, that au-
in table 1, column 2, as follows: thorizes the transportation of a cryo-
genic liquid shall remove the exemp-
TABLE 1
tion number stenciled on the cargo
Column 1 Column 2 tank and stamp the specification plate
(or a plate placed adjacent to the speci-
MC 300 .......................................................... Sept. 2, 1967
MC 301 .......................................................... June 12, 1961 fication plate) ‘‘DOT MC 338’’ followed
MC 302, MC 303, MC 304, MC 305, MC Sept. 2, 1967 by the exemption number, for example,
310, MC 311. ‘‘DOT MC 338–E * * * *’’. (Asterisks to
MC 330 .......................................................... May 15, 1967
be replaced by the exemption number).
343
§ 180.405 49 CFR Ch. I (10–1–18 Edition)
The cargo tank must be remarked prior the cargo tank motor vehicle and its
to the expiration date of the exemp- design to determine if it meets the re-
tion. During the period the cargo tank quirements of the applicable MC 306,
is in service, the owner of a cargo tank MC 307 or MC 312 specification in effect
that is remarked in this manner must at the time of manufacture, except as
retain at its principal place of business specified herein.
a copy of the last exemption in effect. (1) A cargo tank motor vehicle con-
No new construction of cargo tanks structed after August 1, 1981, or the
pursuant to such exemption is author- date specified in the applicable exemp-
ized. tion, in conformance with the fol-
(1) The holding time must be deter- lowing conditions that apply, may be
mined, as required in § 178.338–9 of this remarked and certified in accordance
subchapter, on each cargo tank or on with paragraphs (f) (5) and (6) of this
at least one cargo tank of each design. section:
Any subsequent cargo tank manufac- (i) A vacuum-loaded cargo tank must
tured to the same design type (see have an ASME Code stamped specifica-
§ 178.320), if not individually tested, tion plate marked with a minimum in-
must have the optional test regimen ternal design pressure of 25 psig, and be
performed during the first shipment designed for a minimum external de-
(see § 178.338–9 (b) and (c) of this sub- sign pressure of 15 psig.
chapter). (ii) An outlet equipped with a self-
(2) The holding time determined by closing system which includes an ex-
test for one authorized cryogenic liquid ternal stop-valve must have the stop
may be used as the basis for estab- valve and associated piping protected
lishing the holding time for other au- within the vehicle’s rear-end tank pro-
thorized cryogenic liquids. tection device, vehicle frame or an
(e) MC 331 cargo tanks. The owner of equally adequate accident damage pro-
a MC 331 (§ 178.337 of this subchapter) tection device (See § 178.345–8 of this
cargo tank that conforms to and was subchapter.) The self-closing system
used under an exemption issued before (See § 178.345–11 of this subchapter)
October 1, 1984, that authorizes the must be equipped with a remotely ac-
transportation of ethane, refrigerated tuated means of closure as follows:
liquid; ethane-propane mixture, refrig- (A) For a cargo tank used in other
erated liquid; or hydrogen chloride, re- than corrosive service, the remote
frigerated liquid shall remove the ex- means of closure must be activated for
emption number stenciled on the cargo closure by manual or mechanical
tank and stamp the exemption number means and, in case of fire, by an auto-
on the specification plate (or a plate matic heat activated means.
placed adjacent to the specification (B) For a cargo tank used in corro-
plate), immediately after the DOT sive service, the remote means of clo-
Specification, for example, ‘‘DOT MC sure may be actuated by manual or me-
331–E * * * *’’. (Asterisks to be replaced chanical means only.
by the exemption number.) The cargo (iii) A cargo tank having an
tank must be remarked prior to the ex- unreinforced portion of the shell ex-
piration date of the exemption. During ceeding 60 inches must have the cir-
the period the cargo tank is in service, cumferential reinforcement located so
the owner of a cargo tank that is re- that the thickness and tensile strength
marked in this manner must retain at of shell material in combination with
the owner’s principal place of business the frame and circumferential rein-
a copy of the last exemption in effect. forcement produces a structural integ-
(f) MC 306, MC 307, MC 312 cargo tanks. rity at least equal to that prescribed in
Either a Registered Inspector or a De- § 178.345–3 of this subchapter or the
sign Certifying Engineer and the owner specification in effect at time of manu-
of a MC 306, MC 307 or MC 312 cargo facture.
tank motor vehicle constructed in ac- (iv) A cargo tank having a projection
cordance with and used under an ex- from the tank shell or head that may
emption issued before December 31, contain lading in any tank position is
1990, that authorizes a condition speci- authorized, provided such projection is
fied in this paragraph shall examine as strong as the tank shell or head and
344
is located within the motor vehicle’s turer’s serial number for the cargo
rear-end tank protection or other ap- tank;
propriate accident damage protection (iii) A statement setting forth any
device. modifications made to bring the cargo
(v) A cargo tank may be constructed tank into conformance with § 180.405(f)
of nickel, titanium, or other ASME (1), (2), (3), or (4), or the applicable
sheet or plate materials in accordance specification;
with an exemption. (iv) A statement identifying the per-
(2) A vacuum-loaded cargo tank con- son certifying the cargo tank and the
structed after August 1, 1981, or the date of certification.
date specified in the applicable exemp- (6) The owner of a certified cargo
tion, in conformance with paragraph tank shall remove the exemption num-
(f)(1) of this section, except that an ber stenciled on the cargo tank and
outlet equipped with an external valve shall durably mark the specification
which is not part of a self-closing sys- plate (or a plate placed adjacent to the
tem: specification plate) ‘‘MC + + + –E
(i) Must be equipped with a self-clos- ****####’’ (where ‘‘ + + + ’’ is to be re-
ing system prior to September 1, 1993. placed by the applicable specification
(ii) May be remarked and certified in number, ‘‘* * * *’’ by the exemption
accordance with paragraphs (f)(5) and number and ‘‘# # # #’’ by the alloy.)
(6) of this section after the cargo tank
(7) A cargo tank remarked and cer-
motor vehicle has been equipped with
tified in conformance with this para-
the self-closing system.
graph (f) is excepted from the provi-
(3) A vacuum-loaded cargo tank con-
structed prior to August 1, 1981, in con- sions of § 180.405(c).
formance with paragraph (f)(1) of this (8) During the period the cargo tank
section, except for paragraph (f)(1)(i), is in service, and for one year there-
may be remarked and certified in ac- after, the owner of a cargo tank that is
cordance with paragraphs (f) (5) and (6) certified and remarked in this manner
of this section. must retain on file at its principal
(4) A vacuum-loaded cargo tank con- place of business a copy of the certifi-
structed prior to August 1, 1981, in con- cate and the last exemption in effect.
formance with paragraph (f)(1) of this (g) Cargo tank manhole assemblies. (1)
section, except for paragraph (f)(1)(i) of MC 306, MC 307, and MC 312 cargo tanks
this section, and except that an outlet marked or certified after December 30,
is equipped with an external valve 1990, and DOT 406, DOT 407, and DOT
which is not part of a self-closing sys- 412 cargo tank motor vehicles must be
tem: equipped with manhole assemblies con-
(i) Must be equipped with a self-clos- forming with § 178.345–5 of this sub-
ing system prior to September 1, 1993. chapter.
(ii) May be remarked and certified in (2) On or before August 31, 1995, each
accordance with paragraphs (f)(5) and owner of a cargo tank marked or cer-
(6) of this section after the cargo tank tified before December 31, 1990, author-
motor vehicle has been equipped with ized for the transportation of a haz-
the self-closing system. ardous material, must have the cargo
(5) The owner of a cargo tank for tank equipped with manhole assem-
which a determination has been made blies conforming with § 178.345–5, except
that the cargo tank is in conformance for the dimensional requirements in
with paragraph (f) (1), (2), (3), or (4) of § 178.345–5(a), the hydrostatic testing
this section shall complete a written requirements in § 178.345–5(b), and the
certification, in English, signed by the marking requirements in § 178.345–5(e)
owner and containing at least the fol- of this subchapter. A manhole assem-
lowing information: bly meeting one of the following provi-
(i) A statement certifying that each sions is considered to be in compliance
cargo tank conforms to § 180.405 (f) (1), with this paragraph:
(2), (3), or (4); (i) Manhole assemblies on MC 300, MC

(ii) The applicable DOT exemption 301, MC 302, MC 303, MC 305, MC 306, MC
number, the applicable specification 310, MC 311, and MC 312 cargo tanks
number and the owner’s and manufac- that are marked or certified in writing
345
§ 180.405 49 CFR Ch. I (10–1–18 Edition)
as conforming to § 178.345–5 of this sub- (j) Withdrawal of certification. A speci-

chapter or TTMA RP No. 61–98 (incor- fication cargo tank that for any reason
porated by reference; see § 171.7 of this no longer meets the applicable speci-
subchapter), or are tested and certified fication may not be used to transport
in accordance with TTMA TB No. 107 hazardous materials unless the cargo
(incorporated by reference; see § 171.7 of tank is repaired and retested in accord-
this subchapter). ance with §§ 180.413 and 180.407 prior to
(ii) Manhole assemblies on MC 304 being returned to hazardous materials
and MC 307 cargo tanks. service. If the cargo tank is not in con-
(iii) Manhole assemblies on MC 310, formance with the applicable specifica-
MC 311, and MC 312 cargo tanks with a tion requirements, the specification
test pressure of 36 psig or greater. plate on the cargo tank must be re-
(3) [Reserved] moved, obliterated or securely covered.
(h) Pressure relief system. Properly The details of the conditions necessi-
functioning reclosing pressure relief tating withdrawal of the certification
valves and frangible or fusible vents must be recorded and signed on the
need not be replaced. However, replace- written certificate for that cargo tank.
ment of reclosing pressure relief valves The vehicle owner shall retain the cer-
on MC-specification cargo tanks is au- tificate for at least 1 year after with-
thorized subject to the following re- drawal of the certification.
quirements: (k) DOT-specification cargo tank with
(1) Until August 31, 1998, the owner of no marked design pressure or a marked
a cargo tank may replace a reclosing design pressure of less than 3 psig. The
pressure relief device with a device owner of an MC 300, MC 301, MC 302, MC
which is in compliance with the re- 303, MC 305, MC 306, or MC 312 cargo
quirements for pressure relief devices tank with a pressure relief system set
in effect at the time the cargo tank at 3 psig, must mark or remark the
specification became superseded. If the cargo tank with an MAWP or design
pressure relief device is installed as an pressure of not less than 3 psig.
integral part of a manhole cover as- (l) MC 300, MC 301, MC 302, MC 303,
sembly, the manhole cover must com- MC 305, MC 306 cargo tank—Rear acci-
ply with the requirements of paragraph dent damage protection. (1) Notwith-
(g) of this section. standing the requirements in
(2) After August 31, 1998, replacement § 180.405(b), the applicable specification
for any reclosing pressure relief valve requirement for a rear bumper or rear-
must be capable of reseating to a leak- end tank protection device on MC 300,
tight condition after a pressure surge, MC 301, MC 302, MC 303, MC 305, and MC
and the volume of lading released may 306 cargo tanks does not apply to a
not exceed 1 L. Specific performance cargo tank truck (power unit) until
requirements for these pressure relief July 1, 1992, if the cargo tank truck—
valves are set forth in § 178.345–10(b)(3) (i) Was manufactured before July 1,
of this subchapter. 1989;
(3) As provided in paragraph (c)(2) of (ii) Is used to transport gasoline or
this section, the owner of a cargo tank any other petroleum distillate product;
may elect to modify reclosing pressure and
relief devices to more recent cargo (iii) Is operated in combination with
tank specifications. However, replace- a cargo tank full trailer. However, an
ment devices constructed to the re- empty cargo tank truck, without a
quirements of § 178.345–10 of this sub- cargo tank full trailer attached, may
chapter must provide the minimum be operated without the required rear
venting capacity required by the origi- bumper or rear-end tank protection de-
nal specification to which the cargo vice on a one-time basis while being
tank was designed and constructed. transported to a repair facility for in-
(i) Flammable cryogenic liquids. Each stallation of a rear bumper or rear-end
cargo tank used to transport a flam- protection device.
mable cryogenic liquid must be exam- (2) Each cargo tank shall be provided
ined after each shipment to determine with a rear accident damage protection
its actual holding time (See device to protect the tank and piping
§ 173.318(g)(3) of this subchapter.) in the event of a rear-end collision and
346
reduce the likelihood of damage which chapter for a daily test at 45.72 meters
could result in the loss of lading. The (150 feet).
rear-end protection device must be in (3) Each specification MC 330 and MC
the form of a rear-end tank protection 331 cargo tank in metered delivery
device meeting the requirements of service of greater than 13,247.5 L (3,500
§ 178.345–8(d) or a rear bumper meeting gallons) water capacity transporting a
the following: Division 2.1 material, a Division 2.2
(i) The bumper shall be located at material with a subsidiary hazard, or
least 6 inches to the rear of any vehicle anhydrous ammonia, marked and cer-
component used for loading or unload- tified before July 1, 1999, must have an
ing or that may contain lading while emergency discharge control capability
the vehicle is in transit. as specified in §§ 173.315(n) and 177.840 of
(ii) The dimensions of the bumper this subchapter no later than the date
shall conform to § 393.86 of this title. of its first scheduled pressure test after
(iii) The structure of the bumper July 1, 2001, or July 1, 2003, whichever
must be designed in accordance with is earlier.
§ 178.345–8(d)(3) of this subchapter. (n) Thermal activation. No later than
(m) Specification MC 330, MC 331 cargo the date of its first scheduled leakage
tank motor vehicles, and nonspecification test after July 1, 1999, each specifica-
cargo tank motor vehicles conforming to tion MC 330 or MC 331 cargo tank
§ 173.315(k) of this subchapter, intended motor vehicle and each nonspecifica-
for use in the transportation of liquefied tion cargo tank motor vehicle con-
compressed gases. (1) No later than the forming to § 173.315(k) of this sub-
date of its first scheduled pressure test chapter, marked and certified before
after July 1, 2001, each specification July 1, 1999, that is used to transport a
MC 330 and MC 331 cargo tank motor liquefied compressed gas, other than
vehicle, and each nonspecification carbon dioxide and chlorine, that has a
cargo tank motor vehicle conforming water capacity of 13,247.5 L (3,500 gal-
to § 173.315(k) of this subchapter, lons) or less must be equipped with a
marked and certified before July 1,
means of thermal activation for the in-
2001, that is used to transport a Divi-
ternal self-closing stop valve as speci-
sion 2.1 material, a Division 2.2 mate-
fied in § 178.337–8(a)(4) of this sub-
rial with a subsidiary hazard, a Divi-
chapter.
sion 2.3 material, or anhydrous ammo-
nia must have an emergency discharge (o) On-truck remote control of self-clos-
control capability as specified in ing stop valves—MC 330, MC 331, and MC
§ 173.315(n) of this subchapter. Each 338. On or before October 2, 2006—
passive shut-off system installed prior (1) Each owner of an MC 330 or MC 331
to July 1, 2001, must be certified by a cargo tank motor vehicle marked or
Design Certifying Engineer that it certified before January 1, 1995, must
meets the requirements of § 173.315(n)(2) equip the cargo tank with an on-vehi-
of this subchapter. cle remote means of closure of the in-
(2) The requirement in paragraph ternal self-closing stop valve in con-
(m)(1) of this section does not apply to formance with § 178.337–8(a)(4) of this
a cargo tank equal to or less than subchapter. This requirement does not
13,247.5 L (3,500 gallons) water capacity apply to cargo tanks used only for car-
transporting in metered delivery serv- bon dioxide and marked ‘‘For carbon
ice a Division 2.1 material, a Division dioxide only’’ or intended for use in
2.2 material with a subsidiary hazard, chlorine service only.
or anhydrous ammonia equipped with (2) Each owner of an MC 338 cargo
an off-truck remote shut-off device tank motor vehicle marked or certified
that was installed prior to July 1, 2000. before January 1, 1995, must equip each
The device must be capable of stopping remotely controlled shutoff valve with
the transfer of lading by operation of a an on-vehicle remote means of auto-
transmitter carried by a qualified per- matic closure in conformance with

son attending unloading of the cargo § 178.338–11(c) of this subchapter. This
tank. The device is subject to the re- requirement does not apply to cargo
quirement in § 177.840(o) of this sub- tanks used for the transportation of
347
§ 180.407 49 CFR Ch. I (10–1–18 Edition)
argon, carbon dioxide, helium, kryp- (1) The cargo tank shows evidence of
ton, neon, nitrogen, or xenon, or mix- dents, cuts, gouges, corroded or ab-
tures thereof. raded areas, leakage, or any other con-
[Amdt. 180–2, 54 FR 25032, June 12, 1989] dition that might render it unsafe for
hazardous materials service. At a min-
EDITORIAL NOTE: For FEDERAL REGISTER ci- imum, any area of a cargo tank show-
tations affecting § 180.405, see the List of CFR
Sections Affected, which appears in the
ing evidence of dents, cuts, digs, goug-
Finding Aids section of the printed volume es, or corroded or abraded areas must
and at www.fdsys.gov. be thickness tested in accordance with
the procedures set forth in paragraphs
§ 180.407 Requirements for test and in- (i)(2), (i)(3), (i)(5), and (i)(6) of this sec-
spection of specification cargo tion and evaluated in accordance with
tanks. the criteria prescribed in § 180.411. Any
(a) General. (1) A cargo tank con- signs of leakage must be repaired in ac-
structed in accordance with a DOT cordance with § 180.413. The suitability
specification for which a test or inspec- of any repair affecting the structural
tion specified in this section has be- integrity of the cargo tank must be de-
come due, may not be filled and offered termined either by the testing required
for transportation or transported until in the applicable manufacturing speci-
the test or inspection has been success- fication or in paragraph (g)(1)(iv) of
fully completed. This paragraph does this section.
not apply to any cargo tank filled prior (2) The cargo tank has sustained
to the test or inspection due date. damage to an extent that may ad-
(2) Except during a pressure test, a versely affect its lading retention capa-
cargo tank may not be subjected to a bility. A damaged cargo tank must be
pressure greater than its design pres- pressure tested in accordance with the
sure or MAWP. procedures set forth in paragraph (g) of
(3) A person witnessing or performing this section.
a test or inspection specified in this
(3) The cargo tank has been out of
section must meet the minimum quali-
hazardous materials transportation
fications prescribed in § 180.409.
service for a period of one year or
(4) Each cargo tank must be evalu-
more. Each cargo tank that has been
ated in accordance with the acceptable
out of hazardous materials transpor-
results of tests and inspections pre-
scribed in § 180.411. tation service for a period of one year
(5) Each cargo tank which has suc- or more must be pressure tested in ac-
cessfully passed a test or inspection cordance with § 180.407(g) prior to fur-
specified in this section must be ther use.
marked in accordance with § 180.415. (4) [Reserved]
(6) A cargo tank which fails a pre- (5) The Department so requires based
scribed test or inspection must: on the existence of probable cause that
(i) Be repaired and retested in accord- the cargo tank is in an unsafe oper-
ance with § 180.413; or ating condition.
(ii) Be removed from hazardous mate- (c) Periodic test and inspection. Each
rials service and the specification plate specification cargo tank must be tested
removed, obliterated or covered in a se- and inspected as specified in the fol-
cure manner. lowing table by an inspector meeting
(b) Conditions requiring test and inspec- the qualifications in § 180.409. The
tion of cargo tanks. Without regard to retest date shall be determined from
any other test or inspection require- the specified interval identified in the
ments, a specification cargo tank must following table from the most recent
be tested and inspected in accordance inspection or the CTMV certification
with this section prior to further use if: date.
COMPLIANCE DATES—INSPECTIONS AND TEST UNDER § 180.407(c)
Date by which first test Interval

Test or inspection must be completed period
(cargo tank specification, configuration, and service) (see Note 1) after first test
External Visual Inspection:
348
COMPLIANCE DATES—INSPECTIONS AND TEST UNDER § 180.407(c)—Continued

Date by which first test Interval
Test or inspection must be completed period
(cargo tank specification, configuration, and service) (see Note 1) after first test
All cargo tanks designed to be loaded by vacuum with full open- September 1, 1991 ........................... 6 months.
ing rear heads.
All other cargo tanks ...................................................................... September 1, 1991 ........................... 1 year.
Internal Visual Inspection:
All insulated cargo tanks, except MC 330, MC 331, MC 338 (see September 1, 1991 ........................... 1 year.
Note 4).
All cargo tanks transporting lading corrosive to the tank .............. September 1, 1991 ........................... 1 year.
MC 331 cargo tanks less than 3,500 gallons water capacity in ........................................................... 10 years.
dedicated propane service constructed of nonquenched and
tempered NQT SA–612 steel (see Note 5).
All other cargo tanks, except MC 338 ........................................... September 1, 1995 ........................... 5 years.
Lining Inspection:
All lined cargo tanks transporting lading corrosive to the tank ..... September 1, 1991 ........................... 1 year.
Leakage Test:
MC 330 and MC 331 cargo tanks in chlorine service ................... September 1, 1991 ........................... 2 years.
All other cargo tanks except MC 338 ............................................ September 1, 1991 ........................... 1 year.
Pressure Test:
(Hydrostatic or pneumatic) (See Notes 2 and 3) ..........................
All cargo tanks which are insulated with no manhole or insulated September 1, 1991 ........................... 1 year.
and lined, except MC 338.
All cargo tanks designed to be loaded by vacuum with full open- September 1, 1992 ........................... 2 years.
ing rear heads.
MC 330 and MC 331 cargo tanks in chlorine service ................... September 1, 1992 ........................... 2 years.
MC 331 cargo tanks less than 3,500 gallons water capacity in 10 years.
dedicated propane service constructed of nonquenched and
tempered NQT SA–612 steel (See Note 5).
All other cargo tanks ...................................................................... September 1, 1995 ........................... 5 years.
Thickness Test:
All unlined cargo tanks transporting material corrosive to the September 1, 1992 ........................... 2 years.
tank, except MC 338.
Note 1: If a cargo tank is subject to an applicable inspection or test requirement under the regulations in effect on December
30, 1990, and the due date (as specified by a requirement in effect on December 30, 1990) for completing the required inspec-
tion or test occurs before the compliance date listed in table I, the earlier date applies.
Note 2: Pressure testing is not required for MC 330 or MC 331 cargo tanks in dedicated sodium metal service.
Note 3: Pressure testing is not required for uninsulated lined cargo tanks, with a design pressure MAWP 15 psig or less,
which receive an external visual inspection and lining inspection at least once each year.
Note 4: Insulated cargo tanks equipped with manholes or inspection openings may perform either an internal visual inspection
in conjunction with the external visual inspection or a hydrostatic or pneumatic pressure-test of the cargo tank.
Note 5: A 10-year inspection interval period also applies to cargo tanks constructed of NQT SA–202 or NQT SA–455 steel
provided the materials have full-size equivalent (FSE) Charpy vee notch (CVN) energy test data that demonstrated 75% shear-
area ductility at 32 °F with an average of 3 or more samples >15 ft-lb FSE with no sample <10 ft-lb FSE.
(d) External visual inspection and test- hydrostatically or pneumatically test-

ing. The following applies to the exter- ed in accordance with paragraph
nal visual inspection and testing of (g)(1)(iv) of this section. Those items
cargo tanks: able to be externally inspected must be
(1) Where insulation precludes a com- externally inspected and noted in the
plete external visual inspection as re- inspection report.
quired by paragraphs (d)(2) through (2) The external visual inspection and
(d)(6) of this section, the cargo tank testing must include as a minimum the
also must be given an internal visual following:
inspection in accordance with para- (i) The tank shell and heads must be
graph (e) of this section. If external inspected for corroded or abraded
visual inspection is precluded because areas, dents, distortions, defects in
any part of the cargo tank wall is ex- welds and any other conditions, includ-
ternally lined, coated, or designed to ing leakage, that might render the
prevent an external visual inspection, tank unsafe for transportation service;
those areas of the cargo tank must be (ii) The piping, valves, and gaskets
internally inspected. If internal visual must be carefully inspected for cor-
inspection is precluded because the roded areas, defects in welds, and other
cargo tank is lined, coated, or designed conditions, including leakage, that
so as to prevent access for internal in- might render the tank unsafe for trans-
spection, the tank must be portation service;
349
§ 180.407 49 CFR Ch. I (10–1–18 Edition)
(iii) All devices for tightening man- low-alloy steel, that create air cavities
hole covers must be operative and adjacent to the tank shell that do not
there must be no evidence of leakage at allow for external visual inspection
manhole covers or gaskets; must be thickness tested in accordance
(iv) All emergency devices and valves with paragraphs (i)(2) and (i)(3) of this
including self-closing stop valves, ex- section, at least once every 2 years. At
cess flow valves and remote closure de- least four symmetrically distributed
vices must be free from corrosion, dis- readings must be taken to establish an
tortion, erosion and any external dam- average thickness for the ring stiffener
age that will prevent safe operation. or appurtenance. If any thickness read-
Remote closure devices and self-closing ing is less than the average thickness
stop valves must be functioned to dem- by more than 10%, thickness testing in
onstrate proper operation; accordance with paragraphs (i)(2) and
(v) Missing bolts, nuts and fusible (i)(3) of this section must be conducted
links or elements must be replaced, from the inside of the cargo tank on
and loose bolts and nuts must be tight- the area of the tank wall covered by
ened; the appurtenance or ring stiffener.
(vi) All markings on the cargo tank (5) Corroded or abraded areas of the
required by parts 172, 178 and 180 of this cargo tank wall must be thickness
subchapter must be legible; tested in accordance with the proce-
(vii) [Reserved] dures set forth in paragraphs (i)(2),
(viii) All major appurtenances and (i)(3), (i)(5) and (i)(6) of this section.
structural attachments on the cargo (6) The gaskets on any full opening
tank including, but not limited to, sus- rear head must be:
pension system attachments, con- (i) Visually inspected for cracks or
necting structures, and those elements splits caused by weather or wear; and
of the upper coupler (fifth wheel) as- (ii) Replaced if cuts or cracks which
sembly that can be inspected without are likely to cause leakage, or are of a
dismantling the upper coupler (fifth depth one-half inch or more, are found.
wheel) assembly must be inspected for
(7) The inspector must record the re-
any corrosion or damage which might
sults of the external visual examina-
prevent safe operation;
tion as specified in § 180.417(b).
(ix) For cargo tanks transporting lad-
ing corrosive to the tank, areas cov- (e) Internal visual inspection. (1) When
ered by the upper coupler (fifth wheel) the cargo tank is not equipped with a
assembly must be inspected at least manhole or inspection opening, or the
once in each two year period for cor- cargo tank design precludes an internal
inspection, the tank shall be
roded and abraded areas, dents, distor-
hydrostatically or pneumatically test-
tions, defects in welds, and any other
ed in accordance with 180.407(c) and (g).
condition that might render the tank
unsafe for transportation service. The (2) The internal visual inspection
upper coupler (fifth wheel) assembly must include as a minimum the fol-
must be removed from the cargo tank lowing:
for this inspection. (i) The tank shell and heads must be
(3) All reclosing pressure relief valves inspected for corroded and abraded
must be externally inspected for any areas, dents, distortions, defects in
corrosion or damage which might pre- welds, and any other condition that
vent safe operation. All reclosing pres- might render the tank unsafe for trans-
sure relief valves on cargo tanks car- portation service.
rying lading corrosive to the valve (ii) Tank liners must be inspected as
must be removed from the cargo tank specified in § 180.407(f).
for inspection and testing. Each re- (3) Corroded or abraded areas of the
closing pressure relief valve required to cargo tank wall must be thickness
be removed and tested must be tested tested in accordance with paragraphs
according to the requirements set forth (i)(2), (i)(3), (i)(5) and (i)(6) of this sec-
in paragraph (j) of this section. tion.

(4) Ring stiffeners or other appur- (4) The inspector must record the re-
tenances, installed on cargo tanks con- sults of the internal visual inspection
structed of mild steel or high-strength, as specified in § 180.417(b).
350
(f) Lining inspection. The integrity of in accordance with paragraphs (i)(2),

the lining on all lined cargo tanks, (i)(3), (i)(5) and (i)(6) of this section.
when lining is required by this sub- (4) The inspector must record the re-
chapter, must be verified at least once sults of the lining inspection as speci-
each year as follows: fied in § 180.417(b).
(1) Rubber (elastomeric) lining must (g) Pressure test. All components of
be tested for holes as follows: the cargo tank wall, as defined in
(i) Equipment must consist of: § 178.320(a) of this subchapter, must be
(A) A high frequency spark tester ca- pressure tested as prescribed by this
pable of producing sufficient voltage to paragraph.
ensure proper calibration; (1) Test Procedure—(i) As part of the
pressure test, the inspector must per-
(B) A probe with an ‘‘L’’ shaped 2.4
form an external and internal visual
mm (0.09 inch) diameter wire with up
inspection, except that on an MC 338
to a 30.5 cm (12-inch) bottom leg (end
cargo tank, or a cargo tank not
bent to a 12.7 mm (0.5 inch) radius), or
equipped with a manhole or inspection
equally sensitive probe; and
opening, an internal inspection is not
(C) A steel calibration coupon 30.5 cm required.
× 30.5 cm (12 inches × 12 inches) covered (ii) All self-closing pressure relief
with the same material and thickness valves, including emergency relief
as that to be tested. The material on vents and normal vents, must be re-
the coupon shall have a test hole to the moved from the cargo tank for inspec-
metal substrate made by puncturing tion and testing according to the re-
the material with a 22 gauge hypo- quirements in paragraph (j) of this sec-
dermic needle or comparable piercing tion.
tool. (iii) Except for cargo tanks carrying
(ii) The probe must be passed over lading corrosive to the tank, areas cov-
the surface of the calibration coupon in ered by the upper coupler (fifth wheel)
a constant uninterrupted manner until assembly must be inspected for cor-
the hole is found. The hole is detected roded and abraded areas, dents, distor-
by the white or light blue spark tions, defects in welds, and any other
formed. (A sound lining causes a dark condition that might render the tank
blue or purple spark.) The voltage must unsafe for transportation service. The
be adjusted to the lowest setting that upper coupler (fifth wheel) assembly
will produce a minimum 12.7 mm (0.5 must be removed from the cargo tank
inch) spark measured from the top of for this inspection.
the lining to the probe. To assure that (iv) Each cargo tank must be tested
the setting on the probe has not hydrostatically or pneumatically to
changed, the spark tester must be cali- the internal pressure specified in the
brated periodically using the test cali- following table. At no time during the
bration coupon, and the same power pressure test may a cargo tank be sub-
source, probe, and cable length. ject to pressures that exceed those
(iii) After calibration, the probe must identified in the following table:
be passed over the lining in an uninter-
rupted stroke. Specification Test pressure
(iv) Holes that are found must be re- MC 300, 301, 302, 303, 305, 20.7 kPa (3 psig) or design
paired using equipment and procedures 306. pressure, whichever is
greater.
prescribed by the lining manufacturer MC 304, 307 .......................... 275.8 kPa (40 psig) or 1.5
or lining installer. times the design pressure,
(2) Linings made of other than rubber whichever is greater.
MC 310, 311, 312 .................. 20.7 kPa (3 psig) or 1.5 times
(elastomeric material) must be tested the design pressure, which-
using equipment and procedures pre- ever is greater.
scribed by the lining manufacturer or MC 330, 331 .......................... 1.5 times either the MAWP or
the re-rated pressure,
lining installer. whichever is applicable.
(3) Degraded or defective areas of the MC 338 .................................. 1.25 times either the MAWP
cargo tank liner must be removed and or the re-rated pressure,

whichever is applicable.
the cargo tank wall below the defect DOT 406 ................................ 34.5 kPa (5 psig) or 1.5 times
must be inspected. Corroded areas of the MAWP, whichever is
the tank wall must be thickness tested greater.
351
§ 180.407 49 CFR Ch. I (10–1–18 Edition)
Specification Test pressure leaks. This method must consist either

of coating the entire surface of all
DOT 407 ................................ 275.8 kPa (40 psig) or 1.5
times the MAWP, which- joints under pressure with a solution of
ever is greater. soap and water, or using other equally
DOT 412 ................................ 1.5 times the MAWP. sensitive methods.
(2) When testing an insulated cargo
(v) [Reserved] tank, the insulation and jacketing need
(vi) Each cargo tank of a multi-tank not be removed unless it is otherwise
cargo tank motor vehicle must be test- impossible to reach test pressure and
ed with the adjacent cargo tanks maintain a condition of pressure equi-
empty and at atmospheric pressure. librium after test pressure is reached,
(vii) All closures except pressure re- or the vacuum integrity cannot be
lief devices must be in place during the maintained in the insulation space. If
test. All prescribed loading and unload-
an MC 338 cargo tank used for the
ing venting devices rated at less than
transportation of a flammable gas or
test pressure may be removed during
oxygen, refrigerated liquid is opened
the test. If retained, the devices must
for any reason, the cleanliness must be
be rendered inoperative by clamps,
verified prior to closure using the pro-
plugs, or other equally effective re-
cedures contained in § 178.338–15 of this
straining devices. Restraining devices
subchapter.
may not prevent detection of leaks or
damage the venting devices and must (3) Each MC 330 and MC 331 cargo
be removed immediately after the test tank constructed of quenched and tem-
is completed. pered steel in accordance with Part
(viii) Hydrostatic test method. Each UHT in Section VIII of the ASME Code
cargo tank, including its domes, must (IBR, see § 171.7 of this subchapter), or
be filled with water or other liquid hav- constructed of other than quenched
ing similar viscosity, at a temperature and tempered steel but without
not exceeding 100 °F. The cargo tank postweld heat treatment, used for the
must then be pressurized to not less transportation of anhydrous ammonia
than the pressure specified in para- or any other hazardous materials that
graph (g)(1)(iv) of this section. The may cause corrosion stress cracking,
cargo tank, including its closures, must be internally inspected by the
must hold the prescribed test pressure wet fluorescent magnetic particle
for at least 10 minutes during which method immediately prior to and in
time it shall be inspected for leakage, conjunction with the performance of
bulging or any other defect. the pressure test prescribed in this sec-
(ix) Pneumatic test method. Pneumatic tion. Each MC 330 and MC 331 cargo
testing may involve higher risk than tank constructed of quenched and tem-
hydrostatic testing. Therefore, suitable pered steel in accordance with Part
safeguards must be provided to protect UHT in Section VIII of the ASME Code
personnel and facilities should failure and used for the transportation of liq-
occur during the test. The cargo tank uefied petroleum gas must be inter-
must be pressurized with air or an nally inspected by the wet fluorescent
inert gas. The pneumatic test pressure magnetic particle method immediately
in the cargo tank must be reached by prior to and in conjunction with the
gradually increasing the pressure to performance of the pressure test pre-
one-half of the test pressure. There- scribed in this section. The wet fluores-
after, the pressure must be increased in cent magnetic particle inspection must
steps of approximately one-tenth of the be in accordance with Section V of the
test pressure until the required test ASME Code and CGA Technical Bul-
pressure has been reached. The test letin TB–2 (IBR, see § 171.7 of this sub-
pressure must be held for at least 5 chapter). This paragraph does not
minutes. The pressure must then be re- apply to cargo tanks that do not have
duced to the MAWP, which must be manholes. (See § 180.417(c) for reporting
maintained during the time the entire requirements.)

cargo tank surface is inspected. During (4) All pressure bearing portions of a
the inspection, a suitable method must cargo tank heating system employing a
be used for detecting the existence of medium such as, but not limited to,
352
steam or hot water for heating the lad- be tested with adjacent cargo tanks
ing must be hydrostatically pressure empty and at atmospheric pressure.
tested at least once every 5 years. The Test pressure must be maintained for
test pressure must be at least the max- at least 5 minutes. Cargo tanks in liq-
imum system design operating pressure uefied compressed gas service must be
and must be maintained for five min- externally inspected for leaks during
utes. A heating system employing flues the leakage test. Suitable safeguards
for heating the lading must be tested must be provided to protect personnel
to ensure against lading leakage into should a failure occur. Cargo tanks
the flues or into the atmosphere. may be leakage tested with hazardous
(5) Exceptions. (i) Pressure testing is materials contained in the cargo tank
not required for MC 330 and MC 331 during the test. Leakage test pressure
cargo tanks in dedicated sodium metal must be no less than 80% of MAWP
service. marked on the specification plate ex-
(ii) Pressure testing is not required cept as follows:
for uninsulated lined cargo tanks, with (i) A cargo tank with an MAWP of 690
a design pressure or MAWP of 15 psig kPa (100 psig) or more may be leakage
or less, which receive an external vis- tested at its maximum normal oper-
ual inspection and a lining inspection ating pressure provided it is in dedi-
at least once each year. cated service or services; or
(6) Acceptance criteria. A cargo tank (ii) An MC 330 or MC 331 cargo tank
that leaks, fails to retain test pressure in dedicated liquified petroleum gas
or pneumatic inspection pressure, service may be leakage tested at not
shows distortion, excessive permanent less than 414 kPa (60 psig).
expansion, or other evidence of weak- (iii) An operator of a specification
ness that might render the cargo tank MC 330 or MC 331 cargo tank, and a
unsafe for transportation service, may nonspecification cargo tank authorized
not be returned to service, except as under § 173.315(k) of this subchapter,
follows: A cargo tank with a heating equipped with a meter may check leak
system which does not hold pressure tightness of the internal self-closing
may remain in service as an unheated stop valve by conducting a meter creep
cargo tank if: test. (See appendix B to this part.)
(i) The heating system remains in (iv) An MC 330 or MC 331 cargo tank
place and is structurally sound and no in dedicated service for anhydrous am-
lading may leak into the heating sys- monia may be leakage tested at not
tem, and less than 414 kPa (60 psig).
(ii) The specification plate heating (v) A non-specification cargo tank re-
system information is changed to indi- quired by § 173.8(d) of this subchapter to
cate that the cargo tank has no work- be leakage tested, must be leakage
ing heating system. tested at not less than 16.6 kPa (2.4
(7) The inspector must record the re- psig), or as specified in paragraph (h)(2)
sults of the pressure test as specified in of this section.
§ 180.417(b). (2) Cargo tanks used to transport pe-
(h) Leakage test. The following re- troleum distillate fuels that are
quirements apply to cargo tanks re- equipped with vapor collection equip-
quiring a leakage test: ment may be leak tested in accordance
(1) Each cargo tank must be tested with the Environmental Protection
for leaks in accordance with paragraph Agency’s ‘‘Method 27—Determination
(c) of this section. The leakage test of Vapor Tightness of Gasoline Deliv-
must include testing product piping ery Tank Using Pressure-Vacuum
with all valves and accessories in place Test,’’ as set forth in Appendix A to 40
and operative, except that any venting CFR part 60. Test methods and proce-
devices set to discharge at less than dures and maximum allowable pressure
the leakage test pressure must be re- and vacuum changes are in 40 CFR
moved or rendered inoperative during 63.425(e). The hydrostatic test alter-
the test. All internal or external self- native, using liquid in Environmental
closing stop valves must be tested for Protection Agency’s ‘‘Method 27—De-
leak tightness. Each cargo tank of a termination of Vapor Tightness of Gas-
multi-cargo tank motor vehicle must oline Delivery Tank Using Pressure-
353
§ 180.407 49 CFR Ch. I (10–1–18 Edition)
Vacuum Test,’’ may not be used to sat- (ii) Areas of high shell stress such as
isfy the leak testing requirements of the bottom center of the tank;
this paragraph. The test must be con- (iii) Areas near openings;
ducted using air. (iv) Areas around weld joints;
(3) A cargo tank that fails to retain (v) Areas around shell reinforce-
leakage test pressure may not be re- ments;
turned to service as a specification (vi) Areas around appurtenance at-
cargo tank, except under conditions tachments;
specified in § 180.411(d). (vii) Areas near upper coupler (fifth
(4) After July 1, 2000, Registered In- wheel) assembly attachments;
spectors of specification MC 330 and MC (viii) Areas near suspension system
attachments and connecting struc-
331 cargo tanks, and nonspecification
tures;
cargo tanks authorized under
(ix) Known thin areas in the tank
§ 173.315(k) of this subchapter must vis-
shell and nominal liquid level lines;
ually inspect the delivery hose assem-
and
bly and piping system while the assem-
(x) Connecting structures joining
bly is under leakage test pressure uti-
multiple cargo tanks of carbon steel in
lizing the rejection criteria listed in
a self-supporting cargo tank motor ve-
§ 180.416(g). Delivery hose assemblies hicle.
not permanently attached to the cargo (5) Minimum thicknesses for MC 300,
tank motor vehicle may be inspected MC 301, MC 302, MC 303, MC 304, MC 305,
separately from the cargo tank motor MC 306, MC 307, MC 310, MC 311, and MC
vehicle. In addition to a written record 312 cargo tanks are determined based
of the inspection prepared in accord- on the definition of minimum thick-
ance with § 180.417(b), the Registered ness found in § 178.320(a) of this sub-
Inspector conducting the test must chapter. The following Tables I and II
note the hose identification number, identify the ‘‘In-Service Minimum
the date of the test, and the condition Thickness’’ values to be used to deter-
of the hose assembly and piping system mine the minimum thickness for the
tested. referenced cargo tanks. The column
(5) The inspector must record the re- headed ‘‘Minimum Manufactured
sults of the leakage test as specified in Thickness’’ indicates the minimum
§ 180.417(b). values required for new construction of
(i) Thickness testing. (1) The shell and DOT 400 series cargo tanks, found in
head thickness of all unlined cargo Tables I and II of §§ 178.346–2, 178.347–2,
tanks used for the transportation of and 178.348–2 of this subchapter. In-
materials corrosive to the tank must Service Minimum Thicknesses for MC
be measured at least once every 2 300, MC 301, MC 302, MC 303, MC 304, MC
years, except that cargo tanks meas- 305, MC 306, MC 307, MC 310, MC 311, and
uring less than the sum of the min- MC 312 cargo tanks are based on 90 per-
imum prescribed thickness, plus one- cent of the manufactured thickness
fifth of the original corrosion allow- specified in the DOT specification,
ance, must be tested annually. rounded to three places.
(2) Measurements must be made
using a device capable of accurately TABLE I—IN-SERVICE MINIMUM THICKNESS FOR
measuring thickness to within ±0.002 of MC 300, MC 303, MC 304, MC 306, MC
an inch. 307, MC 310, MC 311, AND MC 312 SPECI-
(3) Any person performing thickness FICATION CARGO TANKS CONSTRUCTED OF
testing must be trained in the proper STEEL AND STEEL ALLOYS
use of the thickness testing device used Nominal In-service
in accordance with the manufacturer’s Minimum manufactured thickness decimal minimum
equiva- thickness
instruction. (US gauge or inches) lent for reference
(4) Thickness testing must be per- (inches) (inches)
formed in the following areas of the 19 ....................................................... 0.0418 0.038
cargo tank wall, as a minimum: 18 ....................................................... 0.0478 0.043

(i) Areas of the tank shell and heads 17 ....................................................... 0.0538 0.048
16 ....................................................... 0.0598 0.054
and shell and head area around any 15 ....................................................... 0.0673 0.061
piping that retains lading; 14 ....................................................... 0.0747 0.067
354
TABLE I—IN-SERVICE MINIMUM THICKNESS FOR (ii) The cargo tank motor vehicle’s
MC 300, MC 303, MC 304, MC 306, MC nameplate must reflect the revised
307, MC 310, MC 311, AND MC 312 SPECI- service limits.
FICATION CARGO TANKS CONSTRUCTED OF (7) An owner of a cargo tank that no
STEEL AND STEEL ALLOYS—Continued longer conforms with the minimum
thickness prescribed for the specifica-
Nominal In-service
decimal minimum tion may not return the cargo tank to
Minimum manufactured thickness
(US gauge or inches) equiva- thickness hazardous materials service. The
lent for reference
(inches) (inches) tank’s specification plate must be re-
moved, obliterated or covered in a se-
13 ....................................................... 0.0897 0.081 cure manner.
12 ....................................................... 0.1046 0.094
11 ....................................................... 0.1196 0.108
(8) The inspector must record the re-
10 ....................................................... 0.1345 0.121 sults of the thickness test as specified
9 ......................................................... 0.1495 0.135 in § 180.417(b).
8 ......................................................... 0.1644 0.148 (9) For MC 331 cargo tanks con-
7 ......................................................... 0.1793 0.161 structed before October 1, 2003, min-
3/16 .................................................... 0.1875 0.169
1/4 ...................................................... 0.2500 0.225
imum thickness shall be determined by
5/16 .................................................... 0.3125 0.281 the thickness indicated on the U1A
3/8 ...................................................... 0.3750 0.338 form minus any corrosion allowance.
For MC 331 cargo tanks constructed
TABLE II—IN-SERVICE MINIMUM THICKNESS FOR after October 1, 2003, the minimum
MC 301, MC 302, MC 304, MC 305, MC thickness will be the value indicated
306, MC 307, MC 311, AND MC 312 SPECI- on the specification plate. If no corro-
FICATION CARGO TANKS CONSTRUCTED OF
sion allowance is indicated on the U1A
ALUMINUM AND ALUMINUM ALLOYS form then the thickness of the tank
shall be the thickness of the material
In-service of construction indicated on the UIA
minimum form with no corrosion allowance.
Minimum manufactured thickness thickness
(inches) (10) For 400-series cargo tanks, min-
imum thickness is calculated accord-
0.078 ...................................................................... 0.070
0.087 ...................................................................... 0.078
ing to tables in each applicable section
0.096 ...................................................................... 0.086 of this subchapter for that specifica-
0.109 ...................................................................... 0.098 tion: § 178.346–2 for DOT 406 cargo
0.130 ...................................................................... 0.117 tanks, § 178.347–2 for DOT 407 cargo
0.141 ...................................................................... 0.127 tanks, and § 178.348–2 for DOT 412 cargo
0.151 ...................................................................... 0.136
0.172 ...................................................................... 0.155
tanks.
0.173 ...................................................................... 0.156 (j) Pressure vent bench test. When re-
0.194 ...................................................................... 0.175 quired by this section, pressure relief
0.216 ...................................................................... 0.194 valves must be tested for proper func-
0.237 ...................................................................... 0.213
tion as follows:
0.270 ...................................................................... 0.243
0.360 ...................................................................... 0.324 (1) Each self-closing pressure relief
0.450 ...................................................................... 0.405 valve must open and reseat to a
0.540 ...................................................................... 0.486 leaktight condition at the pressures
prescribed for the applicable cargo
(6) An owner of a cargo tank that no tank specification or at the following
longer conforms to the minimum pressures:
thickness prescribed for the design as (i) For MC 306 cargo tanks:
manufactured may use the cargo tank (A) With MC 306 reclosing pressure
to transport authorized materials at relief valves, it must open at not less
reduced maximum weight of lading or than 3 psi and not more than 4.4 psi and
reduced maximum working pressure, or must reseat to a leak tight-condition
combinations thereof, provided the fol- at no less than 2.7 psi.
lowing conditions are met: (B) With reclosing pressure relief
(i) A Design Certifying Engineer valves modified as provided in
must certify that the cargo tank de- § 180.405(c) to conform with DOT 406
sign and thickness are appropriate for specifications, according to the pres-
the reduced loading conditions by sures set forth for a DOT 406 cargo
issuance of a revised manufacturer’s tank in § 178.346–3 of this subchapter.
certificate, and (ii) For MC 307 cargo tanks:
355
§ 180.409 49 CFR Ch. I (10–1–18 Edition)
(A) With MC 307 reclosing pressure Sections Affected, which appears in the
relief valves, it must open at not less Finding Aids section of the printed volume
than the cargo tank MAWP and not and at www.fdsys.gov.
more than 110% of the cargo tank § 180.409 Minimum qualifications for
MAWP and must reseat to a leak tight- inspectors and testers.
condition at no less than 90% of the
cargo tank MAWP. (a) Except as otherwise provided in
(B) With reclosing pressure relief this section, any person performing or
valves modified as provided in witnessing the inspections and tests
§ 180.405(c) to conform with DOT 407 specified in § 180.407(c) must—
specifications, according to the pres- (1) Be registered with the Federal
sures set forth for a DOT 407 cargo Motor Carrier Safety Administration
tank in § 178.347–4 of this subchapter. in accordance with part 107, subpart F
(iii) For MC 312 cargo tanks: of this chapter,
(A) With MC 312 reclosing pressure (2) Be familiar with DOT-specifica-
relief valves, it must open at not less tion cargo tanks and trained and expe-
than the cargo tank MAWP and not rienced in use of the inspection and
more than 110% of the cargo tank testing equipment needed, and
MAWP and must reseat to a leak tight- (3) Have the training and experience
condition at no less than 90% of the required to meet the definition of
cargo tank MAWP. ‘‘Registered Inspector’’ in § 171.8 of this
(B) With reclosing pressure relief chapter.
valves modified as provided in (b) A person who only performs an-
§ 180.405(c) to conform with DOT 412 nual external visual inspections and
specifications, according to the pres- leakage tests on a cargo tank motor
sures set forth for a DOT 412 cargo vehicle, owned or operated by that per-
tank in § 178.348–4 of this subchapter. son, with a capacity of less than 13,250
(iv) For MC 330 or MC 331 cargo L (3,500 gallons) used exclusively for
tanks, it must open at not less than flammable liquid petroleum fuels, is
the required set pressure and not more not required to meet the educational
than 110% of the required set pressure and years of experience requirements
and must reseat to a leak-tight condi- set forth in the definition of ‘‘Reg-
tion at no less than 90% of the required istered Inspector’’ in § 171.8 of this sub-
set pressure. chapter. Although not required to meet
(v) For DOT 400-series cargo tanks, the educational and years of experience
according to the pressures set forth for requirements, a person who performs
the applicable cargo tank specification visual inspections or leakage tests or
in §§ 178.346–3, 178.347–4, and 178.348–4, signs the inspection reports must have
respectively, of this subchapter. the knowledge and ability to perform
(vi) For cargo tanks not specified in such inspections and tests and must
this paragraph, it must open at not less perform them as required by this sub-
than the required set pressure and not chapter, and must register with the De-
more than 110% of the required set partment as required by subpart F of
pressure and must reseat to a leak- part 107 of this chapter.
tight condition at no less than 90% of (c) A person who performs only an-
the required set pressure or the pres- nual external visual inspections and
sure prescribed for the applicable cargo leakage tests on a permanently mount-
tank specification. ed non-bulk tank, owned or operated
(2) Normal vents (1 psig vents) must by that person, for petroleum products
be tested according to the testing cri- as authorized by § 173.8(c) of this sub-
teria established by the valve manufac- chapter, is not required to be reg-
turer. istered in accordance with subpart F of
(3) Self-closing pressure relief devices part 107 of this chapter. In addition the
not tested or failing the tests in para- person who signs the inspection report
graph (j)(1) of this section must be re- required by § 180.417(b) of this subpart
paired or replaced. for such non-bulk tanks is not required
to be registered. Although not required

[Amdt. 180–2, 54 FR 25032, June 12, 1989] to register, a person who performs vis-
EDITORIAL NOTE: For FEDERAL REGISTER ci- ual inspections or leakage tests or
tations affecting § 180.407, see the List of CFR signs the inspection reports must have
356
the knowledge and ability to perform not be less than that prescribed in the
such inspections and tests and must applicable specification.
perform them as required by this sub- (c) Weld or structural defects. Any
chapter. cargo tank with a weld defect such as
(d) A motor carrier or cargo tank a crack, pinhole, or incomplete fusion,
owner who meets the requirements of or a structural defect must be taken
paragraph (a) of this section may use out of hazardous materials service
an employee who is not a Registered until repaired.
Inspector to perform a portion of the (d) Leakage. All sources of leakage
pressure retest required by § 180.407(g). must be properly repaired prior to re-
External and internal visual inspec- turning a tank to hazardous materials
tions must be accomplished by a Reg- service.
istered Inspector, but the hydrostatic (e) Relief valves. Any pressure relief
or pneumatic pressure test, as set forth valve that fails to open and reclose at
in § 180.407(g)(1)(viii) and (ix), respec- the prescribed pressure must be re-
tively, may be done by an employee paired or replaced.
who is not a Registered Inspector pro- (f) Liner integrity. Any defect shown
vided that— by the test must be properly repaired.
(1) The employee is familiar with the (g) Pressure test. Any tank that fails
cargo tank and is trained and experi- to meet the acceptance criteria found
enced in the use of the inspection and in the individual specification that ap-
testing equipment used; plies must be properly repaired.
(2) The employer submits certifi- [Amdt. 180–2, 54 FR 25032, June 12, 1989, as
cation that such employee meets the amended at 68 FR 75764, Dec. 31, 2003]
qualification requirements to the Asso-
ciate Administrator, Attn: (PHH–32), § 180.413 Repair, modification, stretch-
Pipeline and Hazardous Materials Safe- ing, rebarrelling, or mounting of
ty Administration, Department of specification cargo tanks.
Transportation, East Building, 1200 (a) General. Any repair, modification,
New Jersey Avenue, SE., Washington, stretching, rebarrelling, or mounting
DC 20590; and of a cargo tank must be performed in
(3) The employer retains a copy of conformance with the requirements of
the tester’s qualifications with the doc- this section.
uments required by § 180.417(b). (1) Except as otherwise provided in
this section, each repair, modification,
[Amdt. 180–2, 55 FR 37069, Sept. 7, 1990, as
amended by Amdt. 180–3, 56 FR 66287, Dec. 20, stretching, or rebarrelling of a speci-
1991; 57 FR 45466, Oct. 1, 1992; Amdt. 180–11, 62 fication cargo tank must be performed
FR 1217, Jan. 8, 1997; 66 FR 45391, Aug. 28, by a repair facility holding a valid Na-
2001; 68 FR 19288, Apr. 18, 2003; 70 FR 56100, tional Board Certificate of Authoriza-
Sept. 23, 2005; 72 FR 55697, Oct. 1, 2007] tion for use of the National Board ‘‘R’’
stamp and must be made in accordance
§ 180.411 Acceptable results of tests with the edition of the National Board
and inspections. Inspection Code in effect at the time
(a) Corroded or abraded areas. The the work is performed.
minimum thickness may not be less (i) Repairs, modifications,
than that prescribed in the applicable stretchings, and rebarrellings per-
specification. formed on non-ASME stamped speci-
(b) Dents, cuts, digs and gouges. For fication cargo tanks may be performed
evaluation procedures, see CGA C–6 by:
(IBR, see § 171.7 of this subchapter). (A) A cargo tank manufacturer hold-
(1) For dents at welds or that include ing a valid ASME Certificate of Au-
a weld, the maximum allowable depth thorization for the use of the ASME
is 1⁄2 inch. For dents away from welds, ‘‘U’’ stamp using the quality control
the maximum allowable depth is 1⁄10 of procedures used to obtain the Certifi-
the greatest dimension of the dent, but cate of Authorization; or
in no case may the depth exceed one (B) A repair facility holding a valid
inch. National Board Certificate of Author-
(2) The minimum thickness remain- ization for use of the National Board
ing beneath a cut, dig, or gouge may ‘‘R’’ stamp using the quality control
357
§ 180.413 49 CFR Ch. I (10–1–18 Edition)
procedures used to obtain the Certifi- (1) DOT 406, DOT 407, and DOT 412
cate of Authorization. cargo tanks must be repaired in ac-
(ii) A repair, modification, stretch- cordance with the specification re-
ing, or rebarrelling of a non-ASME quirements in effect at the time of re-
stamped cargo tank may be done with- pair;
out certification by an Authorized In- (2) MC 300, MC 301, MC 302, MC 303,
spector, completion of the R–1 form, or MC 305, and MC 306 cargo tanks must
being stamped with the ‘‘R’’ stamp. be repaired in accordance with either
(iii) A repair, as defined in § 180.403, of the most recent revision of the original
a DOT specification cargo tank used specification or with the DOT 406 speci-
for the transportation of hazardous fication in effect at the time of repair;
materials in the United States may be (3) MC 304 and MC 307 cargo tanks
performed by a facility in Canada in must be repaired in accordance with ei-
accordance with the Transport Canada ther the most recent revision of the
TDG Regulations (IBR, see § 171.7 of original specification or with the DOT
this subchapter) provided: 407 specification in effect at the time of
(A) The facility holds a valid Certifi- repair;
cate of Authorization from a provincial (4) MC 310, MC 311, and MC 312 cargo
pressure vessel jurisdiction for repair; tanks must be repaired in accordance
with either the most recent revision of
(B) The facility is registered in ac-
the original specification or with the
cordance with the Transport Canada
DOT 412 specification in effect at the
TDG Regulations to repair the cor-
time of repair;
responding TC specification; and
(5) MC 338 cargo tanks must be re-
(C) All repairs are performed using paired in accordance with the speci-
the quality control procedures used to fication requirements in effect at the
obtain the Certificate of Authorization. time of repair; and
(2) Prior to each repair, modification, (6) MC 330 and MC 331 cargo tanks
stretching, rebarrelling, or mounting, must be repaired in accordance with
the cargo tank motor vehicle must be the repair procedures described in CGA
emptied of any hazardous material lad- Technical Bulletin TB–2 (IBR, see
ing. In addition, cargo tank motor ve- § 171.7 of this subchapter) and the Na-
hicles used to transport flammable or tional Board Inspection Code (IBR, see
toxic lading must be sufficiently § 171.7 of this subchapter). Each cargo
cleaned of residue and purged of vapors tank having cracks or other defects re-
so any potential hazard is removed, in- quiring welded repairs must meet all
cluding void spaces between double inspection, test, and heat treatment re-
bulkheads, piping and vapor recovery quirements in § 178.337–16 of this sub-
systems. chapter in effect at the time of the re-
(3) Each person performing a repair, pair, except that postweld heat treat-
modification, stretching, rebarrelling ment after minor weld repairs is not
or mounting of a DOT specification required. When a repair is made of de-
cargo tank must be registered in ac- fects revealed by the wet fluorescent
cordance with subpart F of part 107 of magnetic particle inspection, including
this chapter. those repaired by grinding, the affected
(b) Repair. The suitability of each re- area of the cargo tank must again be
pair affecting the structural integrity examined by the wet fluorescent mag-
or lading retention capability of the netic particle method after hydrostatic
cargo tank must be determined by the testing to assure that all defects have
testing required either in the applica- been removed.
ble manufacturing specification or in (c) Maintenance or replacement of pip-
§ 180.407(g)(1)(iv). Except for a repair ing, valves, hoses, or fittings. After each
performed by a facility in Canada in repair, maintenance or replacement of
accordance with paragraph (a)(1)(iii) of a pipe, valve, hose, or fitting on a cargo
this section, each repair of a cargo tank, that component must be in-
tank involving welding on the shell or stalled in accordance with the provi-
head must be certified by a Registered sions of the applicable specification be-
Inspector. The following provisions fore the cargo tank is returned to serv-
apply to specific cargo tank repairs: ice.
358
(1) After maintenance or replacement until August 31, 1995 and, thereafter to
that does not involve welding on the specification DOT 407 only;
cargo tank wall, the repaired or re- (iii) For specification MC 310, MC 311,
placed piping, valve, hose, or fitting and MC 312 cargo tanks, the provisions
must be tested for leaks. This require- of either specification MC 312 or DOT
ment is met when the piping, valve, 412 until August 31, 1995 and, thereafter
hose, or fitting is tested after installa- to specification DOT 412 only;
tion in accordance with § 180.407(h)(1). (iv) For specification MC 330 cargo
A hose may be tested before or after in- tanks, the provisions of specification
stallation on the cargo tank. MC 331; and
(2) After repair or replacement of pip- (v) For specification MC 338 cargo
ing, valves, or fittings that involves tanks, the provisions of specification
welding on the cargo tank wall, the MC 338. However, structural modifica-
cargo tank must be pressure tested in tions to MC 338 cargo tanks authorized
accordance with the applicable manu- under § 180.405(d) may conform to appli-
facturing specification or cable provisions of the ASME Code in-
§ 180.407(g)(1)(iv). In addition, the af- stead of specification MC 338, provided
fected piping, valve, or fitting must be the structural integrity of the modified
tested in accordance with paragraph cargo tank is at least equivalent to
(c)(1) of this section. that of the original cargo tank.
(3) Hoses on cargo tanks in dedicated (3) The person performing the modi-
liquefied compressed gas, except car- fication, stretching, or rebarrelling
bon dioxide, service are excepted from must:
these testing requirements, but must (i) Have knowledge of the original de-
be tested in accordance with § 180.416(f). sign concept, particularly with respect
(d) Modification, stretching, or rebarrel- to structural design analysis, material
ling. Modification, stretching or re- and welding procedures.
barrelling of a cargo tank motor vehi- (ii) Assure compliance of the rebuilt
cle must conform to the following pro- cargo tank’s structural integrity, vent-
visions: ing, and accident damage protection
(1) The design of the modified, with the applicable specification re-
stretched, or rebarrelled cargo tank quirements.
motor vehicle must be certified in (iii) Assure compliance with all ap-
writing by a Design Certifying Engi- plicable Federal Motor Carrier Safety
neer as meeting the structural integ- Regulations for all newly installed
rity and accident damage protection safety equipment.
requirements of the applicable speci- (iv) Assure the suitability of each
fication. modification, stretching and rebarrel-
(2) Except as provided in paragraph ling that affects the lading retention
(d)(2)(v) of this section, all new mate- capability of the cargo tank by per-
rial and equipment affected by modi- forming the tests required in the appli-
fication, stretching, or rebarrelling cable specification or § 180.407(g)(1)(iv).
must meet the requirements of the (v) Any modification that changes in-
specification in effect at the time such formation displayed on the specifica-
work is performed, and all applicable tion plate requires the installation of a
structural integrity requirements supplemental specification plate,
(§ 178.337–3, § 178.338–3, or § 178.345–3 of nameplate, or both containing the in-
this subchapter). The work must conformation that reflects the cargo tank
form to the requirements of the appli- as modified, stretched or rebarrelled.
cable specification as follows: The plate must include the name of the
(i) For specification MC 300, MC 301, person or facility doing the work, DOT
MC 302, MC 303, MC 305 and MC 306 registration number, date work is com-
cargo tanks, the provisions of either pleted, retest information, and any
specification MC 306 or DOT 406 until other information that differs from the
August 31, 1995 and, thereafter to speci- original plate. The supplemental plates
fication DOT 406 only; must be installed immediately adja-

(ii) For specification MC 304 and MC cent to the existing plate or plates.
307 cargo tanks, the provisions of ei- (vi) On a variable specification cargo
ther specification MC 307 or DOT 407 tank, install a supplemental or new
359
§ 180.415 49 CFR Ch. I (10–1–18 Edition)
variable specification plate, and re- § 180.415 Test and inspection mark-
place the specification listed on the ings.
original specification plate with the (a) Each cargo tank successfully
words ‘‘see variable specification completing the test and inspection re-
plate.’’ quirements contained in § 180.407 must
(4) A Registered Inspector must cer- be marked as specified in this section.
tify that the modified, stretched, or (b) Each cargo tank must be durably
rebarrelled cargo tank conforms to the and legibly marked, in English, with
requirements of this section and the the date (month and year) and the type
applicable specification by issuing a of test or inspection performed, subject
supplemental certificate of compliance. to the following provisions:
The registration number of the Reg- (1) The date must be readily identifi-
istered Inspector must be entered on able with the applicable test or inspec-
the certificate. tion.
(e) Mounting of cargo tanks. Mounting (2) The markings must be in letters
a cargo tank on a cargo tank motor ve- and numbers at least 32 mm (1.25
hicle must be: inches) high, near the specification
(1) Performed as required by para- plate or anywhere on the front head.
graph (d)(2) of this section and certified (3) The type of test or inspection may
by a Design Certifying Engineer if the be abbreviated as follows:
mounting of a cargo tank on a motor (i) V for external visual inspection
vehicle chassis involves welding on the and test;
cargo tank head or shell or any change (ii) I for internal visual inspection;
or modification of the methods of at- (iii) P for pressure test;
tachment; or (iv) L for lining inspection;
(2) In accordance with the original (v) T for thickness test; and
specification for attachment to the (vi) K for leakage test for a cargo
chassis or the specification for attach- tank tested under § 180.407, except
ment to the chassis in effect at the § 180.407(h)(2); and
time of the mounting, and performed (vii) K-EPA27 for a cargo tank tested
under the supervision of a Registered under § 180.407(h)(2) after October 1,
Inspector if the mounting of a cargo 2004.
tank on a motor vehicle chassis does
not involve welding on the cargo tank Examples to paragraph (b). The markings
‘‘10–99 P, V, L’’ represent that in October 1999
head or shell or a change or modifica-
a cargo tank passed the prescribed pressure
tion of the methods of attachment. test, external visual inspection and test, and
(f) Records. Each owner of a cargo the lining inspection. The markings ‘‘2–00 K-
tank motor vehicle must retain at the EPA27’’ represent that in February 2000 a
owner’s principal place of business all cargo tank passed the leakage test under
records of repair, modification, § 180.407(h)(2). The markings ‘‘2–00 K, K-
stretching, or rebarrelling, including EPA27’’ represent that in February 2000 a
cargo tank passed the leakage test under
notation of any tests conducted to both § 180.407(h)(1) and under EPA Method 27
verify the suitability of the repair, in § 180.407(h)(2).
modification, stretching, or rebarrel-
ling made to each cargo tank during (c) For a cargo tank motor vehicle
the time the cargo tank motor vehicle composed of multiple cargo tanks con-
is in service and for one year there- structed to the same specification,
after. Copies of these records must be which are tested and inspected at the
same time, one set of test and inspec-
retained by a motor carrier, if not the
tion markings may be used to satisfy
owner of the cargo tank motor vehicle,
the requirements of this section. For a
at its principal place of business during
cargo tank motor vehicle composed of
the period the cargo tank motor vehi-
multiple cargo tanks constructed to
cle is in the carrier’s service.
different specifications, which are test-

[68 FR 19288, Apr. 18, 2003; 68 FR 52372, Sept. ed and inspected at different intervals,
3, 2003, as amended at 68 FR 75764, Dec. 31, the test and inspection markings must
2003; 82 FR 15897, Mar. 30, 2017] appear in the order of the cargo tank’s
360
corresponding location, from front to for leakage through the valve at least
rear. once each calendar month the cargo
[Amdt. 180–2, 56 FR 27879, June 17, 1991, as
tank is in service. On cargo tanks
amended by Amdt. 180–3, 56 FR 66287, Dec. 20, equipped with a meter, the meter creep
1991; 57 FR 45466, Oct. 1, 1992; Amdt. 180–6, 59 test as outlined in appendix B to this
FR 49135, Sept. 26, 1994; Amdt. 180–10, 61 FR part or a test providing equivalent ac-
51343, Oct. 1, 1996; 68 FR 19290, Apr. 18, 2003; 68 curacy is acceptable. For cargo tanks
FR 52372, Sept. 3, 2003] that are not equipped with a meter, ap-
pendix B to this part outlines one ac-
§ 180.416 Discharge system inspection
and maintenance program for cargo ceptable method that may be used to
tanks transporting liquefied com- check internal self-closing stop valves
pressed gases. for closure.
(a) Applicability. This section is appli- (5) The operator must note each in-
cable to an operator using specification spection in a record. That record must
MC 330, MC 331, and nonspecification include the inspection date, the name
cargo tanks authorized under of the person performing the inspec-
§ 173.315(k) of this subchapter for trans- tion, the hose assembly identification
portation of liquefied compressed gases number, the manufacturer of the hose
other than carbon dioxide. Paragraphs assembly, the date the hose was assem-
(b), (c), (d)(1), (d)(5), (e), (f), and (g)(1) of bled and tested, and an indication that
this section, applicable to delivery the delivery hose assembly and piping
hose assemblies, apply only to hose as- system passed or failed the tests and
semblies installed or carried on the inspections. The operator must retain
cargo tank. a copy of each test and inspection
(b) Hose identification. By July 1, 2000, record at its principal place of business
the operator must assure that each de- or where the vehicle is housed or main-
livery hose assembly is permanently tained until the next test of the same
marked with a unique identification type is successfully completed.
number and maximum working pres- (e) Annual hose leakage test. The
sure. owner of a delivery hose assembly that
(c) Post-delivery hose check. After each is not permanently attached to a cargo
unloading, the operator must visually tank motor vehicle must ensure that
check that portion of the delivery hose the hose assembly is annually tested in
assembly deployed during the unload- accordance with § 180.407(h)(4).
ing. (f) New or repaired delivery hose assem-
(d) Monthly inspections and tests. (1) blies. Each operator of a cargo tank
The operator must visually inspect must ensure each new and repaired de-
each delivery hose assembly at least
livery hose assembly is tested at a min-
once each calendar month the delivery
imum of 120 percent of the hose max-
hose assembly is in service.
imum working pressure.
(2) The operator must visually in-
spect the piping system at least once (1) The operator must visually exam-
each calendar month the cargo tank is ine the delivery hose assembly while it
in service. The inspection must include is under pressure.
fusible elements and all components of (2) Upon successful completion of the
the piping system, including bolts, con- pressure test and inspection, the oper-
nections, and seals. ator must assure that the delivery hose
(3) At least once each calendar month assembly is permanently marked with
a cargo tank is in service, the operator the month and year of the test.
must actuate all emergency discharge (3) After July 1, 2000, the operator
control devices designed to close the must complete a record documenting
internal self-closing stop valve to as- the test and inspection, including the
sure that all linkages operate as de- date, the signature of the inspector,
signed. appendix A to this part outlines the hose owner, the hose identification
acceptable procedures that may be number, the date of original delivery
used for this test. hose assembly and test, notes of any
(4) The operator of a cargo tank must defects observed and repairs made, and
check the internal self-closing stop an indication that the delivery hose as-
valve in the liquid discharge opening sembly passed or failed the tests and
361
§ 180.417 49 CFR Ch. I (10–1–18 Edition)
inspections. A copy of each test and in- cate, the manufacturer’s ASME U1A
spection record must be retained by data report, where applicable, and re-
the operator at its principal place of lated papers certifying that the speci-
business or where the vehicle is housed fication cargo tank identified in the
or maintained until the next test of the documents was manufactured and test-
same type is successfully completed. ed in accordance with the applicable
(g) Rejection criteria. (1) No operator specification. This would include any
may use a delivery hose assembly de- certification of emergency discharge
termined to have any condition identi- control systems required by § 173.315(n)
fied below for unloading liquefied com- of this subchapter or § 180.405(m). The
pressed gases. An operator may remove owner must retain the documents
and replace damaged sections or cor- throughout his ownership of the speci-
rect defects discovered. Repaired hose fication cargo tank and for one year
assemblies may be placed back in serv- thereafter. In the event of a change in
ice if retested successfully in accord- ownership, the prior owner must retain
ance with paragraph (f) of this section. non-fading photo copies of these docu-
(i) Damage to the hose cover that ex- ments for one year.
poses the reinforcement. (2) Each motor carrier who uses a
(ii) Wire braid reinforcement that specification cargo tank motor vehicle
has been kinked or flattened so as to must obtain a copy of the manufactur-
permanently deform the wire braid. er’s certificate and related papers or
(iii) Soft spots when not under pres- the alternative report authorized by
sure, bulging under pressure, or loose paragraph (a)(3)(i) or (ii) of this section
outer covering. and retain the documents as specified
(iv) Damaged, slipping, or excessively in this paragraph (a)(2). A motor car-
worn hose couplings. rier who is not the owner of a cargo
(v) Loose or missing bolts or fas- tank motor vehicle must also retain a
tenings on bolted hose coupling assem- copy of the vehicle certification report
blies. for as long as the cargo tank motor ve-
(2) No operator may use a cargo tank hicle is used by that carrier and for one
with a piping system found to have any year thereafter. The information re-
condition identified in this paragraph quired by this section must be main-
(g)(2) for unloading liquefied com- tained at the company’s principal place
pressed gases. of business or at the location where the
(i) Any external leak identifiable vehicle is housed or maintained. The
without the use of instruments. provisions of this section do not apply
(ii) Bolts that are loose, missing, or to a motor carrier who leases a cargo
severely corroded. tank for less than 30 days.
(iii) Manual stop valves that will not (3) DOT Specification cargo tanks man-
actuate. ufactured before September 1, 1995—(i)
(iv) Rubber hose flexible connectors Non-ASME Code stamped cargo tanks—If
with any condition outlined in para- an owner does not have a manufactur-
graph (g)(1) of this section. er’s certificate for a cargo tank and he
(v) Stainless steel flexible connectors wishes to certify it as a specification
with damaged reinforcement braid. cargo tank, the owner must perform
(vi) Internal self-closing stop valves appropriate tests and inspections,
that fail to close or that permit leak- under the direct supervision of a Reg-
age through the valve detectable with- istered Inspector, to determine if the
out the use of instruments. cargo tank conforms with the applica-
(vii) Pipes or joints that are severely ble specification. Both the owner and
corroded. the Registered Inspector must certify
[64 FR 28051, May 24, 1999, as amended at 78 that the cargo tank fully conforms to
FR 15330, Mar. 11, 2013] the applicable specification. The owner
must retain the certificate, as specified
§ 180.417 Reporting and record reten- in this section.
tion requirements.
(ii) ASME Code Stamped cargo tanks. If

(a) Vehicle certification. (1) Each the owner does not have the manufac-
owner of a specification cargo tank turer’s certificate required by the spec-
must retain the manufacturer’s certifi- ification and the manufacturer’s data
362
report required by the ASME, the upper coupler assemblies, when appli-
owner may contact the National Board cable (visually examined in place, or
for a copy of the manufacturer’s data removed for examination); and, infor-
report, if the cargo tank was registered mation regarding leakage and pressure
with the National Board, or copy the testing, when applicable (pneumatic or
information contained on the cargo hydrostatic testing method, identifica-
tank’s identification and ASME Code tion of the fluid used for the test, test
plates. Additionally, both the owner pressure, and holding time of test);
and the Registered Inspector must cer- (iv) Location of defects found and
tify that the cargo tank fully conforms method of repair;
to the specification. The owner must (v) ASME or National Board Certifi-
retain such documents, as specified in cate of Authorization number of facil-
this section. ity performing repairs, if applicable;
(b) Test or inspection reporting. Each (vi) Name and address of person per-
person performing a test or inspection forming test;
as specified in § 180.407 must prepare a (vii) Registration number of the fa-
written report, in English, in accord- cility or person performing the test;
ance with this paragraph. (viii) Continued qualification state-
(1) Each test or inspection report ment, such as ‘‘cargo tank meets the
must include the following informa- requirements of the DOT specification
tion: identified on this report’’ or ‘‘cargo
(i) Owner’s and manufacturer’s tank fails to meet the requirements of
unique serial number for the cargo the DOT specification identified on
tank; this report’’;
(ii) Name of cargo tank manufac-
(ix) DOT registration number of the
turer;
registered inspector; and
(iii) Cargo tank DOT or MC specifica-
(x) Dated signature of the registered
tion number;
inspector and the cargo tank owner.
(iv) MAWP of the cargo tank;
(v) Minimum thickness of the cargo (3) The owner and the motor carrier,
tank shell and heads when the cargo if not the owner, must each retain a
tank is thickness tested in accordance copy of the test and inspection reports
with § 180.407(d)(5), § 180.407(e)(3), until the next test or inspection of the
§ 180.407(f)(3), or § 180.407(i); same type is successfully completed.
(vi) Indication of whether the cargo This requirement does not apply to a
tank is lined, insulated, or both; and motor carrier leasing a cargo tank for
(vii) Indication of special service of fewer than 30 days.
the cargo tank (e.g., transports mate- (c) Additional requirements for Speci-
rial corrosive to the tank, dedicated fication MC 330 and MC 331 cargo tanks.
service, etc.) (1) After completion of the pressure
(2) Each test or inspection report test specified in § 180.407(g)(3), each
must include the following specific in- motor carrier operating a Specification
formation as appropriate for each indi- MC 330 or MC 331 cargo tank in anhy-
vidual type of test or inspection: drous ammonia, liquefied petroleum
(i) Type of test or inspection per- gas, or any other service that may
formed; cause stress corrosion cracking, must
(ii) Date of test or inspection (month make a written report containing the
and year); following information:
(iii) Listing of all items tested or in- (i) Carrier’s name, address of prin-
spected, including information about cipal place of business, and telephone
pressure relief devices that are re- number;
moved, inspected and tested or re- (ii) Complete identification plate
placed, when applicable (type of device, data required by Specification MC 330
set to discharge pressure, pressure at or MC 331, including data required by
which device opened, pressure at which ASME Code;
device re-seated, and a statement of (iii) Carrier’s equipment number;

disposition of the device (e.g., re- (iv) A statement indicating whether
installed, repaired, or replaced)); infor- or not the tank was stress relieved
mation regarding the inspection of after fabrication;
363
§ 180.501 49 CFR Ch. I (10–1–18 Edition)
(v) Name and address of the person most recent inspection and test reports
performing the test and the date of the made under this section. Copies of such
test; reports must be provided to the lessee
(vi) A statement of the nature and se- if the cargo tank is leased for more
verity of any defects found. In par- than 30 days.
ticular, information must be furnished
[Amdt. 180–2, 54 FR 25032, June 12, 1989, as
to indicate the location of defects de- amended at 55 FR 21038, May 22, 1990; 55 FR
tected, such as in weld, heat-affected 37069, Sept. 7, 1990; 56 FR 27879, June 17, 1991;
zone, the liquid phase, the vapor phase, 58 FR 12905, Mar. 8, 1993; Amdt. 180–2, 59 FR
or the head-to-shell seam. If no defect 1786, Jan. 12, 1994; Amdt. 180–10, 61 FR 51343,
or damage was discovered, that fact Oct. 1, 1996; 63 FR 52850, Oct. 1, 1998; 64 FR
must be reported; 28052, May 24, 1999; 65 FR 50463, Aug. 18, 2000;
(vii) A statement indicating the 67 FR 61016, Sept. 27, 2002; 68 FR 19290, Apr.
18, 2003; 68 FR 52372, Sept. 3, 2003; 69 FR 54047,
methods employed to make repairs,
Sept. 7, 2004; 70 FR 34077, June 13, 2005; 76 FR
who made the repairs, and the date 43532, July 20, 2011]
they were completed. Also, a statement
of whether or not the tank was stress
relieved after repairs and, if so, wheth- Subpart F—Qualification and
er full or local stress relieving was per- Maintenance of Tank Cars
formed;
(viii) A statement of the disposition SOURCE: Amdt. 180–8, 60 FR 49079, Sept. 21,
of the cargo tank, such as ‘‘cargo tank 1995, unless otherwise noted.
scrapped’’ or ‘‘cargo tank returned to
service’’; and § 180.501 Applicability.
(ix) A statement of whether or not (a) This subpart prescribes require-
the cargo tank is used in anhydrous ments, in addition to those contained
ammonia, liquefied petroleum gas, or in parts 107, 171, 172, 173, 174, and 179 of
any other service that may cause this subchapter, applicable to any per-
stress corrosion cracking. Also, if the son who manufactures, fabricates,
cargo tank has been used in anhydrous marks, maintains, repairs, inspects, or
ammonia service since the last report, services tank cars to ensure continuing
a statement indicating whether each qualification.
shipment of ammonia was certified by (b) This subpart also establishes the
its shipper as containing 0.2 percent minimum acceptable framework for an
water by weight. owner’s qualification program for tank
(2) A copy of the report must be re- cars and components. Owners should
tained by the carrier at its principal follow this subpart in developing their
place of business during the period the written procedures (work instructions),
cargo tank is in the carrier’s service as required under § 179.7(d), for use by
and for one year thereafter. Upon a tank car facility employees. The own-
written request to, and with the ap- er’s qualification program for each
proval of, the Field Administrator, Re- tank car, or a fleet of tank cars, must
gional Service Center, Federal Motor identify where to inspect, how to in-
Carrier Safety Administration for the spect, and the acceptance criteria. Al-
region in which a motor carrier has its ternative inspection and test proce-
principal place of business, the carrier dures or intervals based on a damage-
may maintain the reports at a regional tolerance analysis or service reliability
or terminal office. assessment must be approved by the
(3) The requirement in paragraph Associate Administrator for Railroad
(c)(1) of this section does not apply to Safety in accordance with 180.509(l).
a motor carrier leasing a cargo tank Tank car facilities must incorporate
for less than 30 days. the owner’s qualification program in
(d) Supplying certificates and reports. their quality assurance program, as re-
Each person offering a DOT-specifica- quired under § 179.7(a)(2), (b)(3), (b)(5),
tion cargo tank for sale or lease must and (d).
provide the purchaser or lessee a copy (c) Any person who performs a func-
of the cargo tank certificate of compli- tion prescribed in this part shall per-
ance, records of repair, modification, form that function in accordance with
stretching, or rebarrelling; and the this part.
364
(d) Where, in this subpart, a person is construction prescribed in § 179.5, in-

required to make documents available cluding an alteration prescribed in
to FRA upon request, such request § 179.6, or conversion.
means that credentialed FRA per- Objectively reasonable and articulable
sonnel or an authorized representative belief means a belief based on particu-
of the Department may view the docu- larized and identifiable facts that pro-
ments and make copies of them. The vide an objective basis to believe or
document owner’s may seek confiden- suspect that a tank car or a class or de-
tial treatment of the documents pre- sign of tank cars may be in an unsafe
sented. See § 105.30. operating condition.
[Amdt. 180–8, 60 FR 49079, Sept. 21, 1995, as Qualification, as relevant to a tank
amended by Amdt. 179–50, 61 FR 33256, June car, means the car and its components
26, 1996; 77 FR 37986, June 25, 2012] conforms to the specification to which
it was designed, manufactured, or
§ 180.503 Definitions. modified to the requirements of this
The following definitions and those subpart, to the applicable requirements
contained in §§ 171.8 and 179.2 of this of the AAR Specifications for Tank
subchapter apply: Cars (IBR, see § 171.7 of this sub-
Coating/lining owner means the person chapter), and to the owner’s acceptance
with the financial responsibility for criteria. Qualification is accomplished
purchasing and maintaining the integ- by careful and critical examination
rity of the interior coating or lining. that verifies conformance using inspec-
Corrosive to the tank or service equip- tions and tests based on a written pro-
ment means a material identified in Ap- gram approved by the tank car owner
pendix D of this part or a material followed by a written representation of
when in contact with the inner shell of that conformance. A tank car that
the tank or service equipment has a passes the appropriate tests for its
corrosion rate on steel greater than 2.5 specification, has a signed test report,
milli-inch per year (mpy) (0.0025 inch is marked to denote this passage, and
per year). is considered qualified for hazardous
Defects mean abrasions; corrosion; materials transportation under this
cracks; dents; flaws in welds; distor- subchapter.
tions; erosion; missing, damaged, leak-
Tests and inspec-
ing or loose components and fasteners; Qualification of tions § 180.509(*)
and other conditions or imperfections
that may make a tank car unsafe for Tank .......................... Visual Inspection ...... d
Structural Integrity In- e
transportation and/or require it to be spection.
removed from service. Thickness Test: Note f
Design level of reliability and safety 1.
means the level of reliability and safe- Safety System In- h
spection.
ty built into the tank car and, there- Service Equipment ... Service Equipment ... k
fore, inherent in its specification, de- Coating/lining ............ Internal Coatings and i
sign, and manufacture. Linings.
Inspection and test means a careful
and critical examination of a tank car NOTE 1: Subparagraph (f)(2) may require
thickness tests at an interval different from
and its appurtenances performed by the other items for qualification of the tank.
qualified personnel following the own-
er’s qualified procedures. Railworthy, Railworthiness for a tank
Interior heater system means a piping car means that the tank, service equip-
system located within the tank shell ment, safety systems, and all other
that uses a fluid medium to heat the components covered by this subchapter
lading for the purposes of unloading. conform to the HMR, and are otherwise
Maintenance means upkeep, or preser- suitable for continued service and ca-
vation, including repairs necessary and pable of performing their intended
proper to ensure an in-operation tank function until their next qualification.
car’s specification until its next quali- Reactive to the tank or service equip-
fication. ment means a material that, in contact
Modification means any change to a with the inner shell of the tank, or
tank car that affects the certificate of with the service equipment, may react
365
§ 180.505 49 CFR Ch. I (10–1–18 Edition)
to produce heat, gases, and/or pressure § 180.505 Quality assurance program.

which could substantially reduce the
The quality assurance program re-
effectiveness of the packaging or the
safety of its use. quirements of § 179.7 of this subchapter
apply.
Reinforced tank shell butt weld means
the portion of a butt weld covered by a § 180.507 Qualification of tank cars.
reinforcing pad.
Reinforcing pad means an attachment (a) Each tank car marked as meeting
welded directly to the tank supporting a ‘‘DOT’’ specification or any other
major structural components for the tank car used for the transportation of
purpose of preventing damage to the a hazardous material must meet the re-
tank through fatigue, overstressing, quirements of this subchapter or the
denting, puncturing, or tearing. applicable specification to which the
Reliability means the quantified abil- tank was constructed.
ity of an item or structure to operate (b) Tank car specifications no longer
without failure for the specified period authorized for construction. (1) Tank
of its design life or until its next quali- cars prescribed in the following table
fication. are authorized for service provided
Representation means attesting they conform to all applicable safety
through documenting, in writing or by requirements of this subchapter:
marking on the tank (or jacket), that a
tank car is qualified and railworthy. Specification pre- Other specifications per-
scribed in the current Notes
See also §§ 180.511 and 180.517(b). mitted
regulations
Safety system means one or more of
105A200W .................. 105A100W .......................... 1
the following: Thermal protection sys- 105A200ALW .............. 105A100ALW ...................... 1
tems, insulation systems, tank head 105A300W .................. ICC–105, 105A300.
puncture resistance systems, coupler 105A400W .................. 105A400.
vertical restraint systems, and systems 105A500W .................. 105A500.
used to protect discontinuities (e.g., 105A600W .................. 105A600.
skid protection and protective 106A500X ................... ICC–27, BE–27, 106A500.
106A800X ................... 106A800.
housings) as required under this sub-
107A * * * * ............... ............................................. 2
chapter.
Note 1: Tanks built as Specification DOT 105A100W or DOT
Service equipment means equipment 105A100ALW may be altered and converted to DOT
used for loading and unloading (includ- 105A200W and DOT 105A200ALW, respectively.
Note 2: The test pressures of tanks built in the United States
ing an interior heating system), sam-
between January 1, 1941 and December 31, 1955, may be in-
pling, venting, vacuum relief, pressure creased to conform to Specification 107A. Original and re-
relief, and measuring the amount of vised test pressure markings must be indicated and may be
shown on the tank or on a plate attached to the bulkhead of
lading or the lading temperature. the car. Tanks built before 1941 are not authorized.
Service equipment owner means the
party responsible for bearing the cost (2) [Reserved]
of the maintenance of the service (3) Specification DOT-113A175W,
equipment. DOT-113C60W, DOT-113D60W, and DOT-
Tank car owner means the person to 113D120W tank cars may continue in
whom a rail car’s reporting marks are use, but new construction is not au-
assigned, as listed in the Universal Ma- thorized.
chine Language Equipment Register (4) Class DOT 105A and 105S tank cars
(UMLER). used to transport hydrogen chloride,
Tank car tank means the shell, heads, refrigerated liquid under the terms of
tank shell and head weld joints, at- DOT-E 3992 may continue in service,
tachment welds, sumps, nozzles, but new construction is not authorized.
flanges, and all other components weld- (5) Specification DOT-103A-ALW,
ed thereto that are either in contact 103AW, 103ALW, 103ANW, 103BW,
with the lading or contain the lading. 103CW, 103DW, 103EW, and 104W tank
Train consist means a written record cars may continue in use, but new con-
of the contents and location of each struction is not authorized.
rail car in a train.

[Amdt. 180–8, 60 FR 49079, Sept. 21, 1995, as
[77 FR 37986, June 25, 2012, as amended at 81 amended at 68 FR 48572, Aug. 14, 2003; 77 FR
FR 35546, June 2, 2016] 37987, June 25, 2012]
366
§ 180.509 Requirements for inspection condition that may make the tank car
and test of specification tank cars. unsafe for transportation,
(a) General. Each tank car owner (2) The tank car was in an accident
and shows evidence of damage to an ex-
must ensure that a tank car facility:
tent that may adversely affect its ca-
(1) Inspects and tests each item ac-
pability to retain its contents or to
cording to the requirements specified
otherwise remain railworthy.
in this section; (3) The tank bears evidence of dam-
(2) Evaluates each item according to age caused by fire. (4) The Associate
the acceptable results of inspections Administrator for Railroad Safety,
and tests specified in § 180.511; FRA, requires it based on the existence
(3) Marks each tank car as specified of an objectively reasonable and
in § 180.515 that is qualified to transport articulable belief that a tank car or a
hazardous materials; class or design of tank cars may be in
(4) Prepares the documentation as re- an unsafe operating condition.
quired by § 180.517 for each item quali- (c) Frequency of inspection and tests.
fied under this section. A copy of the Each tank car shall have an inspection
documentation required by § 180.517 and test according to the requirements
must be sent to the owner as appro- of this paragraph.
priate and according to the owner’s in- (1) For Class 107 tank cars and tank
structions. cars of riveted construction, the tank
(b) Conditions requiring qualification of car must have a hydrostatic pressure
tank cars. Without regard to the quali- test and visual inspection conforming
fication compliance date requirements to the requirements in effect prior to
of any paragraph of this section, an July 1, 1996, for the tank specification.
owner of a tank car or an internal (2) For Class DOT 113 tank cars, see
coating or lining must ensure an appro- § 173.319(e) of this subchapter.
priate inspection and test according to (3) Fusion welded tank cars must be
the type of defect and the type of main- inspected and tested to be qualified and
tenance or repair performed if: maintained in accordance with the fol-
(1) The tank car shows evidence of lowing table. All qualification require-
abrasion, corrosion, cracks, dents, dis- ments need not be done at the same
tortions, defects in welds, or any other time or at the same facility.
FREQUENCY OF QUALIFICATION INSPECTION AND TESTS
Section 180.509(*) Description Maximum interval
D ............................. Visual inspection ................................................................................................ 10 years.

E .............................. Structural integrity inspection ............................................................................. 10 years.
F .............................. Thickness test .................................................................................................... See § 180.509(f).
H ............................. Safety Systems .................................................................................................. 10 years.
I ............................... Internal coating or lining (for materials corrosive or reactive to the tank) (See See § 180.509(i).
definitions at § 180.503).
J .............................. Leakage pressure test ....................................................................................... After reassembly.
K .............................. Service equipment (including pressure relief device) ........................................ See § 180.509(k).
(d) Visual inspection. At a minimum, for abrasion, corrosion, cracks, dents,

each tank car facility must visually in- distortions, defects in welds, or any
spect the tank externally and inter- other condition that makes the tank
nally as follows: car unsafe for transportation, and for
(1) An internal inspection of the tank DOT 115 class tank cars, an internal in-
shell and heads for abrasion, corrosion, spection of the inner container and ex-
cracks, dents, distortions, defects in ternal inspection of the outer shell and
welds, or any other condition that heads for defects in welds, or any other
makes the tank car unsafe for trans- condition that may make the tank car
portation, and except in the areas unsafe for transportation;

where insulation or a thermal protec- (2) When an internal coating or lin-
tion system precludes it, an external ing, head protection, insulation, or
inspection of the tank shell and heads thermal protection is removed in part
367
§ 180.509 49 CFR Ch. I (10–1–18 Edition)
or in whole, the internal and external make the data available to FRA or an
exposed surface of the tank must be authorized representative of the De-
visually inspected for defects in welds partment upon request.
or any other condition that may make (2) For DOT 115 class tanks, para-
the tank car unsafe for transportation, graphs (e)(1)(i) through (iii) of this sec-
and this inspection must precede any tion apply only to the outer shell fillet
application or reapplication of a coat- welds and to the non-reinforced ex-
ing or lining; posed outer shell butt welds.
(3) An inspection of the service equip- (3) The inspection requirements of
ment, including gaskets, for indica- paragraph (e)(1)(iii) of this section do
tions of corrosion and other conditions not apply to reinforced tank shell butt
that may make the tank car unsafe for welds until the time of lining removal
transportation; or application for tank cars with an in-
(4) An inspection for missing or loose ternal lead, glass, or rubber lining.
bolts, nuts, or elements that may make (4) Each tank car facility must in-
the tank car unsafe for transportation; spect and test the elements identified
(5) An inspection of all closures on in paragraph (e)(1) of this section by
the tank car for conditions that may one or more of the following methods:
make the tank car unsafe for transpor- (i) Dye penetrant testing (PT);
tation, including an inspection of the (ii) Radiographic examination (RT);
protective housings for proper condi-
(iii) Magnetic particle testing (MT);
tion;
(iv) Ultrasonic testing (UT); and
(6) An inspection of excess flow
valves with threaded seats for tight- (v) Direct, remote, or enhanced vis-
ness; and ual inspection, using, for example,
(7) An inspection of the required magnifiers, fiberscopes, borescopes,
markings on the tank car for legibility. and/or machine vision technology (VT).
(e) Structural integrity inspections and (f) Thickness tests. (1) The tank car
tests. (1) Each tank car owner must en- owner must ensure that each tank car
sure the structural elements on the facility measures the thickness of the
tank car qualify with the applicable re- tank car shell, heads, sumps, protec-
quirements of this subchapter. At a tive housing (i.e., domes), and nozzles
minimum, the structural integrity in- on each tank car by using a device ca-
spection and test must include: pable of accurately measuring the
(i) All transverse fillet welds greater thickness to within ±0.05 mm (±0.002
than 0.64 cm (0.25 inch) within 121.92 cm inch).
(4 feet) of the bottom longitudinal cen- (2) The tank car owner must ensure
terline except body bolster pad attach- that each tank car has a thickness test
ment welds; measurement:
(ii) The termination of longitudinal (i) At the time of an internal coating
fillet welds greater than 0.64 cm (0.25 or lining application or replacement,
inch) within 121.92 cm (4 feet) of the or
bottom longitudinal centerline; and (ii) At least once every ten (10) years
(iii) The tank shell butt welds within for a tank that does not have an inter-
60.96 cm (2 feet) of the bottom longitu- nal coating or lining, or
dinal centerline, unless the tank car (iii) At least once every five (5) years
owner can determine by analysis (e.g., for a tank that does not have an inter-
finite element analysis, damage-toler- nal coating or lining when:
ance analysis, or service reliability as- (A) The tank is used to transport a
sessment) that the structure will not material that is corrosive or reactive
develop defects that reduce the design to the tank (see Appendix D of this
level of safety and reliability or fail part) or service equipment as defined
within its operational life or prior to § 180.503, and
the next required inspection. The (B) The remaining shell and head
owner must maintain all documenta- thickness is tested and determined to
tion used to make such determination be at or below line C in Figure A of this
at its principal place of business and paragraph.
368
Where: by measuring the shell or head in the

A. As-built tank shell or head thickness with area of the repair. The thickness test
additional thickness. applies only to the non-lined or coated
B. Required minimum tank shell or head repaired area, and is not a qualification
thickness after forming per part 179. event. Modification of the tank stencil
C. Inspection frequency adjustment point is not required.
(design minimum shell or head thick-
ness, minus 1⁄2 of the table value in para-
(4) Operation of a tank car below the
graph (g) of this section). condemning limit for general corrosion
D. Condemning limit for general corrosion or the condemning limit for localized
(required minimum shell or head thick- corrosion (as shown in Figure A of this
ness, minus the value in paragraph (g) of section) is prohibited.
this section). (5) For sumps, protective housing
E. Condemning limit for localized corrosion (i.e., domes), nozzles, and nozzle rein-
(required minimum shell or head thick- forcing pads, the tank car owner must
ness, minus the table value in paragraph
determine if any reduction in wall
(g) of this section, minus 1.58 mm (1⁄16
inch)). See Note 1 in paragraph (g) of this thickness affects the design levels of
section for diameter limitations and reliability and safety built into sump,
minimum separation distances. protective housing, nozzle, or nozzle re-
F. Allowable shell or head thickness reduc- inforcement. Each tank car owner
tion (table value in paragraph (g) of this must maintain at its principal place of
section). business documentation describing the
G. Additional thickness reduction for local- allowable thickness reductions for
ized areas in paragraph (g) of this sec- sumps, protective housings, and noz-
tion.
zles, and nozzle reinforcements. This
(3) For a localized repair of an inter- documentation must be made available
nal coating or lining where a material to FRA or an authorized representative
corrosive to the tank or service equip- of the Department upon request.
ment as defined § 180.503 has contacted (6) After repairs, alterations, conver-
the tank, a qualified individual must sions, modifications, or blasting of
verify the coating or lining’s conform- tank car that results in a reduction of
ance with paragraph (g) of this section the tank’s thickness, and anytime a
369
ER25JN12.000</GPH>
§ 180.509 49 CFR Ch. I (10–1–18 Edition)
tank car coating or lining is removed, of tank cars used to transport haz-
a qualified individual must measure ardous materials must ensure the lin-
the thickness of the tank in the area of ing complies with § 173.24(b)(2) and
reduced thickness to ensure that the (b)(3) of this subchapter.
thickness of the tank conforms to (2) The owner of the internal coating
paragraph (g) of this section. or lining must establish and maintain
(g) Service life thickness allowance. (1) a record of the service life of the coat-
A tank car found with a thickness ing or lining and commodity combina-
below the required minimum thickness tion, that is, the specific hazardous
after forming for its specification, as materials that were loaded into a tank
stated in part 179 of this subchapter, and the coating or lining in place at
may continue in service if any reduc- the time of loading. The owner of the
tion in the required minimum thick- internal coating or lining must use its
ness is not more than that provided in knowledge of the service life of each
the following table: coating or lining and commodity com-
bination to establish an appropriate in-
ALLOWABLE SHELL THICKNESS REDUCTIONS spection interval for that coating or
Marked tank test Top shell and tank
lining and commodity combination.
Bottom shell This interval must not exceed eight (8)
pressure head
years, unless the coating or lining
60 psig <200 psig 3.17 mm ............... 1.58 mm.
⁄ inch ..................
18 1⁄16 inch. owner can establish, document, and
≥200 psig .............. 0.79 mm ............... 0.79 mm. show that the service history or sci-
1⁄32 inch ................ 1⁄32 inch.
entific analysis of the coating or lining
and commodity pairing supports a
NOTE 1. A tank car owner may add an extra longer inspection interval. The owner
1.58 mm (1⁄16 inch) to the values in the table
for local reductions. Local reductions are
must maintain at its principal place of
those that do not exceed 20.32 linear centi- business a written procedure for col-
meters (8 linear inches) measured at the lecting and documenting the perform-
longest diameter, and are separated from the ance of the coating or lining applied
other local reductions by at least 40.64 cm (16 within the tank car for its service life.
inches). The internal coating or lining owner
NOTE 2. Any reduction in the tank car shell must provide this documentation, in-
thickness may not affect the structural cluding inspection and test, repair, re-
strength of the tank car to the extent that
the tank car no longer conforms to the appli-
moval, and application procedures, to
cable provisions of Section 6.2 of the AAR the FRA or car owner upon request.
Specifications for Tank Cars (IBR, see § 171.7 Further, the offeror must provide com-
of this subchapter). modity information to the car owner
NOTE 3. For DOT 115 class tank cars, shell and the owner of the internal coating
thickness reductions apply only to the outer or lining upon request.
shell of the tank car. There is no shell or (3) The owner of the internal coating
head thickness reduction authorized for the or lining must provide the test method
inner tank.
and acceptance criteria to the tank car
(2) [Reserved] owner and to the person responsible for
(h) Safety system inspections. Each qualifying the coating or lining. The
tank car owner must ensure qualifica- tank car facility inspecting and testing
tion of the tank car safety systems. the internal coating or lining must fol-
However, inspections of foam or cork low the inspection and test procedure,
insulation systems are not required. including the acceptance requirements,
(i) Internal coating and lining inspec- established by the internal coating or
tion and test. (1) At a minimum, the lining owner.
owner of an internal coating or lining (j) Leakage pressure test. Unless the
applied to protect a tank used to trans- design of the service equipment ar-
port a material that is corrosive or re- rangement precludes it (e.g., there is
active to the tank must ensure an in- no fitting to pressurize the tank), each
spection adequate enough to detect de- owner of a tank car must ensure that
fects or other conditions that could re- the tank, service equipment, and clo-
duce the design level of reliability and sures installed, replaced, or reinstalled
safety of the tank is performed. In ad- on the tank car are leak tested. The
dition, the owner of a coating or lining test may be conducted with the lading
370
in the tank. When the test pressure ex- an inspection and test conforming to
ceeds the start-to-discharge or burst this section no later than the date the
pressure of a pressure relief device, the tank car requires a periodic hydro-
device must be rendered inoperative. static pressure test (i.e., the marked
The written procedures and test meth- due date on the tank car for the hydro-
od for leak testing must ensure the static test).
sensitivity and reliability of the test (2) After July 1, 1998, each tank car
method to prevent premature failure. without a metal jacket shall have an
This section does not apply to facilities inspection and test conforming to this
that remove closures for the sole pur- section no later than the date the tank
pose of loading or unloading the lading car requires a periodic hydrostatic
(e.g., blind flanges, pipe plugs, etc.). pressure test (i.e., the marked due date
(k) Service equipment inspection and on the tank car for the hydrostatic
test. (1) Each tank car owner must en- test).
sure the qualification of tank car serv- (3) For tank cars on a 20-year peri-
ice equipment at least once every ten odic hydrostatic pressure test interval
(10) years. The tank car owner must (i.e., Class DOT 103W, 104W, 111A60W1,
analyze the service equipment inspec- 111A100W1, and 111A100W3 tank cars),
tion and test results for any given lad- the next inspection and test date is the
ing and, based on the analysis, adjust midpoint between the compliance date
the inspection and test frequency to in paragraph (l)(1) or (2) of this section
ensure that the design level of reli- and the remaining years until the tank
ability and safety of the equipment is would have had a hydrostatic pressure
met. The owner must maintain at its test.
principal place of business all sup-
[Amdt. 180–8, 60 FR 49079, Sept. 21, 1995, as
porting documentation used to make amended by Amdt. 179–50, 61 FR 33256, June
such analyses and inspection and test 26, 1996; 62 FR 51561, Oct. 1, 1997; 63 FR 52851,
frequency adjustments. The supporting Oct. 1, 1998; 66 FR 45391, Aug. 28, 2001; 68 FR
documentation must be made available 75765, Dec. 31, 2003; 71 FR 54398, Sept. 14, 2006;
to FRA or an authorized representative 77 FR 37987, June 25, 2012]
of the Department upon request.
(2) Each tank car facility must qual- § 180.511 Acceptable results of inspec-
ify service equipment, including re- tions and tests.
closing pressure relief devices and inte- Provided it conforms to other appli-
rior heater systems in accordance with cable requirements of this subchapter,
the applicable provisions of Appendix D a tank car is qualified for use if it suc-
of the AAR Specifications for Tank cessfully passes the inspections and
Cars (IBR, see § 171.7 of this sub- tests set forth below conducted in ac-
chapter). cordance with this subpart. A represen-
(l) Alternative inspection and test pro- tation of that qualification must con-
cedures. When approved by the Asso- sist of marking the tank in accordance
ciate Administrator for Railroad Safe- with § 180.515.
ty, FRA, a tank car owner, or a coating (a) Visual inspection. A tank car suc-
or lining owner may use an alternative cessfully passes the visual inspection
inspection and test procedure or inter- when the inspection shows no struc-
val based on a damage-tolerance anal- tural defect that may cause leakage
ysis (that must include a determina- from or failure of the tank before the
tion of the probable locations and next inspection and test interval.
modes of damage due to fatigue, corro- (b) Structural integrity inspection and
sion, and accidental damage), or based test. A tank car successfully passes the
on a service reliability assessment structural integrity inspection and test
(that must be supported by analysis of when it shows no structural defect that
systematically collected data) in lieu may initiate cracks or propagate
of the other requirements of this sec- cracks and cause failure of the tank be-
tion. fore the next inspection and test inter-
(m) Inspection and test compliance date val.

for tank cars. (1) After July 1, 2000, each (c) Service life shell thickness. A tank
tank car with a metal jacket or with a car successfully passes the service life
thermal protection system shall have shell thickness inspection when the
371
§ 180.513 49 CFR Ch. I (10–1–18 Edition)
tank shell and heads show no thickness (b) Responsibilities of Tank Car Facil-
reduction below that allowed in ity. A tank car facility must obtain the
§ 180.509(g). permission of the equipment owner be-
(d) Safety system inspection. A tank fore performing work affecting alter-
car successfully passes the safety sys- ation, conversion, repair, or qualifica-
tem inspection when each thermal pro- tion of the owner’s equipment. For the
tection system, tank head puncture re- purposes of qualification and mainte-
sistance system, coupler vertical re- nance, the tank car facility must use
straint system, and system used to pro- the written instructions furnished by
tect discontinuities (e.g., breakage the owner or have written confirma-
grooves on bottom outlets and protection from the owner allowing the use of
tive housings) on the tank car conform written instructions furnished by the
to this subchapter and show no indica- owner or have written confirmation
tion of a defect that may reduce reli- from the owner allowing the use of
ability before the next inspection and written instructions furnished by an-
test interval. other. A tank car facility must not use,
copy distribute, forward or provide to
(e) Lining and coating inspection. A
another person the owner’s confiden-
tank car successfully passes the lining
tial and proprietary written instruc-
and coating inspection and test when tions, procedures, manuals, and records
the lining or coating conforms to the without the owner’s permission. A
owner’s acceptance criteria. tank car facility must report all work
(f) Leakage pressure test. A tank car performed to the owner. The tank car
successfully passes the leakage pres- facility must also report observed dam-
sure test when all product piping, fit- age, deterioration, failed components,
tings and closures show no indication or non-compliant parts to the owner. A
of leakage. tank car facility must incorporate the
(g) Hydrostatic test. A Class 107 tank owner’s Quality Assurance Program
car, the inner tank of a Class 115 tank into their own Quality Assurance Pro-
car, or a riveted tank car successfully gram.
passes the hydrostatic test when it (c) Unless the exterior tank car shell
shows no leakage, distortion, excessive or interior tank car jacket has a pro-
permanent expansion, or other evi- tective coating, after a repair that re-
dence of weakness that might render quires the complete removal of the
the tank car unsafe for transportation tank car jacket, the exterior tank car
service. shell and the interior tank car jacket
(h) Service equipment. A tank car suc- must have a protective coating applied
cessfully passes the service equipment to prevent the deterioration of the
inspection and test when this equip- tank shell and tank jacket. Previously
ment conforms to this subchapter and applied coatings that still provide ef-
applicable provisions of Appendix D of fective protection need not be covered
the AAR Specifications for Tank Cars over.
(IBR, see § 171.7 of this subchapter), and (d) After repair, replacement, or
shows no indication of a defect that qualification of tank car service equip-
may reduce reliability during the qual- ment, the tank service equipment must
ification interval. successfully pass the leak test pre-
scribed in § 180.509(j).
[Amdt. 180–8, 60 FR 49079, Sept. 21, 1995, as
amended by Amdt. 179–50, 61 FR 33256, June [77 FR 37990, June 25, 2012]
26, 1996; 66 FR 45187, Aug. 28, 2001; 77 FR 37990,
June 25, 2012] § 180.515 Markings.
(a) When a tank car passes the re-
§ 180.513 Repairs, alterations, conver- quired inspection and test with accept-
sions, and modifications. able results, the tank car facility must
(a) To work on tank cars, a tank car mark the date of the inspection and
facility must comply with the applica- test and due date of the next inspection
ble requirements of this subpart, the and test qualified on the tank car in
AAR Specifications for Tank Cars accordance with the applicable provi-
(IBR, see § 171.7 of this subchapter), and sions of Appendix C of the AAR Speci-
the owner’s requirements. fications for Tank Cars (IBR, see § 171.7
372
of this subchapter). When a tank car prescribed in Section 1.3.15 of the AAR
facility performs multiple inspections Specifications for Tank Cars (IBR, see
and tests at the same time, one date § 171.7 of this subchapter) apply. The
may be used to satisfy the require- builder of the car or a facility per-
ments of this section. One date also forming work on the car may retain
may be shown when multiple inspec- copies of relevant records.
tions and tests have the same due date. (b) Inspection and test reporting. Each
Dates displayed on the ‘‘consolidated tank car that is inspected and tested as
stencil’’ (see the applicable provisions specified in § 180.509 must have a writ-
of Appendix C of the AAR Specifica- ten report, in English, prepared accord-
tions for Tank Cars) take precedence ing to this paragraph. Marking the
over dates modified, and not stenciled, tank car with the specification (or re-
pursuant to interval adjustments for taining the specification marking on
service equipment, linings, and granted the tank) is the representation that all
alternative inspection intervals. of the appropriate inspections and tests
(b) Converted DOT 105, 109, 112, 114, or were performed and the results meet
120 class tank cars must have the new the tank car owner’s acceptance cri-
specification and conversion date per- teria to qualify the car for continued
manently marked in letters and figures use. The report may be created and re-
at least 0.95 cm (0.375 inch) high on the tained electronically, but, upon request
outside of the manway nozzle or the by FRA for a copy of the report, it
edge of the manway nozzle flange on must be made available in common
the left side of the car. The marking readable form. The owner must retain
may have the last numeral of the speci- a copy of the inspection and test re-
fication number omitted (e.g., ‘‘DOT ports until successfully completing the
111A100W’’ instead of ‘‘DOT next inspection and test of the same
111A100W1’’). type. The inspection and test report
(c) When qualified within six months must include the following:
of installation and protected from de- (1) Type of inspection and test per-
terioration, the test date marking of a formed (a checklist is acceptable);
reclosing pressure relief device is the (2) The results of each inspection and
installation date on the tank car. test performed;
(3) Tank car reporting mark and
[Amdt. 180–8, 60 FR 49079, Sept. 21, 1995, as
amended by Amdt. 179–50, 61 FR 33256, June number;
26, 1996; 63 FR 52851, Oct. 1, 1998; 66 FR 45391, (4) Tank car specification;
Aug. 28, 2001; 68 FR 75765, Dec. 31, 2003; 77 FR (5) Inspection and test date (month
37991, June 25, 2012] and year);
(6) Location and description of de-
§ 180.517 Reporting and record reten- fects found and method used to repair
tion requirements. each defect;
(a) Certification and representation. (7) The name and address of the tank
Each owner of a specification tank car car facility and the name and signature
must retain the certificate of construc- of inspector; and
tion (AAR Form 4–2) and related papers (8) The unique code (station stencil)
certifying that the manufacture of the identifying the facility.
specification tank car identified in the [Amdt. 180–2, 54 FR 25032, June 12, 1989, as
documents is in accordance with the amended at 68 FR 75765, Dec. 31, 2003; 77 FR
applicable specification. The builder’s 37991, June 25, 2012]
signature on the certificate of con-
struction and the marking of the tank § 180.519 Periodic retest and inspec-
car with the tank specification is the tion of tank cars other than single-
representation that all of the appro- unit tank car tanks.
priate inspections and tests were suc- (a) General. Unless otherwise pro-
cessfully performed to qualify the tank vided in this subpart, tanks designed to
for use. The owner must retain the doc- be removed from cars for filling and
uments throughout the period of own- emptying and tanks built to a Class
ership of the specification tank car and DOT 107A specification and their safety
for one year thereafter. Upon a change relief devices must be retested periodi-
of ownership, the applicable provisions cally as specified in Retest Table 1 of
373
§ 180.519 49 CFR Ch. I (10–1–18 Edition)
paragraph (b)(5) of this section. Retests (2) Each tank, except tanks built to
may be made at any time during the specification DOT 107A, must also be
calendar year the retest falls due. subjected to interior air pressure test
(b) Pressure test. (1) Each tank must of at least 100 psig under conditions fa-
be subjected to the specified hydro- vorable to detection of any leakage. No
static pressure and its permanent ex- leaks may appear.
pansion determined. Pressure must be (3) Safety relief valves must be re-
maintained for 30 seconds and for as tested by air or gas, must start-to-dis-
long as necessary to secure complete charge at or below the prescribed pres-
expansion of the tank. Before testing,
sure and must be vapor tight at or
the pressure gauge must be shown to be
above the prescribed pressure.
accurate within 1 percent at test meas-
ure. The expansion gauge must be (4) Rupture discs and fusible plugs
shown to be accurate, at test pressure, must be removed from the tank and
to within 1 percent. Expansion must be visually inspected.
recorded in cubic cm. Permanent volu- (5) Tanks must be retested as speci-
metric expansion may not exceed 10 fied in Retest Table 1 of this paragraph
percent of total volumetric expansion (b)(5), and before returning to service
at test pressure and the tank must not after repairs involving welding or heat
leak or show evidence of distress. treatment:
RETEST TABLE 1
Retest interval—years Minimum Retest Pressure relief valve
pressure—psig pressure—psig
Specification Pressure re- Tank hydro-
Tank Start-to-
lief devices d static Tank air test Vapor tight
discharge
expansion c
DOT 27 ................................................. 5 2 500 100 375 300

106A500 ................................................ 5 2 500 100 375 300
106A500X ............................................. 5 2 500 100 375 300
106A800 ................................................ 5 2 800 100 600 480
106A800X ............................................. 5 2 800 100 600 480
106A800NCI .......................................... 5 2 800 100 600 480
107A * * * * ........................................... d5 a2 (b) None None None
110A500–W .......................................... 5 2 500 100 375 300
110A600–W .......................................... 5 2 600 100 500 360
110A800–W .......................................... 5 2 800 100 600 480
110A1000–W ........................................ 5 2 1,000 100 750 600
BE–27 ................................................... 5 2 500 100 375 300
NOTES:
a If DOT 107A * * * * tanks are used for transportation of flammable gases, one rupture disc from each car must be burst at
the interval prescribed. The sample disc must burst at a pressure not exceeding the marked test pressure of the tank and not
less than 70 percent of the marked test pressure. If the sample disc does not burst within the prescribed limits, all discs on the
car must be replaced.
b The hydrostatic expansion test pressure must at least equal the marked test pressure.
c See § 180.519(b)(1).
d Safety relief valves of the spring-loaded type on tanks used exclusively for fluorinated hydrocarbons and mixtures thereof
which are free from corroding components may be retested every 5 years.
(6) The month and year of test, fol- Dates of previous tests and all pre-
lowed by a ‘‘V’’ if visually inspected as scribed markings must be kept legible.
described in paragraph (c) of this sec- (c) Visual inspection. Tanks of Class
tion, must be plainly and permanently DOT 106A and DOT 110A-W specifica-
stamped into the metal of one head or tions (§§ 179.300 and 179.301 of this sub-
chime of each tank with successful test chapter) used exclusively for trans-
results; for example, 01–90 for January porting fluorinated hydrocarbons and
1990. On DOT 107A**** tanks, the date mixtures thereof, and that are free
must be stamped into the metal of the from corroding components, may be
marked end, except that if all tanks given a periodic complete internal and
mounted on a car have been tested, the external visual inspection in place of
date may be stamped into the metal of the periodic hydrostatic retest. Visual
a plate permanently applied to the
bulkhead on the ‘‘A’’ end of the car.
374
inspections shall be made only by com- form to the requirements of this sub-
petent persons. The tank must be ac- chapter and the applicable design spec-
cepted or rejected in accordance with ification to which the portable tank
the criteria in CGA C–6 (IBR, see § 171.7 was constructed.
of this subchapter). (c) The following portable tanks are
(d) Written records. The results of the authorized for use provided they con-
pressure test and visual inspection form to all applicable safety require-
must be recorded on a suitable data ments of this subchapter: 51, 56, 57, 60,
sheet. Completed copies of these re- IM 101, IM 102 and UN portable tanks.
ports must be retained by the owner (d) A portable tank that also meets
and by the person performing the pres- the definition of ‘‘container’’ in 49 CFR
sure test and visual inspection as long 450.3(a)(3) must conform to the require-
as the tank is in service. The informa- ments in parts 450 through 453 of this
tion to be recorded and checked on title for compliance with Annex II of
these data sheets are: Date of test and the Convention for Safe Containers
inspection; DOT specification number; (CSC).
tank identification (registered symbol (e) Exemption portable tanks based on
and serial number, date of manufacture DOT 51 portable tanks. The owner of a
and ownership symbol); type of protec- portable tank constructed in accord-
tive coating (painted, etc., and state- ance with and used under an exemption
ment as to need for refinishing or re- issued prior to August 31, 1996, which
coating); conditions checked (leakage, was in conformance with the require-
corrosion, gouges, dents or digs, broken ments for Specification DOT 51 port-
or damaged chime or protective ring, able tanks with the exception of the lo-
fire, fire damage, internal condition); cation of fill and discharge outlets,
test pressure; results of tests; and dis- shall examine the portable tank and its
position of tank (returned to service, design to determine if it meets the out-
returned to manufacturer for repair, or let requirements in effect on October 1,
scrapped); and identification of the per- 1996. If the owner determines that the
son conducting the retest or inspec- portable tank is in compliance with all
tion. requirements of the DOT 51 specifica-
[Amdt. 180–8, 60 FR 49079, Sept. 21, 1995, as tion, the exemption number stenciled
amended by Amdt. 179–50, 61 FR 33257, June on the portable tank shall be removed
26, 1996; 65 FR 58633, Sept. 29, 2000; 66 FR and the specification plate (or a plate
45187, 45392, Aug. 28, 2001; 68 FR 75765, Dec. 31, placed adjacent to the specification
2003]
plate) shall be durably marked ‘‘DOT
51–E*****’’ (where ***** is to be re-
Subpart G—Qualification and placed by the exemption number). Dur-
Maintenance of Portable Tanks ing the period the portable tank is in
service, and for one year thereafter,
SOURCE: 66 FR 33453, June 21, 2001, unless the owner of the portable tank must
otherwise noted. retain on file, at its principal place of
business, a copy of the last exemption
§ 180.601 Applicability. in effect.
This subpart prescribes require-
ments, in addition to those contained § 180.605 Requirements for periodic
in parts 107, 171, 172, 173, and 178 of this testing, inspection and repair of
subchapter, applicable to any person portable tanks.
responsible for the continuing quali- (a) A portable tank constructed in
fication, maintenance or periodic re- accordance with a DOT specification
testing of a portable tank. for which a test or inspection specified
in this subpart has become due, must
§ 180.603 Qualification of portable be tested or inspected prior to being re-
tanks. turned for transportation.
(a) Each portable tank used for the (b) Conditions requiring test and inspec-
transportation of hazardous materials tion of portable tanks. Without regard to

must be an authorized packaging. any other test or inspection require-
(b) To qualify as an authorized pack- ments, a Specification or UN portable
aging, each portable tank must con- tank must be tested and inspected in
375
§ 180.605 49 CFR Ch. I (10–1–18 Edition)
accordance with this section prior to the portable tank and its fittings tak-
further use if any of the following con- ing into account the hazardous mate-
ditions exist: rials intended to be transported; a
(1) The portable tank shows evidence leakage test; and a test of the satisfac-
of dents, corroded or abraded areas, tory operation of all service equip-
leakage, or any other condition that ment. Sheathing, thermal insulation,
might render it unsafe for transpor- etc. need only be removed to the extent
tation service. required for reliable appraisal of the
(2) The portable tank has been in an condition of the portable tank. For
accident and has been damaged to an portable tanks intended for the trans-
extent that may adversely affect its portation of a single hazardous mate-
ability to retain the hazardous mate-
rial, the internal examination may be
rial.
waived if it is leakage tested in accord-
(3) The portable tank has been out of
hazardous materials transportation ance with the procedures in paragraph
service for a period of one year or (h) of this section prior to each filling,
more. or if approved by the Associate Admin-
(4) The portable tank has been modi- istrator. Portable tanks used for dedi-
fied from its original design specifica- cated transportation of refrigerated
tion. liquefied gases that are not fitted with
(5) The portable tank is in an unsafe inspection openings are excepted from
operating condition based on the exist- the internal inspection requirement.
ence of probable cause. (e) Periodic inspection and test. The 5
(c) Schedule for periodic inspections year periodic inspection and test must
and tests. Each Specification portable include an internal and external exam-
tank must be tested and inspected in ination and, unless excepted, a pressure
accordance with the following sched- test as specified in this section.
ule: Sheathing, thermal insulation, etc.
(1) Each IM or UN portable tank need only to be removed to the extent
must be given an initial inspection and required for reliable appraisal of the
test before being placed into service, a condition of the portable tank. Except
periodic inspection and test at least for DOT Specification 56 and 57 port-
once every 5 years, and an inter- able tanks, reclosing pressure relief de-
mediate periodic inspection and test at
vices must be removed from the tank
least every 2.5 years following the ini-
and tested separately unless they can
tial inspection and the last 5 year peri-
be tested while installed on the port-
odic inspection and test.
(2) Each Specification 51 portable able tank. For portable tanks where
tank must be given a periodic inspec- the shell and equipment have been
tion and test at least once every five pressure-tested separately, after as-
years. sembly they must be subjected to-
(3) Each Specification 56 or 57 port- gether to a leakage test and effectively
able tank must be given a periodic in- tested and inspected for corrosion.
spection and test at least once every Portable tanks used for the transpor-
2.5 years. tation of refrigerated, liquefied gases
(4) Each Specification 60 portable are excepted from the requirement for
tank must be given a periodic inspec- internal inspection and the hydraulic
tion and test at the end of the first 4- pressure test during the 5-year periodic
year period after the original test; at inspection and test, if the portable
least once every 2 years thereafter up tanks were pressure tested to a min-
to a total of 12 years of service; and at imum test pressure of 1.3 times the de-
least once annually thereafter. Re- sign pressure using an inert gas as pre-
testing is not required on a rubber- scribed in § 178.338–16(a) and (b) of this
lined tank except before each relining. subchapter before putting the portable
(d) Intermediate periodic inspection and tank into service initially and after
test. For IM and UN portable tanks the any exceptional inspections and tests
intermediate 2.5 year periodic inspec- specified in paragraph (f) of this sec-
tion and test must include at least an
tion.
internal and external examination of
376
(f) Exceptional inspection and test. The least 3 psig applied to the entire tank.
exceptional inspection and test is nec- Each Specification 51 or 56 portable
essary when a portable tank shows evi- tank must be tested by a minimum
dence of damaged or corroded areas, or pressure (air or hydrostatic) of at least
leakage, or other conditions that indi- 2 psig or at least one and one-half
cate a deficiency that could affect the times the design pressure (maximum
integrity of the portable tank. The ex- allowable working pressure, or re-rated
tent of the exceptional inspection and pressure) of the tank, whichever is
test must depend on the amount of greater. The leakage test for portable
damage or deterioration of the portable tanks used for refrigerated liquefied
tank. It must include at least the in- gas must be performed at 90% of
spection and a pressure test according MAWP. Leakage tests for all other
to paragraph (e) of this section. Pres- portable tanks must be at a pressure of
sure relief devices need not be tested or at least 25% of MAWP. During each air
replaced unless there is reason to be- pressure test, the entire surface of all
lieve the relief devices have been af- joints under pressure must be coated
fected by the damage or deterioration. with or immersed in a solution of soap
(g) Internal and external examination. and water, heavy oil, or other material
The internal and external examina- suitable for the purpose of detecting
tions must ensure that: leaks. The pressure must be held for a
(1) The shell is inspected for pitting, period of time sufficiently long to as-
corrosion, or abrasions, dents, distor- sure detection of leaks, but in no case
tions, defects in welds or any other less than five minutes. During the air
conditions, including leakage, that or hydrostatic test, relief devices may
might render the portable tank unsafe be removed, but all the closure fittings
for transportation. The wall thickness must be in place and the relief device
must be verified by appropriate meas- openings plugged. Lagging need not be
urement if this inspection indicates a removed from a lagged tank if it is pos-
reduction of wall thickness; sible to maintain the required test
(2) The piping, valves, and gaskets pressure at constant temperature with
are inspected for corroded areas, de- the tank disconnected from the source
fects, and other conditions, including of pressure.
leakage, that might render the port- (2) Each Specification 60 portable
able tank unsafe for filling, discharge tank must be retested by completely
or transportation; filling the tank with water or other liq-
(3) Devices for tightening manhole uid having a similar viscosity, the tem-
covers are operative and there is no perature of the liquid must not exceed
leakage at manhole covers or gaskets; 37.7 °C (100 °F) during the test, and ap-
(4) Missing or loose bolts or nuts on plying a pressure of 60 psig. The port-
any flanged connection or blank flange able tank must be capable of holding
are replaced or tightened; the prescribed pressure for at least 10
(5) All emergency devices and valves minutes without leakage, evidence of
are free from corrosion, distortion and impending failure, or failure. All clo-
any damage or defect that could pre- sures shall be in place while the test is
vent their normal operation. Remote made and the pressure shall be gauged
closure devices and self-closing stop- at the top of the tank. Safety devices
valves must be operated to dem- and/or vents shall be plugged during
onstrate proper operation; this test.
(6) Required markings on the port- (3) Each Specification IM or UN port-
able tank are legible and in accordance able tank, except for UN portable
with the applicable requirements; and tanks used for non-refrigerated and re-
(7) The framework, the supports and frigerated liquefied gases, and all pip-
the arrangements for lifting the porting, valves and accessories, except
able tank are in satisfactory condition. pressure relief devices, must be
(h) Pressure test procedures for speci- hydrostatically tested with water, or
fication 51, 56, 57, 60, IM or UN portable other liquid of similar density and vis-
tanks. (1) Each Specification 57 port- cosity, to a pressure not less than 150%
able tank must be leak tested by a of its maximum allowable working
minimum sustained air pressure of at pressure. UN portable tanks used for
377
§ 180.605 49 CFR Ch. I (10–1–18 Edition)
the transportation of non-refrigerated might render the portable tank unsafe

liquefied gases must be hydrostatically for service shall be repaired to the sat-
tested with water, or other liquid of isfaction of the witnessing approval
similar density and viscosity, to a pres- agency. The repaired tank must be re-
sure not less than 130% of its maximum tested to the original pressure test re-
allowable working pressure. UN port- quirements. Upon successful comple-
able tanks used for the transportation tion of the hydrostatic or pneumatic
of refrigerated liquefied gases may be test, as applicable, the witnessing ap-
tested hydrostatically or pneumati- proval agency shall apply its name,
cally using an inert gas to a pressure identifying mark or identifying num-
not less than 1.3 times the design pres- ber in accordance with paragraph (k) of
sure. For pneumatic testing, due re- this section.
gard for protection of all personnel (i) Rejection criteria. When evidence of
must be taken because of the potential any unsafe condition is discovered, the
hazard involved in such a test. The portable tank may not be returned to
pneumatic test pressure in the portable service until it has been repaired and
tank must be reached by gradually in- the pressure test is repeated and
creasing the pressure to one-half of the passed.
test pressure. Thereafter, the test pres- (j) Repair. The repair of a portable
sure must be increased in steps of ap- tank is authorized, provided such re-
proximately one-tenth of the test pres- pairs are made in accordance with the
sure until the required test pressure requirements prescribed in the speci-
has been reached. The pressure must fication for the tank’s original design
then be reduced to a value equal to and construction. In addition to any
four-fifths of the test pressure and held other provisions of the specification,
for a sufficient time to permit inspec- no portable tank may be repaired so as
tion of the portable tank for leaks. The to cause leakage or cracks or so as to
minimum test pressure for a portable increase the likelihood of leakage or
tank is determined on the basis of the cracks near areas of stress concentra-
hazardous materials that are intended tion due to cooling metal shrinkage in
to be transported in the portable welding operations, sharp fillets, rever-
tanks. For liquid, solid and non-refrig- sal of stresses, or otherwise. No field
erated liquefied gases, the minimum welding may be done except to non-
test pressure for specific hazardous ma- pressure parts. Any cutting, burning or
terials are specified in the applicable T welding operations on the shell of an
Codes assigned to a particular haz- IM or UN portable tank must be done
ardous material in the § 172.101 Table of with the approval of the approval agen-
this subchapter. While under pressure cy and be done in accordance with the
the tank shall be inspected for leakage, requirements of this subchapter, tak-
distortion, or any other condition ing into account the pressure vessel
which might render the tank unsafe for code used for the construction of the
service. A portable tank fails to meet shell. A pressure test to the original
the requirements of the pressure test test pressure must be performed after
if, during the test, there is permanent the work is completed.
distortion of the tank exceeding that (k) Inspection and test markings. (1)
permitted by the applicable specifica- Each IM or UN portable tank must be
tion; if there is any leakage; or if there durably and legibly marked, in
are any deficiencies that would render English, with the date (month and
the portable tank unsafe for transpor- year) of the last pressure test, the iden-
tation. Any portable tank that fails tification markings of the approval
must be rejected and may not be used agency witnessing the test, when re-
again for the transportation of a haz- quired, and the date of the last visual
ardous material unless the tank is ade- inspection. The marking must be
quately repaired, and, thereafter, a placed on or near the metal identifica-
successful test is conducted in accord- tion plate, in letters and numerals of
ance with the requirements of this not less than 3 mm (0.118 inches) high
paragraph. An approval agency shall when on the metal identification plate,
witness the hydrostatic or pneumatic and 12 mm (0.47 inches) high when on
test. Any damage or deficiency that the portable tank.
378
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 180, App. B
(2) Each Specification DOT 51, 56, 57 vated to verify that the toggle handle moves
or 60 portable tank must be durably to the closed position.
and legibly marked, in English, with [64 FR 28052, May 24, 1999, as amended at 67
the date (month and year) of the most FR 15744, Apr. 3, 2002]
recent periodic retest. The marking
must be placed on or near the metal APPENDIX B TO PART 180—ACCEPTABLE
certification plate and must be in ac- INTERNAL SELF-CLOSING STOP
cordance with § 178.3 of this subchapter. VALVE LEAKAGE TESTS FOR CARGO
The letters and numerals must not be TANKS TRANSPORTING LIQUEFIED
less than 3 mm (0.118 inches) high when COMPRESSED GASES
on the metal certification plate, and 12
For internal self-closing stop valve leakage
mm (0.47 inches) high when on the
testing, leakage is defined as any leakage
portable tank, except that a portable through the internal self-closing valve or to
tank manufactured under a previously the atmosphere that is detectable when the
authorized specification may continue valve is in the closed position. On some
to be marked with smaller markings if valves this will require the closure of the
originally authorized under that speci- pressure by-pass port.
fication (for example, DOT Specifica-
(a) Meter Creep Test.
tion 57 portable tanks).
(l) Record retention. The owner of each 1. An operator of a cargo tank equipped
portable tank or his authorized agent with a calibrated meter may check the inter-
shall retain a written record of the nal self-closing stop valve for leakage
through the valve seat using the meter as a
date and results of all required inspec-
flow measurement indicator. The test is ini-
tions and tests, including an ASME tiated by starting the delivery process or re-
manufacturer’s date report, if applica- turning product to the cargo tank through
ble, and the name and address of the the delivery system. This may be performed
person performing the inspection or at an idle. After the flow is established, the
test, in accordance with the applicable operator closes the internal self-closing stop
specification. The manufacturer’s data valve and monitors the meter flow. The
report, including a certificate(s) signed meter flow must stop within 30 seconds with
no meter creep within 5 seconds after the
by the manufacturer, and the author-
meter stops.
ized design approval agency, as appli-
2. On pump-actuated pressure differential
cable, indicating compliance with the internal self-closing stop valves, the valve
applicable specification of the portable must be closed with the remote actuator to
tank, must be retained in the files of assure that it is functioning. On other types
the owner, or his authorized agent, of internal self-closing stop valves, the
during the time that such portable valve(s) may be closed using either the nor-
tank is used for such service, except for mal valve control or the discharge control
Specifications 56 and 57 portable tanks. system (e.g., remote).
3. Rejection criteria: Any detectable meter
[Amdt. 180–2, 54 FR 25032, June 12, 1989, as creep within the first five seconds after ini-
amended at 67 FR 15744, Apr. 3, 2002; 68 FR tial meter stoppage.
45042, July 31, 2003; 74 FR 53189, Oct. 16, 2009;
82 FR 15897, Mar. 30, 2017] (b) Internal Self-Closing Stop Valve Test.
An operator of a cargo tank that is not
APPENDIX A TO PART 180—INTERNAL equipped with a meter may check the inter-
SELF-CLOSING STOP VALVE EMER- nal self-closing stop valve(s) for leakage as
GENCY CLOSURE TEST FOR LIQUEFIED follows:
COMPRESSED GASES 1. The internal self-closing stop valve must
be in the closed position.
1. In performing this test, all internal self- 2. All of the material in the downstream
closing stop valves must be opened. Each piping must be evacuated, and the piping
emergency discharge control remote actu- must be returned to atmospheric tempera-
ator (on-truck and off-truck) must be oper- ture and pressure.
ated to ensure that each internal self-closing 3. The outlet must be monitored for 30 sec-
stop valve’s lever, piston, or other valve indi- onds for detectable leakage.
cator has moved to the closed position.

4. Rejection criteria. Any detectable leak-
2. On pump-actuated pressure differential age is considered unacceptable.
internal valves, the three-way toggle valve
handle or its cable attachment must be acti- [64 FR 28052, May 24, 1999]
379
Pt. 180, App. C 49 CFR Ch. I (10–1–18 Edition)
APPENDIX C TO PART 180—EDDY CUR- symbol; owner’s name or symbol, if present;

RENT EXAMINATION WITH VISUAL IN- serial number; and, date of manufacture.
SPECTION FOR DOT 3AL CYLINDERS (iii) Name of test operator performing the
eddy current examination.
MANUFACTURED OF ALUMINUM (iv) Date of eddy current examination.
ALLOY 6351–T6 (vi) Acceptance/condemnation results (e.g.,
pass or fail).
1. Examination Procedure. Each facility per- (vii) Retester identification number.
forming eddy current examination with vis- 8. Personnel Qualification Requirements.
ual inspection must develop, update, and Each person who performs eddy current and
maintain a written examination procedure visual examinations, and evaluates and cer-
applicable to the test equipment it uses to tifies retest results must be certified by the
perform eddy current examinations. employer that he/she has been properly
2. Visual examinations. Visual examinations trained and tested in the eddy current and
of the neck and shoulder area of the cylinder visual examination procedures.
must be conducted in accordance with CGA 9. Training Records. A record of current
pamphlet C–6.1 (IBR; see § 171.7 of this sub- training must be maintained for each em-
chapter). ployee who performs eddy current and visual
3. Eddy Current Equipment. A reference ring examinations in accordance with § 172.704(d).
and probe for each DOT–3AL cylinder manu-
factured of aluminum alloy 6351–T6 to be in- [71 FR 51129, Aug. 29, 2006]
spected must be available at the examina-
tion facility. Eddy current equipment must APPENDIX D TO PART 180—HAZARDOUS
be capable of accurately detecting the MATERIALS CORROSIVE TO TANKS OR
notches on the standard reference ring. SERVICE EQUIPMENT
4. Eddy Current Reference Ring. The ref-
This list contains materials identified ei-
erence ring must be produced to represent
ther by proper shipping name in 49 CFR
each cylinder to be tested. The reference ring
172.101 or shipped under an ‘‘n.o.s.’’ shipping
must include artificial notches to simulate a
description that, under certain conditions,
neck crack. The size of the artificial notch
can corrode carbon steel tanks or service
(depth and length) must have a depth less
equipment at a rate that may reduce the de-
than or equal to 1⁄3 of the wall thickness of
sign level of reliability and safety of the
the neck and a length greater than or equal
tank or equipment to an unsafe level before
to two threads. The standard reference must
the next qualification. Materials identified
have a drawing that includes the diameter of
on this list are considered corrosive to the
the ring, and depth and length of each notch.
tank or service equipment.
5. Condemnation Criteria. A cylinder must While every effort was made to identify
be condemned if the eddy current examina- materials deemed corrosive to the tank or
tion combined with visual examination re- service equipment, owners and operators are
veals any crack in the neck or shoulder of 2 cautioned that this list may not be inclusive.
thread lengths or more. Tank car owners and operators are reminded
6. Examination equipment records. Records of of their duty to ensure that no in-service
eddy current inspection equipment shall con- tank will deteriorate below the specified
tain the following information: minimum thickness requirements in this
(i) Equipment manufacturer, model num- subchapter. See § 180.509(f)(3). In addition,
ber and serial number. FRA states a tank car owner must designate
(ii) Probe description and unique identi- an internal coating or lining appropriately
fication (e.g., serial number, part number, based on its knowledge of the chemical and
etc.). not rely simply on this list. Regarding future
7. Eddy current examination reporting and thickness tests, this list may also be modi-
record retention requirements. Daily records of fied based on an analysis of the test results
eddy current examinations must be main- by the car owner, the Department of Trans-
tained by the person who performs the re- portation, or the Association of American
qualification until either the expiration of Railroads’ Tank Car Committee.
the requalification period or until the cyl-
inder is again requalified, whichever occurs Hazardous Materials Table Proper Shipping
first. These records shall be made available Names (See § 172.101)
for inspection by a representative of the De- Acetic acid, glacial or Acetic acid solution
partment on request. Eddy current examina- Aluminum chloride, solution
tion records shall contain the following in- Arsenic acid, liquid
formation: Arsenic acid, solid
(i) Specification of each standard reference Butyric acid
ring used to perform the eddy current exam- Ferric chloride, solution
ination. Fertilizer ammoniating solution (Nitrogen
(ii) DOT specification or exemption num- fertilizer solution)
ber of the cylinder; manufacturer’s name or Fluoroboric acid
380
Pipeline and Hazardous Materials Safety Admin., DOT Pt. 180, App. D
Fluorosilicic acid Zinc chloride, solution
Formaldehyde, solutions, flammable
Formaldehyde, solutions Materials Transported Under an ‘‘N.O.S.’’
Hydrobromic acid Description
Hydrochloric acid Benzoic acid (Environmentally hazardous
Hydrochloric acid solution substance, liquid, n.o.s., (RQ 5,000 pounds)
Hydrofluoric acid and Sulfuric acid mixtures Bisulphites, aqueous solution, n.o.s. (Ammo-
Hydrofluoric acid nium bisulfide)
Hydrogen peroxide and peroxyacetic acid Black liquor (Corrosive liquids, n.o.s. (con-
mixtures, stabilized tains sulfuric acid))
Hydrogen, peroxide, aqueous solutions Calcium lignosulfonate (not regulated under
Hydrogen peroxide, stabilized or Hydrogen this subchapter)
peroxide aqueous solutions, stabilized Hexanoic acid (Corrosive liquids, n.o.s. (con-
Hypochlorite solutions tains hexanoic acid))
Nitric acid Lignin liquor (not regulated under this sub-
Phenyl phosphorus dichloride chapter)
Phenyl phosphorus thiodichloride Lithium chloride (not regulated under this
Phosphoric acid solution subchapter)
Phosphoric acid, solid Sodium polyacrylate (not regulated under
Phosphorus trichloride (Phosphorus chloride) this subchapter)
Sodium chlorate Titanium sulfate solution (Corrosive liquids,
Sodium chlorate, aqueous solution n.o.s. (contains sulfuric acid))
Sodium hydrosulfide White liquor (not regulated under this sub-
Sulfur, molten chapter)
Sulfuric acid
[77 FR 37991, June 25, 2012]
Sulfuric acid, fuming
Sulfuric acid, spent
Zinc chloride, anhydrous PARTS 181–185 [RESERVED]
381
SUBCHAPTER D—PIPELINE SAFETY
PARTS 186–189 [RESERVED] Subpart D—Procedures for Adoption of

Rules
PART 190—PIPELINE SAFETY EN- 190.301 Scope.
FORCEMENT AND REGULATORY 190.303 Delegations.
PROCEDURES 190.305 Regulatory dockets.
190.307 Records.
190.309 Where to file petitions.
Subpart A—General
190.311 General.
Sec. 190.313 Initiation of rulemaking.
190.1 Purpose and scope. 190.315 Contents of notices of proposed rule-
190.3 Definitions. making.
190.5 Service. 190.317 Participation by interested persons.
190.7 Subpoenas; witness fees. 190.319 Petitions for extension of time to
190.9 Petitions for finding or approval. comment.
190.11 Availability of informal guidance and 190.321 Contents of written comments.
interpretive assistance. 190.323 Consideration of comments received.
190.325 Additional rulemaking proceedings.
Subpart B—Enforcement 190.327 Hearings.
190.329 Adoption of final rules.
190.201 Purpose and scope. 190.331 Petitions for rulemaking.
190.203 Inspections and investigations. 190.333 Processing of petition.
190.205 Warnings. 190.335 Petitions for reconsideration.
190.206 Amendment of plans or procedures. 190.337 Proceedings on petitions for recon-
190.207 Notice of probable violation. sideration.
190.208 Response options. 190.338 Appeals.
190.209 Case file. 190.339 Direct final rulemaking.
190.210 Separation of functions. 190.341 Special permits.
190.211 Hearing. 190.343 Information made available to the
190.212 Presiding official, powers, and du- public and request for protection of con-
ties. fidential commercial information.
190.213 Final order.
190.215 Reserved. Subpart E—Cost Recovery for Design
Reviews
COMPLIANCE ORDERS
190.401 Scope.
190.217 Compliance orders generally.
190.219 Consent order.
190.405 Notification.
CIVIL PENALTIES 190.407 Master Agreement.
190.409 Fee structure.
190.221 Civil penalties generally. 190.411 Procedures for billing and payment
190.223 Maximum penalties. of fee.
190.225 Assessment considerations.
190.227 Payment of penalty. AUTHORITY: 49 U.S.C. 60101 et seq.
SOURCE: 45 FR 20413, Mar. 27, 1980, unless
CRIMINAL PENALTIES
otherwise noted.
190.229–190.231 [Reserved]
EDITORIAL NOTE: Nomenclature changes to
SPECIFIC RELIEF part 190 appear at 78 FR 58908, Sept. 25, 2013.
190.233 Corrective action orders.

190.235 Injunctive action. Subpart A—General
190.236 Emergency orders.
190.237 Petitions for review. § 190.1 Purpose and scope.
190.239 Safety orders. (a) This part prescribes procedures
190.241 Finality. used by the Pipeline and Hazardous
190.243 Petitions for reconsideration. Materials Safety Administration in
carrying out duties regarding pipeline

Subpart C—Criminal Enforcement
safety under 49 U.S.C. 60101 et seq. (the
190.291 Criminal penalties generally. pipeline safety laws) and 33 U.S.C. 1321
190.293 Referral for prosecution. (the water pollution control laws).
383
§ 190.3 49 CFR Ch. I (10–1–18 Edition)
(b) This subpart defines certain terms and Hazardous Materials Safety Ad-
and prescribes procedures that are ap- ministration, U.S. Department of
plicable to each proceeding described Transportation.
in this part. Operator means any owner or oper-
[45 FR 20413, Mar. 27, 1980, as amended by
ator.
Amdt. 190–6, 61 FR 18512, Apr. 26, 1996; 70 FR Person means any individual, firm,
11137, Mar. 8, 2005; Amdt. 190–16, 78 FR 58908, joint venture, partnership, corporation,
Sept. 25, 2013] association, State, municipality, coop-
erative association, or joint stock asso-
§ 190.3 Definitions. ciation, and includes any trustee, re-
As used in this part: ceiver, assignee, or personal represent-
Administrator means the Adminis- ative thereof.
trator, Pipeline and Hazardous Mate- Presiding Official means the person
rials Safety Administration or his or who conducts any hearing relating to
her delegate. civil penalty assessments, compliance
Associate Administrator means the As- orders, orders directing amendment,
sociate Administrator for Pipeline safety orders, or corrective action or-
Safety, or his or her delegate. ders and who has the duties and powers
Chief Counsel means the Chief Coun- set forth in § 190.212.
sel of PHMSA. Regional Director means the head of
Day means a 24-hour period ending at any one of the Regional Offices of the
11:59 p.m. Unless otherwise specified, a Office of Pipeline Safety, or a designee
day refers to a calendar day. appointed by the Regional Director.
Emergency order means a written Regional Offices are located in Tren-
order imposing restrictions, prohibi- ton, NJ (Eastern Region); Atlanta,
tions, or safety measures on affected Georgia (Southern Region); Kansas
entities. City, Missouri (Central Region); Hous-
Hearing means an informal con- ton, Texas (Southwest Region); and
ference or a proceeding for oral presen- Lakewood, Colorado (Western Region).
tation. Unless otherwise specifically Respondent means a person upon
prescribed in this part, the use of whom OPS has served an enforcement
‘‘hearing’’ is not intended to require a action described in this part.
hearing on the record in accordance PHMSA means the Pipeline and Haz-
with section 554 of title 5, U.S.C. ardous Materials Safety Administra-
Imminent hazard means the existence tion of the United States Department
of a condition relating to a gas or haz- of Transportation.
ardous liquid pipeline facility that pre- State means a State of the United
sents a substantial likelihood that States, the District of Columbia and
death, serious illness, severe personal the Commonwealth of Puerto Rico.
injury, or a substantial endangerment [Amdt. 190–6, 61 FR 18513, Apr. 26, 1996, as
to health, property, or the environ- amended at 68 FR 11749, Mar. 12, 2003; 70 FR
ment may occur before the reasonably 11137, Mar. 8, 2005; Amdt. 190–15, 74 FR 62505,
foreseeable completion date of a formal Nov. 30, 2009; Amdt. 190–16, 78 FR 58908, Sept.
administrative proceeding begun to 25, 2013; Amdt. 190–18, 81 FR 70985, Oct. 14,
lessen the risk of such death, illness, 2016; Amdt. 190–19, 82 FR 7995, Jan. 23, 2017]
injury or endangerment.
New and novel technologies means any § 190.5 Service.
products, designs, materials, testing, (a) Each order, notice, or other docu-
construction, inspection, or oper- ment required to be served under this
ational procedures that are not ad- part, with the exception of emergency
dressed in 49 CFR parts 192, 193, or 195, orders under § 190.236, will be served
due to technology or design advances personally, by certified mail, overnight
and innovation for new construction. courier, or electronic transmission by
Technologies that are addressed in con- facsimile or other electronic means
sensus standards that are incorporated that includes reliable acknowledge-
by reference into parts 192, 193, and 195 ment of actual receipt.
are not ‘‘new or novel technologies.’’ (b) Service upon a person’s duly au-
OPS means the Office of Pipeline thorized representative or agent con-
Safety, which is part of the Pipeline stitutes service upon that person.
384
(c) Service by certified mail or over- made available prior to the return
night courier is complete upon mail- date.
ing. Service by electronic transmission (e) When the person to be served is
is complete upon transmission and ac- not a natural person, delivery of a copy
knowledgement of receipt. An official of the subpoena and tender of the fees
receipt for the mailing from the U.S. may be achieved by handing them to a
Postal Service or overnight courier, or designated agent or representative for
a facsimile or other electronic trans- service, or to any officer, director, or
mission confirmation, constitutes agent in charge of any office of the per-
prima facie evidence of service. son, or by mailing them by certified
[45 FR 20413, Mar. 27, 1980, as amended at 73 mail to that agent or representative
FR 16567, Mar. 28, 2008; Amdt. 190–16, 78 FR and the fees are made available prior to
58909, Sept. 25, 2013; Amdt. 190–18, 81 FR 70985, the return date.
Oct. 14, 2016] (f) The original subpoena bearing a
certificate of service shall be filed with
§ 190.7 Subpoenas; witness fees. the official having responsibility for
(a) The Administrator, Chief Counsel, the proceeding in connection with
or the official designated by the Ad- which the subpoena was issued.
ministrator to preside over a hearing (g) A subpoenaed witness shall be
convened in accordance with this part, paid the same fees and mileage as
may sign and issue subpoenas individ- would be paid to a witness in a pro-
ually on his or her own initiative at ceeding in the district courts of the
any time, including pursuant to an in- United States. The witness fees and
spection or investigation, or upon re- mileage shall be paid by the person at
quest and adequate showing by a par- whose instance the subpoena was
ticipant to an enforcement proceeding issued.
that the information sought will mate- (h) Notwithstanding the provisions of
rially advance the proceeding. paragraph (g) of this section, and upon
(b) A subpoena may require the at- request, the witness fees and mileage
tendance of a witness, or the produc- may be paid by the PHMSA if the offi-
tion of documentary or other tangible cial who issued the subpoena deter-
evidence in the possession or under the mines on the basis of good cause
control of person served, or both. shown, that:
(c) A subpoena may be served person- (1) The presence of the subpoenaed
ally by any person who is not an inter- witness will materially advance the
ested person and is not less than 18 proceeding; and
years of age, or by certified mail. (2) The person at whose instance the
(d) Service of a subpoena upon the subpoena was issued would suffer a se-
person named in the subpoena is rious hardship if required to pay the
achieved by delivering a copy of the witness fees and mileage.
subpoena to the person and by paying (i) Any person to whom a subpoena is
the fees for one day’s attendance and directed may, prior to the time speci-
mileage, as specified by paragraph (g) fied therein for compliance, but in no
of this section. When a subpoena is event more than 10 days after the date
issued at the instance of any officer or of service of such subpoena, apply to
agency of the United States, fees and the official who issued the subpoena, or
mileage need not be tendered at the if the person is unavailable, to the Ad-
time of service. Delivery of a copy of a ministrator to quash or modify the
subpoena and tender of the fees to a subpoena. The application shall con-
natural person may be made by hand- tain a brief statement of the reasons
ing them to the person, leaving them relied upon in support of the action
at the person’s office with a person in sought therein. The Administrator, or
charge, leaving them at the person’s this issuing official, as the case may
residence with a person of suitable age be, may:
and discretion residing there, by mail- (1) Deny the application;
ing them by certified mail to the per- (2) Quash or modify the subpoena; or
son at the last known address, or by (3) Condition a grant or denial of the
any method whereby actual notice is application to quash or modify the sub-
given to the person and the fees are poena upon the satisfaction of certain
385
§ 190.9 49 CFR Ch. I (10–1–18 Edition)
just and reasonable requirements. The tration, 1200 New Jersey Avenue, SE,
denial may be summary. Washington, DC 20590.
(j) Upon refusal to obey a subpoena (c) All petitions must be received at
served upon any person under the pro- least 90 days prior to the date by which
visions of this section, the PHMSA the operator requests the finding or ap-
may request the Attorney General to proval to be made.
seek the aid of the U. S. District Court (d) The Administrator will make all
for any District in which the person is findings or approvals of petitions initi-
found to compel that person, after no- ated under this section. A participating
tice, to appear and give testimony, or state agency receiving petitions initi-
to appear and produce the subpoenaed ated under this section shall provide
documents before the PHMSA, or both. the Administrator a written rec-
[45 FR 20413, Mar. 27, 1980, as amended by ommendation as to the disposition of
Amdt. 190–6, 61 FR 18513, Apr. 26, 1996; Amdt. any petition received by them. Where
190–7, 63 FR 7722, Feb. 17, 1998; 70 FR 11137, the Administrator does not reverse or
Mar. 8, 2005; Amdt. 190–16, 78 FR 58909, Sept. modify a recommendation made by a
25, 2013] state agency within 10 business days of
its receipt, the recommended disposi-
§ 190.9 Petitions for finding or ap-
proval. tion shall constitute the Administra-
tor’s decision on the petition.
(a) In circumstances where a rule
contained in parts 192, 193 and 195 of [Amdt. 190–5, 59 FR 17280, Apr. 12, 1994, as
this chapter authorizes the Adminis- amended by Amdt. 190–6, 61 FR 18513, Apr. 26,
1996; 70 FR 11137, Mar. 8, 2005; 73 FR 16566,
trator to make a finding or approval,
Mar. 28, 2008]
an operator may petition the Adminis-
trator for such a finding or approval. § 190.11 Availability of informal guid-
(b) Each petition must refer to the ance and interpretive assistance.
rule authorizing the action sought and
contain information or arguments that (a) Availability of telephonic and Inter-
justify the action. Unless otherwise net assistance. PHMSA has established
specified, no public proceeding is held a Web site and a telephone line to OPS
on a petition before it is granted or de- headquarters where information on and
nied. After a petition is received, the advice about compliance with the pipe-
Administrator or participating state line safety regulations specified in 49
agency notifies the petitioner of the CFR parts 190–199 is available. The Web
disposition of the petition or, if the re- site and telephone line are staffed by
quest requires more extensive consider- personnel from PHMSA’s OPS from 9:00
ation or additional information or a.m. through 5:00 p.m., Eastern Time,
comments are requested and delay is Monday through Friday, with the ex-
expected, of the date by which action ception of Federal holidays. When the
will be taken. lines are not staffed, individuals may
(1) For operators seeking a finding or leave a recorded voicemail message or
approval involving intrastate pipeline post a message on the OPS Web site.
transportation, petitions must be sent The telephone number for the OPS in-
to: formation line is (202) 366–4595 and the
(i) The State agency certified to par- OPS Web site can be accessed via the
ticipate under 49 U.S.C. 60105. Internet at http://phmsa.dot.gov/pipeline.
(ii) Where there is no state agency (b) Availability of written interpreta-
certified to participate, the Adminis- tions. A written regulatory interpreta-
trator, Pipeline and Hazardous Mate- tion, response to a question, or an
rials Safety Administration, 1200 New opinion concerning a pipeline safety
Jersey Avenue, SE, Washington, DC issue may be obtained by submitting a
20590. written request to the Office of Pipe-
(2) For operators seeking a finding or line Safety (PHP–30), PHMSA, U.S. De-
approval involving interstate pipeline partment of Transportation, 1200 New

transportation, petitions must be sent Jersey Avenue SE., Washington, DC
to the Administrator, Pipeline and 20590–0001. The requestor must include
Hazardous Materials Safety Adminis- his or her return address and should
386
also include a daytime telephone num- (c) If the Associate Administrator or

ber. Written requests should be sub- Regional Director believes that further
mitted at least 120 days before the time information is needed to determine ap-
the requestor needs a response. propriate action, the Associate Admin-
[Amdt. 190–16, 78 FR 58909, Sept. 25, 2013] istrator or Regional Director may no-
tify the pipeline operator in writing
that the operator is required to provide
Subpart B—Enforcement specific information within 30 days
§ 190.201 Purpose and scope. from the time the notification is re-
ceived by the operator, unless other-
(a) This subpart describes the en- wise specified in the notification. The
forcement authority and sanctions ex-
notification must provide a reasonable
ercised by the Associate Administrator
description of the specific information
for achieving and maintaining pipeline
required. An operator may request an
safety and compliance under 49 U.S.C.
extension of time to respond by pro-
60101 et seq., 33 U.S.C. 1321(j), and any
viding a written justification as to why
regulation or order issued thereunder.
such an extension is necessary and pro-
It also prescribes the procedures gov-
posing an alternative submission date.
erning the exercise of that authority
A request for an extension may ask for
and the imposition of those sanctions.
(b) A person who is the subject of ac- the deadline to be stayed while the ex-
tion pursuant to this subpart may be tension is considered. General state-
represented by legal counsel at all ments of hardship are not acceptable
stages of the proceeding. bases for requesting an extension.
(d) To the extent necessary to carry
[45 FR 20413, Mar. 27, 1980, as amended by out the responsibilities under 49 U.S.C.
Amdt. 190–6, 61 FR 18513, Apr. 26, 1996; Amdt. 60101 et seq., the Administrator, or the
190–16, 78 FR 58909, Sept. 25, 2013]
Associate Administrator, may require
§ 190.203 Inspections and investiga- testing of portions of pipeline facilities
tions. that have been involved in, or affected
by, an accident. However, before exer-
(a) Officers, employees, or agents au-
cising this authority, the Adminis-
thorized by the Associate Adminis-
trator, or the Associate Administrator,
trator for Pipeline Safety, PHMSA,
upon presenting appropriate creden- shall make every effort to negotiate a
tials, are authorized to enter upon, in- mutually acceptable plan with the
spect, and examine, at reasonable owner of those facilities and, where ap-
times and in a reasonable manner, the propriate, the National Transportation
records and properties of persons to the Safety Board for performing the test-
extent such records and properties are ing.
relevant to determining the compli- (e) If a representative of the U.S. De-
ance of such persons with the require- partment of Transportation inspects or
ments of 49 U.S.C. 60101 et seq., or regu- investigates an accident or incident in-
lations or orders issued thereunder. volving a pipeline facility, the operator
(b) Inspections are ordinarily con- must make available to the representa-
ducted pursuant to one of the fol- tive all records and information that
lowing: pertain to the event in any way, in-
(1) Routine scheduling by the Re- cluding integrity management plans
gional Director of the Region in which and test results. The operator must
the facility is located; provide all reasonable assistance in the
(2) A complaint received from a mem- investigation. Any person who ob-
ber of the public; structs an inspection or investigation
(3) Information obtained from a pre- by taking actions that were known or
vious inspection; reasonably should have been known to
(4) Report from a State Agency par- prevent, hinder, or impede an inves-
ticipating in the Federal Program tigation without good cause will be
under 49 U.S.C. 60105; subject to administrative civil pen-

(5) Pipeline accident or incident; or alties under this subpart.
(6) Whenever deemed appropriate by (f) When OPS determines that the in-
the Associate Administrator. formation obtained from an inspection
387
§ 190.205 49 CFR Ch. I (10–1–18 Edition)
or from other appropriate sources war- (2) Whether the plans or procedures
rants further action, OPS may initiate are appropriate for the particular type
one or more of the enforcement proof pipeline transportation or facility,
ceedings prescribed in this subpart. and for the location of the facility;
[45 FR 20413, Mar. 27, 1980, as amended by (3) The reasonableness of the plans or
Amdt. 190–3, 56 FR 31090, July 9, 1991; Amdt. procedures; and
190–6, 61 FR 18513, Apr. 26, 1996; Amdt. 190–7, (4) The extent to which the plans or
61 FR 27792, June 3, 1996; Amdt. 190–7, 63 FR procedures contribute to public safety.
7722, Feb. 17, 1998; 70 FR 11137, Mar. 8, 2005;
Amdt. 190–16, 78 FR 58909, Sept. 25, 2013] (c) An order directing amendment of
an operator’s plans or procedures pre-
§ 190.205 Warnings. scribed in this section may be in addi-
Upon determining that a probable tion to, or in conjunction with, other
violation of 49 U.S.C. 60101 et seq., 33 appropriate enforcement actions pre-
U.S.C. 1321(j), or any regulation or scribed in this subpart.
order issued thereunder has occurred, [Amdt. 190–16, 78 FR 58910, Sept. 25, 2013]
the Associate Administrator or a Re-
gional Director may issue a written § 190.207 Notice of probable violation.
warning notifying the operator of the
probable violation and advising the op- (a) Except as otherwise provided by
erator to correct it or be subject to po- this subpart, a Regional Director be-
tential enforcement action in the fu- gins an enforcement proceeding by
ture. The operator may submit a re- serving a notice of probable violation
sponse to a warning, but is not required on a person charging that person with
to. An adjudication under this subpart a probable violation of 49 U.S.C. 60101 et
to determine whether a violation oc- seq., 33 U.S.C. 1321(j), or any regulation
curred is not conducted for warnings. or order issued thereunder.
[Amdt. 190–16, 78 FR 58909, Sept. 25, 2013]
(b) A notice of probable violation
issued under this section shall include:
§ 190.206 Amendment of plans or pro- (1) Statement of the provisions of the
cedures. laws, regulations or orders which the
(a) A Regional Director begins a pro- respondent is alleged to have violated
ceeding to determine whether an opera- and a statement of the evidence upon
tor’s plans or procedures required which the allegations are based;
under parts 192, 193, 195, and 199 of this (2) Notice of response options avail-
subchapter are inadequate to assure able to the respondent under § 190.208;
safe operation of a pipeline facility by (3) If a civil penalty is proposed under
issuing a notice of amendment. The no- § 190.221, the amount of the proposed
tice will specify the alleged inadequa- civil penalty and the maximum civil
cies and the proposed revisions of the penalty for which respondent is liable
plans or procedures and provide an op- under law; and
portunity to respond. The notice will (4) If a compliance order is proposed
allow the operator 30 days following re- under § 190.217, a statement of the re-
ceipt of the notice to submit written medial action being sought in the form
comments, revised procedures, or a re- of a proposed compliance order.
quest for a hearing under § 190.211. (c) The Regional Director may amend
(b) After considering all material
a notice of probable violation at any
presented in writing or at the hearing,
time prior to issuance of a final order
if applicable, the Associate Adminis-
under § 190.213. If an amendment in-
trator determines whether the plans or
cludes any new material allegations of
procedures are inadequate as alleged.
fact, proposes an increased civil pen-
The Associate Administrator issues an
order directing amendment of the plans alty amount, or proposes new or addi-
or procedures if they are inadequate, or tional remedial action under § 190.217,
withdraws the notice if they are not. In the respondent will have the oppor-
tunity to respond under § 190.208.
determining the adequacy of an opera-

tor’s plans or procedures, the Associate [45 FR 20413, Mar. 27, 1980, as amended by
Administrator may consider: Amdt. 190–6, 61 FR 18513, Apr. 26, 1996; Amdt.
(1) Relevant pipeline safety data; 190–16, 78 FR 58910, Sept. 25, 2013]
388
§ 190.208 Response options. (c) Before or after responding in ac-

cordance with paragraph (a) of this sec-
Within 30 days of receipt of a notice
tion or, when applicable paragraph (b)
of probable violation, the respondent
must answer the Regional Director of this section, the respondent may re-
who issued the notice in the following quest a copy of the violation report
manner: from the Regional Director as set forth
(a) When the notice contains a pro- in § 190.209. The Regional Director will
posed civil penalty— provide the violation report to the re-
spondent within five business days of
(1) If the respondent is not contesting
receiving a request.
an allegation of probable violation, pay
the proposed civil penalty as provided (d) Failure to respond in accordance
in § 190.227 and advise the Regional Di- with paragraph (a) of this section or,
rector of the payment. The payment when applicable paragraph (b) of this
authorizes the Associate Administrator section, constitutes a waiver of the
to make a finding of violation and to right to contest the allegations in the
issue a final order under § 190.213; notice of probable violation and au-
(2) If the respondent is not contesting thorizes the Associate Administrator,
an allegation of probable violation but without further notice to the respond-
wishes to submit a written expla- ent, to find the facts as alleged in the
nation, information, or other materials notice of probable violation and to
the respondent believes may warrant issue a final order under § 190.213.
mitigation or elimination of the pro- (e) All materials submitted by opera-
posed civil penalty, the respondent tors in response to enforcement actions
may submit such materials. This au- may be placed on publicly accessible
thorizes the Associate Administrator Web sites. A respondent seeking con-
to make a finding of violation and to fidential treatment under 5 U.S.C.
issue a final order under § 190.213; 552(b) for any portion of its responsive
(3) If the respondent is contesting one materials must provide a second copy
or more allegations of probable viola- of such materials along with the com-
tion but is not requesting a hearing plete original document. A respondent
under § 190.211, the respondent may sub- may redact the portions it believes
mit a written response in answer to the qualify for confidential treatment in
allegations; or the second copy but must provide a
(4) The respondent may request a written explanation for each redaction.
hearing under § 190.211. [Amdt. 190–16, 78 FR 58910, Sept. 25, 2013]
(b) When the notice contains a pro-
posed compliance order— § 190.209 Case file.
(1) If the respondent is not contesting
(a) The case file, as defined in this
an allegation of probable violation,
section, is available to the respondent
agree to the proposed compliance
in all enforcement proceedings con-
order. This authorizes the Associate
Administrator to make a finding of ducted under this subpart.
violation and to issue a final order (b) The case file of an enforcement
under § 190.213; proceeding consists of the following:
(2) Request the execution of a con- (1) In cases commenced under
sent order under § 190.219; § 190.206, the notice of amendment and
(3) If the respondent is contesting one the relevant procedures;
or more of the allegations of probable (2) In cases commenced under
violation or compliance terms, but is § 190.207, the notice of probable viola-
not requesting a hearing under § 190.211, tion and the violation report;
the respondent may object to the pro- (3) In cases commenced under
posed compliance order and submit § 190.233, the corrective action order or
written explanations, information, or notice of proposed corrective action
other materials in answer to the alle- order and the data report, if one is pre-
gations in the notice of probable viola- pared;

tion; or (4) In cases commenced under
(4) The respondent may request a § 190.239, the notice of proposed safety
hearing under § 190.211. order;
389
§ 190.210 49 CFR Ch. I (10–1–18 Edition)
(5) Any documents and other mate- raise at the hearing. The issues may re-
rial submitted by the respondent in relate to the allegations in the notice,
sponse to the enforcement action; the proposed corrective action, or the
(6) In cases involving a hearing, any proposed civil penalty amount. A re-
material submitted during and after spondent’s failure to specify an issue
the hearing as set forth in § 190.211; and may result in waiver of the respond-
(7) The Regional Director’s written ent’s right to raise that issue at the
evaluation of response material sub- hearing. The respondent’s request must
mitted by the respondent and rec- also indicate whether or not the re-
ommendation for final action, if one is spondent will be represented by counsel
prepared. at the hearing. The respondent may
[Amdt. 190–16, 78 FR 58910, Sept. 25, 2013]
withdraw a request for a hearing in
writing and provide a written response.
§ 190.210 Separation of functions. (c) Telephonic and in-person hearings.
A telephone hearing will be held if the
(a) General. An agency employee who
amount of the proposed civil penalty or
assists in the investigation or prosecu-
the cost of the proposed corrective ac-
tion of an enforcement case may not
tion is less than $25,000, unless the re-
participate in the decision of that case
spondent or OPS submits a written re-
or a factually related one, but may par-
quest for an in-person hearing. In-per-
ticipate as a witness or counsel at a
son hearings will normally be held at
hearing as set forth in this subpart.
the office of the appropriate OPS Re-
Likewise, an agency employee who pre-
gion. Hearings may be held by video
pares a decision in an enforcement case
teleconference if the necessary equip-
may not have served in an investiga-
ment is available to all parties.
tive or prosecutorial capacity in that
(d) Pre-hearing submissions. If OPS or
case or a factually related one.
the respondent intends to introduce
(b) Prohibition on ex parte communica-
material, including records, docu-
tions. A party to an enforcement pro-
ments, and other exhibits not already
ceeding, including the respondent, its
in the case file, the material must be
representative, or an agency employee
submitted to the Presiding Official and
having served in an investigative or
the other party at least 10 days prior to
prosecutorial capacity in the pro-
the date of the hearing, unless the Pre-
ceeding, may not communicate pri-
siding Official sets a different deadline
vately with the Associate Adminis-
or waives the deadline for good cause.
trator, Presiding Official, or attorney
(e) Conduct of the hearing. The hear-
drafting the recommended decision
ing is conducted informally without
concerning information that is rel-
strict adherence to rules of evidence.
evant to the questions to be decided in
The Presiding Official regulates the
the proceeding. A party may commu-
course of the hearing and gives each
nicate with the Presiding Official re-
party an opportunity to offer facts,
garding administrative or procedural
statements, explanations, documents,
issues, such as for scheduling a hear-
testimony or other evidence that is rel-
ing.
evant and material to the issues under
[Amdt. 190–16, 78 FR 58911, Sept. 25, 2013] consideration. The parties may call
witnesses on their own behalf and ex-
§ 190.211 Hearing. amine the evidence and witnesses pre-
(a) General. This section applies to sented by the other party. After the
hearings conducted under this part re- evidence in the case has been pre-
lating to civil penalty assessments, sented, the Presiding Official will per-
compliance orders, orders directing mit reasonable discussion of the issues
amendment, safety orders, and correc- under consideration.
tive action orders. The Presiding Offi- (f) Written transcripts. If a respondent
cial will convene hearings conducted elects to transcribe a hearing, the re-
under this section. spondent must make arrangements
(b) Hearing request and statement of with a court reporter at cost to the re-
issues. A request for a hearing must be spondent and submit a complete copy
accompanied by a statement of the of the transcript for the case file. The
issues that the respondent intends to respondent must notify the Presiding
390
Official in advance if it intends to tran- (2) Receive evidence and inquire into
scribe a hearing. the relevant and material facts;
(g) Post-hearing submission. The re- (3) Require the submission of docu-
spondent and OPS may request an op- ments and other information;
portunity to submit further written (4) Direct that documents or briefs
material after the hearing for inclusion relate to issues raised during the
in the record. The Presiding Official course of the hearing;
will allow a reasonable time for the (5) Set the date for filing documents,
submission of the material and will briefs, and other items;
specify the submission date. If the ma-
(6) Prepare a recommended decision;
terial is not submitted within the time
and
prescribed, the case will proceed to
final action without the material. (7) Exercise the authority necessary
(h) Preparation of decision. After con- to carry out the responsibilities of the
sideration of the case file, the Pre- Presiding Official under this subpart.
siding Official prepares a recommended [Amdt. 190–16, 78 FR 58911, Sept. 25, 2013]
decision in the case, which is then for-
warded to the Associate Administrator § 190.213 Final order.
for issuance of a final order.
(a) In an enforcement proceeding
[Amdt. 190–16, 78 FR 58911, Sept. 25, 2013] commenced under § 190.207, an attorney
from the Office of Chief Counsel pre-
§ 190.212 Presiding official, powers, pares a recommended decision after ex-
and duties. piration of the 30-day response period
(a) General. The Presiding Official for prescribed in § 190.208. If a hearing is
a hearing conducted under § 190.211 is held, the Presiding Official prepares
an attorney on the staff of the Deputy the recommended decision as set forth
Chief Counsel who is not engaged in in § 190.211. The recommended decision
any investigative or prosecutorial is forwarded to the Associate Adminis-
functions, such as the issuance of no- trator who considers the case file and
tices under this subpart. If the des- issues a final order. The final order in-
ignated Presiding Official is unavail- cludes—
able, the Deputy Chief Counsel may (1) A statement of findings and deter-
delegate the powers and duties speci-
minations on all material issues, in-
fied in this section to another attorney
cluding a determination as to whether
in the Office of Chief Counsel who is
not engaged in any investigative or each alleged violation has been proved;
prosecutorial functions under this sub- (2) If a civil penalty is assessed, the
part. amount of the penalty and the proce-
(b) Time and place of the hearing. The dures for payment of the penalty, pro-
Presiding Official will set the date, vided that the assessed civil penalty
time and location of the hearing. To may not exceed the penalty proposed in
the extent practicable, the Presiding the notice of probable violation; and
Official will accommodate the parties’ (3) If a compliance order is issued, a
schedules when setting the hearing. statement of the actions required to be
Reasonable notice of the hearing will taken by the respondent and the time
be provided to all parties. by which such actions must be accom-
(c) Powers and duties of Presiding Offi- plished.
cial. The Presiding Official will conduct (b) In cases where a substantial delay
a fair and impartial hearing and take is expected in the issuance of a final
all action necessary to avoid delay in order, notice of that fact and the date
the disposition of the proceeding and by which it is expected that action will
maintain order. The Presiding Official be taken is provided to the respondent
has all powers necessary to achieve upon request and whenever practicable.
those ends, including, but not limited
to the power to: [Amdt. 190–16, 78 FR 58911, Sept. 25, 2013]

(1) Regulate the course of the hearing
and conduct of the parties and their
counsel;
391
§ 190.215 49 CFR Ch. I (10–1–18 Edition)
§ 190.215 [Reserved] cial in accordance with 49 U.S.C.

60112(c).
COMPLIANCE ORDERS
[45 FR 20413, Mar. 27, 1980, as amended by
Amdt. 190–6, 61 FR 18514, Apr. 26, 1996; Amdt.
§ 190.217 Compliance orders generally. 190–16, 78 FR 58912, Sept. 25, 2013]
When a Regional Director has reason
to believe that a person is engaging in CIVIL PENALTIES
conduct that violates 49 U.S.C. 60101 et
§ 190.221 Civil penalties generally.
seq., 33 U.S.C. 1321(j), or any regulation
or order issued thereunder, and if the When a Regional Director has reason
nature of the violation and the public to believe that a person has committed
interest so warrant, the Regional Di- an act violating 49 U.S.C. 60101 et seq.,
rector may initiate proceedings under 33 U.S.C. 1321(j), or any regulation or
§§ 190.207 through 190.213 to determine order issued thereunder, the Regional
the nature and extent of the violations Director may initiate proceedings
under §§ 190.207 through 190.213 to deter-
and for the issuance of an order direct-
mine the nature and extent of the vio-
ing compliance.
lations and appropriate civil penalty.
[Amdt. 190–16, 78 FR 58912, Sept. 25, 2013]
[Amdt. 190–16, 78 FR 58912, Sept. 25, 2013]
§ 190.219 Consent order. § 190.223 Maximum penalties.
(a) At any time prior to the issuance (a) Any person found to have violated
of a compliance order under § 190.217, a a provision of 49 U.S.C. 60101, et seq., or
corrective action order under § 190.233, any regulations or orders issued there-
or a safety order under § 190.239, the Re- under, is subject to an administrative
gional Director and the respondent civil penalty not to exceed $209,002 for
may agree to resolve the case by execu- each violation for each day the viola-
tion of a consent agreement and order, tion continues, with a maximum ad-
which may be jointly executed by the ministrative civil penalty not to ex-
parties and issued by the Associate Ad- ceed $2,090,022 for any related series of
ministrator. Upon execution, the con- violations.
sent order is considered a final order (b) Any person found to have violated
under § 190.213. a provision of 33 U.S.C. 1321(j) or any
(b) A consent order executed under regulation or order issued thereunder
paragraph (a) of this section shall in- is subject to an administrative civil
clude: penalty under 33 U.S.C. 1321(b)(6), as
(1) An admission by the respondent of adjusted by 40 CFR 19.4.
all jurisdictional facts; (c) Any person found to have violated
any standard or order under 49 U.S.C.
(2) An express waiver of further pro-
60103 is subject to an administrative
cedural steps and of all right to seek civil penalty not to exceed $76,352,
judicial review or otherwise challenge which may be in addition to other pen-
or contest the validity of that order; alties to which such person may be
(3) An acknowledgement that the no- subject under paragraph (a) of this sec-
tice of probable violation may be used tion.
to construe the terms of the consent (d) Any person who is determined to
order; and have violated any standard or order
(4) A statement of the actions re- under 49 U.S.C. 60129 is subject to an
quired of the respondent and the time administrative civil penalty not to ex-
by which such actions shall be accom- ceed $1,214, which may be in addition to
plished. other penalties to which such person
(c) Prior to the execution of a con- may be subject under paragraph (a) of
sent agreement and order arising out of this section.
a corrective action order under (e) Separate penalties for violating a
§ 190.233, the Associate Administrator regulation prescribed under this sub-

will notify any appropriate State offi- chapter and for violating an order
issued under §§ 190.206, 190.213, 190.233,
or 190.239 may not be imposed under
392
this section if both violations are based terest and penalties, in accordance
on the same act. with 31 U.S.C. 3717 and 49 CFR part 89.
[Amdt. 190–16, 78 FR 58912, Sept. 25, 2013, as [Amdt. 190–7, 61 FR 27792, June 3, 1996, as
amended at 81 FR 42566, June 30, 2016; Amdt. amended at 70 FR 11138, Mar. 8, 2005; 73 FR
190–17, 82 FR 19328, Apr. 27, 2017] 16567, Mar. 28, 2008; Amdt. 190–16, 78 FR 58912,
Sept. 25, 2013]
§ 190.225 Assessment considerations.
In determining the amount of a civil §§ 190.229–190.231 [Reserved]
penalty under this part, SPECIFIC RELIEF
(a) The Associate Administrator will
consider: § 190.233 Corrective action orders.
(1) The nature, circumstances and
(a) Generally. Except as provided by
gravity of the violation, including ad-
paragraph (b) of this section, if the As-
verse impact on the environment;
sociate Administrator finds, after rea-
(2) The degree of the respondent’s
sonable notice and opportunity for
culpability;
hearing in accord with paragraph (c) of
(3) The respondent’s history of prior
this section, a particular pipeline facil-
offenses;
ity is or would be hazardous to life,
(4) Any good faith by the respondent
property, or the environment, the As-
in attempting to achieve compliance;
sociate Administrator may issue an
(5) The effect on the respondent’s
order pursuant to this section requir-
ability to continue in business; and
ing the operator of the facility to take
(b) The Associate Administrator may
corrective action. Corrective action
consider:
may include suspended or restricted
(1) The economic benefit gained from
use of the facility, physical inspection,
violation, if readily ascertainable,
testing, repair, replacement, or other
without any reduction because of sub-
appropriate action.
sequent damages; and
(b) Waiver of notice and expedited re-
(2) Such other matters as justice may
view. The Associate Administrator may
require.
waive the requirement for notice and
[Amdt. 190–16, 78 FR 58912, Sept. 25, 2013] opportunity for hearing under para-
graph (a) of this section before issuing
§ 190.227 Payment of penalty. an order whenever the Associate Ad-
(a) Except for payments exceeding ministrator determines that the failure
$10,000, payment of a civil penalty pro- to do so would result in the likelihood
posed or assessed under this subpart of serious harm to life, property, or the
may be made by certified check or environment. When an order is issued
money order (containing the CPF Num- under this paragraph, a respondent
ber for the case), payable to ‘‘U.S. De- that contests the order may obtain ex-
partment of Transportation,’’ to the pedited review of the order either by
Federal Aviation Administration, Mike answering in writing to the order with-
Monroney Aeronautical Center, Finan- in 10 days of receipt or requesting a
cial Operations Division (AMZ–341), hearing under § 190.211 to be held as
P.O. Box 25770, Oklahoma City, OK soon as practicable in accordance with
73125, or by wire transfer through the paragraph (c)(2) of this section. For
Federal Reserve Communications Sys- purposes of this section, the term ‘‘ex-
tem (Fedwire) to the account of the pedited review’’ is defined as the proc-
U.S. Treasury, or via https:// ess for making a prompt determination
www.pay.gov. Payments exceeding of whether the order should remain in
$10,000 must be made by wire transfer. effect or be amended or terminated.
(b) Payment of a civil penalty as- The expedited review of an order issued
sessed in a final order issued under under this paragraph will be complete
§ 190.213 or affirmed in a decision on a upon issuance of such determination.
petition for reconsideration must be (c) Notice and hearing:
made within 20 days after receipt of the (1) Written notice that OPS intends
final order or decision. Failure to do so to issue an order under this section
will result in the initiation of collec- will be served upon the owner or oper-
tion action, including the accrual of in- ator of an alleged hazardous facility in
393
§ 190.233 49 CFR Ch. I (10–1–18 Edition)
accordance with § 190.5. The notice hazardous to life, property, or the envi-
must allege the existence of a haz- ronment, the Associate Administrator
ardous facility and state the facts and withdraws the notice or terminates the
circumstances supporting the issuance order issued under paragraph (b) of this
of a corrective action order. The notice section, and promptly notifies the op-
must provide the owner or operator erator in writing by service as pre-
with an opportunity to respond within scribed in § 190.5.
10 days of receipt. (d) The Associate Administrator may
(2) An owner or operator that elects find a pipeline facility to be hazardous
to exercise its opportunity for a hear- under paragraph (a) of this section:
ing under this section must notify the (1) If under the facts and cir-
Associate Administrator of that elec-
cumstances the Associate Adminis-
tion in writing within 10 days of re-
trator determines the particular facil-
ceipt of the notice provided under para-
ity is hazardous to life, property, or
graph (c)(1) of this section, or the order
under paragraph (b) of this section the environment; or
when applicable. The absence of such (2) If the pipeline facility or a compo-
written notification waives an owner nent thereof has been constructed or
or operator’s opportunity for a hearing. operated with any equipment, mate-
(3) At any time after issuance of a rial, or technique which the Associate
notice or order under this section, the Administrator determines is hazardous
respondent may request a copy of the to life, property, or the environment,
case file as set forth in § 190.209. unless the operator involved dem-
(4) A hearing under this section is onstrates to the satisfaction of the As-
conducted pursuant to § 190.211. The sociate Administrator that, under the
hearing should be held within 15 days particular facts and circumstances in-
of receipt of the respondent’s request volved, such equipment, material, or
for a hearing. technique is not hazardous.
(5) After conclusion of a hearing (e) In making a determination under
under this section, the Presiding Offi- paragraph (d) of this section, the Asso-
cial submits a recommended decision ciate Administrator shall consider, if
to the Associate Administrator as to relevant:
whether or not the facility is or would (1) The characteristics of the pipe
be hazardous to life, property, or the and other equipment used in the pipe-
environment, and if necessary, requir- line facility involved, including its age,
ing expeditious corrective action. If a manufacturer, physical properties (in-
notice or order is contested in writing cluding its resistance to corrosion and
without a hearing, an attorney from deterioration), and the method of its
the Office of Chief Counsel prepares the manufacture, construction or assem-
recommended decision. The rec- bly;
ommended decision should be sub-
(2) The nature of the materials trans-
mitted to the Associate Administrator
ported by such facility (including their
within five business days after conclu-
corrosive and deteriorative qualities),
sion of the hearing or after receipt of
the sequence in which such materials
the respondent’s written objection if no
hearing is held. Upon receipt of the rec- are transported, and the pressure re-
ommendation, the Associate Adminis- quired for such transportation;
trator will proceed in accordance with (3) The characteristics of the geo-
paragraphs (d) through (h) of this sec- graphical areas in which the pipeline
tion. If the Associate Administrator facility is located, in particular the cli-
finds the facility is or would be haz- matic and geologic conditions (includ-
ardous to life, property, or the environ- ing soil characteristics) associated
ment, the Associate Administrator with such areas, and the population
issues a corrective action order in ac- density and population and growth pat-
cordance with this section, or confirms terns of such areas;
(or amends) the corrective action order (4) Any recommendation of the Na-
issued under paragraph (b) of this sectional Transportation Safety Board
tion. If the Associate Administrator issued in connection with any inves-
does not find the facility is or would be tigation conducted by the Board; and
394
(5) Such other factors as the Asso- relief as is necessary or appropriate, in-
ciate Administrator may consider ap- cluding mandatory or prohibitive in-
propriate. junctive relief, interim equitable relief,
(f) A corrective action order shall civil penalties, and punitive damages
contain the following information: as provided under 49 U.S.C. 60120 and 49
(1) A finding that the pipeline facility U.S.C. 5123.
is or would be hazardous to life, prop-
[70 FR 11139, Mar. 8, 2005]
erty, or the environment.
(2) The relevant facts which form the § 190.236 Emergency orders.
basis of that finding.
(3) The legal basis for the order. (a) Determination of imminent hazard.
(4) The nature and description of any When the Administrator determines
particular corrective action required of that a violation of a provision of the
the respondent. Federal pipeline safety laws, or a regu-
(5) The date by which the required lation or order prescribed under those
corrective action must be taken or laws, an unsafe condition or practice,
completed and, where appropriate, the or a combination of unsafe conditions
duration of the order. and practices, constitutes or is causing
(6) If the opportunity for a hearing an imminent hazard, as defined in
was waived pursuant to paragraph (b) § 190.3, the Administrator may issue or
of this section, a statement that an op- impose an emergency order, without
portunity for a hearing will be avail- advance notice or an opportunity for a
able at a particular time and location hearing. The basis for any action taken
after issuance of the order. under this section will be set forth in
(g) The Associate Administrator will writing that describes:
terminate a corrective action order (1) The violation, condition, or prac-
whenever the Associate Administrator tice that constitutes or is causing the
determines that the facility is no imminent hazard;
longer hazardous to life, property, or (2) Those subject to the order;
the environment. If appropriate, how- (3) The restrictions, prohibitions, or
ever, a notice of probable violation safety measures imposed;
may be issued under § 190.207. (4) The standards and procedures for
(h) At any time after a corrective ac- obtaining relief from the order;
tion order issued under this section has (5) How the order is tailored to abate
become effective, the Associate Admin- the imminent hazard and the reasons
istrator may request the Attorney the authorities under 49 U.S.C. 60112
General to bring an action for appro- and 60117(l) are insufficient to do so;
priate relief in accordance with (6) How the considerations listed in
§ 190.235. paragraph (c) of this section were
(i) Upon petition by the Attorney taken into account.
General, the District Courts of the (b) Consultation requirement. In evalu-
United States shall have jurisdiction to ating the considerations under para-
enforce orders issued under this section graph (c), the Administrator shall con-
by appropriate means. sult as the Administrator determines
[70 FR 11138, Mar. 8, 2005, as amended by appropriate, with appropriate Federal
Amdt. 190–16, 78 FR 58912, Sept. 25, 2013] agencies, State agencies, and other en-
tities knowledgeable in pipeline safety
§ 190.235 Civil actions generally. or operations.
Whenever it appears to the Associate (c) Considerations. Prior to issuing an
Administrator that a person has en- emergency order, the Administrator
gaged, is engaged, or is about to engage must consider the following:
in any act or practice constituting a (1) The impact of the emergency
violation of any provision of 49 U.S.C. order on public health and safety;
60101 et seq., or any regulations issued (2) The impact, if any, of the emer-
thereunder, the Administrator, or the gency order on the national or regional
person to whom the authority has been economy or national security;

delegated, may request the Attorney (3) The impact of the emergency
General to bring an action in the ap- order on the ability of owners and oper-
propriate U.S. District Court for such ators of pipeline facilities to maintain
395
§ 190.237 49 CFR Ch. I (10–1–18 Edition)
reliability and continuity of service to cided under paragraph (c)(2) of this sec-
customers; and tion, a petition for review including a
(4) The result of consultations with formal hearing request will be deemed
appropriate Federal agencies, State assigned to the Office of Hearings three
agencies, and other entities knowledge- days after the Associate Administrator
able in pipeline safety or operations. for Pipeline Safety receives it.
(d) Service. The Administrator will (2) No hearing requested. For a peti-
publish emergency orders in the FED- tion for review of an emergency order
ERAL REGISTER, as soon as practicable that does not include a formal hearing
upon issuance. In addition, OPS will request or fails to state material facts
post emergency orders on its Web site. in dispute, the Associate Adminis-
The emergency order will contain fil- trator for Pipeline Safety must issue
ing and service requirements, including an administrative decision on the mer-
the address of DOT Docket Operations its within 30 days of receipt of the peti-
and of all persons to be served with pe- tion. The Associate Administrator for
titions for review. Pipeline Safety’s decision constitutes
[Amdt. 190–18, 81 FR 70985, Oct. 14, 2016] the agency’s final decision.
(3) Consolidation. If the Associate Ad-
§ 190.237 Petitions for review. ministrator for Pipeline Safety re-
(a) Requirements. An entity that is ceives more than one petition for re-
subject to and aggrieved by an emer- view of an emergency order, and those
gency order may petition the Adminis- petitions share common issues of law
trator for review to determine whether or fact, the Associate Administrator
the order will remain in place, be modi- for Pipeline Safety may consolidate
fied, or terminated. A petition for re- those petitions for the purposes of com-
view must: plying with this section.
(1) Be in writing; (4) Agency authority to request a formal
(2) State with particularity each part hearing. In the event that a petitioner
of the emergency order that is sought does not request a formal hearing, the
to be amended or rescinded and include Associate Administrator for Pipeline
all information, evidence and argu- Safety may still reassign the petition
ments in support thereof; to the Office of Hearings, DOT, when a
(3) State whether a formal hearing in reasonable basis exists for the reassign-
accordance with 5 U.S.C. 554 is re- ment.
quested, and, if so, the material facts (d) Hearings. Formal hearings must
in dispute giving rise to the request for be conducted by an Administrative
a hearing; and, Law Judge assigned by the Chief Ad-
(4) Be filed and served in accordance ministrative Law Judge of the Office of
with paragraph (f) of this section. Hearings. The Administrative Law
(b) Response to the petition for review. Judge may:
An attorney designated by the Office of (1) Administer oaths and affirma-
Chief Counsel may file and serve, in actions;
cordance with paragraph (f) of this sec- (2) Issue subpoenas as provided by the
tion, a response, including appropriate appropriate agency regulations (49 CFR
pleadings, within five days of receipt of 190.7 and 49 U.S.C. 60117);
the petition by the Chief Counsel. (3) Adopt the relevant Federal Rules
(c) Associate Administrator for Pipeline of Civil Procedure for the United
Safety Responsibilities—(1) Hearing re- States District Courts for the proce-
quested. Upon receipt of a petition for dures governing the hearings when ap-
review of an emergency order that in- propriate;
cludes a formal hearing request and (4) Adopt the relevant Federal Rules
states material facts in dispute, the of Evidence for United States Courts
Associate Administrator for Pipeline and Magistrates for the submission of
Safety will immediately assign the pe- evidence when appropriate;
tition to the Office of Hearings, DOT. (5) Take or cause depositions to be
Unless the Associate Administrator for taken;

Pipeline Safety issues an order stating (6) Examine witnesses at the hearing;
that the petition fails to set forth ma- (7) Rule on offers of proof and receive
terial facts in dispute and will be de- relevant evidence;
396
(8) Convene, recess, adjourn or other- cept as otherwise provided herein. The
wise regulate the course of the hearing; emergency order must state all rel-
(9) Hold conferences for settlement, evant service requirements and list the
simplification of the issues, or any persons to be served and may be up-
other proper purpose; and, dated as necessary.
(10) Take any other action authorized (3) Certificate of service. Each order,
by or consistent with the provisions of pleading, motion, notice, or other doc-
this part and permitted by law that ument must be accompanied by a cer-
may expedite the hearing or aid in the tificate of service specifying the man-
disposition of an issue raised. ner in which and the date on which
(e) Parties. The petitioner may appear service was made.
and be heard in person or by an author- (4) If applicable, service upon a per-
ized representative. PHMSA will be son’s duly authorized representative,
represented by an attorney designated agent for service, or an organization’s
by the Office of Chief Counsel. president constitutes service upon that
(f) Filing and service. (1) Each peti- person.
tion, pleading, motion, notice, order, or (g) Report and recommendation. The
other document submitted in connec- Administrative Law Judge must issue
tion with an order issued under this a report and recommendation at the
subpart must be filed (commercially close of the record. The report and rec-
delivered or submitted electronically) ommendation must:
with: U.S. Department of Transpor- (1) Contain findings of fact and con-
tation, Docket Operations, M–30, West clusions of law and the grounds for the
Building Ground Floor, Room W12–140, decision based on the material issues of
1200 New Jersey Avenue SE., Wash- fact or law presented on the record;
ington, DC 20590. All documents filed (2) Be served on the parties to the
will be published on the Department’s proceeding; and
docket management Web site, http:// (3) Be issued no later than 25 days
www.regulations.gov. The emergency after receipt of the petition for review
order must state the above filing re- by the Associate Administrator of
quirements and the address of DOT Pipeline Safety.
Docket Operations. (h) Petition for reconsideration. (1) A
(2) Service. Each document filed in ac- party aggrieved by the Administrative
cordance with paragraph (f)(1) of this Law Judge’s report and recommenda-
section must be concurrently served tion, may file a petition for reconsider-
upon the following persons: ation with the Associate Administrator
(i) Associate Administrator for Pipe- of Pipeline Safety within one day of
line Safety, OPS, Pipeline and Haz- service of the report and recommenda-
ardous Materials Safety Administra- tion. The opposing party may file a re-
tion, U.S. Department of Transpor- sponse to the petition for reconsider-
tation, 1200 New Jersey Avenue SE., ation within one day of service of a pe-
East Building, Washington, DC 20590. tition for reconsideration.
(ii) Chief Counsel, PHC, Pipeline and (2) The Associate Administrator of
Hazardous Materials Safety Adminis- Pipeline Safety must issue a final
tration, U.S. Department of Transpor- agency decision within three days of
tation, 1200 New Jersey Avenue SE., service of the final pleading outlined in
East Building, Washington, DC 20590 paragraph (h)(1) of this section, but no
(facsimile: 202–366–7041). later than 30 days after receipt of the
(iii) If the petition for review re- original petition for review.
quests a formal hearing, the Chief Ad- (3) The Associate Administrator of
ministrative Law Judge, U.S. Depart- Pipeline Safety’s decision on the mer-
ment of Transportation, Office of Hear- its of a petition for reconsideration
ings, M–20, Room E12–320, 1200 New Jer- constitutes the agency’s final decision.
sey Avenue SE., Washington, DC 20590 (i) Judicial review. After the issuance
(facsimile: 202–366–7536). of a final agency decision pursuant to
(iv) Service must be made personally, paragraph (c)(2) or (h)(3) of this sec-
by commercial delivery service, or by tion, or the issuance of a written deter-
electronic means if consented to in mination by the Administrator pursu-
writing by the party to be served, ex- ant to paragraph (j) of this section, a
397
§ 190.239 49 CFR Ch. I (10–1–18 Edition)
person subject to, and aggrieved by, an serve written notice of a proposed safe-
emergency order issued under section ty order under § 190.5 to an operator of
190.236 may seek judicial review of the the pipeline facility. The notice will al-
order in the appropriate District Court lege the existence of a condition that
of the United States. The filing of an poses a pipeline integrity risk to public
action seeking judicial review does not safety, property, or the environment,
stay or modify the force and effect of and state the facts and circumstances
the agency’s final decision under para- that support issuing a safety order for
graph (c)(2) or (h)(3) of this section, or the specified pipeline or portion there-
the written determination under para- of. The notice will also specify pro-
graph (j) of this section, unless stayed posed testing, evaluations, integrity
or modified by the Administrator. assessment, or other actions to be
(j) Expiration of order. If the Associate taken by the operator and may propose
Administrator of Pipeline Safety, or that the operator submit a work plan
the Administrative Law Judge, where and schedule to address the conditions
appropriate, has not disposed of the pe- identified in the notice. The notice will
tition for review within 30 days of re- also provide the operator with its re-
ceipt, the emergency order will cease sponse options, including procedures
to be effective unless the Adminis- for requesting informal consultation
trator issuing the emergency order de- and a hearing. An operator receiving a
termines, in writing, that the immi- notice will have 30 days to respond to
nent hazard providing a basis for the the PHMSA official who issued the no-
emergency order continues to exist. tice.
(k) Time. In computing any period of (2) Informal consultation. Upon timely
time prescribed by this part or by an request by the operator, PHMSA will
order issued by the Administrative provide an opportunity for informal
Law Judge, the day of filing of the pe- consultation concerning the proposed
tition for review or of any other act, safety order. Such informal consulta-
event, or default from which the des- tion shall commence within 30 days,
ignated period of time begins to run provided that PHMSA may extend this
will not be included. The last day of time by request or otherwise for good
the period so computed will be in- cause. Informal consultation provides
cluded, unless it is a Saturday, Sunday, an opportunity for the respondent to
or Federal holiday, in which event the explain the circumstances associated
period runs until the end of the next with the risk condition(s) identified in
day which is not one of the aforemen- the notice and, where appropriate, to
tioned days. present a proposal for corrective ac-
[Amdt. 190–18, 81 FR 70986, Oct. 14, 2016] tion, without prejudice to the opera-
tor’s position in any subsequent hear-
§ 190.239 Safety orders. ing. If the respondent and Regional Di-
(a) When may PHMSA issue a safety rector agree within 30 days of the infor-
order? If the Associate Administrator mal consultation on a plan for the op-
finds, after notice and an opportunity erator to address each risk condition,
for hearing under paragraph (b) of this they may enter into a written consent
section, that a particular pipeline fa- agreement and the Associate Adminis-
cility has a condition or conditions trator may issue a consent order incor-
that pose a pipeline integrity risk to porating the terms of the agreement. If
public safety, property, or the environ- a consent agreement is reached, no fur-
ment, the Associate Administrator ther hearing will be provided in the
may issue an order requiring the oper- matter and any pending hearing re-
ator of the facility to take necessary quest will be considered withdrawn. If
corrective action. Such action may in- a consent agreement is not reached
clude physical inspection, testing, re- within 30 days of the informal con-
pair or other appropriate action to sultation (or if informal consultation is
remedy the identified risk condition. not requested), the Associate Adminis-
(b) How is an operator notified of the trator may proceed under paragraphs
proposed issuance of a safety order and (b)(3) through (5) of this section. If
what are its responses options? (1) Notice PHMSA subsequently determines that
of proposed safety order. PHMSA will an operator has failed to comply with
398
the terms of a consent order, PHMSA sociate Administrator will issue a safe-
may obtain any administrative or judi- ty order under this section. If the Asso-
cial remedies available under 49 U.S.C. ciate Administrator does not find that
60101 et seq. and this part. If a consent the facility has such a condition, or
agreement is not reached, any admis- concludes that a safety order is other-
sions made by the operator during the wise not warranted, the Associate Ad-
informal consultation shall be excluded ministrator will withdraw the notice
from the record in any subsequent and promptly notify the operator in
hearing. Nothing in this paragraph (b) writing by service as prescribed in
precludes PHMSA from terminating § 190.5. Nothing in this subsection pre-
the informal consultation process if it cludes PHMSA and the operator from
has reason to believe that the operator entering into a consent agreement at
is not engaging in good faith discus- any time before a safety order is
sions or otherwise concludes that fur- issued.
ther consultation would not be produc-
(6) Termination of safety order. Once
tive or in the public interest.
all remedial actions set forth in the
(3) Hearing. An operator receiving a
notice of proposed safety order may safety order and associated work plans
contest the notice, or any portion are completed, as determined by
thereof, by filing a written request for PHMSA, the Associate Administrator
a hearing within 30 days following re- will notify the operator that the safety
ceipt of the notice or within 10 days order has been lifted. The Associate
following the conclusion of informal Administrator shall suspend or termi-
consultation that did not result in a nate a safety order whenever the Asso-
consent agreement, as applicable. In ciate Administrator determines that
the absence of a timely request for a the pipeline facility no longer has a
hearing, the Associate Administrator condition or conditions that pose a
may issue a safety order in the form of pipeline integrity risk to public safety,
the proposed order in accordance with property, or the environment.
paragraphs (c) through (g) of this sec- (c) How is the determination made that
tion. a pipeline facility has a condition that
(4) Conduct of hearing. An attorney poses an integrity risk? The Associate
from the Office of Chief Counsel, will Administrator may find a pipeline fa-
serve as the Presiding Official in a cility to have a condition that poses a
hearing under this section. The hearing pipeline integrity risk to public safety,
will be conducted informally, without property, or the environment under
strict adherence to formal rules of evi- paragraph (a) of this section:
dence in accordance with § 190.211. The (1) If under the facts and cir-
respondent may submit any relevant cumstances the Associate Adminis-
information or materials, call wit- trator determines the particular facil-
nesses, and present arguments on the
ity has such a condition; or
issue of whether a safety order should
be issued to address the alleged pres- (2) If the pipeline facility or a compo-
ence of a condition that poses a pipe- nent thereof has been constructed or
line integrity risk to public safety, operated with any equipment, mate-
property, or the environment. rial, or technique with a history of
(5) Post-hearing action. Following a being susceptible to failure when used
hearing under this section, the Pre- in pipeline service, unless the operator
siding Official will submit a rec- involved demonstrates that such equip-
ommendation to the Associate Admin- ment, material, or technique is not
istrator concerning issuance of a final susceptible to failure given the manner
safety order. Upon receipt of the rec- it is being used for a particular facil-
ommendation, the Associate Adminis- ity.
trator may proceed under paragraphs (d) What factors must PHMSA consider
(c) through (g) of this section. If the in making a determination that a risk
Associate Administrator finds the fa- condition is present? In making a deter-

cility to have a condition that poses a mination under paragraph (c) of this
pipeline integrity risk to public safety, section, the Associate Administrator
property, or the environment, the As- shall consider, if relevant:
399
§ 190.241 49 CFR Ch. I (10–1–18 Edition)
(1) The characteristics of the pipe under § 190.207 or taking other enforce-
and other equipment used in the pipe- ment action if noncompliance is identi-
line facility involved, including its age, fied at the facilities that are the sub-
manufacturer, physical properties (in- ject of a safety order proceeding.
cluding its resistance to corrosion and (g) May I petition for reconsideration of
deterioration), and the method of its a safety order? Yes, a petition for recon-
manufacture, construction or assem- sideration may be submitted in accord-
bly; ance with § 190.243.
(2) The nature of the materials trans-
ported by such facility (including their [73 FR 16567, Mar. 28, 2008, as amended at 74
FR 2893, Jan. 16, 2009; Amdt. 190–16, 78 FR
corrosive and deteriorative qualities),
58913, Sept. 25, 2013]
the sequence in which such materials
are transported, and the pressure re- § 190.241 Finality.
quired for such transportation;
(3) The characteristics of the geo- Except as otherwise provided by
graphical areas where the pipeline fa- § 190.243, an order directing amendment
cility is located, in particular the cli- issued under § 190.206, a final order
matic and geologic conditions (includ- issued under § 190.213, a corrective ac-
ing soil characteristics) associated tion order issued under § 190.233, or a
with such areas; safety order issued under § 190.239 is
(4) For hazardous liquid pipelines, the considered final administrative action
proximity of the pipeline to an unusu- on that enforcement proceeding.
ally sensitive area; [Amdt. 190–16, 78 FR 58913, Sept. 25, 2013]
(5) The population density and
growth patterns of the area in which § 190.243 Petitions for reconsideration.
the pipeline facility is located;
(6) Any relevant recommendation of (a) A respondent may petition the
the National Transportation Safety Associate Administrator for reconsid-
Board issued in connection with any eration of an order directing amend-
investigation conducted by the Board; ment of plans or procedures issued
(7) The likelihood that the condition under § 190.206, a final order issued
will impair the serviceability of the under § 190.213, or a safety order issued
pipeline; under § 190.239. The written petition
(8) The likelihood that the condition must be received no later than 20 days
will worsen over time; and after receipt of the order by the re-
(9) The likelihood that the condition spondent. A copy of the petition must
is present or could develop on other be provided to the Chief Counsel of the
areas of the pipeline. Pipeline and Hazardous Materials Safe-
(e) What information will be included in ty Administration, East Building, 2nd
a safety order? A safety order shall con- Floor, Mail Stop E26–105, 1200 New Jer-
tain the following: sey Ave. SE., Washington, DC 20590 or
(1) A finding that the pipeline facility by email to phmsachiefcounsel@dot.gov.
has a condition that poses a pipeline Petitions received after that time will
integrity risk to public safety, prop- not be considered. The petition must
erty, or the environment; contain a brief statement of the com-
(2) The relevant facts which form the plaint and an explanation as to why
basis of that finding; the order should be reconsidered.
(3) The legal basis for the order; (b) If the respondent requests the
(4) The nature and description of any consideration of additional facts or ar-
particular corrective actions to be re- guments, the respondent must submit
quired of the operator; and the reasons why they were not pre-
(5) The date(s) by which the required sented prior to issuance of the final
corrective actions must be taken or order.
completed and, where appropriate, the (c) The filing of a petition under this
duration of the order. section stays the payment of any civil
(f) Can PHMSA take other enforcement penalty assessed. However, unless the
actions on the affected facilities? Nothing Associate Administrator otherwise pro-
in this section precludes PHMSA from vides, the order, including any required
issuing a Notice of Probable Violation corrective action, is not stayed.
400
(d) The Associate Administrator may commerce (as those terms are defined
grant or deny, in whole or in part, any in 49 U.S.C. 60101 et seq.) will, upon con-
petition for reconsideration without viction, be subject to a fine under title
further proceedings. If the Associate 18, United States Code, imprisonment
Administrator reconsiders an order for a term not to exceed 20 years, or
under this section, a final decision on both, for each offense.
reconsideration may be issued without (c) Any person who willfully and
further proceedings, or, in the alter- knowingly defaces, damages, removes,
native, additional information, data, or destroys any pipeline sign, right-of-
and comment may be requested by the way marker, or marine buoy required
Associate Administrator, as deemed by 49 U.S.C. 60101 et seq. or any regula-
appropriate. tion or order issued thereunder will,
(e) It is the policy of the Associate upon conviction, be subject to a fine
Administrator to expeditiously issue under title 18, United States Code, im-
notice of the action taken on a petition prisonment for a term not to exceed 1
for reconsideration. In cases where a year, or both, for each offense.
substantial delay is expected, notice of (d) Any person who willfully and
that fact and the date by which it is knowingly engages in excavation activ-
expected that action will be taken is ity without first using an available
provided to the respondent upon re- one-call notification system to estab-
quest and whenever practicable. lish the location of underground facili-
(f) If the Associate Administrator re- ties in the excavation area; or without
considers an order under this section, considering location information or
the decision on reconsideration is the markings established by a pipeline fa-
final administrative action on that en- cility operator; and
forcement proceeding. (1) Subsequently damages a pipeline
(g) Any application for judicial re- facility resulting in death, serious bod-
view must be filed no later than 89 days ily harm, or property damage exceed-
after the issuance of the decision in ac- ing $50,000;
cordance with 49 U.S.C. 60119(a). (2) Subsequently damages a pipeline
(h) Judicial review of agency action facility and knows or has reason to
under 49 U.S.C. 60119(a) will apply the know of the damage but fails to
standards of review established in 5 promptly report the damage to the op-
U.S.C. 706. erator and to the appropriate authori-
ties; or
[Amdt. 190–16, 78 FR 58913, Sept. 25, 2013]
(3) Subsequently damages a haz-
ardous liquid pipeline facility that re-
Subpart C—Criminal Enforcement sults in the release of more than 50 bar-
rels of product; will, upon conviction,
SOURCE: Amdt. 190–16, 78 FR 58914, Sept. 25, be subject to a fine under title 18,
2013, unless otherwise noted. United States Code, imprisonment for
a term not to exceed 5 years, or both,
§ 190.291 Criminal penalties generally. for each offense.
(a) Any person who willfully and (e) No person shall be subject to
knowingly violates a provision of 49 criminal penalties under paragraph (a)
U.S.C. 60101 et seq. or any regulation or of this section for violation of any reg-
order issued thereunder will upon con- ulation and the violation of any order
viction be subject to a fine under title issued under §§ 190.217, 190.219 or 190.291
18, United States Code, and imprison- if both violations are based on the
ment for not more than five years, or same act.
both, for each offense.
(b) Any person who willfully and § 190.293 Referral for prosecution.
knowingly injures or destroys, or at- If a PHMSA employee becomes aware
tempts to injure or destroy, any inter- of any actual or possible activity sub-
state transmission facility, any inter- ject to criminal penalties under
state pipeline facility, or any intra- § 190.291, the employee reports it to the
state pipeline facility used in inter- Office of Chief Counsel, Pipeline and
state or foreign commerce or in any ac- Hazardous Materials Safety Adminis-
tivity affecting interstate or foreign tration, and to his or her supervisor.
401
§ 190.301 49 CFR Ch. I (10–1–18 Edition)
The Chief Counsel may refer the report Room W12–140, 1200 New Jersey Avenue,
to OPS for investigation. If appro- SE., Washington, DC 20590. You may
priate, the Chief Counsel refers the re- obtain a copy during normal business
port to the Department of Justice for hours, excluding Federal holidays, for a
criminal prosecution of the offender. fee, with the exception of material
which the Administrator of PHMSA de-
Subpart D—Procedures for termines should be withheld from pub-
Adoption of Rules lic disclosure under 5 U.S.C. 552(b) or
any other applicable statutory provi-
SOURCE: Amdt. 190–8, 61 FR 50909, Sept. 27, sion.
1996, unless otherwise noted.
[Amdt. 190–8, 61 FR 50909, Sept. 27, 1996, as
§ 190.301 Scope. amended at 70 FR 11137, 11139, Mar. 8, 2005; 73
FR 16566, Mar. 28, 2008; 73 FR 16568, Mar. 28,
This subpart prescribes general rule- 2008]
making procedures for the issue,
amendment, and repeal of Pipeline § 190.307 Records.
Safety Program regulations of the
Records of the Pipeline and Haz-
Pipeline and Hazardous Materials Safe-
ty Administration of the Department ardous Materials Safety Administra-
of Transportation. tion relating to rulemaking pro-
ceedings are available for inspection as
[Amdt. 190–8, 61 FR 50909, Sept. 27, 1996, as provided in section 552(b) of title 5,
amended at 70 FR 11137, Mar. 8, 2005]
United States Code, and part 7 of the
§ 190.303 Delegations. Regulations of the Office of the Sec-
retary of Transportation (part 7 of this
For the purposes of this subpart, Ad-
title).
ministrator means the Administrator,
Pipeline and Hazardous Materials Safe- [Amdt. 190–8, 61 FR 50909, Sept. 27, 1996, as
ty Administration, or his or her dele- amended at 70 FR 11137, Mar. 8, 2005]
gate.
§ 190.309 Where to file petitions.
[Amdt. 190–8, 61 FR 50909, Sept. 27, 1996, as
amended at 70 FR 11137, Mar. 8, 2005] Petitions for extension of time to
comment submitted under § 190.319, pe-
§ 190.305 Regulatory dockets. titions for hearings submitted under
(a) Information and data considered § 190.327, petitions for rulemaking sub-
relevant by the Administrator relating mitted under § 190.331, and petitions for
to rulemaking actions, including no- reconsideration submitted under
tices of proposed rulemaking; com- § 190.335 must be submitted to: Admin-
ments received in response to notices; istrator, Pipeline and Hazardous Mate-
petitions for rulemaking and reconsid- rials Safety Administration, U.S. De-
eration; denials of petitions for rule- partment of Transportation, 1200 New
making and reconsideration; records of Jersey Avenue, SE, Washington, D.C.
additional rulemaking proceedings 20590–0001.
under § 190.325; and final regulations
are maintained by the Pipeline and [Amdt. 190–8, 61 FR 50909, Sept. 27, 1996, as
amended at 70 FR 11137, Mar. 8, 2005; 73 FR
Hazardous Materials Safety Adminis-
16566, Mar. 28, 2008]
tration at 1200 New Jersey Avenue, SE,
Washington, D.C. 20590–0001. § 190.311 General.
(b) Once a public docket is estab-
lished, docketed material may be Unless the Administrator, for good
accessed at http://www.regulations.gov. cause, finds that notice is impracti-
Public comments also may be sub- cable, unnecessary, or contrary to the
mitted at http://www.regulations.gov. public interest, and incorporates that
Comment submissions must identify finding and a brief statement of the
the docket number. You may also ex- reasons for it in the rule, a notice of
amine public docket material at the of- proposed rulemaking is issued and in-
fices of the Docket Operations Facility terested persons are invited to partici-
(M–30), U.S. Department of Transpor- pate in the rulemaking proceedings
tation, West Building, First Floor, with respect to each substantive rule.
402
§ 190.313 Initiation of rulemaking. § 190.309 and received by PHMSA not

The Administrator initiates rule- later than 10 days before expiration of
making on his or her own motion; how- the time stated in the notice. The fil-
ever, in so doing, the Administrator ing of the petition does not automati-
may use discretion to consider the rec- cally extend the time for petitioner’s
ommendations of other agencies of the comments. A petition is granted only if
United States or of other interested the petitioner shows good cause for the
persons including those of any tech- extension, and if the extension is con-
nical advisory body established by sistent with the public interest. If an
statute for that purpose. extension is granted, it is granted to
all persons, and it is published in the
§ 190.315 Contents of notices of pro- FEDERAL REGISTER.
posed rulemaking.
(a) Each notice of proposed rule- [Amdt. 190–16, 78 FR 58914, Sept. 25, 2013]
making is published in the FEDERAL
§ 190.321 Contents of written com-
REGISTER, unless all persons subject to ments.
it are named and are personally served
with a copy of it. All written comments must be in
(b) Each notice, whether published in English. Any interested person should
the FEDERAL REGISTER or personally submit as part of written comments all
served, includes: material considered relevant to any
(1) A statement of the time, place, statement of fact. Incorporation of ma-
and nature of the proposed rulemaking terial by reference should be avoided;
proceeding; however, where necessary, such incor-
(2) A reference to the authority under porated material must be identified by
which it is issued; document title and page.
(3) A description of the subjects and
issues involved or the substance and [Amdt. 190–16, 78 FR 58914, Sept. 25, 2013]
terms of the proposed regulation;
(4) A statement of the time within § 190.323 Consideration of comments
received.
which written comments must be sub-
mitted; and All timely comments and the rec-
(5) A statement of how and to what ommendations of any technical advi-
extent interested persons may partici- sory body established by statute for
pate in the proceeding. the purpose of reviewing the proposed
rule concerned are considered before
§ 190.317 Participation by interested final action is taken on a rulemaking
persons.
proposal. Late filed comments are con-
(a) Any interested person may par- sidered so far as practicable.
ticipate in rulemaking proceedings by
submitting comments in writing con- § 190.325 Additional rulemaking pro-
taining information, views or argu- ceedings.
ments in accordance with instructions
The Administrator may initiate any
for participation in the rulemaking
further rulemaking proceedings that
document.
(b) The Administrator may invite the Administrator finds necessary or
any interested person to participate in desirable. For example, interested per-
the rulemaking proceedings described sons may be invited to make oral argu-
in § 190.325. ments, to participate in conferences
(c) For the purposes of this subpart, between the Administrator or the Ad-
an interested person includes any Fed- ministrator’s representative and inter-
eral or State government agency or ested persons, at which minutes of the
any political subdivision of a State. conference are kept, to appear at infor-
mal hearings presided over by officials
§ 190.319 Petitions for extension of designated by the Administrator at
time to comment.
which a transcript of minutes are kept,

A petition for extension of the time or participate in any other proceeding
to submit comments must be sub- to assure informed administrative ac-
mitted to PHMSA in accordance with tion and to protect the public interest.
403
§ 190.327 49 CFR Ch. I (10–1–18 Edition)
§ 190.327 Hearings. (b) Each petition filed under this sec-

tion must—
(a) If a notice of proposed rulemaking
(1) Summarize the proposed action
does not provide for a hearing, any in- and explain its purpose;
terested person may petition the Ad- (2) State the text of the proposed rule
ministrator for an informal hearing. or amendment, or specify the rule pro-
The petition must be received by the posed to be repealed;
Administrator not later than 20 days (3) Explain the petitioner’s interest
before expiration of the time stated in in the proposed action and the interest
the notice. The filing of the petition of any party the petitioner represents;
does not automatically result in the and
scheduling of a hearing. A petition is (4) Provide information and argu-
granted only if the petitioner shows ments that support the proposed ac-
good cause for a hearing. If a petition tion, including relevant technical, sci-
for a hearing is granted, notice of the entific or other data as available to the
hearing is published in the FEDERAL petitioner, and any specific known
REGISTER. cases that illustrate the need for the
(b) Sections 556 and 557 of title 5, proposed action.
United States Code, do not apply to (c) If the potential impact of the pro-
hearings held under this subpart. Un- posed action is substantial, and infor-
less otherwise specified, hearings held mation and data related to that impact
under this subpart are informal, non- are available to the petitioner, the As-
adversarial fact-finding proceedings, at sociate Administrator or the Chief
which there are no formal pleadings or Counsel may request the petitioner to
adverse parties. Any regulation issued provide—
in a case in which an informal hearing (1) The costs and benefits to society
is held is not necessarily based exclu- and identifiable groups within society,
sively on the record of the hearing. quantifiable and otherwise;
(c) The Administrator designates a (2) The direct effects (including pre-
representative to conduct any hearing emption effects) of the proposed action
held under this subpart. The Chief on States, on the relationship between
Counsel designates a member of his or the Federal Government and the
her staff to serve as legal officer at the States, and on the distribution of
hearing. power and responsibilities among the
various levels of government;
[Amdt. 190–8, 61 FR 50909, Sept. 27, 1996. Re- (3) The regulatory burden on small
designated and amended by Amdt. 190–16, 78
businesses, small organizations and
FR 58914, Sept. 25, 2013]
small governmental jurisdictions;
§ 190.329 Adoption of final rules. (4) The recordkeeping and reporting
requirements and to whom they would
Final rules are prepared by rep- apply; and
resentatives of the Office of Pipeline (5) Impacts on the quality of the nat-
Safety and the Office of the Chief ural and social environments.
Counsel. The regulation is then sub- (d) The Associate Administrator or
mitted to the Administrator for consid- Chief Counsel may return a petition
eration. If the Administrator adopts that does not comply with the require-
the regulation, it is published in the ments of this section, accompanied by
FEDERAL REGISTER, unless all persons a written statement indicating the de-
subject to it are named and are person- ficiencies in the petition.
ally served with a copy of it.
§ 190.333 Processing of petition.
§ 190.331 Petitions for rulemaking. (a) General. Unless the Associate Ad-
(a) Any interested person may peti- ministrator or the Chief Counsel other-
tion the Associate Administrator for wise specifies, no public hearing, argu-
Pipeline Safety to establish, amend, or ment, or other proceeding is held di-
repeal a substantive regulation, or may rectly on a petition before its disposi-

petition the Chief Counsel to establish, tion under this section.
amend, or repeal a procedural regula- (b) Grants. If the Associate Adminis-
tion. trator or the Chief Counsel determines
404
that the petition contains adequate Associate Administrator or the Chief

justification, he or she initiates rule- Counsel determines to reconsider any
making action under this subpart. regulation, a final decision on recon-
(c) Denials. If the Associate Adminis- sideration may be issued without fur-
trator or the Chief Counsel determines ther proceedings, or an opportunity to
that the petition does not justify rule- submit comment or information and
making, the petition is denied. data as deemed appropriate, may be
(d) Notification. The Associate Admin- provided. Whenever the Associate Ad-
istrator or the Chief Counsel will no- ministrator or the Chief Counsel deter-
tify a petitioner, in writing, of the de- mines that a petition should be granted
cision to grant or deny a petition for or denied, the Office of the Chief Coun-
rulemaking. sel prepares a notice of the grant or de-
§ 190.335 Petitions for reconsideration. nial of a petition for reconsideration,
for issuance to the petitioner, and the
(a) Except as provided in § 190.339(d), Associate Administrator or the Chief
any interested person may petition the
Counsel issues it to the petitioner. The
Associate Administrator for reconsid-
Associate Administrator or the Chief
eration of any regulation issued under
Counsel may consolidate petitions re-
this subpart, or may petition the Chief
lating to the same rules.
Counsel for reconsideration of any pro-
cedural regulation issued under this (b) It is the policy of the Associate
subpart and contained in this subpart. Administrator or the Chief Counsel to
The petition must be received not later issue notice of the action taken on a
than 30 days after publication of the petition for reconsideration within 90
rule in the FEDERAL REGISTER. Peti- days after the date on which the regu-
tions filed after that time will be con- lation in question is published in the
sidered as petitions filed under § 190.331. FEDERAL REGISTER, unless it is found
The petition must contain a brief impracticable to take action within
statement of the complaint and an ex- that time. In cases where it is so found
planation as to why compliance with and the delay beyond that period is ex-
the rule is not practicable, is unreason- pected to be substantial, notice of that
able, or is not in the public interest. fact and the date by which it is ex-
(b) If the petitioner requests the con- pected that action will be taken is
sideration of additional facts, the peti- issued to the petitioner and published
tioner must state the reason they were in the FEDERAL REGISTER.
not presented to the Associate Admin-
istrator or the Chief Counsel within § 190.338 Appeals.
the prescribed time. (a) Any interested person may appeal
(c) The Associate Administrator or a denial of the Associate Administrator
the Chief Counsel does not consider or the Chief Counsel, issued under
repetitious petitions. § 190.333 or § 190.337, to the Adminis-
(d) Unless the Associate Adminis- trator.
trator or the Chief Counsel otherwise
(b) An appeal must be received within
provides, the filing of a petition under
20 days of service of written notice to
this section does not stay the effective-
petitioner of the Associate Administra-
ness of the rule.
tor’s or the Chief Counsel’s decision, or
[Amdt. 190–8, 61 FR 50909, Sept. 27, 1996. Re- within 20 days from the date of publica-
designated and amended by Amdt. 190–16, 78 tion of the decision in the FEDERAL
FR 58914, Sept. 25, 2013]
REGISTER, and should set forth the con-
§ 190.337 Proceedings on petitions for tested aspects of the decision as well as
reconsideration. any new arguments or information.
(a) The Associate Administrator or (c) Unless the Administrator other-
the Chief Counsel may grant or deny, wise provides, the filing of an appeal
in whole or in part, any petition for re- under this section does not stay the ef-
fectiveness of any rule.
consideration without further pro-

ceedings, except where a grant of the [Amdt. 190–8, 61 FR 50909, Sept. 27, 1996. Re-
petition would result in issuance of a designated and amended by Amdt. 190–16, 78
new final rule. In the event that the FR 58914, Sept. 25, 2013]
405
§ 190.339 49 CFR Ch. I (10–1–18 Edition)
§ 190.339 Direct final rulemaking. direct final rule in whole or in part.

(a) Where practicable, the Adminis- The Administrator may then incor-
trator will use direct final rulemaking porate the adverse comment into a sub-
to issue the following types of rules: sequent direct final rule or may pub-
(1) Minor, substantive changes to reg- lish a notice of proposed rulemaking. A
ulations; notice of proposed rulemaking will pro-
(2) Incorporation by reference of the vide an opportunity for public com-
latest edition of technical or industry ment, generally a minimum of 60 days,
standards; and will be processed in accordance
(3) Extensions of compliance dates; with §§ 190.311–190.329.
and
§ 190.341 Special permits.
(4) Other noncontroversial rules
where the Administrator determines (a) What is a special permit? A special
that use of direct final rulemaking is permit is an order by which PHMSA
in the public interest, and that a regu- waives compliance with one or more of
lation is unlikely to result in adverse the Federal pipeline safety regulations
comment. under the standards set forth in 49
(b) The direct final rule will state an U.S.C. 60118(c) and subject to condi-
effective date. The direct final rule will tions set forth in the order. A special
also state that unless an adverse com- permit is issued to a pipeline operator
ment or notice of intent to file an ad- (or prospective operator) for specified
verse comment is received within the facilities that are or, absent waiver,
specified comment period, generally 60 would be subject to the regulation.
days after publication of the direct (b) How do I apply for a special permit?
final rule in the FEDERAL REGISTER, Applications for special permits must
the Administrator will issue a con- be submitted at least 120 days before
firmation document, generally within the requested effective date using any
15 days after the close of the comment of the following methods:
period, advising the public that the di- (1) Direct fax to PHMSA at: 202–366–
rect final rule will either become effec- 4566; or
tive on the date stated in the direct (2) Mail, express mail, or overnight
final rule or at least 30 days after the courier to the Associate Administrator
publication date of the confirmation for Pipeline Safety, Pipeline and Haz-
document, whichever is later. ardous Materials Safety Administra-
(c) For purposes of this section, an tion, 1200 New Jersey Avenue, SE., East
adverse comment is one which explains Building, Washington, DC 20590.
why the rule would be inappropriate, (c) What information must be contained
including a challenge to the rule’s unin the application? Applications must
derlying premise or approach, or would contain the following information:
be ineffective or unacceptable without (1) The name, mailing address, and
a change. Comments that are frivolous telephone number of the applicant and
or insubstantial will not be considered whether the applicant is an operator;
adverse under this procedure. A com- (2) A detailed description of the pipe-
ment recommending a rule change in line facilities for which the special per-
addition to the rule will not be consid- mit is sought, including:
ered an adverse comment, unless the (i) The beginning and ending points
commenter states why the rule would of the pipeline mileage to be covered
be ineffective without the additional and the Counties and States in which it
change. is located;
(d) Only parties who filed comments (ii) Whether the pipeline is interstate
to a direct final rule issued under this or intrastate and a general description
section may petition under § 190.335 for of the right-of-way including proximity
reconsideration of that direct final of the affected segments to populated
rule. areas and unusually sensitive areas;
(e) If an adverse comment or notice (iii) Relevant pipeline design and
of intent to file an adverse comment is construction information including the

received, a timely document will be year of installation, the material,
published in the FEDERAL REGISTER ad- grade, diameter, wall thickness, and
vising the public and withdrawing the coating type; and
406
(iv) Relevant operating information mental protection, or are otherwise in

including operating pressure, leak his- the public interest. If the Associate Ad-
tory, and most recent testing or assess- ministrator determines that the appli-
ment results; cation does not comply with the re-
(3) A list of the specific regulation(s) quirements of this section or that a
from which the applicant seeks relief; waiver is not justified, the application
(4) An explanation of the unique cir- will be denied. Whenever the Associate
cumstances that the applicant believes Administrator grants or denies an ap-
make the applicability of that regula- plication, notice of the decision will be
tion or standard (or portion thereof) provided to the applicant. PHMSA will
unnecessary or inappropriate for its fa- post all special permits on its Web site
cility; at http://www.phmsa.dot.gov/.
(5) A description of any measures or (e) How does PHMSA handle special
activities the applicant proposes to un- permit renewals? (1) The grantee of the
dertake as an alternative to compli- special permit must apply for a re-
ance with the relevant regulation, in- newal of the permit 180 days prior to
cluding an explanation of how such the permit expiration.
measures will mitigate any safety or (2) If, at least 180 days before an ex-
environmental risks; isting special permit expires the holder
(6) A description of any positive or files an application for renewal that is
negative impacts on affected stake- complete and conforms to the require-
holders and a statement indicating how ments of this section, the special per-
operating the pipeline pursuant to a mit will not expire until final adminis-
special permit would be in the public trative action on the application for re-
interest; newal has been taken:
(7) A certification that operation of (i) Direct fax to PHMSA at: 202–366–
the applicant’s pipeline under the re- 4566; or
quested special permit would not be in-
(ii) Express mail, or overnight cou-
consistent with pipeline safety;
rier to the Associate Administrator for
(8) Any other information PHMSA
Pipeline Safety, Pipeline and Haz-
may need to process the application in-
ardous Materials Safety Administra-
cluding environmental analysis where
tion, 1200 New Jersey Avenue SE.,
necessary.
Washington, DC 20590.
(d) How does PHMSA handle special
permit applications?—(1) Public notice. (f) What information must be included
Upon receipt of an application or rein the renewal application? (1) The re-
newal of a special permit, PHMSA will newal application must include a copy
of the original special permit, the
provide notice to the public of its in-
docket number on the special permit,
tent to consider the application and in-
and the following information as appli-
vite comment. In addition, PHMSA
cable:
may consult with other Federal agen-
cies before granting or denying an ap- (i) A summary report in accordance
plication or renewal on matters that with the requirements of the original
PHMSA believes may have significance special permit including verification
for proceedings under their areas of re- that the grantee’s operations and
sponsibility. maintenance plan (O&M Plan) is con-
(2) Grants, renewals, and denials. If the sistent with the conditions of the spe-
Associate Administrator determines cial permit;
that the application complies with the (ii) Name, mailing address and tele-
requirements of this section and that phone number of the special permit
the waiver of the relevant regulation grantee;
or standard is not inconsistent with (iii) Location of special permit—
pipeline safety, the Associate Adminis- areas on the pipeline where the special
trator may grant the application, in permit is applicable including: Diame-
whole or in part, for a period of time ter, mile posts, county, and state;
from the date granted. Conditions may (iv) Applicable usage of the special
be imposed on the grant if the Asso- permit—original and future; and
ciate Administrator concludes they are (v) Data for the special permit seg-
necessary to assure safety, environment and area identified in the special
407
§ 190.341 49 CFR Ch. I (10–1–18 Edition)
permit as needing additional inspec- (3) The existing special permit will
tions to include, as applicable: remain in effect until PHMSA acts on
(A) Pipe attributes: Pipe diameter, the application for renewal by granting
wall thickness, grade, seam type; and or denying the request.
pipe coating including girth weld coat- (g) Can a special permit be requested on
ing; an emergency basis? Yes. PHMSA may
(B) Operating Pressure: Maximum al- grant an application for an emergency
lowable operating pressure (MAOP); special permit without notice and com-
class location (including boundaries on ment or hearing if the Associate Ad-
aerial photography); ministrator determines that such ac-
(C) High Consequence Areas (HCAs): tion is in the public interest, is not in-
HCA boundaries on aerial photography; consistent with pipeline safety, and is
necessary to address an actual or im-
(D) Material Properties: Pipeline ma-
pending emergency involving pipeline
terial documentation for all pipe, fit-
transportation. For purposes of this
tings, flanges, and any other facilities
section, an emergency event may be
included in the special permit. Mate-
local, regional, or national in scope and
rial documentation must include: Yield
includes significant fuel supply disrup-
strength, tensile strength, chemical
tions and natural or manmade disas-
composition, wall thickness, and seam
ters such as hurricanes, floods, earth-
type;
quakes, terrorist acts, biological out-
(E) Test Pressure: Hydrostatic test breaks, releases of dangerous radio-
pressure and date including pressure logical, chemical, or biological mate-
and temperature charts and logs and rials, war-related activities, or other
any known test failures or leaks; similar events. PHMSA will determine
(F) In-line inspection (ILI): Summary on a case-by-case basis what duration
of ILI survey results from all ILI tools is necessary to address the emergency.
used on the special permit segments However, as required by statute, no
during the previous five years or latest emergency special permit may be
ILI survey result; issued for a period of more than 60
(G) Integrity Data and Integration: days. Each emergency special permit
The following information, as applica- will automatically expire on the date
ble, for the past five (5) years: Hydro- specified in the permit. Emergency spe-
static test pressure including any cial permits may be renewed upon ap-
known test failures or leaks; cas- plication to PHMSA only after notice
ings(any shorts); any in-service rup- and opportunity for a hearing on the
tures or leaks; close interval survey renewal.
(CIS) surveys; depth of cover surveys; (h) How do I apply for an emergency
rectifier readings; test point survey special permit? Applications for emer-
readings; alternating current/direct gency special permits may be sub-
current (AC/DC) interference surveys; mitted to PHMSA using any of the fol-
pipe coating surveys; pipe coating and lowing methods:
anomaly evaluations from pipe exca- (1) Direct fax to the Crisis Manage-
vations; stress corrosion cracking ment Center at: 202–366–3768;
(SCC), selective seam weld corrosion (2) Direct e-mail to PHMSA at:
(SSWC) and hard spot excavations and phmsa.pipeline-
findings; and pipe exposures from en- emergencyspecpermit@dot.gov; or
croachments; (3) Express mail/overnight courier to
(H) In-service: Any in-service rup- the Associate Administrator for Pipe-
tures or leaks including repair type line Safety, Pipeline and Hazardous
and failure investigation findings; and Materials Safety Administration, 1200
(I) Aerial Photography: Special per- New Jersey Avenue, SE., East Build-
mit segment and special permit inspec- ing, Washington, DC 20590.
tion area, if applicable. (i) What must be contained in an appli-
(2) PHMSA may request additional cation for an emergency special permit? In
operational, integrity or environ- addition to the information required

mental assessment information prior under paragraph (c) of this section, ap-
to granting any request for special per- plications for emergency special per-
mit renewal. mits must include:
408
(1) An explanation of the actual or the reasons for it, and provide an op-
impending emergency and how the ap- portunity to show cause why the pro-
plicant is affected; posed action should not be taken.
(2) A citation of the regulations that (i) The holder may file a written re-
are implicated and the specific reasons sponse that shows cause why the pro-
the permit is necessary to address the posed action should not be taken with-
emergency (e.g., lack of accessibility, in 30 days of receipt of notice of the
damaged equipment, insufficient man- proposed action.
power); (ii) After considering the holder’s
(3) A statement indicating how oper- written response, or after 30 days have
ating the pipeline pursuant to an emer- passed without response since receipt
gency special permit is in the public of the notice, PHMSA will notify the
interest (e.g., continuity of service, holder in writing of the final decision
service restoration); with a brief statement of reasons.
(4) A description of any proposed al- (3) If necessary to avoid a risk of sig-
ternatives to compliance with the reg- nificant harm to persons, property, or
ulation (e.g., additional inspections the environment, PHMSA may in the
and tests, shortened reassessment in- notification declare the proposed ac-
tervals); and tion immediately effective.
(5) A description of any measures to (4) Unless otherwise specified, the
be taken after the emergency situation terms and conditions of a corrective
or permit expires—whichever comes action order, compliance order, or
first—to confirm long-term operational other order applicable to a pipeline fa-
reliability of the pipeline facility. cility covered by a special permit will
NOTE TO PARAGRAPH (g): If PHMSA deter- take precedence over the terms of the
mines that handling of the application on an special permit.
emergency basis is not warranted, PHMSA (5) A special permit holder may seek
will notify the applicant and process the ap- reconsideration of a decision under
plication under normal special permit proce- paragraph (h) of this section as pro-
dures of this section. vided in paragraph (i) of this section.
(j) In what circumstances will PHMSA (k) Can a denial of a request for a spe-
revoke, suspend, or modify a special per- cial permit or a revocation of an existing
mit? (1) PHMSA may revoke, suspend, special permit be appealed? Reconsider-
or modify a special permit on a finding ation of the denial of an application for
that: a special permit or a revocation of an
(i) Intervening changes in Federal existing special permit may be sought
law mandate revocation, suspension, or by petition to the Associate Adminis-
modification of the special permit; trator. Petitions for reconsideration
(ii) Based on a material change in must be received by PHMSA within 20
conditions or circumstances, continued calendar days of the notice of the grant
adherence to the terms of the special or denial and must contain a brief
permit would be inconsistent with safe- statement of the issue and an expla-
ty; nation of why the petitioner believes
(iii) The application contained inac- that the decision being appealed is not
curate or incomplete information, and in the public interest. The Associate
the special permit would not have been Administrator may grant or deny, in
granted had the application been accu- whole or in part, any petition for re-
rate and complete; consideration without further pro-
(iv) The application contained delib- ceedings. The Associate Administra-
erately inaccurate or incomplete infor- tor’s decision is the final administra-
mation; or tive action.
(v) The holder has failed to comply (l) Are documents related to an applica-
with any material term or condition of tion for a special permit available for pub-
the special permit. lic inspection? Documents related to an
(2) Except as provided in paragraph application, including the application
(h)(3) of this section, before a special itself, are available for public inspec-
permit is modified, suspended or re- tion on regulations.gov or the Docket
voked, PHMSA will notify the holder Operations Facility to the extent such
in writing of the proposed action and documents do not include information
409
§ 190.343 49 CFR Ch. I (10–1–18 Edition)
exempt from public disclosure under 5 mation over your objections, we will
U.S.C. 552(b). Applicants may request notify you in writing at least five busi-
confidential treatment under part 7 of ness days before the intended disclo-
this title. sure date.
(m) Am I subject to enforcement action [Amdt. 190–19, 82 FR 7995, Jan. 23, 2017]
for non-compliance with the terms and
conditions of a special permit? Yes.
PHMSA inspects for compliance with Subpart E—Cost Recovery for
the terms and conditions of special per- Design Reviews
mits and if a probable violation is iden-
tified, PHMSA will initiate one or SOURCE: Amdt. 190–19, 82 FR 7996, Jan. 23,
more of the enforcement actions under 2017, unless otherwise noted.
subpart B of this part.
§ 190.401 Scope.
[73 FR 16568, Mar. 28, 2008, as amended at 74
FR 2893, Jan. 16, 2009; Amdt. 190–16, 78 FR
If PHMSA conducts a facility design
58914, Sept. 25, 2013; Amdt. 190–19, 82 FR 7995, and/or construction safety review or in-
Jan. 23, 2017] spection in connection with a proposal
to construct, expand, or operate a gas,
§ 190.343 Information made available hazardous liquid or carbon dioxide
to the public and request for pro- pipeline facility, or a liquefied natural
tection of confidential commercial gas facility that meets the applica-
information. bility requirements in § 190.403, PHMSA
When you submit information to may require the applicant proposing
PHMSA during a rulemaking pro- the project to pay the costs incurred by
ceeding, as part of your application for PHMSA relating to such review, in-
special permit or renewal, or for any cluding the cost of design and con-
other reason, we may make that infor- struction safety reviews or inspections.
mation publicly available unless you
ask that we keep the information con- § 190.403 Applicability.
fidential. The following paragraph specifies
(a) Asking for protection of confidential which projects will be subject to the
commercial information. You may ask us cost recovery requirements of this sec-
to give confidential treatment to infor- tion.
mation you give to the agency by tak- (a) This section applies to any
ing the following steps: project that—
(1) Mark ‘‘confidential’’ on each page (1) Has design and construction costs
of the original document you would totaling at least $2,500,000,000, as peri-
like to keep confidential. odically adjusted by PHMSA, to take
(2) Send us, along with the original into account increases in the Consumer
document, a second copy of the origi- Price Index for all urban consumers
nal document with the confidential published by the Department of Labor,
commercial information deleted. based on—
(3) Explain why the information you (i) The cost estimate provided to the
are submitting is confidential commer- Federal Energy Regulatory Commis-
cial information. sion in an application for a certificate
(b) PHMSA decision. PHMSA will of public convenience and necessity for
treat as confidential the information a gas pipeline facility or an application
that you submitted in accordance with for authorization for a liquefied nat-
this section, unless we notify you oth- ural gas pipeline facility; or
erwise. If PHMSA decides to disclose (ii) A good faith estimate developed
the information, PHMSA will review by the applicant proposing a hazardous
your request to protect confidential liquid or carbon dioxide pipeline facil-
commercial information under the cri- ity and submitted to the Associate Ad-
teria set forth in the Freedom of Infor- ministrator. The good faith estimate
mation Act (FOIA), 5 U.S.C. 552, includ- for design and construction costs must
ing following the consultation proce- include all of the applicable cost items
dures set out in the Departmental contained in the Federal Energy Regu-
FOIA regulations, 49 CFR 7.29. If latory Commission application ref-
PHMSA decides to disclose the infor- erenced in § 190.403(a)(1)(i) for a gas or
410
LNG facility. In addition, an applicant associated with the facility design

must take into account all survey, de- safety review.
sign, material, permitting, right-of (a) A Master Agreement, at a min-
way acquisition, construction, testing, imum, includes:
commissioning, start-up, construction (1) Itemized list of direct costs to be
financing, environmental protection, recovered by PHMSA;
inspection, material transportation, (2) Scope of work for conducting the
sales tax, project contingency, and all facility design safety review and an es-
other applicable costs, including all timated total cost;
segments, facilities, and multi-year
(3) Description of the method of peri-
phases of the project;
odic billing, payment, and auditing of
(2) Uses new or novel technologies or cost recovery fees;
design, as defined in § 190.3.
(4) Minimum account balance which
(b) The Associate Administrator may the applicant must maintain with
not collect design safety review fees
PHMSA at all times;
under this section and 49 U.S.C. 60301
(5) Provisions for reconciling dif-
for the same design safety review.
ferences between total amount billed
(c) The Associate Administrator,
and the final cost of the design review,
after receipt of the design specifica-
including provisions for returning any
tions, construction plans and proce-
dures, and related materials, deter- excess payments to the applicant at
mines if cost recovery is necessary. the conclusion of the project;
The Associate Administrator’s deter- (6) A principal point of contact for
mination is based on the amount of both PHMSA and the applicant; and
PHMSA resources needed to ensure (7) Provisions for terminating the
safety and environmental protection. agreement.
(8) A project reimbursement cost
§ 190.405 Notification. schedule based upon the project timing
For any new pipeline facility con- and scope.
struction project in which PHMSA will (b) [Reserved]
conduct a design review, the applicant
proposing the project must notify § 190.409 Fee structure.
PHMSA and provide the design speci- The fee charged is based on the direct
fications, construction plans and proce- costs that PHMSA incurs in con-
dures, project schedule and related ma- ducting the facility design safety re-
terials at least 120 days prior to the view (including construction review
commencement of any of the following and inspections), and will be based only
activities: Route surveys for construc- on costs necessary for conducting the
tion, material manufacturing, offsite facility design safety review. ‘‘Nec-
facility fabrications, construction essary for’’ means that but for the fa-
equipment move-in activities, onsite or cility design safety review, the costs
offsite fabrications, personnel support would not have been incurred and that
facility construction, and any offsite or the costs cover only those activities
onsite facility construction. To the
and items without which the facility
maximum extent practicable, but not
design safety review cannot be com-
later than 90 days after receiving such
pleted.
design specifications, construction
plans and procedures, and related ma- (a) Costs qualifying for cost recovery
terials, PHMSA will provide written include, but are not limited to—
comments, feedback, and guidance on (1) Personnel costs based upon total
the project. cost to PHMSA;
(2) Travel, lodging and subsistence;
§ 190.407 Master Agreement. (3) Vehicle mileage;
PHMSA and the applicant will enter (4) Other direct services, materials
and supplies;
into an agreement within 60 days after

PHMSA received notification from the (5) Other direct costs as may be spec-
applicant provided in § 190.405, out- ified in the Master Agreement.
lining PHMSA’s recovery of the costs (b) [Reserved]
411
§ 190.411 49 CFR Ch. I (10–1–18 Edition)
§ 190.411 Procedures for billing and 191.15 Transmission systems; gathering sys-
payment of fee. tems; liquefied natural gas facilities; and
underground natural gas storage facili-
All PHMSA cost calculations for bill- ties: Incident report.
ing purposes are determined from the 191.17 Transmission systems; gathering sys-
best available PHMSA records. tems; liquefied natural gas facilities; and
(a) PHMSA bills an applicant for cost underground natural gas storage facili-
recovery fees as specified in the Master ties: Annual report.
Agreement, but the applicant will not 191.21 OMB control number assigned to in-
be billed more frequently than quar- formation collection.
191.22 National Registry of Pipeline and
terly.
LNG operators.
(1) PHMSA will itemize cost recovery 191.23 Reporting safety-related conditions.
bills in sufficient detail to allow inde- 191.25 Filing safety-related condition re-
pendent verification of calculations. ports.
(2) [Reserved] 191.29 National Pipeline Mapping System.
(b) PHMSA will monitor the appli-
AUTHORITY: 49 U.S.C. 5121, 60102, 60103,
cant’s account balance. Should the ac- 60104, 60108, 60117, 60118, 60124, 60132, and 60141;
count balance fall below the required and 49 CFR 1.97.
minimum balance specified in the Mas-
ter Agreement, PHMSA may request at § 191.1 Scope.
any time the applicant submit pay- (a) This part prescribes requirements
ment within 30 days to maintain the for the reporting of incidents, safety-
minimum balance. related conditions, annual pipeline
(c) PHMSA will provide an updated summary data, National Operator Reg-
estimate of costs to the applicant on or istry information, and other miscella-
near October 1st of each calendar year. neous conditions by operators of under-
(d) Payment of cost recovery fees is ground natural gas storage facilities
due within 30 days of issuance of a bill and natural gas pipeline facilities lo-
for the fees. If payment is not made cated in the United States or Puerto
within 30 days, PHMSA may charge an Rico, including underground natural
annual rate of interest (as set by the gas storage facilities and pipelines
Department of Treasury’s Statutory within the limits of the Outer Conti-
Debt Collection Authorities) on any nental Shelf as that term is defined in
outstanding debt, as specified in the the Outer Continental Shelf Lands Act
Master Agreement. (43 U.S.C. 1331).
(e) Payment of the cost recovery fee (b) This part does not apply to—
by the applicant does not obligate or
(1) Offshore gathering of gas in State
prevent PHMSA from taking any par-
waters upstream from the outlet flange
ticular action during safety inspections
of each facility where hydrocarbons are
on the project.
produced or where produced hydro-
carbons are first separated, dehy-
PART 191—TRANSPORTATION OF drated, or otherwise processed, which-
NATURAL AND OTHER GAS BY ever facility is farther downstream;
PIPELINE; ANNUAL REPORTS, IN- (2) Pipelines on the Outer Conti-
CIDENT REPORTS, AND SAFETY- nental Shelf (OCS) that are producer-
RELATED CONDITION REPORTS operated and cross into State waters
without first connecting to a trans-
Sec. porting operator’s facility on the OCS,
191.1 Scope. upstream (generally seaward) of the
191.3 Definitions. last valve on the last production facil-
191.5 Immediate notice of certain incidents. ity on the OCS. Safety equipment pro-
191.7 Report submission requirements. tecting PHMSA-regulated pipeline seg-
191.9 Distribution system: Incident report. ments is not excluded. Producing oper-
191.11 Distribution system: Annual report. ators for those pipeline segments up-
191.12 Distribution Systems: Mechanical
Fitting Failure reports
stream of the last valve of the last pro-
191.13 Distribution systems reporting trans- duction facility on the OCS may peti-
mission pipelines; transmission or gath- tion the Administrator, or designee, for
ering systems reporting distribution approval to operate under PHMSA reg-
pipelines. ulations governing pipeline design,
412
construction, operation, and mainte- an underground natural gas storage fa-

nance under 49 CFR 190.9. cility. Activation of an emergency
(3) Pipelines on the Outer Conti- shutdown system for reasons other
nental Shelf upstream of the point at than an actual emergency does not
which operating responsibility trans- constitute an incident.
fers from a producing operator to a (3) An event that is significant in the
transporting operator; or judgment of the operator, even though
(4) Onshore gathering of gas— it did not meet the criteria of para-
(i) Through a pipeline that operates graph (1) or (2) of this definition.
at less than 0 psig (0 kPa); LNG facility means a liquefied natural
(ii) Through a pipeline that is not a gas facility as defined in § 193.2007 of
regulated onshore gathering line (as part 193 of this chapter;
determined in § 192.8 of this sub-
Master Meter System means a pipeline
chapter); and
system for distributing gas within, but
(iii) Within inlets of the Gulf of Mex-
ico, except for the requirements in not limited to, a definable area, such as
§ 192.612. a mobile home park, housing project,
or apartment complex, where the oper-
[Amdt. 191–5, 49 FR 18960, May 3, 1984, as ator purchases metered gas from an
amended by Amdt. 191–6, 53 FR 24949, July 1, outside source for resale through a gas
1988; Amdt. 191–11, 61 FR 27793, June 3, 1996;
Amdt. 191–12, 62 FR 61695, Nov. 19, 1997;
distribution pipeline system. The gas
Amdt. 191–15, 68 FR 46111, Aug. 5, 2003; 70 FR distribution pipeline system supplies
11139, Mar. 8, 2005; 75 FR 72904, Nov. 26, 2010; the ultimate consumer who either pur-
Amdt. 191–24, 81 FR 91871, Dec. 19, 2016] chases the gas directly through a
meter or by other means, such as by
§ 191.3 Definitions. rents;
As used in this part and the PHMSA Municipality means a city, county, or
Forms referenced in this part— any other political subdivision of a
Administrator means the Adminis- State;
trator, Pipeline and Hazardous Mate- Offshore means beyond the line of or-
rials Safety Administration or his or dinary low water along that portion of
her delegate the coast of the United States that is
Confirmed Discovery means when it in direct contact with the open seas
can be reasonably determined, based on and beyond the line marking the sea-
information available to the operator ward limit of inland waters;
at the time a reportable event has oc- Operator means a person who engages
curred, even if only based on a prelimi- in the transportation of gas;
nary evaluation. Outer Continental Shelf means all sub-
Gas means natural gas, flammable
merged lands lying seaward and out-
gas, or gas which is toxic or corrosive;
side the area of lands beneath navi-
Incident means any of the following
gable waters as defined in Section 2 of
events:
the Submerged Lands Act (43 U.S.C.
(1) An event that involves a release of
1301) and of which the subsoil and sea-
gas from a pipeline, gas from an under-
bed appertain to the United States and
ground natural gas storage facility, liq-
uefied natural gas, liquefied petroleum are subject to its jurisdiction and con-
gas, refrigerant gas, or gas from an trol.
LNG facility, and that results in one or Person means any individual, firm,
more of the following consequences: joint venture, partnership, corporation,
(i) A death, or personal injury neces- association, State, municipality, coop-
sitating in-patient hospitalization; erative association, or joint stock asso-
(ii) Estimated property damage of ciation, and includes any trustee, re-
$50,000 or more, including loss to the ceiver, assignee, or personal represent-
operator and others, or both, but ex- ative thereof;
cluding cost of gas lost; or Pipeline or Pipeline System means all
(iii) Unintentional estimated gas loss parts of those physical facilities

of three million cubic feet or more. through which gas moves in transpor-
(2) An event that results in an emer- tation, including, but not limited to,
gency shutdown of an LNG facility or pipe, valves, and other appurtenance
413
§ 191.5 49 CFR Ch. I (10–1–18 Edition)
attached to pipe, compressor units, me- all other significant facts that are
tering stations, regulator stations, de- known by the operator that are rel-
livery stations, holders, and fabricated evant to the cause of the incident or
assemblies. extent of the damages. If there are no
State includes each of the several changes or revisions to the initial re-
States, the District of Columbia, and port, the operator must confirm the es-
the Commonwealth of Puerto Rico; timates in its initial report.
Transportation of gas means the gath-
ering, transmission, or distribution of [Amdt. 191–4, 47 FR 32720, July 29, 1982, as
gas by pipeline, or the storage of gas in amended by Amdt. 191–5, 49 FR 18960, May 3,
1984; Amdt. 191–8, 54 FR 40878, Oct. 4, 1989; 75
or affecting interstate or foreign com- FR 72905, Nov. 26, 2010; Amdt. 191–25, 82 FR
merce. 7997, Jan. 23, 2017]
Underground natural gas storage facil-
ity means an underground natural gas § 191.7 Report submission require-
storage facility as defined in § 192.3 of ments.
this chapter.
(a) General. Except as provided in
[35 FR 320, Jan. 8, 1970, as amended by Amdt. paragraphs (b) and (e) of this section,
191–5, 49 FR 18960, May 3, 1984; Amdt. 191–10, an operator must submit each report
61 FR 18516, Apr. 26, 1996; Amdt. 191–12, 62 FR
61695, Nov. 19, 1997; 68 FR 11749, Mar. 12, 2003;
required by this part electronically to
70 FR 11139, Mar. 8, 2005; 75 FR 72905, Nov. 26, the Pipeline and Hazardous Materials
2010; Amdt. 191–24, 81 FR 91871, Dec. 19, 2016; Safety Administration at http://por-
Amdt. 191–25, 82 FR 7997, Jan. 23, 2017] tal.phmsa.dot.gov/pipeline unless an al-
ternative reporting method is author-
§ 191.5 Immediate notice of certain in- ized in accordance with paragraph (d)
cidents. of this section.
(a) At the earliest practicable mo- (b) Exceptions: An operator is not re-
ment following discovery, but no later quired to submit a safety-related con-
than one hour after confirmed dis- dition report (§ 191.25) electronically.
covery, each operator must give notice (c) Safety-related conditions. An oper-
in accordance with paragraph (b) of ator must submit concurrently to the
this section of each incident as defined applicable State agency a safety-re-
in § 191.3. lated condition report required by
(b) Each notice required by para- § 191.23 for intrastate pipeline transpor-
graph (a) of this section must be made tation or when the State agency acts
to the National Response Center either as an agent of the Secretary with re-
by telephone to 800–424–8802 (in Wash-
spect to interstate transmission facili-
ington, DC, 202 267–2675) or electroni-
ties.
cally at http://www.nrc.uscg.mil and
must include the following informa- (d) Alternative Reporting Method. If
tion: electronic reporting imposes an undue
(1) Names of operator and person burden and hardship, an operator may
making report and their telephone submit a written request for an alter-
numbers. native reporting method to the Infor-
(2) The location of the incident. mation Resources Manager, Office of
(3) The time of the incident. Pipeline Safety, Pipeline and Haz-
(4) The number of fatalities and per- ardous Materials Safety Administra-
sonal injuries, if any. tion, PHP–20, 1200 New Jersey Avenue,
(5) All other significant facts that are SE, Washington DC 20590. The request
known by the operator that are rel- must describe the undue burden and
evant to the cause of the incident or hardship. PHMSA will review the re-
extent of the damages. quest and may authorize, in writing, an
(c) Within 48 hours after the con- alternative reporting method. An au-
firmed discovery of an incident, to the thorization will state the period for
extent practicable, an operator must which it is valid, which may be indefi-
revise or confirm its initial telephonic nite. An operator must contact
notice required in paragraph (b) of this PHMSA at 202–366–8075, or electroni-

section with an estimate of the amount cally to
of product released, an estimate of the informationresourcesmanager@dot.gov or
number of fatalities and injuries, and make arrangements for submitting a
414
report that is due after a request for al- § 191.12 Distribution Systems: Mechan-
ternative reporting is submitted but ical Fitting Failure Reports
before an authorization or denial is re- Each mechanical fitting failure, as
ceived. required by § 192.1009, must be sub-
(e) National Pipeline Mapping System mitted on a Mechanical Fitting Failure
(NPMS). An operator must provide the Report Form PHMSA F–7100.1–2. An op-
NPMS data to the address identified in erator must submit a mechanical fit-
the NPMS Operator Standards manual ting failure report for each mechanical
available at www.npms.phmsa.dot.gov or fitting failure that occurs within a cal-
by contacting the PHMSA Geographic endar year not later than March 15 of
Information Systems Manager at (202) the following year (for example, all me-
366–4595. chanical failure reports for calendar
year 2011 must be submitted no later
[75 FR 72905, Nov. 26, 2010, as amended at by than March 15, 2012). Alternatively, an
Amdt. 191–23, 80 FR 12777, Mar. 11, 2015] operator may elect to submit its re-
ports throughout the year. In addition,
§ 191.9 Distribution system: Incident an operator must also report this infor-
report. mation to the State pipeline safety au-
(a) Except as provided in paragraph thority if a State has obtained regu-
(c) of this section, each operator of a latory authority over the operator’s
distribution pipeline system shall sub- pipeline.
mit Department of Transportation [76 FR 5499, Feb. 1, 2011]
Form RSPA F 7100.1 as soon as prac-
ticable but not more than 30 days after § 191.13 Distribution systems reporting
detection of an incident required to be transmission pipelines; trans-
mission or gathering systems re-
reported under § 191.5. porting distribution pipelines.
(b) When additional relevant infor-
Each operator, primarily engaged in
mation is obtained after the report is
gas distribution, who also operates gas
submitted under paragraph (a) of this
transmission or gathering pipelines
section, the operator shall make sup- shall submit separate reports for these
plementary reports as deemed nec- pipelines as required by §§ 191.15 and
essary with a clear reference by date 191.17. Each operator, primarily en-
and subject to the original report. gaged in gas transmission or gathering,
(c) Master meter operators are not who also operates gas distribution
required to submit an incident report pipelines shall submit separate reports
as required by this section. for these pipelines as required by
§§ 191.9 and 191.11.
[Amdt. 191–5, 49 FR 18960, May 3, 1984, as
amended at 75 FR 72905, Nov. 26, 2010] [Amdt. 191–5, 49 FR 18961, May 3, 1984]
§ 191.11 Distribution system: Annual § 191.15 Transmission systems; gath-

report. ering systems; liquefied natural gas
facilities; and underground natural
(a) General. Except as provided in gas storage facilities: Incident re-
paragraph (b) of this section, each op- port.
erator of a distribution pipeline system (a) Transmission or Gathering. Each
must submit an annual report for that operator of a transmission or a gath-
system on DOT Form PHMSA F 7100.1– ering pipeline system must submit
1. This report must be submitted each DOT Form PHMSA F 7100.2 as soon as
year, not later than March 15, for the practicable but not more than 30 days
preceding calendar year. after detection of an incident required
(b) Not required. The annual report re- to be reported under § 191.5 of this part.
quirement in this section does not (b) LNG. Each operator of a liquefied
apply to a master meter system or to a natural gas plant or facility must sub-
petroleum gas system that serves fewer mit DOT Form PHMSA F 7100.3 as soon
than 100 customers from a single as practicable but not more than 30
source. days after detection of an incident re-
quired to be reported under § 191.5 of
[75 FR 72905, Nov. 26, 2010] this part.
415
§ 191.17 49 CFR Ch. I (10–1–18 Edition)
(c) Underground natural gas storage fa- (b) LNG. Each operator of a liquefied
cility. Each operator of an underground natural gas facility must submit an an-
natural gas storage facility must sub- nual report for that system on DOT
mit DOT Form PHMSA F7100.2 as soon Form PHMSA 7100.3–1 This report must
as practicable but not more than 30 be submitted each year, not later than
days after detection of an incident re- March 15, for the preceding calendar
quired to be reported under § 191.5. year, except that for the 2010 reporting
(d) Supplemental report. Where addi- year the report must be submitted by
tional related information is obtained
June 15, 2011.
after a report is submitted under para-
graph (a), (b) or (c) of this section, the (c) Underground natural gas storage fa-
operator must make a supplemental re- cility. Each operator of an underground
port as soon as practicable with a clear natural gas storage facility must sub-
reference by date to the original re- mit an annual report on DOT PHMSA
port. Form 7100.4–1 by March 15, for the pre-
ceding calendar year except that the
[75 FR 72905, Nov. 26, 2010; as amended by first report must be submitted by July
Amdt. 191–24, 81 FR 91871, Dec. 19, 2016]
18, 2017.
§ 191.17 Transmission systems; gath- [75 FR 72905, Nov. 26, 2010, as amended by
ering systems; liquefied natural gas Amdt. 191–24, 81 FR 91871, Dec. 19, 2016]
facilities; and underground natural
gas storage facilities: Annual re-
port. § 191.21 OMB control number assigned
to information collection.
(a) Transmission or Gathering. Each
operator of a transmission or a gath- This section displays the control
ering pipeline system must submit an number assigned by the Office of Man-
annual report for that system on DOT agement and Budget (OMB) to the in-
Form PHMSA 7100.2.1. This report formation collection requirements in
must be submitted each year, not later this part. The Paperwork Reduction
than March 15, for the preceding cal- Act requires agencies to display a cur-
endar year, except that for the 2010 re- rent control number assigned by the
porting year the report must be sub- Director of OMB for each agency infor-
mitted by June 15, 2011. mation collection requirement.
OMB CONTROL NUMBER 2137–0522
Section of 49 CFR part 191 where identi- Form No.
fied
191.5 ........................................................... Telephonic.

191.9 ........................................................... PHMSA 7100.1, PHMSA 7100.3.
191.11 ......................................................... PHMSA 7100.1–1, PHMSA 7100.3–1.
191.12 ......................................................... PHMSA 7100.1–2.
191.15 ......................................................... PHMSA 7100.2, PHMSA 7100.3.
191.17 ......................................................... PHMSA 7100.2–1, PHMSA 7100.3–1.PHMSA 7100.4–1.
191.22 ......................................................... PHMSA 1000.1, PHMSA 1000.2.
[75 FR 72905, Nov. 26, 2010, as amended by mary responsibility. To obtain an

Amdt. 191–24, 81 FR 91871, Dec. 19, 2016] OPID, an operator must complete an
OPID Assignment Request DOT Form
§ 191.22 National Registry of Pipeline PHMSA F 1000.1 through the National
and LNG operators. Registry of Pipeline, Underground Nat-
(a) OPID request. Effective January 1, ural Gas Storage Facility, and LNG
2012, each operator of a gas pipeline, Operators in accordance with § 191.7.
gas pipeline facility, underground nat- (b) OPID validation. An operator who
ural gas storage facility, LNG plant or has already been assigned one or more
LNG facility must obtain from PHMSA OPID by January 1, 2011, must validate
an Operator Identification Number the information associated with each

(OPID). An OPID is assigned to an op- OPID through the National Registry of
erator for the pipeline or pipeline sys- Pipeline, Underground Natural Gas
tem for which the operator has pri- Storage Facility, and LNG Operators
416
at http://opsweb.phmsa.dot.gov, and cor- an existing pipeline, pipeline segment,

rect that information as necessary, no pipeline facility, underground natural
later than June 30, 2012. gas storage facility, or LNG facility;
(c) Changes. Each operator of a gas (iv) The acquisition or divestiture of
pipeline, gas pipeline facility, under- 50 or more miles of a pipeline or pipe-
ground natural gas storage facility, line system subject to Part 192 of this
LNG plant, or LNG facility must notify subchapter;
PHMSA electronically through the Na- (v) The acquisition or divestiture of
tional Registry of Pipeline, Under- an existing LNG plant or LNG facility
ground Natural Gas Storage Facility, subject to Part 193 of this subchapter;
and LNG Operators at http:// or
opsweb.phmsa.dot.gov of certain events. (vi) The acquisition or divestiture of
(1) An operator must notify PHMSA an existing underground natural gas
of any of the following events not later storage facility subject to part 192 of
than 60 days before the event occurs: this subchapter.
(i) Construction or any planned reha- (d) Reporting. An operator must use
bilitation, replacement, modification, the OPID issued by PHMSA for all re-
upgrade, uprate, or update of a facility, porting requirements covered under
other than a section of line pipe, that this subchapter and for submissions to
costs $10 million or more. If 60 day no- the National Pipeline Mapping System.
tice is not feasible because of an emer-
gency, an operator must notify PHMSA [Amdt. 191–21, 75 FR 72906, Nov. 26, 2010, as
as soon as practicable; amended by Amdt. 191–24, 81 FR 91871, Dec.
(ii) Construction of 10 or more miles 19, 2016; Amdt. 191–25, 82 FR 7997, Jan. 23,
2017]
of a new or replacement pipeline;
(iii) Construction of a new LNG plant § 191.23 Reporting safety-related con-
or LNG facility; or ditions.
(iv) Construction of a new under-
ground natural gas storage facility or (a) Except as provided in paragraph
the abandonment, drilling or well (b) of this section, each operator shall
workover (including replacement of report in accordance with § 191.25 the
wellhead, tubing, or a new casing) of an existence of any of the following safe-
injection, withdrawal, monitoring, or ty-related conditions involving facili-
observation well for an underground ties in service:
natural gas storage facility. (1) In the case of a pipeline (other
(v) Reversal of product flow direction than an LNG facility) that operates at
when the reversal is expected to last a hoop stress of 20 percent or more of
more than 30 days. This notification is its specified minimum yield strength,
not required for pipeline systems al- general corrosion that has reduced the
ready designed for bi-directional flow; wall thickness to less than that re-
or quired for the maximum allowable op-
(vi) A pipeline converted for service erating pressure, and localized corro-
under § 192.14 of this chapter, or a sion pitting to a degree where leakage
change in commodity as reported on might result.
the annual report as required by (2) In the case of an underground nat-
§ 191.17. ural gas storage facility, including in-
(2) An operator must notify PHMSA jection, withdrawal, monitoring, or ob-
of any of the following events not later servation well, general corrosion that
than 60 days after the event occurs: has reduced the wall thickness to less
(i) A change in the primary entity re- than that required for the maximum
sponsible (i.e., with an assigned OPID) well operating pressure, and localized
for managing or administering a safety corrosion pitting to a degree where
program required by this part covering leakage might result.
pipeline facilities operated under mul- (3) Unintended movement or abnor-
tiple OPIDs. mal loading by environmental causes,
(ii) A change in the name of the oper- such as an earthquake, landslide, or

ator; flood, that impairs the serviceability of
(iii) A change in the entity (e.g., a pipeline or the structural integrity or
company, municipality) responsible for reliability of an underground natural
417
§ 191.25 49 CFR Ch. I (10–1–18 Edition)
gas storage facility, including injec- (1) Exists on a master meter system
tion, withdrawal, monitoring, or obser- or a customer-owned service line;
vation well for an underground natural (2) Is an incident or results in an in-
gas storage facility, or LNG facility cident before the deadline for filing the
that contains, controls, or processes safety-related condition report;
gas or LNG. (3) Exists on a pipeline (other than an
(4) Any crack or other material de- LNG facility or Underground Natural
fect that impairs the structural integ- Gas Storage facility) that is more than
rity or reliability of an underground 220 yards (200 meters) from any build-
natural gas storage facility or LNG fa- ing intended for human occupancy or
cility that contains, controls, or proc- outdoor place of assembly, except that
esses gas or LNG. reports are required for conditions
(5) Any material defect or physical within the right-of-way of an active
damage that impairs the serviceability railroad, paved road, street, or high-
of a pipeline that operates at a hoop way; or
stress of 20% or more of its specified (4) Is corrected by repair or replace-
minimum yield strength or under- ment in accordance with applicable
ground natural gas storage facility, in- safety standards before the deadline for
cluding injection, withdrawal, moni- filing the safety-related condition re-
toring, or observations well for an un- port, except that reports are required
derground natural gas storage facility. for conditions under paragraph (a)(1) of
this section other than localized corro-
(6) Any malfunction or operating
sion pitting on an effectively coated
error that causes the pressure of a
and cathodically protected pipeline.
pipeline or underground natural gas
storage facility or LNG facility that [Amdt. 191–6, 53 FR 24949, July 1, 1988, as
contains or processes gas or LNG to amended by Amdt. 191–14, 63 FR 37501, July
rise above its maximum well operating 13, 1998; Amdt. 191–24, 81 FR 91872, Dec. 19,
2016]
pressure (or working pressure for LNG
facilities) plus the margin (build-up) § 191.25 Filing safety-related condition
allowed for operation of pressure lim- reports.
iting or control devices.
(a) Each report of a safety-related
(7) A leak in a pipeline or an under- condition under § 191.23(a) must be filed
ground natural gas storage facility, in- (received by OPS within five working
cluding injection, withdrawal, moni- days, not including Saturday, Sunday,
toring, or observation well for an un- or Federal Holidays) after the day a
derground natural gas storage facility, representative of the operator first de-
or LNG facility that contains or proc- termines that the condition exists, but
esses gas or LNG that constitutes an not later than 10 working days after
emergency. the day a representative of the oper-
(8) Inner tank leakage, ineffective in- ator discovers the condition. Separate
sulation, or frost heave that impairs conditions may be described in a single
the structural integrity of an LNG report if they are closely related. Re-
storage tank. ports may be transmitted by electronic
(9) Any safety-related condition that mail to
could lead to an imminent hazard and InformationResourcesManager@dot.gov
causes (either directly or indirectly by or by facsimile at (202) 366–7128.
remedial action of the operator), for (b) The report must be headed ‘‘Safe-
purposes other than abandonment, a ty-Related Condition Report’’ and pro-
20% or more reduction in operating vide the following information:
pressure or shutdown of operation of a (1) Name and principal address of op-
pipeline or an underground natural gas erator.
storage facility, including injection, (2) Date of report.
withdrawal, monitoring, or observation (3) Name, job title, and business tele-
well for an underground natural gas phone number of person submitting the
storage facility, or an LNG facility report.

that contains or processes gas or LNG. (4) Name, job title, and business tele-
(b) A report is not required for any phone number of person who deter-
safety-related condition that— mined that the condition exists.
418
(5) Date condition was discovered and have occurred since the previous year’s
date condition was first determined to submission, the operator must comply
exist. with the guidance provided in the
(6) Location of condition, with ref- NPMS Operator Standards manual
erence to the State (and town, city, or available at www.npms.phmsa.dot.gov or
county) or offshore site, and as appro- contact the PHMSA Geographic Infor-
priate, nearest street address, offshore mation Systems Manager at (202) 366–
platform, survey station number, mile- 4595.
post, landmark, or name of pipeline. [Amdt. 191–23, 80 FR 12777, Mar. 11, 2015]
(7) Description of the condition, in-
cluding circumstances leading to its
discovery, any significant effects of the PART 192—TRANSPORTATION OF
condition on safety, and the name of NATURAL AND OTHER GAS BY
the commodity transported or stored. PIPELINE: MINIMUM FEDERAL
(8) The corrective action taken (in- SAFETY STANDARDS
cluding reduction of pressure or shut-
down) before the report is submitted Subpart A—General
and the planned follow-up or future
Sec.
corrective action, including the antici- 192.1 What is the scope of this part?
pated schedule for starting and con- 192.3 Definitions.
cluding such action. 192.5 Class locations.
[Amdt. 191–6, 53 FR 24949, July 1, 1988; 53 FR 192.7 What documents are incorporated by
29800, Aug. 8, 1988, as amended by Amdt. 191– reference partly or wholly in this part?
7, 54 FR 32344, Aug. 7, 1989; Amdt. 191–8, 54 FR 192.8 How are onshore gathering lines and
40878, Oct. 4, 1989; Amdt. 191–10, 61 FR 18516, regulated onshore gathering lines deter-
Apr. 26, 1996; Amdt. 191–23, 80 FR 12777, Mar. mined?
11, 2015] 192.9 What requirements apply to gathering
lines?
§ 191.29 National Pipeline Mapping 192.10 Outer continental shelf pipelines.
System. 192.11 Petroleum gas systems.
192.12 Underground natural gas storage fa-
(a) Each operator of a gas trans- cilities.
mission pipeline or liquefied natural 192.13 What general requirements apply to
gas facility must provide the following pipelines regulated under this part?
geospatial data to PHMSA for that 192.14 Conversion to service subject to this
part.
pipeline or facility:
192.15 Rules of regulatory construction.
(1) Geospatial data, attributes, 192.16 Customer notification.
metadata and transmittal letter appro-
priate for use in the National Pipeline Subpart B—Materials
Mapping System. Acceptable formats
and additional information are speci- 192.51 Scope.
192.53 General.
fied in the NPMS Operator Standards
192.55 Steel pipe.
Manual available at 192.57 [Reserved]
www.npms.phmsa.dot.gov or by con- 192.59 Plastic pipe.
tacting the PHMSA Geographic Infor- 192.61 [Reserved]
mation Systems Manager at (202) 366– 192.63 Marking of materials.
4595. 192.65 Transportation of pipe.
(2) The name of and address for the
operator. Subpart C—Pipe Design
(3) The name and contact informa- 192.101 Scope.
tion of a pipeline company employee, 192.103 General.
to be displayed on a public Web site, 192.105 Design formula for steel pipe.
who will serve as a contact for ques- 192.107 Yield strength (S) for steel pipe.
tions from the general public about the 192.109 Nominal wall thickness (t) for steel
operator’s NPMS data. pipe.
192.111 Design factor (F) for steel pipe.
(b) The information required in para-
192.112 Additional design requirements for
graph (a) of this section must be sub- steel pipe using alternative maximum al-
mitted each year, on or before March lowable operating pressure.
15, representing assets as of December 192.113 Longitudinal joint factor (E) for
31 of the previous year. If no changes steel pipe.
419
192.115 Temperature derating factor (T) for 192.229 Limitations on welders.
steel pipe. 192.231 Protection from weather.
192.117–192.119 [Reserved] 192.233 Miter joints.
192.121 Design of plastic pipe. 192.235 Preparation for welding.
192.123 Design limitations for plastic pipe. 192.241 Inspection and test of welds.
192.125 Design of copper pipe. 192.243 Nondestructive testing.
192.245 Repair or removal of defects.
Subpart D—Design of Pipeline Components
Subpart F—Joining of Materials Other Than
192.141 Scope. by Welding
192.143 General requirements.
192.144 Qualifying metallic components. 192.271 Scope.
192.145 Valves. 192.273 General.
192.147 Flanges and flange accessories. 192.275 Cast iron pipe.
192.149 Standard fittings. 192.277 Ductile iron pipe.
192.150 Passage of internal inspection de- 192.279 Copper pipe.
vices. 192.281 Plastic pipe.
192.151 Tapping. 192.283 Plastic pipe: Qualifying joining pro-
192.153 Components fabricated by welding. cedures.
192.155 Welded branch connections. 192.285 Plastic pipe: Qualifying persons to
192.157 Extruded outlets. make joints.
192.159 Flexibility. 192.287 Plastic pipe: Inspection of joints.
192.161 Supports and anchors.
192.163 Compressor stations: Design and Subpart G—General Construction Require-
construction. ments for Transmission Lines and Mains
192.165 Compressor stations: Liquid re-
moval. 192.301 Scope.
192.167 Compressor stations: Emergency 192.303 Compliance with specifications or
shutdown. standards.
192.169 Compressor stations: Pressure lim- 192.305 Inspection: General.
iting devices. 192.307 Inspection of materials.
192.171 Compressor stations: Additional 192.309 Repair of steel pipe.
safety equipment. 192.311 Repair of plastic pipe.
192.173 Compressor stations: Ventilation. 192.313 Bends and elbows.
192.175 Pipe-type and bottle-type holders. 192.315 Wrinkle bends in steel pipe.
192.177 Additional provisions for bottle-type 192.317 Protection from hazards.
holders. 192.319 Installation of pipe in a ditch.
192.179 Transmission line valves. 192.321 Installation of plastic pipe.
192.181 Distribution line valves. 192.323 Casing.
192.183 Vaults: Structural design require- 192.325 Underground clearance.
ments. 192.327 Cover.
192.185 Vaults: Accessibility. 192.328 Additional construction require-
192.187 Vaults: Sealing, venting, and ven- ments for steel pipe using alternative
tilation. maximum allowable operating pressure.
192.189 Vaults: Drainage and waterproofing.
192.191 Design pressure of plastic fittings. Subpart H—Customer Meters, Service
192.193 Valve installation in plastic pipe. Regulators, and Service Lines
192.195 Protection against accidental over-
pressuring. 192.351 Scope.
192.197 Control of the pressure of gas deliv- 192.353 Customer meters and regulators: Lo-
ered from high-pressure distribution sys- cation.
tems. 192.355 Customer meters and regulators:
192.199 Requirements for design of pressure Protection from damage.
relief and limiting devices. 192.357 Customer meters and regulators: In-
192.201 Required capacity of pressure reliev- stallation.
ing and limiting stations. 192.359 Customer meter installations: Oper-
192.203 Instrument, control, and sampling ating pressure.
pipe and components. 192.361 Service lines: Installation.
192.363 Service lines: Valve requirements.
Subpart E—Welding of Steel in Pipelines 192.365 Service lines: Location of valves.
192.367 Service lines: General requirements
192.221 Scope. for connections to main piping.
192.225 Welding procedures. 192.369 Service lines: Connections to cast
192.227 Qualification of welders and welding iron or ductile iron mains.

operators. 192.371 Service lines: Steel.
192.229 Limitations on welders and welding 192.373 Service lines: Cast iron and ductile
operators. iron.
420
192.375 Service lines: Plastic. 192.507 Test requirements for pipelines to
192.377 Service lines: Copper. operate at a hoop stress less than 30 per-
192.379 New service lines not in use. cent of SMYS and at or above 100 p.s.i.
192.381 Service lines: Excess flow valve per- (689 kPa) gage.
formance standards. 192.509 Test requirements for pipelines to
192.383 Excess flow valve installation. operate below 100 p.s.i. (689 kPa) gage.
192.385 Manual service line shut-off valve 192.511 Test requirements for service lines.
installation. 192.513 Test requirements for plastic pipe-
lines.
Subpart I—Requirements for Corrosion 192.515 Environmental protection and safety
Control requirements.
192.517 Records.
192.451 Scope.
192.452 How does this subpart apply to con- Subpart K—Uprating
verted pipelines and regulated onshore
192.551 Scope.
gathering lines?
192.553 General requirements.
192.453 General. 192.555 Uprating to a pressure that will
192.455 External corrosion control: Buried produce a hoop stress of 30 percent or
or submerged pipelines installed after more of SMYS in steel pipelines.
July 31, 1971. 192.557 Uprating: Steel pipelines to a pres-
192.457 External corrosion control: Buried sure that will produce a hoop stress less
or submerged pipelines installed before than 30 percent of SMYS; plastic, cast
August 1, 1971. iron, and ductile iron pipelines.
192.459 External corrosion control: Exam-
ination of buried pipeline when exposed. Subpart L—Operations
192.461 External corrosion control: Protec-
tive coating. 192.601 Scope.
192.463 External corrosion control: Cathodic 192.603 General provisions.
protection. 192.605 Procedural manual for operations,
192.465 External corrosion control: Moni- maintenance, and emergencies.
toring. 192.607 [Reserved]
192.467 External corrosion control: Elec- 192.609 Change in class location: Required
trical isolation. study.
192.469 External corrosion control: Test sta- 192.611 Change in class location: Confirma-
tions. tion or revision of maximum allowable
192.471 External corrosion control: Test operating pressure.
leads. 192.612 Underwater inspection and reburial
192.473 External corrosion control: Inter- of pipelines in the Gulf of Mexico and its
ference currents. inlets.
192.475 Internal corrosion control: General. 192.613 Continuing surveillance.
192.476 Internal corrosion control: Design 192.614 Damage prevention program.
and construction of transmission line. 192.615 Emergency plans.
192.616 Public awareness.
192.477 Internal corrosion control: Moni-
192.617 Investigation of failures.
toring.
192.619 What is the maximum allowable op-
192.479 Atmospheric corrosion control: Gen-
erating pressure for steel or plastic pipe-
eral.
lines?
192.481 Atmospheric corrosion control: Mon- 192.620 Alternative maximum allowable op-
itoring. erating pressure for certain steel pipe-
192.483 Remedial measures: General. lines.
192.485 Remedial measures: Transmission 192.621 Maximum allowable operating pres-
lines. sure: High-pressure distribution systems.
192.487 Remedial measures: Distribution 192.623 Maximum and minimum allowable
lines other than cast iron or ductile iron operating pressure; Low-pressure dis-
lines. tribution systems.
192.489 Remedial measures: Cast iron and 192.625 Odorization of gas.
ductile iron pipelines. 192.627 Tapping pipelines under pressure.
192.490 Direct assessment. 192.629 Purging of pipelines.
192.491 Corrosion control records. 192.631 Control room management.
Subpart J—Test Requirements Subpart M—Maintenance

192.501 Scope. 192.701 Scope.
192.503 General requirements. 192.703 General.

192.505 Strength test requirements for steel 192.705 Transmission lines: Patrolling.
pipeline to operate at a hoop stress of 30 192.706 Transmission lines: Leakage sur-
percent or more of SMYS. veys.
421
192.707 Line markers for mains and trans- 192.909 How can an operator change its in-
mission lines. tegrity management program?
192.709 Transmission lines: Record keeping. 192.911 What are the elements of an integ-
192.711 Transmission lines: General require- rity management program?
ments for repair procedures. 192.913 When may an operator deviate its
192.713 Transmission lines: Permanent field program from certain requirements of
repair of imperfections and damages. this subpart?
192.715 Transmission lines: Permanent field 192.915 What knowledge and training must
repair of welds. personnel have to carry out an integrity
192.717 Transmission lines: Permanent field management program?
repair of leaks. 192.917 How does an operator identify poten-
192.719 Transmission lines: Testing of re- tial threats to pipeline integrity and use
pairs. the threat identification in its integrity
192.721 Distribution systems: Patrolling. program?
192.723 Distribution systems: Leakage sur- 192.919 What must be in the baseline assess-
veys. ment plan?
192.725 Test requirements for reinstating 192.921 How is the baseline assessment to be
service lines. conducted?
192.727 Abandonment or deactivation of fa- 192.923 How is direct assessment used and
cilities. for what threats?
192.925 What are the requirements for using
192.731 Compressor stations: Inspection and
External Corrosion Direct Assessment
testing of relief devices.
(ECDA)?
192.735 Compressor stations: Storage of
192.927 What are the requirements for using
combustible materials.
Internal Corrosion Direct Assessment
192.736 Compressor stations: Gas detection.
(ICDA)?
192.739 Pressure limiting and regulating 192.929 What are the requirements for using
stations: Inspection and testing. Direct Assessment for Stress Corrosion
192.740 Pressure regulating, limiting, and Cracking (SCCDA)?
overpressure protection—Individual serv- 192.931 How may Confirmatory Direct As-
ice lines directly connected to produc- sessment (CDA) be used?
tion, gathering, or transmission pipe- 192.933 What actions must be taken to ad-
lines. dress integrity issues?
192.741 Pressure limiting and regulating 192.935 What additional preventive and
stations: Telemetering or recording mitigative measures must an operator
gauges. take?
192.743 Pressure limiting and regulating 192.937 What is a continual process of eval-
stations: Capacity of relief devices. uation and assessment to maintain a
192.745 Valve maintenance: Transmission pipeline’s integrity?
lines. 192.939 What are the required reassessment
192.747 Valve maintenance: Distribution intervals?
systems. 192.941 What is a low stress reassessment?
192.749 Vault maintenance. 192.943 When can an operator deviate from
192.751 Prevention of accidental ignition. these reassessment intervals?
192.753 Caulked bell and spigot joints. 192.945 What methods must an operator use
192.755 Protecting cast-iron pipelines. to measure program effectiveness?
192.947 What records must an operator
Subpart N—Qualification of Pipeline keep?
Personnel 192.949 How does an operator notify
PHMSA?
192.801 Scope. 192.951 Where does an operator file a report?
192.803 Definitions.
192.805 Qualification Program. Subpart P—Gas Distribution Pipeline
192.807 Recordkeeping. Integrity Management (IM)
192.809 General.
192.1001 What definitions apply to this sub-
Subpart O—Gas Transmission Pipeline part?
Integrity Management 192.1003 What do the regulations in this sub-
part cover?
192.901 What do the regulations in this sub- 192.1005 What must a gas distribution oper-
part cover? ator (other than a master meter or small
192.903 What definitions apply to this sub- LPG operator) do to implement this sub-
part? part?
192.905 How does an operator identify a high 192.1007 What are the required elements of
consequence area? an integrity management plan?
192.907 What must an operator do to imple- 192.1009 What must an operator report when
ment this subpart? a mechanical fitting fails?
422
192.1011 What records must an operator tion the Administrator, or designee, for
keep? approval to operate under PHMSA reg-
192.1013 When may an operator deviate from ulations governing pipeline design,
required periodic inspections of this
construction, operation, and mainte-
part?
192.1015 What must a master meter or small
nance under 49 CFR 190.9;
liquefied petroleum gas (LPG) operator (3) Pipelines on the Outer Conti-
do to implement this subpart? nental Shelf upstream of the point at
APPENDIX A TO PART 192 [RESERVED] which operating responsibility trans-
APPENDIX B TO PART 192—QUALIFICATION OF fers from a producing operator to a
PIPE transporting operator;
APPENDIX C TO PART 192—QUALIFICATION OF (4) Onshore gathering of gas—
WELDERS FOR LOW STRESS LEVEL PIPE (i) Through a pipeline that operates
APPENDIX D TO PART 192—CRITERIA FOR CA- at less than 0 psig (0 kPa);
THODIC PROTECTION AND DETERMINATION (ii) Through a pipeline that is not a
OF MEASUREMENTS regulated onshore gathering line (as
APPENDIX E TO PART 192—GUIDANCE ON DE- determined in § 192.8); and
TERMINING HIGH CONSEQUENCE AREAS AND
ON CARRYING OUT REQUIREMENTS IN THE
(iii) Within inlets of the Gulf of Mex-
INTEGRITY MANAGEMENT RULE ico, except for the requirements in
§ 192.612; or
AUTHORITY: 49 U.S.C. 5103, 60102, 60104, (5) Any pipeline system that trans-
60108, 60109, 60110, 60113, 60116, 60118, 60137,
ports only petroleum gas or petroleum
60141; and 49 CFR 1.97.
gas/air mixtures to—
SOURCE: 35 FR 13257, Aug. 19, 1970, unless (i) Fewer than 10 customers, if no
otherwise noted. portion of the system is located in a
EDITORIAL NOTE: Nomenclature changes to public place; or
part 192 appear at 71 FR 33406, June 9, 2006. (ii) A single customer, if the system
is located entirely on the customer’s
Subpart A—General premises (no matter if a portion of the
system is located in a public place).
§ 192.1 What is the scope of this part? [35 FR 13257, Aug. 19, 1970, as amended by
(a) This part prescribes minimum Amdt. 192–27, 41 FR 34605, Aug. 16, 1976;
safety requirements for pipeline facili- Amdt. 192–67, 56 FR 63771, Dec. 5, 1991; Amdt.
ties and the transportation of gas, in- 192–78, 61 FR 28782, June 6, 1996; Amdt. 192–81,
62 FR 61695, Nov. 19, 1997; Amdt. 192–92, 68 FR
cluding pipeline facilities and the 46112, Aug. 5, 2003; 70 FR 11139, Mar. 8, 2005;
transportation of gas within the limits Amdt. 192–102, 71 FR 13301, Mar. 15, 2006;
of the outer continental shelf as that Amdt. 192–103, 72 FR 4656, Feb. 1, 2007]
term is defined in the Outer Conti-
nental Shelf Lands Act (43 U.S.C. 1331). § 192.3 Definitions.
(b) This part does not apply to— As used in this part:
(1) Offshore gathering of gas in State Abandoned means permanently re-
waters upstream from the outlet flange moved from service.
of each facility where hydrocarbons are Active corrosion means continuing
produced or where produced hydro- corrosion that, unless controlled, could
carbons are first separated, dehy- result in a condition that is detri-
drated, or otherwise processed, which- mental to public safety.
ever facility is farther downstream; Administrator means the Adminis-
(2) Pipelines on the Outer Conti- trator, Pipeline and Hazardous Mate-
nental Shelf (OCS) that are producer- rials Safety Administration or his or
operated and cross into State waters her delegate.
without first connecting to a trans- Alarm means an audible or visible
porting operator’s facility on the OCS, means of indicating to the controller
upstream (generally seaward) of the that equipment or processes are out-
last valve on the last production facil- side operator-defined, safety-related
ity on the OCS. Safety equipment pro- parameters.
tecting PHMSA-regulated pipeline seg- Control room means an operations
ments is not excluded. Producing oper- center staffed by personnel charged

ators for those pipeline segments up- with the responsibility for remotely
stream of the last valve of the last pro- monitoring and controlling a pipeline
duction facility on the OCS may peti- facility.
423
§ 192.3 49 CFR Ch. I (10–1–18 Edition)
Controller means a qualified indi- compressor stations, between a com-

vidual who remotely monitors and con- pressor station and storage facilities,
trols the safety-related operations of a between a compressor station and a
pipeline facility via a SCADA system block valve, or between adjacent block
from a control room, and who has oper- valves.
ational authority and accountability Listed specification means a specifica-
for the remote operational functions of tion listed in section I of appendix B of
the pipeline facility. this part.
Customer meter means the meter that Low-pressure distribution system means
measures the transfer of gas from an a distribution system in which the gas
operator to a consumer. pressure in the main is substantially
Distribution line means a pipeline the same as the pressure provided to
other than a gathering or transmission the customer.
line. Main means a distribution line that
Electrical survey means a series of serves as a common source of supply
closely spaced pipe-to-soil readings for more than one service line.
over pipelines which are subsequently Maximum actual operating pressure
analyzed to identify locations where a means the maximum pressure that oc-
corrosive current is leaving the pipe- curs during normal operations over a
line. period of 1 year.
Exposed underwater pipeline means an Maximum allowable operating pressure
underwater pipeline where the top of (MAOP) means the maximum pressure
the pipe protrudes above the under- at which a pipeline or segment of a
water natural bottom (as determined pipeline may be operated under this
by recognized and generally accepted part.
practices) in waters less than 15 feet Municipality means a city, county, or
(4.6 meters) deep, as measured from any other political subdivision of a
mean low water. State.
Gas means natural gas, flammable Offshore means beyond the line of or-
gas, or gas which is toxic or corrosive. dinary low water along that portion of
Gathering line means a pipeline that the coast of the United States that is
transports gas from a current produc- in direct contact with the open seas
tion facility to a transmission line or and beyond the line marking the sea-
main. ward limit of inland waters.
Gulf of Mexico and its inlets means the Operator means a person who engages
waters from the mean high water mark in the transportation of gas.
of the coast of the Gulf of Mexico and Outer Continental Shelf means all sub-
its inlets open to the sea (excluding merged lands lying seaward and out-
rivers, tidal marshes, lakes, and ca- side the area of lands beneath navi-
nals) seaward to include the territorial gable waters as defined in Section 2 of
sea and Outer Continental Shelf to a the Submerged Lands Act (43 U.S.C.
depth of 15 feet (4.6 meters), as meas- 1301) and of which the subsoil and sea-
ured from the mean low water. bed appertain to the United States and
Hazard to navigation means, for the are subject to its jurisdiction and con-
purposes of this part, a pipeline where trol.
the top of the pipe is less than 12 Person means any individual, firm,
inches (305 millimeters) below the un- joint venture, partnership, corporation,
derwater natural bottom (as deter- association, State, municipality, coop-
mined by recognized and generally ac- erative association, or joint stock asso-
cepted practices) in waters less than 15 ciation, and including any trustee, re-
feet (4.6 meters) deep, as measured ceiver, assignee, or personal represent-
from the mean low water. ative thereof.
High-pressure distribution system Petroleum gas means propane, pro-
means a distribution system in which pylene, butane, (normal butane or
the gas pressure in the main is higher isobutanes), and butylene (including
than the pressure provided to the cus- isomers), or mixtures composed pre-
tomer. dominantly of these gases, having a
Line section means a continuous run vapor pressure not exceeding 208 psi
of transmission line between adjacent (1434 kPa) gage at 100 °F (38 °C).
424
Pipe means any pipe or tubing used in based system or systems used by a con-
the transportation of gas, including troller in a control room that collects
pipe-type holders. and displays information about a pipe-
Pipeline means all parts of those line facility and may have the ability
physical facilities through which gas to send commands back to the pipeline
moves in transportation, including facility.
pipe, valves, and other appurtenance Transmission line means a pipeline,
attached to pipe, compressor units, me- other than a gathering line, that: (1)
tering stations, regulator stations, de- Transports gas from a gathering line or
livery stations, holders, and fabricated storage facility to a distribution cen-
assemblies. ter, storage facility, or large volume
Pipeline environment includes soil re- customer that is not down-stream from
sistivity (high or low), soil moisture a distribution center; (2) operates at a
(wet or dry), soil contaminants that hoop stress of 20 percent or more of
may promote corrosive activity, and SMYS; or (3) transports gas within a
other known conditions that could af- storage field.
fect the probability of active corrosion.
NOTE: A large volume customer may re-
Pipeline facility means new and exist-
ceive similar volumes of gas as a distribu-
ing pipelines, rights-of-way, and any tion center, and includes factories, power
equipment, facility, or building used in plants, and institutional users of gas.
the transportation of gas or in the
treatment of gas during the course of Transportation of gas means the gath-
transportation. ering, transmission, or distribution of
Service line means a distribution line gas by pipeline or the storage of gas, in
that transports gas from a common or affecting interstate or foreign com-
source of supply to an individual cus- merce.
tomer, to two adjacent or adjoining Underground natural gas storage facil-
residential or small commercial cus- ity means a facility that stores natural
tomers, or to multiple residential or gas in an underground facility incident
small commercial customers served to natural gas transportation, includ-
through a meter header or manifold. A ing—
service line ends at the outlet of the (1) A depleted hydrocarbon reservoir;
customer meter or at the connection to (2) An aquifer reservoir; or
a customer’s piping, whichever is fur- (3) A solution-mined salt cavern res-
ther downstream, or at the connection ervoir, including associated material
to customer piping if there is no meter. and equipment used for injection, with-
Service regulator means the device on drawal, monitoring, or observation
a service line that controls the pres- wells, and wellhead equipment, piping,
sure of gas delivered from a higher rights-of-way, property, buildings,
pressure to the pressure provided to compressor units, separators, metering
the customer. A service regulator may equipment, and regulator equipment.
serve one customer or multiple cus- Welder means a person who performs
tomers through a meter header or manual or semi-automatic welding.
manifold. Welding operator means a person who
SMYS means specified minimum operates machine or automatic welding
yield strength is: equipment.
(1) For steel pipe manufactured in ac-
cordance with a listed specification, [Amdt. 192–13, 38 FR 9084, Apr. 10, 1973]
the yield strength specified as a min- EDITORIAL NOTE: For FEDERAL REGISTER ci-
imum in that specification; or tations affecting § 192.3, see the List of CFR
(2) For steel pipe manufactured in ac- Sections Affected, which appears in the
cordance with an unknown or unlisted Finding Aids section of the printed volume
specification, the yield strength deter- and at www.fdsys.gov.
mined in accordance with § 192.107(b).
State means each of the several § 192.5 Class locations.
States, the District of Columbia, and (a) This section classifies pipeline lo-
the Commonwealth of Puerto Rico. cations for purposes of this part. The
Supervisory Control and Data Acquisi- following criteria apply to classifica-
tion (SCADA) system means a computer- tions under this section.
425
§ 192.7 49 CFR Ch. I (10–1–18 Edition)
(1) A ‘‘class location unit’’ is an on- of the Director of the Federal Register
shore area that extends 220 yards (200 in 5 U.S.C. 552(a) and 1 CFR part 51.
meters) on either side of the centerline The materials listed in this section
of any continuous 1- mile (1.6 kilo- have the full force of law. To enforce
meters) length of pipeline. any edition other than that specified in
(2) Each separate dwelling unit in a this section, PHMSA must publish a
multiple dwelling unit building is notice of change in the FEDERAL REG-
counted as a separate building intended ISTER.
for human occupancy. (1) Availability of standards incor-
(b) Except as provided in paragraph
porated by reference. All of the mate-
(c) of this section, pipeline locations
rials incorporated by reference are
are classified as follows:
(1) A Class 1 location is: available for inspection from several
(i) An offshore area; or sources, including the following:
(ii) Any class location unit that has (i) The Office of Pipeline Safety,
10 or fewer buildings intended for Pipeline and Hazardous Materials Safe-
human occupancy. ty Administration, 1200 New Jersey Av-
(2) A Class 2 location is any class lo- enue SE., Washington, DC 20590. For
cation unit that has more than 10 but more information contact 202–366–4046
fewer than 46 buildings intended for or go to the PHMSA Web site at: http://
human occupancy. www.phmsa.dot.gov/pipeline/regs.
(3) A Class 3 location is: (ii) The National Archives and
(i) Any class location unit that has 46 Records Administration (NARA). For
or more buildings intended for human information on the availability of this
occupancy; or material at NARA, call 202–741–6030 or
(ii) An area where the pipeline lies go to the NARA Web site at: http://
within 100 yards (91 meters) of either a www.archives.gov/federallregister/
building or a small, well-defined out- codeloflfederallregulations/
side area (such as a playground, recre- ibrllocations.html.
ation area, outdoor theater, or other
(iii) Copies of standards incorporated
place of public assembly) that is occu-
pied by 20 or more persons on at least by reference in this part can also be
5 days a week for 10 weeks in any 12- purchased or are otherwise made avail-
month period. (The days and weeks able from the respective standards-de-
need not be consecutive.) veloping organization at the addresses
(4) A Class 4 location is any class lo- provided in the centralized IBR section
cation unit where buildings with four below.
or more stories above ground are prev- (2) [Reserved]
alent. (b) American Petroleum Institute
(c) The length of Class locations 2, 3, (API), 1220 L Street NW., Washington,
and 4 may be adjusted as follows: DC 20005, phone: 202–682–8000, http://
(1) A Class 4 location ends 220 yards api.org/.
(200 meters) from the nearest building (1) API Recommended Practice 5L1,
with four or more stories above ground. ‘‘Recommended Practice for Railroad
(2) When a cluster of buildings in- Transportation of Line Pipe,’’ 7th edi-
tended for human occupancy requires a tion, September 2009, (API RP 5L1),
Class 2 or 3 location, the class location IBR approved for § 192.65(a).
ends 220 yards (200 meters) from the
(2) API Recommended Practice 5LT,
nearest building in the cluster.
‘‘Recommended Practice for Truck
[Amdt. 192–78, 61 FR 28783, June 6, 1996; 61 FR Transportation of Line Pipe,’’ First
35139, July 5, 1996, as amended by Amdt. 192– edition, March 2012, (API RP 5LT), IBR
85, 63 FR 37502, July 13, 1998]
approved for § 192.65(c).
§ 192.7 What documents are incor- (3) API Recommended Practice 5LW,
porated by reference partly or ‘‘Recommended Practice for Transpor-
wholly in this part? tation of Line Pipe on Barges and Ma-
(a) This part prescribes standards, or rine Vessels,’’ 3rd edition, September
portions thereof, incorporated by ref- 2009, (API RP 5LW), IBR approved for
erence into this part with the approval § 192.65(b).
426
(4) API Recommended Practice 80, (2) ASME/ANSI B16.5–2003, ‘‘Pipe

‘‘Guidelines for the Definition of On- Flanges and Flanged Fittings, ‘‘Octo-
shore Gas Gathering Lines,’’ 1st edi- ber 2004, (ASME/ANSI B16.5), IBR ap-
tion, April 2000, (API RP 80), IBR approved for §§ 192.147(a) and 192.279.
proved for § 192.8(a). (3) ASME/ANSI B31G–1991 (Re-
(5) API Recommended Practice 1162, affirmed 2004), ‘‘Manual for Deter-
‘‘Public Awareness Programs for Pipe- mining the Remaining Strength of Cor-
line Operators,’’ 1st edition, December roded Pipelines,’’ 2004, (ASME/ANSI
2003, (API RP 1162), IBR approved for B31G), IBR approved for §§ 192.485(c) and
§ 192.616(a), (b), and (c). 192.933(a).
(6) API Recommended Practice 1165, (4) ASME/ANSI B31.8–2007, ‘‘Gas
‘‘Recommended Practice for Pipeline Transmission and Distribution Piping
SCADA Displays,’’ First edition, Janu- Systems,’’ November 30, 2007, (ASME/
ary 2007, (API RP 1165), IBR approved ANSI B31.8), IBR approved for
for § 192.631(c). §§ 192.112(b) and 192.619(a).
(7) API Specification 5L, ‘‘Specifica- (5) ASME/ANSI B31.8S–2004, ‘‘Supple-
tion for Line Pipe,’’ 45th edition, effec- ment to B31.8 on Managing System In-
tive July 1, 2013, (API Spec 5L), IBR ap- tegrity of Gas Pipelines,’’ 2004, (ASME/
proved for §§ 192.55(e); 192.112(a), (b), (d), ANSI B31.8S–2004), IBR approved for
(e); 192.113; and Item I, Appendix B to §§ 192.903 note to Potential impact radius;
Part 192.
192.907 introductory text, (b); 192.911 in-
(8) ANSI/API Specification 6D,
troductory text, (i), (k), (l), (m);
‘‘Specification for Pipeline
192.913(a), (b), (c); 192.917 (a), (b), (c),
Valves,’’23rd edition, effective October
(d), (e); 192.921(a); 192.923(b); 192.925(b);
1, 2008, including Errata 1 (June 2008),
192.927(b), (c); 192.929(b); 192.933(c), (d);
Errata2 (/November 2008), Errata 3
192.935 (a), (b); 192.937(c); 192.939(a); and
(February 2009), Errata 4 (April 2010),
192.945(a).
Errata 5 (November 2010), Errata 6 (Au-
gust 2011) Addendum 1 (October 2009), (6) ASME Boiler & Pressure Vessel
Addendum 2 (August 2011), and Adden- Code, Section I, ‘‘Rules for Construc-
dum 3 (October 2012), (ANSI/API Spec tion of Power Boilers 2007,’’ 2007 edi-
6D), IBR approved for § 192.145(a). tion, July 1, 2007, (ASME BPVC, Sec-
(9) API Standard 1104, ‘‘Welding of tion I), IBR approved for § 192.153(b).
Pipelines and Related Facilities,’’ 20th (7) ASME Boiler & Pressure Vessel
edition, October 2005, including errata/ Code, Section VIII, Division 1 ‘‘Rules
addendum (July 2007) and errata 2 for Construction of Pressure Vessels,’’
(2008), (API Std 1104), IBR approved for 2007 edition, July 1, 2007, (ASME BPVC,
§§ 192.225(a); 192.227(a); 192.229(c); Section VIII, Division 1), IBR approved
192.241(c); and Item II, Appendix B. for §§ 192.153(a), (b), (d); and 192.165(b).
(10) API Recommended Practice 1170, (8) ASME Boiler & Pressure Vessel
‘‘Design and Operation of Solution- Code, Section VIII, Division 2 ‘‘Alter-
mined Salt Caverns Used for Natural nate Rules, Rules for Construction of
Gas Storage,’’ First edition, July 2015 Pressure Vessels,’’ 2007 edition, July 1,
(API RP 1170), IBR approved for § 192.12. 2007, (ASME BPVC, Section VIII, Divi-
(11) API Recommended Practice 1171, sion 2), IBR approved for §§ 192.153(b),
‘‘Functional Integrity of Natural Gas (d); and 192.165(b).
Storage in Depleted Hydrocarbon Res- (9) ASME Boiler & Pressure Vessel
ervoirs and Aquifer Reservoirs,’’ First Code, Section IX: ‘‘Qualification
edition, September 2015, (API RP 1171), Standard for Welding and Brazing Pro-
IBR approved for § 192.12. cedures, Welders, Brazers, and Welding
(c) ASME International (ASME), and Brazing Operators,’’ 2007 edition,
Three Park Avenue, New York, NY July 1, 2007, ASME BPVC, Section IX,
10016, 800–843–2763 (U.S./Canada), http:// IBR approved for §§ 192.225(a); 192.227(a);
www.asme.org/. and Item II, Appendix B to Part 192.
(1) ASME/ANSI B16.1–2005, ‘‘Gray (d) American Society for Testing and
Iron Pipe Flanges and Flanged Fit- Materials (ASTM), 100 Barr Harbor
tings: (Classes 25, 125, and 250),’’ August Drive, PO Box C700, West
31, 2006, (ASME/ANSI B16.1), IBR ap- Conshohocken, PA 19428, phone: (610)
proved for § 192.147(c). 832–9585, Web site: http://www.astm.org/.
427
§ 192.7 49 CFR Ch. I (10–1–18 Edition)
(1) ASTM A53/A53M–10, ‘‘Standard § 192.113 and Item I, Appendix B to Part

Specification for Pipe, Steel, Black and 192.
Hot-Dipped, Zinc-Coated, Welded and (10) ASTM D638–03, ‘‘Standard Test
Seamless,’’ approved October 1, 2010, Method for Tensile Properties of Plas-
(ASTM A53/A53M), IBR approved for tics,’’ 2003, (ASTM D638), IBR approved
§ 192.113; and Item II, Appendix B to for § 192.283(a) and (b).
Part 192. (11) ASTM D2513–87, ‘‘Standard Speci-
(2) ASTM A106/A106M–10, ‘‘Standard fication for Thermoplastic Gas Pres-
Specification for Seamless Carbon sure Pipe, Tubing, and Fittings,’’
Steel Pipe for High-Temperature Serv- (ASTM D2513–87), IBR approved for
ice,’’ approved October 1, 2010, (ASTM § 192.63(a).
A106/A106M), IBR approved for § 192.113; (12) ASTM D2513–99, ‘‘Standard Speci-
and Item I, Appendix B to Part 192. fication for Thermoplastic Gas Pres-
(3) ASTM A333/A333M–11, ‘‘Standard sure Pipe, Tubing, and Fittings,’’
Specification for Seamless and Welded (ASTM D 2513–99), IBR approved for
Steel Pipe for Low-Temperature Serv- §§ 192.191(b); 192.281(b); 192.283(a) and
ice,’’ approved April 1, 2011, (ASTM Item 1, Appendix B to Part 192.
A333/A333M), IBR approved for § 192.113; (13) ASTM D2513–09a, ‘‘Standard
and Item I, Appendix B to Part 192. Specification for Polyethylene (PE)
Gas Pressure Pipe, Tubing, and Fit-
(4) ASTM A372/A372M–10, ‘‘Standard
tings,’’ approved December 1, 2009,
Specification for Carbon and Alloy
(ASTM D2513–09a), IBR approved for
Steel Forgings for Thin-Walled Pres-
§§ 192.123(e); 192.191(b); 192.283(a); and
sure Vessels,’’ approved October 1, 2010,
Item 1, Appendix B to Part 192.
(ASTM A372/A372M), IBR approved for
(14) ASTM D2517–00, ‘‘Standard Speci-
§ 192.177(b).
fication for Reinforced Epoxy Resin
(5) ASTM A381–96 (reapproved 2005), Gas Pressure Pipe and Fittings,’’
‘‘Standard Specification for Metal-Arc (ASTM D 2517), IBR approved for
Welded Steel Pipe for Use with High- §§ 192.191(a); 192.281(d); 192.283(a); and
Pressure Transmission Systems,’’ ap- Item I, Appendix B to Part 192.
proved October 1, 2005, (ASTM A381), (15) ASTM F1055–1998, ‘‘Standard
IBR approved for § 192.113; and Item I, Specification for Electrofusion Type
Appendix B to Part 192. Polyethylene Fittings for Outside Di-
(6) ASTM A578/A578M–96 (reapproved ameter Controller Polyethylene Pipe
2001), ‘‘Standard Specification for and Tubing,’’ (ASTM F1055), IBR ap-
Straight-Beam Ultrasonic Examina- proved for § 192.283(a).
tion of Plain and Clad Steel Plates for (e) Gas Technology Institute (GTI),
Special Applications,’’ (ASTM A578/ formerly the Gas Research Institute
A578M), IBR approved for § 192.112(c). (GRI)), 1700 S. Mount Prospect Road,
(7) ASTM A671/A671M–10, ‘‘Standard Des Plaines, IL 60018, phone: 847–768–
Specification for Electric-Fusion-Weld- 0500, Web site: www.gastechnology.org.
ed Steel Pipe for Atmospheric and (1) GRI 02/0057 (2002) ‘‘Internal Corro-
Lower Temperatures,’’ approved April sion Direct Assessment of Gas Trans-
1, 2010, (ASTM A671/A671M), IBR ap- mission Pipelines Methodology,’’ (GRI
proved for § 192.113; and Item I, Appen- 02/0057), IBR approved for § 192.927(c).
dix B to Part 192. (2) [Reserved]
(8) ASTM A672/A672M–09, ‘‘Standard (f) Manufacturers Standardization
Specification for Electric-Fusion-Weld- Society of the Valve and Fittings In-
ed Steel Pipe for High-Pressure Service dustry, Inc. (MSS), 127 Park St. NE.,
at Moderate Temperatures,’’ approved Vienna, VA 22180, phone: 703–281–6613,
October 1, 2009, (ASTM A672/672M), IBR Web site: http://www.mss-hq.org/.
approved for § 192.113 and Item I, Ap- (1) MSS SP–44–2010, Standard Prac-
pendix B to Part 192. tice, ‘‘Steel Pipeline Flanges,’’ 2010 edi-
(9) ASTM A691/A691M–09, ‘‘Standard tion, (including Errata (May 20, 2011)),
Specification for Carbon and Alloy (MSS SP–44), IBR approved for
Steel Pipe, Electric-Fusion-Welded for § 192.147(a).

High-Pressure Service at High Tem- (2) [Reserved]
peratures,’’ approved October 1, 2009, (g) NACE International (NACE), 1440
(ASTM A691/A691M), IBR approved for South Creek Drive, Houston, TX 77084:
428
phone: 281–228–6223 or 800–797–6223, Web (2) [Reserved]

site: http://www.nace.org/Publications/.
[35 FR 13257, Aug. 19, 1970]
(1) ANSI/NACE SP0502–2010, Standard
Practice, ‘‘Pipeline External Corrosion EDITORIAL NOTE: For FEDERAL REGISTER ci-
Direct Assessment Methodology,’’ re- tations affecting § 192.7, see the List of CFR
vised June 24, 2010, (NACE SP0502), IBR Sections Affected, which appears in the
approved for §§ 192.923(b); 192.925(b); Finding Aids section of the printed volume
192.931(d); 192.935(b) and 192.939(a). and at www.fdsys.gov.
(2) [Reserved]
§ 192.8 How are onshore gathering
(h) National Fire Protection Associa- lines and regulated onshore gath-
tion (NFPA), 1 Batterymarch Park, ering lines determined?
Quincy, Massachusetts 02169, phone: 1
617 984–7275, Web site: http:// (a) An operator must use API RP 80
www.nfpa.org/. (incorporated by reference, see § 192.7),
(1) NFPA–30 (2012), ‘‘Flammable and to determine if an onshore pipeline (or
Combustible Liquids Code,’’ 2012 edi- part of a connected series of pipelines)
tion, June 20, 2011, including Errata 30– is an onshore gathering line. The deter-
12–1 (September 27, 2011) and Errata 30– mination is subject to the limitations
12–2 (November 14, 2011), (NFPA–30), listed below. After making this deter-
IBR approved for § 192.735(b). mination, an operator must determine
(2) NFPA–58 (2004), ‘‘Liquefied Petro- if the onshore gathering line is a regu-
leum Gas Code (LP-Gas Code),’’ lated onshore gathering line under
(NFPA–58), IBR approved for § 192.11(a), paragraph (b) of this section.
(b), and (c). (1) The beginning of gathering, under
(3) NFPA–59 (2004), ‘‘Utility LP-Gas section 2.2(a)(1) of API RP 80, may not
Plant Code,’’ (NFPA–59), IBR approved extend beyond the furthermost down-
for § 192.11(a), (b); and (c). stream point in a production operation
(4) NFPA–70 (2011), ‘‘National Elec- as defined in section 2.3 of API RP 80.
trical Code,’’ 2011 edition, issued Au- This furthermost downstream point
gust 5, 2010, (NFPA–70), IBR approved does not include equipment that can be
for §§ 192.163(e); and 192.189(c). used in either production or transpor-
(i) Pipeline Research Council Inter- tation, such as separators or
national, Inc. (PRCI), c/o Technical dehydrators, unless that equipment is
Toolboxes, 3801 Kirby Drive, Suite 520, involved in the processes of ‘‘produc-
P.O. Box 980550, Houston, TX 77098, tion and preparation for transportation
phone: 713–630–0505, toll free: 866–866– or delivery of hydrocarbon gas’’ within
6766, Web site: http://www.ttoolboxes.com/ the meaning of ‘‘production oper-
. (Contract number PR–3–805.) ation.’’
(1) AGA, Pipeline Research Com- (2) The endpoint of gathering, under
mittee Project, PR–3–805, ‘‘A Modified
section 2.2(a)(1)(A) of API RP 80, may
Criterion for Evaluating the Remain-
not extend beyond the first down-
ing Strength of Corroded Pipe,’’ (De-
stream natural gas processing plant,
cember 22, 1989), (PRCI PR–3–805 (R–
unless the operator can demonstrate,
STRENG)), IBR approved for
using sound engineering principles,
§§ 192.485(c); 192.933(a) and (d).
(2) [Reserved] that gathering extends to a further
(j) Plastics Pipe Institute, Inc. (PPI), downstream plant.
105 Decker Court, Suite 825 Irving TX (3) If the endpoint of gathering, under
75062, phone: 469–499–1044, http:// section 2.2(a)(1)(C) of API RP 80, is de-
www.plasticpipe.org/. termined by the commingling of gas
(1) PPI TR–3/2008 HDB/HDS/PDB/SDB/ from separate production fields, the
MRS Policies (2008), ‘‘Policies and Pro- fields may not be more than 50 miles
cedures for Developing Hydrostatic De- from each other, unless the Adminis-
sign Basis (HDB), Pressure Design trator finds a longer separation dis-
Basis (PDB), Strength Design Basis tance is justified in a particular case
(SDB), and Minimum Required (see 49 CFR § 190.9).

Strength (MRS) Ratings for Thermo- (4) The endpoint of gathering, under
plastic Piping Materials or Pipe, ’’ May section 2.2(a)(1)(D) of API RP 80, may
2008, IBR approved for § 192.121. not extend beyond the furthermost
429
§ 192.9 49 CFR Ch. I (10–1–18 Edition)
downstream compressor used to in- with a feature described in the second

crease gathering line pressure for de- column that lies in an area described in
livery to another pipeline. the third column; and
(b) For purposes of § 192.9, ‘‘regulated (2) As applicable, additional lengths
onshore gathering line’’ means: of line described in the fourth column
(1) Each onshore gathering line (or to provide a safety buffer:
segment of onshore gathering line)
Type Feature Area Safety buffer
A ......... —Metallic and the MAOP produces a Class 2, 3, or 4 location (see § 192.5) None.
hoop stress of 20 percent or more
of SMYS. If the stress level is un-
known, an operator must determine
the stress level according to the
applicable provisions in subpart C
of this part.
—Non-metallic and the MAOP is
more than 125 psig (862 kPa).
B ......... —Metallic and the MAOP produces a Area 1. Class 3 or 4 location ............. If the gathering line is in Area 2(b) or
hoop stress of less than 20 percent Area 2. An area within a Class 2 lo- 2(c), the additional lengths of line
of SMYS. If the stress level is un- cation the operator determines by extend upstream and downstream
known, an operator must determine using any of the following three from the area to a point where the
the stress level according to the methods: line is at least 150 feet (45.7 m)
applicable provisions in subpart C (a) A Class 2 location. ........................ from the nearest dwelling in the
of this part. (b) An area extending 150 feet (45.7 area. However, if a cluster of dwell-
—Non-metallic and the MAOP is 125 m) on each side of the centerline of ings in Area 2 (b) or 2(c) qualifies a
psig (862 kPa) or less. any continuous 1 mile (1.6 km) of line as Type B, the Type B classi-
pipeline and including more than 10 fication ends 150 feet (45.7 m)
but fewer than 46 dwellings. from the nearest dwelling in the
(c) An area extending 150 feet (45.7 cluster.
m) on each side of the centerline of
any continous 1000 feet (305 m) of
pipeline and including 5 or more
dwellings.
[Amdt. 192–102, 71 FR 13302, Mar. 15, 2006] (d) Type B lines. An operator of a
Type B regulated onshore gathering
§ 192.9 What requirements apply to line must comply with the following
gathering lines? requirements:
(a) Requirements. An operator of a (1) If a line is new, replaced, relo-
gathering line must follow the safety cated, or otherwise changed, the de-
requirements of this part as prescribed sign, installation, construction, initial
by this section. inspection, and initial testing must be
(b) Offshore lines. An operator of an in accordance with requirements of
offshore gathering line must comply this part applicable to transmission
with requirements of this part applica- lines;
ble to transmission lines, except the re- (2) If the pipeline is metallic, control
quirements in § 192.150 and in subpart O corrosion according to requirements of
of this part. subpart I of this part applicable to
(c) Type A lines. An operator of a transmission lines;
Type A regulated onshore gathering (3) Carry out a damage prevention
line must comply with the require- program under § 192.614;
ments of this part applicable to trans- (4) Establish a public education pro-
mission lines, except the requirements gram under § 192.616;
in § 192.150 and in subpart O of this (5) Establish the MAOP of the line
part. However, an operator of a Type A under § 192.619; and
regulated onshore gathering line in a (6) Install and maintain line markers
Class 2 location may demonstrate com- according to the requirements for
pliance with subpart N by describing transmission lines in § 192.707.

the processes it uses to determine the (7) Conduct leakage surveys in ac-
qualification of persons performing op- cordance with § 192.706 using leak de-
erations and maintenance tasks. tection equipment and promptly repair
430
hazardous leaks that are discovered in operator. For those instances in which
accordance with § 192.703(c). the transfer points are not identifiable
(e) Compliance deadlines. An operator by a durable marking, each operator
of a regulated onshore gathering line will have until September 15, 1998 to
must comply with the following dead- identify the transfer points. If it is not
lines, as applicable. practicable to durably mark a transfer
(1) An operator of a new, replaced, re- point and the transfer point is located
located, or otherwise changed line above water, the operator must depict
must be in compliance with the appli- the transfer point on a schematic lo-
cable requirements of this section by cated near the transfer point. If a
the date the line goes into service, un- transfer point is located subsea, then
less an exception in § 192.13 applies. the operator must identify the transfer
(2) If a regulated onshore gathering point on a schematic which must be
line existing on April 14, 2006 was not maintained at the nearest upstream fa-
previously subject to this part, an op- cility and provided to PHMSA upon re-
erator has until the date stated in the quest. For those cases in which adjoin-
second column to comply with the ap- ing operators have not agreed on a
plicable requirement for the line listed transfer point by September 15, 1998
in the first column, unless the Admin- the Regional Director and the MMS
istrator finds a later deadline is justi- Regional Supervisor will make a joint
fied in a particular case: determination of the transfer point.
[Amdt. 192–81, 62 FR 61695, Nov. 19, 1997, as
Requirement Compliance deadline
amended at 70 FR 11139, Mar. 8, 2005]
Control corrosion according to April 15, 2009.
Subpart I requirements for § 192.11 Petroleum gas systems.
transmission lines.
Carry out a damage preven- October 15, 2007. (a) Each plant that supplies petro-
tion program under leum gas by pipeline to a natural gas
§ 192.614. distribution system must meet the re-
Establish MAOP under October 15, 2007. quirements of this part and NFPA 58
§ 192.619.
Install and maintain line mark- April 15, 2008. and NFPA 59 (incorporated by ref-
ers under § 192.707. erence, see § 192.7).
Establish a public education April 15, 2008. (b) Each pipeline system subject to
program under § 192.616.
Other provisions of this part April 15, 2009.
this part that transports only petro-
as required by paragraph leum gas or petroleum gas/air mixtures
(c) of this section for Type must meet the requirements of this
A lines. part and of ANSI/NFPA 58 and 59.
(c) In the event of a conflict between
(3) If, after April 14, 2006, a change in this part and NFPA 58 and NFPA 59
class location or increase in dwelling (incorporated by reference, see § 192.7),
density causes an onshore gathering NFPA 58 and NFPA 59 prevail.
line to be a regulated onshore gath-
ering line, the operator has 1 year for [Amdt. 192–78, 61 FR 28783, June 6, 1996, as
amended by Amdt. 192–119, 80 FR 180, Jan. 5,
Type B lines and 2 years for Type A 2015; 80 FR 46847, Aug. 6, 2015]
lines after the line becomes a regulated
onshore gathering line to comply with § 192.12 Underground natural gas stor-
this section. age facilities.
[Amdt. 192–102, 71 FR 13301, Mar. 15, 2006, as Underground natural gas storage fa-
amended by Amdt. 192–120, 80 FR 12777, Mar. cilities must meet the following re-
11, 2015] quirements:
(a) Each underground natural gas
§ 192.10 Outer continental shelf pipe- storage facility that uses a solution-
lines. mined salt cavern reservoir for gas
Operators of transportation pipelines storage constructed after July 18, 2017
on the Outer Continental Shelf (as de- must meet all requirements and rec-
fined in the Outer Continental Shelf ommendations of API RP 1170 (incor-
Lands Act; 43 U.S.C. 1331) must identify porated by reference, see § 192.7).
on all their respective pipelines the (b) Each underground natural gas
specific points at which operating re- storage facility that uses a solution-
sponsibility transfers to a producing mined salt cavern reservoir for storage
431
§ 192.13 49 CFR Ch. I (10–1–18 Edition)
including those constructed not later section, as to why compliance with a

than July 18, 2017 must meet the oper- provision of the recommended practice
ations, maintenance, integrity dem- is not practicable and not necessary for
onstration and verification, moni- safety with respect to specified under-
toring, threat and hazard identifica- ground storage facilities or equipment.
tion, assessment, remediation, site se- The justifications for any deviation
curity, emergency response and pre- from any provision of API RP 1170 and
paredness, and recordkeeping require- API RP 1171 must be technically re-
ments and recommendations of API RP viewed and documented by a subject
1170, sections 9, 10, and 11 (incorporated matter expert to ensure there will be
by reference, see § 192.7) by January 18, no adverse impact on design, construc-
2018. tion, operations, maintenance, integ-
(c) Each underground natural gas rity, emergency preparedness and re-
storage facility that uses a depleted sponse, and overall safety and must be
hydrocarbon reservoir or an aquifer dated and approved by a senior execu-
reservoir for storage constructed after tive officer, vice president, or higher
July 18, 2017 must meet all require- office with responsibility of the under-
ments and recommendations of API RP ground natural gas storage facility. An
1171 (incorporated by reference, see operator must discontinue use of any
§ 192.7). variance where PHMSA determines and
(d) Each underground natural gas provides notice that the variance ad-
storage facility that uses a depleted
versely impacts design, construction,
hydrocarbon reservoir or an aquifer
operations, maintenance, integrity,
reservoir for gas storage, including
emergency preparedness and response,
those constructed not later than July
or overall safety.
18, 2017 must meet the operations,
maintenance, integrity demonstration [Amdt. 192–122, 81 FR 91873, Dec. 19, 2016]
and verification, monitoring, threat
and hazard identification, assessment, § 192.13 What general requirements
remediation, site security, emergency apply to pipelines regulated under
response and preparedness, and record- this part?
keeping requirements and rec- (a) No person may operate a segment
ommendations of API RP 1171, sections of pipeline listed in the first column
8, 9, 10, and 11 (incorporated by ref- that is readied for service after the
erence, see § 192.7) by January 18, 2018. date in the second column, unless:
(e) Operators of underground gas (1) The pipeline has been designed, in-
storage facilities must establish and stalled, constructed, initially in-
follow written procedures for oper- spected, and initially tested in accord-
ations, maintenance, and emergencies ance with this part; or
implementing the requirements of API
(2) The pipeline qualifies for use
RP 1170 and API RP 1171, as required
under this part according to the re-
under this section, including the effec-
quirements in § 192.14.
tive dates as applicable, and incor-
porate such procedures into their writ- Pipeline Date
ten procedures for operations, mainte-
nance, and emergencies established Offshore gathering line .......... July 31, 1977.
Regulated onshore gathering March 15 2007.
pursuant to § 192.605. line to which this part did
(f) With respect to the incorporation not apply until April 14,
by reference of API RP 1170 and API 2006.
RP 1171 in this section, the non-manda- All other pipelines .................. March 12, 1971.
tory provisions (i.e., provisions con-
taining the word ‘‘should’’ or other (b) No person may operate a segment
non-mandatory language) are adopted of pipeline listed in the first column
as mandatory provisions under the au- that is replaced, relocated, or other-
thority of the pipeline safety laws ex- wise changed after the date in the sec-
cept when the operator includes or ref- ond column, unless the replacement,
erences written technical justifications relocation or change has been made ac-
in its program or procedural manual, cording to the requirements in this
described in paragraph (a)(5) of this part.
432
Pipeline Date before the conversion occurs as re-

quired by § 191.22 of this chapter.
Offshore gathering line .......... July 31, 1977.
Regulated onshore gathering March 15, 2007. [Amdt. 192–30, 42 FR 60148, Nov. 25, 1977, as
line to which this part did amended by Amdt. 192–123, 82 FR 7997, Jan.
not apply until April 14, 23, 2017]
2006.
All other pipelines .................. November 12, 1970. § 192.15 Rules of regulatory construc-
tion.
(c) Each operator shall maintain,
(a) As used in this part:
modify as appropriate, and follow the
Includes means including but not lim-
plans, procedures, and programs that it
ited to.
is required to establish under this part. May means ‘‘is permitted to’’ or ‘‘is
[35 FR 13257, Aug. 19, 1970, as amended by authorized to’’.
Amdt. 192–27, 41 FR 34605, Aug. 16, 1976; May not means ‘‘is not permitted to’’
Amdt. 192–30, 42 FR 60148, Nov. 25, 1977; or ‘‘is not authorized to’’.
Amdt. 192–102, 71 FR 13303, Mar. 15, 2006] Shall is used in the mandatory and
imperative sense.
§ 192.14 Conversion to service subject (b) In this part:
to this part. (1) Words importing the singular in-
(a) A steel pipeline previously used in clude the plural;
service not subject to this part quali- (2) Words importing the plural in-
fies for use under this part if the oper- clude the singular; and
ator prepares and follows a written (3) Words importing the masculine
procedure to carry out the following gender include the feminine.
requirements:
§ 192.16 Customer notification.
(1) The design, construction, oper-
ation, and maintenance history of the (a) This section applies to each oper-
pipeline must be reviewed and, where ator of a service line who does not
sufficient historical records are not maintain the customer’s buried piping
available, appropriate tests must be up to entry of the first building down-
performed to determine if the pipeline stream, or, if the customer’s buried
is in a satisfactory condition for safe piping does not enter a building, up to
operation. the principal gas utilization equipment
(2) The pipeline right-of-way, all or the first fence (or wall) that sur-
aboveground segments of the pipeline, rounds that equipment. For the pur-
and appropriately selected under- pose of this section, ‘‘customer’s buried
ground segments must be visually in- piping’’ does not include branch lines
spected for physical defects and oper- that serve yard lanterns, pool heaters,
ating conditions which reasonably or other types of secondary equipment.
could be expected to impair the Also, ‘‘maintain’’ means monitor for
corrosion according to § 192.465 if the
strength or tightness of the pipeline.
customer’s buried piping is metallic,
(3) All known unsafe defects and con-
survey for leaks according to § 192.723,
ditions must be corrected in accord-
and if an unsafe condition is found,
ance with this part. shut off the flow of gas, advise the cus-
(4) The pipeline must be tested in ac- tomer of the need to repair the unsafe
cordance with subpart J of this part to condition, or repair the unsafe condi-
substantiate the maximum allowable tion.
operating pressure permitted by sub- (b) Each operator shall notify each
part L of this part. customer once in writing of the fol-
(b) Each operator must keep for the lowing information:
life of the pipeline a record of the in- (1) The operator does not maintain
vestigations, tests, repairs, replace- the customer’s buried piping.
ments, and alterations made under the (2) If the customer’s buried piping is
requirements of paragraph (a) of this not maintained, it may be subject to
section. the potential hazards of corrosion and

(c) An operator converting a pipeline leakage.
from service not previously covered by (3) Buried gas piping should be—
this part must notify PHMSA 60 days (i) Periodically inspected for leaks;
433
§ 192.51 49 CFR Ch. I (10–1–18 Edition)
(ii) Periodically inspected for corro- § 192.55 Steel pipe.

sion if the piping is metallic; and
(a) New steel pipe is qualified for use
(iii) Repaired if any unsafe condition
under this part if:
is discovered.
(4) When excavating near buried gas (1) It was manufactured in accord-
piping, the piping should be located in ance with a listed specification;
advance, and the excavation done by (2) It meets the requirements of—
hand. (i) Section II of appendix B to this
(5) The operator (if applicable), part; or
plumbing contractors, and heating con- (ii) If it was manufactured before No-
tractors can assist in locating, inspect- vember 12, 1970, either section II or III
ing, and repairing the customer’s bur- of appendix B to this part; or
ied piping. (3) It is used in accordance with para-
(c) Each operator shall notify each graph (c) or (d) of this section.
customer not later than August 14, (b) Used steel pipe is qualified for use
1996, or 90 days after the customer first under this part if:
receives gas at a particular location, (1) It was manufactured in accord-
whichever is later. However, operators ance with a listed specification and it
of master meter systems may continu- meets the requirements of paragraph
ously post a general notice in a promi-
II-C of appendix B to this part;
nent location frequented by customers.
(2) It meets the requirements of:
(d) Each operator must make the fol-
lowing records available for inspection (i) Section II of appendix B to this
by the Administrator or a State agency part; or
participating under 49 U.S.C. 60105 or (ii) If it was manufactured before No-
60106: vember 12, 1970, either section II or III
(1) A copy of the notice currently in of appendix B to this part;
use; and (3) It has been used in an existing
(2) Evidence that notices have been line of the same or higher pressure and
sent to customers within the previous 3 meets the requirements of paragraph
years. II-C of appendix B to this part; or
[Amdt. 192–74, 60 FR 41828, Aug. 14, 1995, as
(4) It is used in accordance with para-
amended by Amdt. 192–74A, 60 FR 63451, Dec. graph (c) of this section.
11, 1995; Amdt. 192–83, 63 FR 7723, Feb. 17, (c) New or used steel pipe may be
1998] used at a pressure resulting in a hoop
stress of less than 6,000 p.s.i. (41 MPa)
Subpart B—Materials where no close coiling or close bending
is to be done, if visual examination in-
§ 192.51 Scope. dicates that the pipe is in good condi-
This subpart prescribes minimum re- tion and that it is free of split seams
quirements for the selection and quali- and other defects that would cause
fication of pipe and components for use leakage. If it is to be welded, steel pipe
in pipelines. that has not been manufactured to a
listed specification must also pass the
§ 192.53 General. weldability tests prescribed in para-
Materials for pipe and components graph II-B of appendix B to this part.
must be: (d) Steel pipe that has not been pre-
(a) Able to maintain the structural viously used may be used as replace-
integrity of the pipeline under tem- ment pipe in a segment of pipeline if it
perature and other environmental con- has been manufactured prior to Novem-
ditions that may be anticipated; ber 12, 1970, in accordance with the
(b) Chemically compatible with any same specification as the pipe used in
gas that they transport and with any constructing that segment of pipeline.
other material in the pipeline with
which they are in contact; and

(c) Qualified in accordance with the
applicable requirements of this sub-
part.
434
(e) New steel pipe that has been cold § 192.61 [Reserved]
expanded must comply with the man-
datory provisions of API Spec 5L (in- § 192.63 Marking of materials.
corporated by reference, see § 192.7). (a) Except as provided in paragraph
[35 FR 13257, Aug. 19, 1970, as amended by
(d) of this section, each valve, fitting,
Amdt. 191–1, 35 FR 17660, Nov. 17, 1970; Amdt. length of pipe, and other component
192–12, 38 FR 4761, Feb. 22, 1973; Amdt. 192–51, must be marked—
51 FR 15335, Apr. 23, 1986; 58 FR 14521, Mar. 18, (1) As prescribed in the specification
1993; Amdt. 192–85, 63 FR 37502, July 13, 1998; or standard to which it was manufac-
Amdt. 192–119, 80 FR 180, Jan. 5, 2015; 80 FR tured, except that thermoplastic pipe
46847, Aug. 6, 2015] and fittings made of plastic materials
other than polyethylene must be
§ 192.57 [Reserved] marked in accordance with ASTM
D2513–87 (incorporated by reference, see
§ 192.59 Plastic pipe. § 192.7);
(a) New plastic pipe is qualified for (2) To indicate size, material, manu-
use under this part if: facturer, pressure rating, and tempera-
(1) It is manufactured in accordance ture rating, and as appropriate, type,
with a listed specification; and grade, and model.
(2) It is resistant to chemicals with (b) Surfaces of pipe and components
that are subject to stress from internal
which contact may be anticipated.
pressure may not be field die stamped.
(b) Used plastic pipe is qualified for
(c) If any item is marked by die
use under this part if: stamping, the die must have blunt or
(1) It was manufactured in accord- rounded edges that will minimize
ance with a listed specification; stress concentrations.
(2) It is resistant to chemicals with (d) Paragraph (a) of this section does
which contact may be anticipated; not apply to items manufactured be-
(3) It has been used only in natural fore November 12, 1970, that meet all of
gas service; the following:
(4) Its dimensions are still within the (1) The item is identifiable as to type,
tolerances of the specification to which manufacturer, and model.
it was manufactured; and (2) Specifications or standards giving
(5) It is free of visible defects. pressure, temperature, and other ap-
(c) For the purpose of paragraphs propriate criteria for the use of items
(a)(1) and (b)(1) of this section, where are readily available.
pipe of a diameter included in a listed [Amdt. 192–1, 35 FR 17660, Nov. 17, 1970, as
specification is impractical to use, pipe amended by Amdt. 192–31, 43 FR 883, Apr. 3,
of a diameter between the sizes in- 1978; Amdt. 192–61, 53 FR 36793, Sept. 22, 1988;
Amdt. 192–62, 54 FR 5627, Feb. 6, 1989; Amdt.
cluded in a listed specification may be
192–61A, 54 FR 32642, Aug. 9, 1989; 58 FR 14521,
used if it: Mar. 18, 1993; Amdt. 192–76, 61 FR 26122, May
(1) Meets the strength and design cri- 24, 1996; 61 FR 36826, July 15, 1996; Amdt. 192–
teria required of pipe included in that 114, 75 FR 48603, Aug. 11, 2010; Amdt. 192–119,
listed specification; and 80 FR 180, Jan. 5, 2015]
(2) Is manufactured from plastic com-
§ 192.65 Transportation of pipe.
pounds which meet the criteria for ma-
terial required of pipe included in that (a) Railroad. In a pipeline to be oper-
listed specification. ated at a hoop stress of 20 percent or
(d) Rework and/or regrind material is more of SMYS, an operator may not in-
not allowed in plastic pipe produced stall pipe having an outer diameter to
wall thickness of 70 to 1, or more, that
after March 6, 2015 used under this
is transported by railroad unless the
part.
transportation is performed by API RP
[35 FR 13257, Aug. 19, 1970, as amended by 5L1 (incorporated by reference, see
Amdt. 192–19, 40 FR 10472, Mar. 6, 1975; Amdt. § 192.7).

192–58, 53 FR 1635, Jan. 21, 1988; Amdt. 192–119, (b) Ship or barge. In a pipeline to be
80 FR 180, Jan. 5, 2015] operated at a hoop stress of 20 percent
or more of SMYS, an operator may not
435
§ 192.101 49 CFR Ch. I (10–1–18 Edition)
use pipe having an outer diameter to (b) If steel pipe that has been sub-
wall thickness ratio of 70 to 1, or more, jected to cold expansion to meet the
that is transported by ship or barge on SMYS is subsequently heated, other
both inland and marine waterways un- than by welding or stress relieving as a
less the transportation is performed in part of welding, the design pressure is
accordance with API RP 5LW (incor- limited to 75 percent of the pressure de-
porated by reference, see § 192.7). termined under paragraph (a) of this
(c) Truck. In a pipeline to be operated section if the temperature of the pipe
at a hoop stress of 20 percent or more exceeds 900 °F (482 °C) at any time or is
of SMYS, an operator may not use pipe held above 600 °F (316 °C) for more than
having an outer diameter to wall 1 hour.
thickness ratio of 70 to 1, or more, that [35 FR 13257, Aug. 19, 1970, as amended by
is transported by truck unless the Amdt. 192–47, 49 FR 7569, Mar. 1, 1984; Amdt.
transportation is performed in accord- 192–85, 63 FR 37502, July 13, 1998]
ance with API RP 5LT (incorporated by
reference, see § 192.7). § 192.107 Yield strength (S) for steel
pipe.
[Amdt. 192–114, 75 FR 48603, Aug. 11, 2010, as
amended by Amdt. 192–119, 80 FR 180, Jan. 5, (a) For pipe that is manufactured in
2015; Amdt. 192–120, 80 FR 12777, Mar. 11, 2015] accordance with a specification listed
in section I of appendix B of this part,
the yield strength to be used in the de-
Subpart C—Pipe Design sign formula in § 192.105 is the SMYS
§ 192.101 Scope. stated in the listed specification, if
that value is known.
This subpart prescribes the minimum (b) For pipe that is manufactured in
requirements for the design of pipe. accordance with a specification not
listed in section I of appendix B to this
§ 192.103 General.
part or whose specification or tensile
Pipe must be designed with sufficient properties are unknown, the yield
wall thickness, or must be installed strength to be used in the design for-
with adequate protection, to withstand mula in § 192.105 is one of the following:
anticipated external pressures and (1) If the pipe is tensile tested in ac-
loads that will be imposed on the pipe cordance with section II-D of appendix
after installation. B to this part, the lower of the fol-
lowing:
§ 192.105 Design formula for steel pipe. (i) 80 percent of the average yield
(a) The design pressure for steel pipe strength determined by the tensile
is determined in accordance with the tests.
following formula: (ii) The lowest yield strength deter-
mined by the tensile tests.
P = (2 St/D) × F × E × T
(2) If the pipe is not tensile tested as
P = Design pressure in pounds per square provided in paragraph (b)(1) of this sec-
inch (kPa) gauge. tion, 24,000 p.s.i. (165 MPa).
S = Yield strength in pounds per square inch
(kPa) determined in accordance with [35 FR 13257, Aug. 19, 1970, as amended by
§ 192.107. Amdt. 192–78, 61 FR 28783, June 6, 1996; Amdt.
D = Nominal outside diameter of the pipe in 192–83, 63 FR 7723, Feb. 17, 1998; Amdt. 192–85,
inches (millimeters). 63 FR 37502, July 13, 1998]
t = Nominal wall thickness of the pipe in
inches (millimeters). If this is unknown, § 192.109 Nominal wall thickness (t)
it is determined in accordance with for steel pipe.
§ 192.109. Additional wall thickness re- (a) If the nominal wall thickness for
quired for concurrent external loads in steel pipe is not known, it is deter-
accordance with § 192.103 may not be in- mined by measuring the thickness of
cluded in computing design pressure.
each piece of pipe at quarter points on
F = Design factor determined in accordance
with § 192.111. one end.
E = Longitudinal joint factor determined in (b) However, if the pipe is of uniform

accordance with § 192.113. grade, size, and thickness and there are
T = Temperature derating factor determined more than 10 lengths, only 10 percent
in accordance with § 192.115. of the individual lengths, but not less
436
than 10 lengths, need be measured. The (3) Is supported by a vehicular, pedes-

thickness of the lengths that are not trian, railroad, or pipeline bridge; or
measured must be verified by applying (4) Is used in a fabricated assembly,
a gauge set to the minimum thickness (including separators, mainline valve
found by the measurement. The nomi- assemblies, cross-connections, and
nal wall thickness to be used in the de- river crossing headers) or is used with-
sign formula in § 192.105 is the next wall in five pipe diameters in any direction
thickness found in commercial speci- from the last fitting of a fabricated as-
fications that is below the average of sembly, other than a transition piece
all the measurements taken. However,
or an elbow used in place of a pipe bend
the nominal wall thickness used may
which is not associated with a fab-
not be more than 1.14 times the small-
ricated assembly.
est measurement taken on pipe less
than 20 inches (508 millimeters) in out- (c) For Class 2 locations, a design fac-
side diameter, nor more than 1.11 times tor of 0.50, or less, must be used in the
the smallest measurement taken on design formula in § 192.105 for uncased
pipe 20 inches (508 millimeters) or more steel pipe that crosses the right-of-way
in outside diameter. of a hard surfaced road, a highway, a
public street, or a railroad.
Amdt. 192–85, 63 FR 37502, July 13, 1998] (d) For Class 1 and Class 2 locations,
a design factor of 0.50, or less, must be
§ 192.111 Design factor (F) for steel used in the design formula in § 192.105
pipe. for—
(a) Except as otherwise provided in (1) Steel pipe in a compressor station,
paragraphs (b), (c), and (d) of this sec- regulating station, or measuring sta-
tion, the design factor to be used in the tion; and
design formula in § 192.105 is deter- (2) Steel pipe, including a pipe riser,
mined in accordance with the following on a platform located offshore or in in-
table: land navigable waters.
Design [35 FR 13257, Aug. 19, 1970, as amended by
Class location factor (F) Amdt. 192–27, 41 FR 34605, Aug. 16, 1976]
1 ........................................................................... 0.72
2 ........................................................................... 0.60 § 192.112 Additional design require-
3 ........................................................................... 0.50 ments for steel pipe using alter-
4 ........................................................................... 0.40 native maximum allowable oper-
ating pressure.
(b) A design factor of 0.60 or less
must be used in the design formula in For a new or existing pipeline seg-
§ 192.105 for steel pipe in Class 1 loca- ment to be eligible for operation at the
tions that: alternative maximum allowable oper-
(1) Crosses the right-of-way of an un- ating pressure (MAOP) calculated
improved public road, without a casing; under § 192.620, a segment must meet
(2) Crosses without a casing, or the following additional design require-
makes a parallel encroachment on, the ments. Records for alternative MAOP
right-of-way of either a hard surfaced must be maintained, for the useful life
road, a highway, a public street, or a of the pipeline, demonstrating compli-
railroad; ance with these requirements:
To address this design issue: The pipeline segment must meet these additional requirements:
(a) General standards for the (1) The plate, skelp, or coil used for the pipe must be micro-alloyed, fine grain, fully killed, con-
steel pipe. tinuously cast steel with calcium treatment.
(2) The carbon equivalents of the steel used for pipe must not exceed 0.25 percent by weight,
as calculated by the Ito-Bessyo formula (Pcm formula) or 0.43 percent by weight, as cal-
culated by the International Institute of Welding (IIW) formula.
(3) The ratio of the specified outside diameter of the pipe to the specified wall thickness must
be less than 100. The wall thickness or other mitigative measures must prevent denting and
ovality anomalies during construction, strength testing and anticipated operational stresses.
(4) The pipe must be manufactured using API Spec 5L, product specification level 2 (incor-
porated by reference, see § 192.7) for maximum operating pressures and minimum and
maximum operating temperatures and other requirements under this section.
437
§ 192.112 49 CFR Ch. I (10–1–18 Edition)
(b) Fracture control ................... (1) The toughness properties for pipe must address the potential for initiation, propagation and
arrest of fractures in accordance with:
(i) API Spec 5L (incorporated by reference, see § 192.7); or
(ii) American Society of Mechanical Engineers (ASME) B31.8 (incorporated by reference, see
§ 192.7); and
(iii) Any correction factors needed to address pipe grades, pressures, temperatures, or gas
compositions not expressly addressed in API Spec 5L , product specification level 2 or
ASME B31.8 (incorporated by reference, see § 192.7).
(2) Fracture control must:
(i) Ensure resistance to fracture initiation while addressing the full range of operating tempera-
tures, pressures, gas compositions, pipe grade and operating stress levels, including max-
imum pressures and minimum temperatures for shut-in conditions, that the pipeline is ex-
pected to experience. If these parameters change during operation of the pipeline such that
they are outside the bounds of what was considered in the design evaluation, the evaluation
must be reviewed and updated to assure continued resistance to fracture initiation over the
operating life of the pipeline;
(ii) Address adjustments to toughness of pipe for each grade used and the decompression be-
havior of the gas at operating parameters;
(iii) Ensure at least 99 percent probability of fracture arrest within eight pipe lengths with a
probability of not less than 90 percent within five pipe lengths; and
(iv) Include fracture toughness testing that is equivalent to that described in supplementary re-
quirements SR5A, SR5B, and SR6 of API Specification 5L (incorporated by reference, see
§ 192.7) and ensures ductile fracture and arrest with the following exceptions:
(A) The results of the Charpy impact test prescribed in SR5A must indicate at least 80 percent
minimum shear area for any single test on each heat of steel; and
(B) The results of the drop weight test prescribed in SR6 must indicate 80 percent average
shear area with a minimum single test result of 60 percent shear area for any steel test
samples. The test results must ensure a ductile fracture and arrest.
(3) If it is not physically possible to achieve the pipeline toughness properties of paragraphs
(b)(1) and (2) of this section, additional design features, such as mechanical or composite
crack arrestors and/or heavier walled pipe of proper design and spacing, must be used to
ensure fracture arrest as described in paragraph (b)(2)(iii) of this section.
(c) Plate/coil quality control ...... (1) There must be an internal quality management program at all mills involved in producing
steel, plate, coil, skelp, and/or rolling pipe to be operated at alternative MAOP. These pro-
grams must be structured to eliminate or detect defects and inclusions affecting pipe quality.
(2) A mill inspection program or internal quality management program must include (i) and ei-
ther (ii) or (iii):
(i) An ultrasonic test of the ends and at least 35 percent of the surface of the plate/coil or pipe
to identify imperfections that impair serviceability such as laminations, cracks, and inclu-
sions. At least 95 percent of the lengths of pipe manufactured must be tested. For all pipe-
lines designed after December 22, 2008, the test must be done in accordance with ASTM
A578/A578M Level B, or API Spec 5L Paragraph 7.8.10 (incorporated by reference, see
§ 192.7) or equivalent method, and either
(ii) A macro etch test or other equivalent method to identify inclusions that may form centerline
segregation during the continuous casting process. Use of sulfur prints is not an equivalent
method. The test must be carried out on the first or second slab of each sequence graded
with an acceptance criteria of one or two on the Mannesmann scale or equivalent; or
(iii) A quality assurance monitoring program implemented by the operator that includes audits
of: (a) all steelmaking and casting facilities, (b) quality control plans and manufacturing pro-
cedure specifications, (c) equipment maintenance and records of conformance, (d) applica-
ble casting superheat and speeds, and (e) centerline segregation monitoring records to en-
sure mitigation of centerline segregation during the continuous casting process.
(d) Seam quality control ........... (1) There must be a quality assurance program for pipe seam welds to assure tensile strength
provided in API Spec 5L (incorporated by reference, see § 192.7) for appropriate grades.
(2) There must be a hardness test, using Vickers (Hv10) hardness test method or equivalent
test method, to assure a maximum hardness of 280 Vickers of the following:
(i) A cross section of the weld seam of one pipe from each heat plus one pipe from each
welding line per day; and
(ii) For each sample cross section, a minimum of 13 readings (three for each heat affected
zone, three in the weld metal, and two in each section of pipe base metal).
(3) All of the seams must be ultrasonically tested after cold expansion and mill hydrostatic
testing.
(e) Mill hydrostatic test ............. (1) All pipe to be used in a new pipeline segment installed after October 1, 2015, must be
hydrostatically tested at the mill at a test pressure corresponding to a hoop stress of 95 per-
cent SMYS for 10 seconds.
(2) Pipe in operation prior to December 22, 2008, must have been hydrostatically tested at the
mill at a test pressure corresponding to a hoop stress of 90 percent SMYS for 10 seconds.
(3) Pipe in operation on or after December 22, 2008, but before October 1, 2015, must have
been hydrostatically tested at the mill at a test pressure corresponding to a hoop stress of
95 percent SMYS for 10 seconds. The test pressure may include a combination of internal
test pressure and the allowance for end loading stresses imposed by the pipe mill hydro-
static testing equipment as allowed by ‘‘ANSI/API Spec 5L’’ (incorporated by reference, see
§ 192.7).
(f) Coating ................................. (1) The pipe must be protected against external corrosion by a non-shielding coating.
438
(2) Coating on pipe used for trenchless installation must be non-shielding and resist abrasions
and other damage possible during installation.
(3) A quality assurance inspection and testing program for the coating must cover the surface
quality of the bare pipe, surface cleanliness and chlorides, blast cleaning, application tem-
perature control, adhesion, cathodic disbondment, moisture permeation, bending, coating
thickness, holiday detection, and repair.
(g) Fittings and flanges ............. (1) There must be certification records of flanges, factory induction bends and factory weld
ells. Certification must address material properties such as chemistry, minimum yield
strength and minimum wall thickness to meet design conditions.
(2) If the carbon equivalents of flanges, bends and ells are greater than 0.42 percent by
weight, the qualified welding procedures must include a pre-heat procedure.
(3) Valves, flanges and fittings must be rated based upon the required specification rating
class for the alternative MAOP.
(h) Compressor stations ........... (1) A compressor station must be designed to limit the temperature of the nearest downstream
segment operating at alternative MAOP to a maximum of 120 degrees Fahrenheit (49 de-
grees Celsius) or the higher temperature allowed in paragraph (h)(2) of this section unless a
long-term coating integrity monitoring program is implemented in accordance with paragraph
(h)(3) of this section.
(2) If research, testing and field monitoring tests demonstrate that the coating type being used
will withstand a higher temperature in long-term operations, the compressor station may be
designed to limit downstream piping to that higher temperature. Test results and acceptance
criteria addressing coating adhesion, cathodic disbondment, and coating condition must be
provided to each PHMSA pipeline safety regional office where the pipeline is in service at
least 60 days prior to operating above 120 degrees Fahrenheit (49 degrees Celsius). An op-
erator must also notify a State pipeline safety authority when the pipeline is located in a
State where PHMSA has an interstate agent agreement, or an intrastate pipeline is regu-
lated by that State.
(3) Pipeline segments operating at alternative MAOP may operate at temperatures above 120
degrees Fahrenheit (49 degrees Celsius) if the operator implements a long-term coating in-
tegrity monitoring program. The monitoring program must include examinations using direct
current voltage gradient (DCVG), alternating current voltage gradient (ACVG), or an equiva-
lent method of monitoring coating integrity. An operator must specify the periodicity at which
these examinations occur and criteria for repairing identified indications. An operator must
submit its long-term coating integrity monitoring program to each PHMSA pipeline safety re-
gional office in which the pipeline is located for review before the pipeline segments may be
operated at temperatures in excess of 120 degrees Fahrenheit (49 degrees Celsius). An op-
erator must also notify a State pipeline safety authority when the pipeline is located in a
State where PHMSA has an interstate agent agreement, or an intrastate pipeline is regu-
lated by that State.
[73 FR 62175, Oct. 17, 2008, as amended by Amdt. 192–111, 74 FR 62505, Nov. 30, 2009; Amdt. 192–
119, 80 FR 180, Jan. 5, 2015; Amdt. 192–120, 80 FR 12777, Mar. 11, 2015]
§ 192.113 Longitudinal joint factor (E) for steel pipe.
The longitudinal joint factor to be determined in accordance with the fol-

used in the design formula in § 192.105 is lowing table:
Longitudinal joint
Specification Pipe class factor (E)
ASTM A 53/A53M ................... Seamless ....................................................................................................... 1.00

Electric resistance welded ............................................................................. 1.00
Furnace butt welded ...................................................................................... .60
ASTM A 106 ............................ Seamless ....................................................................................................... 1.00
ASTM A 333/A 333M .............. Seamless ....................................................................................................... 1.00
ASTM A 381 ............................ Double submerged arc welded ..................................................................... 1.00
ASTM A 671 ............................ Electric-fusion-welded .................................................................................... 1.00
API Spec 5L ............................ Seamless ....................................................................................................... 1.00
Electric flash welded ...................................................................................... 1.00
Submerged arc welded ................................................................................. 1.00

Furnace butt welded ...................................................................................... .60
Other ....................................... Pipe over 4 inches (102 millimeters) ............................................................. .80
Other ....................................... Pipe 4 inches (102 millimeters) or less ......................................................... .60
439
§ 192.115 49 CFR Ch. I (10–1–18 Edition)
If the type of longitudinal joint cannot Gas temperature in degrees Temperature

be determined, the joint factor to be Fahrenheit (Celsius) derating factor (T)
used must not exceed that designated 300 °F (149 °C) ....................................... 0.967
for ‘‘Other.’’ 350 °F (177 °C) ....................................... 0.933
400 °F (204 °C) ....................................... 0.900
[Amdt. 192–37, 46 FR 10159, Feb. 2, 1981, as
450 °F (232 °C) ....................................... 0.867
amended by Amdt. 192–51, 51 FR 15335, Apr.
23, 1986; Amdt. 192–62, 54 FR 5627, Feb. 6, 1989;
58 FR 14521, Mar. 18, 1993; Amdt. 192–85, 63 FR For intermediate gas temperatures, the
37502, July 13, 1998; Amdt. 192–94, 69 FR 32894, derating factor is determined by inter-
June 14, 2004; Amdt. 192–119, 80 FR 180, Jan. polation.
5, 2015]
§ 192.115 Temperature derating factor Amdt. 192–85, 63 FR 37502, July 13, 1998]
(T) for steel pipe.
§§ 192.117–192.119 [Reserved]
The temperature derating factor to
be used in the design formula in § 192.121 Design of plastic pipe.
§ 192.105 is determined as follows:
Subject to the limitations of § 192.123,
Gas temperature in degrees Temperature the design pressure for plastic pipe is
Fahrenheit (Celsius) derating factor (T)
determined by either of the following
250 °F (121 °C) or less ........................... 1.000 formulas:
t
P = 2S (DF)
(D − t)
2S
P= (DF)
(SDR − 1)
Where: 4-inch or less, and a SDR of 11 or greater (i.e.,

P = Design pressure, gauge, psig (kPa). thicker pipe wall).
S = For thermoplastic pipe, the HDB is de-
[Amdt. 192–111, 74 FR 62505, Nov. 30, 2009, as
termined in accordance with the listed speci-
fication at a temperature equal to 73 °F (23
11, 2010]
°C), 100 °F (38 °C), 120 °F (49 °C), or 140 °F (60
°C). In the absence of an HDB established at
the specified temperature, the HDB of a § 192.123 Design limitations for plastic
higher temperature may be used in deter- pipe.
mining a design pressure rating at the speci- (a) Except as provided in paragraph
fied temperature by arithmetic interpolation
(e) and paragraph (f) of this section,
using the procedure in Part D.2 of PPI TR–3/
2008, HDB/PDB/SDB/MRS Policies (incor- the design pressure may not exceed a
porated by reference, see § 192.7). For rein- gauge pressure of 100 psig (689 kPa) for
forced thermosetting plastic pipe, 11,000 psig plastic pipe used in:
(75,842 kPa). [Note: Arithmetic interpolation (1) Distribution systems; or
is not allowed for PA–11 pipe.] (2) Classes 3 and 4 locations.
t = Specified wall thickness, inches (mm). (b) Plastic pipe may not be used
D = Specified outside diameter, inches (mm).
SDR = Standard dimension ratio, the ratio of where operating temperatures of the
the average specified outside diameter to the pipe will be:
minimum specified wall thickness, cor- (1) Below ¥20 °F (¥20 °C), or ¥40 °F
responding to a value from a common num- (¥40 °C) if all pipe and pipeline compo-
bering system that was derived from the nents whose operating temperature
American National Standards Institute pre-
will be below ¥29 °C (¥20 °F) have a
ferred number series 10.

D F = 0.32 or temperature rating by the manufac-
= 0.40 for PA–11 pipe produced after January turer consistent with that operating
23, 2009 with a nominal pipe size (IPS or CTS) temperature; or
440
ER30NO09.008</MATH>
(2) Above the following applicable § 192.125 Design of copper pipe.

temperatures: (a) Copper pipe used in mains must
(i) For thermoplastic pipe, the tem-
have a minimum wall thickness of 0.065
perature at which the HDB used in the
inches (1.65 millimeters) and must be
design formula under § 192.121 is deter-
hard drawn.
mined.
(b) Copper pipe used in service lines
(ii) For reinforced thermosetting
must have wall thickness not less than
plastic pipe, 150 °F (66 °C).
that indicated in the following table:
(c) The wall thickness for thermo-
plastic pipe may not be less than 0.062 Wall thickness inch (milli-
Standard Nominal
inches (1.57 millimeters). meter)
size inch O.D. inch
(d) The wall thickness for reinforced (millimeter) (millimeter) Nominal Tolerance
thermosetting plastic pipe may not be 12
⁄ (13) .625 (16) .040 (1.06) .0035 (.0889)
less than that listed in the following ⁄
58 (16) .750 (19) .042 (1.07) .0035 (.0889)
table: ⁄
34 (19) .875 (22) .045 (1.14) .004 (.102)
1 (25) 1.125 (29) .050 (1.27) .004 (.102)
Minimum 11⁄4 (32) 1.375 (35) .055 (1.40) .0045 (.1143)
wall thick- 11⁄2 (38) 1.625 (41) .060 (1.52) .0045 (.1143)
Nominal size in inches (millimeters). ness inches
(millime-
ters). (c) Copper pipe used in mains and
2 (51) ................................................................. 0.060 (1.52) service lines may not be used at pres-
3 (76) ................................................................. 0.060 (1.52) sures in excess of 100 p.s.i. (689 kPa)
4 (102) ............................................................... 0.070 (1.78) gage.
6 (152) ............................................................... 0.100 (2.54)
(d) Copper pipe that does not have an
(e) The design pressure for thermo- internal corrosion resistant lining may
plastic pipe produced after July 14, 2004 not be used to carry gas that has an av-
may exceed a gauge pressure of 100 psig erage hydrogen sulfide content of more
(689 kPa) provided that: than 0.3 grains/100 ft3 (6.9/m3) under
(1) The design pressure does not ex- standard conditions. Standard condi-
ceed 125 psig (862 kPa); tions refers to 60 °F and 14.7 psia (15.6
(2) The material is a polyethylene °C and one atmosphere) of gas.
(PE) pipe with the designation code as [35 FR 13257, Aug. 19, 1970, as amended by
specified within ASTM D2513–09a (in- Amdt. 192–62, 54 FR 5628, Feb. 6, 1989; Amdt.
corporated by reference, see § 192.7); 192–85, 63 FR 37502, July 13, 1998]
(3) The pipe size is nominal pipe size
(IPS) 12 or less; and Subpart D—Design of Pipeline
(4) The design pressure is determined Components
in accordance with the design equation
defined in § 192.121. § 192.141 Scope.
(f) The design pressure for poly- This subpart prescribes minimum re-
amide-11 (PA–11) pipe produced after quirements for the design and installa-
January 23, 2009 may exceed a gauge tion of pipeline components and facili-
pressure of 100 psig (689 kPa) provided ties. In addition, it prescribes require-
that: ments relating to protection against
(1) The design pressure does not ex- accidental overpressuring.
ceed 200 psig (1379 kPa);
(2) The pipe size is nominal pipe size § 192.143 General requirements.
(IPS or CTS) 4-inch or less; and
(a) Each component of a pipeline
(3) The pipe has a standard dimension
must be able to withstand operating
ratio of SDR–11 or greater (i.e., thicker
pressures and other anticipated load-
pipe wall).
ings without impairment of its service-
[35 FR 13257, Aug. 19, 1970, as amended by ability with unit stresses equivalent to
Amdt. 192–31, 43 FR 13883, Apr. 3, 1978; Amdt. those allowed for comparable material
192–78, 61 FR 28783, June 6, 1996; Amdt. 192–85, in pipe in the same location and kind
63 FR 37502, July 13, 1998; Amdt. 192–93, 68 FR
of service. However, if design based
53900, Sept. 15, 2003; 69 FR 32894, June 14, 2004;
Amdt. 192–94, 69 FR 54592, Sept. 9, 2004; Amdt. upon unit stresses is impractical for a
192–103, 71 FR 33407, June 9, 2006; 73 FR 79005, particular component, design may be
Dec. 24, 2008; Amdt. 192–114, 75 FR 48603, Aug. based upon a pressure rating estab-
11, 2010; Amdt. 192–119, 80 FR 181, Jan. 5, 2015] lished by the manufacturer by pressure
441
§ 192.144 49 CFR Ch. I (10–1–18 Edition)
testing that component or a prototype (i) With the valve in the fully open
of the component. position, the shell must be tested with
(b) The design and installation of no leakage to a pressure at least 1.5
pipeline components and facilities times the maximum service rating.
must meet applicable requirements for (ii) After the shell test, the seat must
corrosion control found in subpart I of be tested to a pressure not less than 1.5
this part. times the maximum service pressure
[Amdt. 48, 49 FR 19824, May 10, 1984, as rating. Except for swing check valves,
amended at 72 FR 20059, Apr. 23, 2007] test pressure during the seat test must
be applied successively on each side of
§ 192.144 Qualifying metallic compo- the closed valve with the opposite side
nents. open. No visible leakage is permitted.
Notwithstanding any requirement of (iii) After the last pressure test is
this subpart which incorporates by ref- completed, the valve must be operated
erence an edition of a document listed through its full travel to demonstrate
in § 192.7 or Appendix B of this part, a freedom from interference.
metallic component manufactured in (c) Each valve must be able to meet
accordance with any other edition of the anticipated operating conditions.
that document is qualified for use (d) No valve having shell (body, bon-
under this part if— net, cover, and/or end flange) compo-
(a) It can be shown through visual in- nents made of ductile iron may be used
spection of the cleaned component that at pressures exceeding 80 percent of the
no defect exists which might impair pressure ratings for comparable steel
the strength or tightness of the compo- valves at their listed temperature.
nent; and However, a valve having shell compo-
(b) The edition of the document nents made of ductile iron may be used
under which the component was manu- at pressures up to 80 percent of the
factured has equal or more stringent pressure ratings for comparable steel
requirements for the following as an valves at their listed temperature, if:
edition of that document currently or (1) The temperature-adjusted service
previously listed in § 192.7 or appendix pressure does not exceed 1,000 p.s.i. (7
B of this part: Mpa) gage; and
(1) Pressure testing; (2) Welding is not used on any ductile
(2) Materials; and iron component in the fabrication of
(3) Pressure and temperature ratings. the valve shells or their assembly.
[Amdt. 192–45, 48 FR 30639, July 5, 1983, as (e) No valve having shell (body, bon-
amended by Amdt. 192–94, 69 FR 32894, June net, cover, and/or end flange) compo-
14, 2004] nents made of cast iron, malleable
iron, or ductile iron may be used in the
§ 192.145 Valves. gas pipe components of compressor sta-
(a) Except for cast iron and plastic tions.
valves, each valve must meet the min- [35 FR 13257, Aug. 19, 1970, as amended by
imum requirements of ANSI/API Spec Amdt. 192–62, 54 FR 5628, Feb. 6, 1989; Amdt.
6D (incorporated by reference, see 192–85, 63 FR 37502, July 13, 1998; Amdt. 192–
§ 192.7), or to a national or inter- 94, 69 FR 32894, June 14, 2004; Amdt. 192–114,
national standard that provides an 75 FR 48603, Aug. 11, 2010; Amdt. 192–119, 80
equivalent performance level. A valve FR 181, Jan. 5, 2015]
may not be used under operating condi-
tions that exceed the applicable pres- § 192.147 Flanges and flange acces-
sure-temperature ratings contained in sories.
those requirements. (a) Each flange or flange accessory
(b) Each cast iron and plastic valve (other than cast iron) must meet the
must comply with the following: minimum requirements of ASME/ANSI
(1) The valve must have a maximum B 16.5 and MSS SP–44 (incorporated by
service pressure rating for tempera- reference, see § 192.7), or the equivalent.
tures that equal or exceed the max- (b) Each flange assembly must be
imum service temperature. able to withstand the maximum pres-
(2) The valve must be tested as part sure at which the pipeline is to be oper-
of the manufacturing, as follows: ated and to maintain its physical and
442
chemical properties at any tempera- (6) Transmission lines, operated in

ture to which it is anticipated that it conjunction with a distribution system
might be subjected in service. which are installed in Class 4 locations;
(c) Each flange on a flanged joint in (7) Offshore transmission lines, ex-
cast iron pipe must conform in dimen- cept transmission lines 103⁄4 inches (273
sions, drilling, face and gasket design millimeters) or more in outside diame-
to ASME/ANSI B16.1 (incorporated by ter on which construction begins after
reference, see § 192.7)and be cast inte- December 28, 2005, that run from plat-
grally with the pipe, valve, or fitting. form to platform or platform to shore
unless—
[35 FR 13257, Aug. 19, 1970, as amended by (i) Platform space or configuration is
Amdt. 192–62, 54 FR 5628, Feb. 6, 1989; 58 FR incompatible with launching or re-
14521, Mar. 18, 1993; Amdt. 192–119, 80 FR 181, trieving instrumented internal inspec-
Jan. 5, 2015]
tion devices; or
(ii) If the design includes taps for lat-
§ 192.149 Standard fittings.
eral connections, the operator can
(a) The minimum metal thickness of demonstrate, based on investigation or
threaded fittings may not be less than experience, that there is no reasonably
specified for the pressures and tem- practical alternative under the design
peratures in the applicable standards circumstances to the use of a tap that
referenced in this part, or their equiva- will obstruct the passage of instru-
lent. mented internal inspection devices;
(b) Each steel butt-welding fitting and
must have pressure and temperature (8) Other piping that, under § 190.9 of
ratings based on stresses for pipe of the this chapter, the Administrator finds
same or equivalent material. The ac- in a particular case would be impracti-
tual bursting strength of the fitting cable to design and construct to ac-
must at least equal the computed commodate the passage of instru-
bursting strength of pipe of the des- mented internal inspection devices.
ignated material and wall thickness, as (c) An operator encountering emer-
determined by a prototype that was gencies, construction time constraints
tested to at least the pressure required or other unforeseen construction prob-
for the pipeline to which it is being lems need not construct a new or re-
added. placement segment of a transmission
line to meet paragraph (a) of this sec-
§ 192.150 Passage of internal inspection, if the operator determines and
tion devices. documents why an impracticability
prohibits compliance with paragraph
(a) Except as provided in paragraphs
(a) of this section. Within 30 days after
(b) and (c) of this section, each new
discovering the emergency or construc-
transmission line and each replace- tion problem the operator must peti-
ment of line pipe, valve, fitting, or tion, under § 190.9 of this chapter, for
other line component in a transmission approval that design and construction
line must be designed and constructed to accommodate passage of instru-
to accommodate the passage of instrumented internal inspection devices
mented internal inspection devices. would be impracticable. If the petition
(b) This section does not apply to: (1) is denied, within 1 year after the date
Manifolds; of the notice of the denial, the operator
(2) Station piping such as at com- must modify that segment to allow
pressor stations, meter stations, or passage of instrumented internal in-
regulator stations; spection devices.
(3) Piping associated with storage fa-
[Amdt. 192–72, 59 FR 17281, Apr. 12, 1994, as
cilities, other than a continuous run of amended by Amdt. 192–85, 63 FR 37502, July
transmission line between a com- 13, 1998; Amdt. 192–97, 69 FR 36029, June 28,
pressor station and storage facilities; 2004]
(4) Cross-overs;
(5) Sizes of pipe for which an instru- § 192.151 Tapping.
mented internal inspection device is (a) Each mechanical fitting used to
not commercially available; make a hot tap must be designed for at
443
§ 192.153 49 CFR Ch. I (10–1–18 Edition)
least the operating pressure of the (4) Prefabricated units that the man-
pipeline. ufacturer certifies have been tested to
(b) Where a ductile iron pipe is at least twice the maximum pressure
tapped, the extent of full-thread en- to which they will be subjected under
gagement and the need for the use of the anticipated operating conditions.
outside-sealing service connections, (c) Orange-peel bull plugs and or-
tapping saddles, or other fixtures must ange-peel swages may not be used on
be determined by service conditions. pipelines that are to operate at a hoop
(c) Where a threaded tap is made in stress of 20 percent or more of the
cast iron or ductile iron pipe, the di- SMYS of the pipe.
ameter of the tapped hole may not be (d) Except for flat closures designed
more than 25 percent of the nominal di- in accordance with the ASME BPVC
ameter of the pipe unless the pipe is re- (Section VIII, Division 1 or 2), flat clo-
inforced, except that sures and fish tails may not be used on
(1) Existing taps may be used for re- pipe that either operates at 100 p.s.i.
placement service, if they are free of (689 kPa) gage or more, or is more than
cracks and have good threads; and 3 inches in (76 millimeters) nominal di-
(2) A 11⁄4-inch (32 millimeters) tap ameter.
may be made in a 4-inch (102 millime- (e) A component having a design
ters) cast iron or ductile iron pipe, pressure established in accordance with
without reinforcement. paragraph (a) or paragraph (b) of this
section and subject to the strength
However, in areas where climate, soil,
testing requirements of § 192.505(b)
and service conditions may create un-
must be tested to at least 1.5 times the
usual external stresses on cast iron
MAOP.
pipe, unreinforced taps may be used
only on 6-inch (152 millimeters) or larg- [35 FR 13257, Aug. 19, 1970, as amended by
er pipe. Amdt. 192–1, 35 FR 17660, Nov. 17, 1970; 58 FR
14521, Mar. 18, 1993; Amdt. 192–68, 58 FR 45268,
[35 FR 13257, Aug. 19, 1970, as amended by Aug. 27, 1993; Amdt. 192–85, 63 FR 37502, July
Amdt. 192–85, 63 FR 37502, July 13, 1998] 13, 1998; Amdt. 192–119, 80 FR 181, Jan. 5, 2015;
Amdt. 192–120, 80 FR 12778, Mar. 11, 2015;
§ 192.153 Components fabricated by Amdt. 192–119, 80 FR 46847, Aug. 6, 2015]
welding.
(a) Except for branch connections § 192.155 Welded branch connections.
and assemblies of standard pipe and fit- Each welded branch connection made
tings joined by circumferential welds, to pipe in the form of a single connec-
the design pressure of each component tion, or in a header or manifold as a se-
fabricated by welding, whose strength ries of connections, must be designed
cannot be determined, must be estab- to ensure that the strength of the pipe-
lished in accordance with paragraph line system is not reduced, taking into
UG–101 of the ASME Boiler and Pres- account the stresses in the remaining
sure Vessel Code (BPVC) (Section VIII, pipe wall due to the opening in the pipe
Division 1) (incorporated by reference, or header, the shear stresses produced
see § 192.7). by the pressure acting on the area of
(b) Each prefabricated unit that uses the branch opening, and any external
plate and longitudinal seams must be loadings due to thermal movement,
designed, constructed, and tested in ac- weight, and vibration.
cordance with section 1 of the ASME
BPVC (Section VIII, Division 1 or Sec- § 192.157 Extruded outlets.
tion VIII, Division 2) (incorporated by Each extruded outlet must be suit-
reference, see § 192.7), except for the fol- able for anticipated service conditions
lowing: and must be at least equal to the de-
(1) Regularly manufactured butt- sign strength of the pipe and other fit-
welding fittings. tings in the pipeline to which it is at-
(2) Pipe that has been produced and tached.
tested under a specification listed in

appendix B to this part. § 192.159 Flexibility.
(3) Partial assemblies such as split Each pipeline must be designed with
rings or collars. enough flexibility to prevent thermal
444
expansion or contraction from causing nected to new branches must have a

excessive stresses in the pipe or compo- firm foundation for both the header
nents, excessive bending or unusual and the branch to prevent detrimental
loads at joints, or undesirable forces or lateral and vertical movement.
moments at points of connection to [35 FR 13257, Aug. 19, 1970, as amended by
equipment, or at anchorage or guide Amdt. 192–58, 53 FR 1635, Jan. 21, 1988]
points.
§ 192.163 Compressor stations: Design
§ 192.161 Supports and anchors. and construction.
(a) Each pipeline and its associated (a) Location of compressor building. Ex-
equipment must have enough anchors cept for a compressor building on a
or supports to: platform located offshore or in inland
(1) Prevent undue strain on con- navigable waters, each main com-
nected equipment; pressor building of a compressor sta-
(2) Resist longitudinal forces caused tion must be located on property under
by a bend or offset in the pipe; and the control of the operator. It must be
(3) Prevent or damp out excessive vi- far enough away from adjacent prop-
bration. erty, not under control of the operator,
(b) Each exposed pipeline must have to minimize the possibility of fire
enough supports or anchors to protect being communicated to the compressor
the exposed pipe joints from the max- building from structures on adjacent
imum end force caused by internal property. There must be enough open
pressure and any additional forces space around the main compressor
caused by temperature expansion or building to allow the free movement of
contraction or by the weight of the fire-fighting equipment.
pipe and its contents. (b) Building construction. Each build-
(c) Each support or anchor on an ex- ing on a compressor station site must
posed pipeline must be made of dura- be made of noncombustible materials if
ble, noncombustible material and must it contains either—
be designed and installed as follows: (1) Pipe more than 2 inches (51 milli-
(1) Free expansion and contraction of meters) in diameter that is carrying
the pipeline between supports or an- gas under pressure; or
chors may not be restricted. (2) Gas handling equipment other
(2) Provision must be made for the than gas utilization equipment used for
service conditions involved. domestic purposes.
(3) Movement of the pipeline may not (c) Exits. Each operating floor of a
cause disengagement of the support main compressor building must have at
equipment. least two separated and unobstructed
(d) Each support on an exposed pipe- exits located so as to provide a conven-
line operated at a stress level of 50 per- ient possibility of escape and an unob-
cent or more of SMYS must comply structed passage to a place of safety.
with the following: Each door latch on an exit must be of
(1) A structural support may not be a type which can be readily opened
welded directly to the pipe. from the inside without a key. Each
(2) The support must be provided by a swinging door located in an exterior
member that completely encircles the wall must be mounted to swing out-
pipe. ward.
(3) If an encircling member is welded (d) Fenced areas. Each fence around a
to a pipe, the weld must be continuous compressor station must have at least
and cover the entire circumference. two gates located so as to provide a
(e) Each underground pipeline that is convenient opportunity for escape to a
connected to a relatively unyielding place of safety, or have other facilities
line or other fixed object must have affording a similarly convenient exit
enough flexibility to provide for pos- from the area. Each gate located with-
sible movement, or it must have an an- in 200 feet (61 meters) of any com-
chor that will limit the movement of pressor plant building must open out-
the pipeline. ward and, when occupied, must be
(f) Except for offshore pipelines, each openable from the inside without a
underground pipeline that is being con- key.
445
§ 192.165 49 CFR Ch. I (10–1–18 Edition)
(e) Electrical facilities. Electrical in the vicinity of gas headers and in

equipment and wiring installed in com- the compressor building, except that:
pressor stations must conform to the (i) Electrical circuits that supply
NFPA–70, so far as that code is applica- emergency lighting required to assist
ble. station personnel in evacuating the
[35 FR 13257, Aug. 19, 1970, as amended by compressor building and the area in
Amdt. 192–27, 41 FR 34605, Aug. 16, 1976; the vicinity of the gas headers must re-
Amdt. 192–37, 46 FR 10159, Feb. 2, 1981; 58 FR main energized; and
14521, Mar. 18, 1993; Amdt. 192–85, 63 FR 37502, (ii) Electrical circuits needed to pro-
37503, July 13, 1998; Amdt. 192–119, 80 FR 181, tect equipment from damage may re-
Jan. 5, 2015] main energized.
§ 192.165 Compressor stations: Liquid (4) It must be operable from at least
removal. two locations, each of which is:
(a) Where entrained vapors in gas (i) Outside the gas area of the sta-
may liquefy under the anticipated pres- tion;
sure and temperature conditions, the (ii) Near the exit gates, if the station
compressor must be protected against is fenced, or near emergency exits, if
the introduction of those liquids in not fenced; and
quantities that could cause damage. (iii) Not more than 500 feet (153 me-
(b) Each liquid separator used to re- ters) from the limits of the station.
move entrained liquids at a compressor (b) If a compressor station supplies
station must: gas directly to a distribution system
(1) Have a manually operable means with no other adequate source of gas
of removing these liquids. available, the emergency shutdown
(2) Where slugs of liquid could be car- system must be designed so that it will
ried into the compressors, have either not function at the wrong time and
automatic liquid removal facilities, an cause an unintended outage on the dis-
automatic compressor shutdown de- tribution system.
vice, or a high liquid level alarm; and (c) On a platform located offshore or
(3) Be manufactured in accordance in inland navigable waters, the emer-
with section VIII ASME Boiler and gency shutdown system must be de-
Pressure Vessel Code (BPVC) (incor- signed and installed to actuate auto-
porated by reference, see § 192.7) and the matically by each of the following
additional requirements of § 192.153(e) events:
except that liquid separators con- (1) In the case of an unattended com-
structed of pipe and fittings without pressor station:
internal welding must be fabricated (i) When the gas pressure equals the
with a design factor of 0.4, or less. maximum allowable operating pressure
[35 FR 13257, Aug. 19, 1970, as amended by plus 15 percent; or
Amdt. 192–119, 80 FR 181, Jan. 5, 2015; Amdt. (ii) When an uncontrolled fire occurs
192–120, 80 FR 12778, Mar. 11, 2015] on the platform; and
(2) In the case of a compressor sta-
§ 192.167 Compressor stations: Emer-
gency shutdown. tion in a building:
(i) When an uncontrolled fire occurs
(a) Except for unattended field com- in the building; or
pressor stations of 1,000 horsepower (746
(ii) When the concentration of gas in
kilowatts) or less, each compressor sta-
air reaches 50 percent or more of the
tion must have an emergency shut-
lower explosive limit in a building
down system that meets the following:
which has a source of ignition.
(1) It must be able to block gas out of
the station and blow down the station For the purpose of paragraph (c)(2)(ii)
piping. of this section, an electrical facility
(2) It must discharge gas from the which conforms to Class 1, Group D, of
blowdown piping at a location where the National Electrical Code is not a
the gas will not create a hazard. source of ignition.

(3) It must provide means for the [35 FR 13257, Aug. 19, 1970, as amended by
shutdown of gas compressing equip- Amdt. 192–27, 41 FR 34605, Aug. 16, 1976;
ment, gas fires, and electrical facilities Amdt. 192–85, 63 FR 37503, July 13, 1998]
446
§ 192.169 Compressor stations: Pres- vent the accumulation of liquids in the

sure limiting devices. holder, in connecting pipe, or in auxil-
(a) Each compressor station must iary equipment, that might cause cor-
have pressure relief or other suitable rosion or interfere with the safe oper-
protective devices of sufficient capac- ation of the holder.
ity and sensitivity to ensure that the (b) Each pipe-type or bottle-type
maximum allowable operating pressure holder must have minimum clearance
of the station piping and equipment is from other holders in accordance with
not exceeded by more than 10 percent. the following formula:
(b) Each vent line that exhausts gas C = (3D*P*F)/1000) in inches; (C =
from the pressure relief valves of a (3D*P*F*)/6,895) in millimeters
compressor station must extend to a
location where the gas may be dis- in which:
charged without hazard. C = Minimum clearance between pipe con-
tainers or bottles in inches (millimeters).
§ 192.171 Compressor stations: Addi- D = Outside diameter of pipe containers or
tional safety equipment. bottles in inches (millimeters).
(a) Each compressor station must P = Maximum allowable operating pressure,
have adequate fire protection facilities. psi (kPa) gauge.
If fire pumps are a part of these facili- F = Design factor as set forth in § 192.111 of
this part.
ties, their operation may not be af-
fected by the emergency shutdown sys- [35 FR 13257, Aug. 19, 1970, as amended by
tem. Amdt. 192–85, 63 FR 37503, July 13, 1998;
(b) Each compressor station prime Amdt. 192–123, 82 FR 7997, Jan. 23, 2017]
mover, other than an electrical induc-
tion or synchronous motor, must have § 192.177 Additional provisions for bot-
tle-type holders.
an automatic device to shut down the
unit before the speed of either the (a) Each bottle-type holder must be—
prime mover or the driven unit exceeds (1) Located on a site entirely sur-
a maximum safe speed. rounded by fencing that prevents ac-
(c) Each compressor unit in a com- cess by unauthorized persons and with
pressor station must have a shutdown minimum clearance from the fence as
or alarm device that operates in the follows:
event of inadequate cooling or lubrica-
tion of the unit. Minimum clear-
Maximum allowable operating pressure ance feet (me-
(d) Each compressor station gas enters)
gine that operates with pressure gas in-
Less than 1,000 p.s.i. (7 MPa) gage ........... 25 (7.6)
jection must be equipped so that stop-
1,000 p.s.i. (7 MPa) gage or more .............. 100 (31)
page of the engine automatically shuts
off the fuel and vents the engine dis-
(2) Designed using the design factors
tribution manifold.
set forth in § 192.111; and
(e) Each muffler for a gas engine in a
compressor station must have vent (3) Buried with a minimum cover in
slots or holes in the baffles of each accordance with § 192.327.
compartment to prevent gas from (b) Each bottle-type holder manufac-
being trapped in the muffler. tured from steel that is not weldable
under field conditions must comply
§ 192.173 Compressor stations: Ventila- with the following:
tion. (1) A bottle-type holder made from
Each compressor station building alloy steel must meet the chemical and
must be ventilated to ensure that em- tensile requirements for the various
ployees are not endangered by the ac- grades of steel in ASTM A372/372M (in-
cumulation of gas in rooms, sumps, at- corporated by reference, see § 192.7).
tics, pits, or other enclosed places. (2) The actual yield-tensile ratio of
the steel may not exceed 0.85.
§ 192.175 Pipe-type and bottle-type
(3) Welding may not be performed on

holders. the holder after it has been heat treat-
(a) Each pipe-type and bottle-type ed or stress relieved, except that cop-
holder must be designed so as to pre- per wires may be attached to the small
447
§ 192.179 49 CFR Ch. I (10–1–18 Edition)
diameter portion of the bottle end clo- overhead electric line, so that the gas
sure for cathodic protection if a local- is directed away from the electrical
ized thermit welding process is used. conductors.
(4) The holder must be given a mill (d) Offshore segments of transmission
hydrostatic test at a pressure that pro- lines must be equipped with valves or
duces a hoop stress at least equal to 85 other components to shut off the flow
percent of the SMYS. of gas to an offshore platform in an
(5) The holder, connection pipe, and emergency.
components must be leak tested after [35 FR 13257, Aug. 19, 1970, as amended by
installation as required by subpart J of Amdt. 192–27, 41 FR 34606, Aug. 16, 1976;
this part. Amdt. 192–78, 61 FR 28784, June 6, 1996; Amdt.
[35 FR 13257, Aug. 19, 1970, as amended by 192–85, 63 FR 37503, July 13, 1998]
Amdt. 192–58, 53 FR 1635, Jan. 21, 1988; Amdt.
192–62, 54 FR 5628, Feb. 6, 1989; 58 FR 14521, § 192.181 Distribution line valves.
Mar. 18, 1993; Amdt. 192–85, 63 FR 37503, July (a) Each high-pressure distribution
13, 1998; Amdt. 192–119, 80 FR 181, Jan. 5, 2015] system must have valves spaced so as
to reduce the time to shut down a sec-
§ 192.179 Transmission line valves. tion of main in an emergency. The
(a) Each transmission line, other valve spacing is determined by the op-
than offshore segments, must have sec- erating pressure, the size of the mains,
tionalizing block valves spaced as fol- and the local physical conditions.
lows, unless in a particular case the (b) Each regulator station control-
Administrator finds that alternative ling the flow or pressure of gas in a dis-
spacing would provide an equivalent tribution system must have a valve in-
level of safety: stalled on the inlet piping at a distance
(1) Each point on the pipeline in a from the regulator station sufficient to
Class 4 location must be within 21⁄2 permit the operation of the valve dur-
miles (4 kilometers)of a valve. ing an emergency that might preclude
(2) Each point on the pipeline in a access to the station.
Class 3 location must be within 4 miles (c) Each valve on a main installed for
(6.4 kilometers) of a valve. operating or emergency purposes must
(3) Each point on the pipeline in a comply with the following:
Class 2 location must be within 71⁄2 (1) The valve must be placed in a
miles (12 kilometers) of a valve. readily accessible location so as to fa-
(4) Each point on the pipeline in a cilitate its operation in an emergency.
Class 1 location must be within 10 (2) The operating stem or mechanism
miles (16 kilometers) of a valve. must be readily accessible.
(b) Each sectionalizing block valve (3) If the valve is installed in a buried
on a transmission line, other than off- box or enclosure, the box or enclosure
shore segments, must comply with the must be installed so as to avoid trans-
following: mitting external loads to the main.
(1) The valve and the operating de-
vice to open or close the valve must be § 192.183 Vaults: Structural design re-
readily accessible and protected from quirements.
tampering and damage. (a) Each underground vault or pit for
(2) The valve must be supported to valves, pressure relieving, pressure
prevent settling of the valve or move- limiting, or pressure regulating sta-
ment of the pipe to which it is at- tions, must be able to meet the loads
tached. which may be imposed upon it, and to
(c) Each section of a transmission protect installed equipment.
line, other than offshore segments, be- (b) There must be enough working
tween main line valves must have a space so that all of the equipment re-
blowdown valve with enough capacity quired in the vault or pit can be prop-
to allow the transmission line to be erly installed, operated, and main-
blown down as rapidly as practicable. tained.
Each blowdown discharge must be lo- (c) Each pipe entering, or within, a
cated so the gas can be blown to the at- regulator vault or pit must be steel for
mosphere without hazard and, if the sizes 10 inch (254 millimeters), and less,
transmission line is adjacent to an except that control and gage piping
448
may be copper. Where pipe extends (3) If the vault or pit is ventilated,
through the vault or pit structure, pro- paragraph (a) or (c) of this section ap-
vision must be made to prevent the plies.
passage of gases or liquids through the (c) If a vault or pit covered by para-
opening and to avert strains in the graph (b) of this section is ventilated
pipe. by openings in the covers or gratings
[35 FR 13257, Aug. 19, 1970, as amended by and the ratio of the internal volume, in
Amdt. 192–85, 63 FR 37503, July 13, 1998] cubic feet, to the effective ventilating
area of the cover or grating, in square
§ 192.185 Vaults: Accessibility. feet, is less than 20 to 1, no additional
Each vault must be located in an ac- ventilation is required.
cessible location and, so far as prac- [35 FR 13257, Aug. 19, 1970, as amended by
tical, away from: Amdt. 192–85, 63 FR 37503, July 13, 1998]
(a) Street intersections or points
where traffic is heavy or dense; § 192.189 Vaults: Drainage and water-
(b) Points of minimum elevation, proofing.
catch basins, or places where the ac- (a) Each vault must be designed so as
cess cover will be in the course of sur- to minimize the entrance of water.
face waters; and (b) A vault containing gas piping
(c) Water, electric, steam, or other may not be connected by means of a
facilities. drain connection to any other under-
ground structure.
§ 192.187 Vaults: Sealing, venting, and
ventilation. (c) Electrical equipment in vaults
must conform to the applicable re-
Each underground vault or closed top quirements of Class 1, Group D, of the
pit containing either a pressure regu- National Electrical Code, NFPA–70 (in-
lating or reducing station, or a pres- corporated by reference, see § 192.7).
sure limiting or relieving station, must
be sealed, vented or ventilated as fol- [35 FR 13257, Aug. 19, 1970, as amended by
lows: Amdt. 192–76, 61 FR 26122, May 24, 1996; Amdt.
(a) When the internal volume exceeds 192–119, 80 FR 181, Jan. 5, 2015]
200 cubic feet (5.7 cubic meters):
§ 192.191 Design pressure of plastic fit-
(1) The vault or pit must be venti- tings.
lated with two ducts, each having at
least the ventilating effect of a pipe 4 (a) Thermosetting fittings for plastic
inches (102 millimeters) in diameter; pipe must conform to ASTM D 2517,
(2) The ventilation must be enough to (incorporated by reference, see § 192.7).
minimize the formation of combustible (b) Thermoplastic fittings for plastic
atmosphere in the vault or pit; and pipe must conform to ASTM D2513–99
(3) The ducts must be high enough for plastic materials other than poly-
above grade to disperse any gas-air ethylene or ASTM D2513–09a for poly-
mixtures that might be discharged. ethylene plastic materials.
(b) When the internal volume is more [Amdt. 192–114, 75 FR 48603, Aug. 11, 2010, as
than 75 cubic feet (2.1 cubic meters) but amended by Amdt. 192–119, 80 FR 181, Jan. 5,
less than 200 cubic feet (5.7 cubic me- 2015]
ters):
(1) If the vault or pit is sealed, each § 192.193 Valve installation in plastic
opening must have a tight fitting cover pipe.
without open holes through which an Each valve installed in plastic pipe
explosive mixture might be ignited, must be designed so as to protect the
and there must be a means for testing
plastic material against excessive tor-
the internal atmosphere before remov-
sional or shearing loads when the valve
ing the cover;
or shutoff is operated, and from any
(2) If the vault or pit is vented, there

other secondary stresses that might be
must be a means of preventing external
sources of ignition from reaching the exerted through the valve or its enclo-
vault atmosphere; or sure.
449
§ 192.195 49 CFR Ch. I (10–1–18 Edition)
§ 192.195 Protection against accidental of any connected and properly adjusted

overpressuring. gas utilization equipment.
(a) General requirements. Except as (6) A self-contained service regulator
provided in § 192.197, each pipeline that with no external static or control lines.
is connected to a gas source so that the (b) If the maximum actual operating
maximum allowable operating pressure pressure of the distribution system is
could be exceeded as the result of pres- 60 p.s.i. (414 kPa) gage, or less, and a
sure control failure or of some other service regulator that does not have all
type of failure, must have pressure re- of the characteristics listed in para-
lieving or pressure limiting devices graph (a) of this section is used, or if
that meet the requirements of §§ 192.199 the gas contains materials that seri-
and 192.201. ously interfere with the operation of
(b) Additional requirements for distribu- service regulators, there must be suit-
tion systems. Each distribution system able protective devices to prevent un-
that is supplied from a source of gas safe overpressuring of the customer’s
that is at a higher pressure than the appliances if the service regulator
maximum allowable operating pressure fails.
for the system must— (c) If the maximum actual operating
(1) Have pressure regulation devices pressure of the distribution system ex-
capable of meeting the pressure, load, ceeds 60 p.s.i. (414 kPa) gage, one of the
and other service conditions that will following methods must be used to reg-
be experienced in normal operation of ulate and limit, to the maximum safe
the system, and that could be activated value, the pressure of gas delivered to
in the event of failure of some portion the customer:
of the system; and (1) A service regulator having the
(2) Be designed so as to prevent acci- characteristics listed in paragraph (a)
dental overpressuring. of this section, and another regulator
located upstream from the service reg-
§ 192.197 Control of the pressure of gas ulator. The upstream regulator may
delivered from high-pressure dis- not be set to maintain a pressure high-
tribution systems. er than 60 p.s.i. (414 kPa) gage. A device
(a) If the maximum actual operating must be installed between the up-
pressure of the distribution system is stream regulator and the service regu-
60 p.s.i. (414 kPa) gage, or less and a lator to limit the pressure on the inlet
service regulator having the following of the service regulator to 60 p.s.i. (414
characteristics is used, no other pres- kPa) gage or less in case the upstream
sure limiting device is required: regulator fails to function properly.
(1) A regulator capable of reducing This device may be either a relief valve
distribution line pressure to pressures or an automatic shutoff that shuts, if
recommended for household appliances. the pressure on the inlet of the service
(2) A single port valve with proper regulator exceeds the set pressure (60
orifice for the maximum gas pressure p.s.i. (414 kPa) gage or less), and re-
at the regulator inlet. mains closed until manually reset.
(3) A valve seat made of resilient ma- (2) A service regulator and a moni-
terial designed to withstand abrasion toring regulator set to limit, to a max-
of the gas, impurities in gas, cutting by imum safe value, the pressure of the
the valve, and to resist permanent de- gas delivered to the customer.
formation when it is pressed against (3) A service regulator with a relief
the valve port. valve vented to the outside atmos-
(4) Pipe connections to the regulator phere, with the relief valve set to open
not exceeding 2 inches (51 millimeters) so that the pressure of gas going to the
in diameter. customer does not exceed a maximum
(5) A regulator that, under normal safe value. The relief valve may either
operating conditions, is able to regu- be built into the service regulator or it
late the downstream pressure within may be a separate unit installed down-
the necessary limits of accuracy and to stream from the service regulator. This
limit the build-up of pressure under no- combination may be used alone only in
flow conditions to prevent a pressure those cases where the inlet pressure on
that would cause the unsafe operation the service regulator does not exceed
450
the manufacturer’s safe working pres- (h) Except for a valve that will iso-
sure rating of the service regulator, late the system under protection from
and may not be used where the inlet its source of pressure, be designed to
pressure on the service regulator ex- prevent unauthorized operation of any
ceeds 125 p.s.i. (862 kPa) gage. For high- stop valve that will make the pressure
er inlet pressures, the methods in para- relief valve or pressure limiting device
graph (c) (1) or (2) of this section must inoperative.
be used. [35 FR 13257, Aug. 19, 1970, as amended by
(4) A service regulator and an auto- Amdt. 192–1, 35 FR 17660, Nov. 17, 1970]
matic shutoff device that closes upon a
rise in pressure downstream from the § 192.201 Required capacity of pres-
regulator and remains closed until sure relieving and limiting stations.
manually reset. (a) Each pressure relief station or
[35 FR 13257, Aug. 19, 1970, as amended by pressure limiting station or group of
Amdt. 192–1, 35 FR 17660, Nov. 7, 1970; Amdt. those stations installed to protect a
192–85, 63 FR 37503, July 13, 1998; Amdt. 192– pipeline must have enough capacity,
93, 68 FR 53900, Sept. 15, 2003] and must be set to operate, to insure
the following:
§ 192.199 Requirements for design of (1) In a low pressure distribution sys-
pressure relief and limiting devices. tem, the pressure may not cause the
Except for rupture discs, each pres- unsafe operation of any connected and
sure relief or pressure limiting device properly adjusted gas utilization equip-
must: ment.
(a) Be constructed of materials such (2) In pipelines other than a low pres-
that the operation of the device will sure distribution system:
not be impaired by corrosion; (i) If the maximum allowable oper-
(b) Have valves and valve seats that ating pressure is 60 p.s.i. (414 kPa) gage
are designed not to stick in a position or more, the pressure may not exceed
that will make the device inoperative; the maximum allowable operating
(c) Be designed and installed so that pressure plus 10 percent, or the pres-
it can be readily operated to determine sure that produces a hoop stress of 75
if the valve is free, can be tested to de- percent of SMYS, whichever is lower;
termine the pressure at which it will (ii) If the maximum allowable oper-
operate, and can be tested for leakage ating pressure is 12 p.s.i. (83 kPa) gage
when in the closed position; or more, but less than 60 p.s.i. (414 kPa)
(d) Have support made of noncombus- gage, the pressure may not exceed the
tible material; maximum allowable operating pressure
(e) Have discharge stacks, vents, or plus 6 p.s.i. (41 kPa) gage; or
outlet ports designed to prevent accu- (iii) If the maximum allowable oper-
mulation of water, ice, or snow, located ating pressure is less than 12 p.s.i. (83
where gas can be discharged into the kPa) gage, the pressure may not exceed
atmosphere without undue hazard; the maximum allowable operating
(f) Be designed and installed so that pressure plus 50 percent.
the size of the openings, pipe, and fit- (b) When more than one pressure reg-
tings located between the system to be ulating or compressor station feeds
protected and the pressure relieving de- into a pipeline, relief valves or other
vice, and the size of the vent line, are protective devices must be installed at
adequate to prevent hammering of the each station to ensure that the com-
valve and to prevent impairment of re- plete failure of the largest capacity
lief capacity; regulator or compressor, or any single
(g) Where installed at a district regu- run of lesser capacity regulators or
lator station to protect a pipeline sys- compressors in that station, will not
tem from overpressuring, be designed impose pressures on any part of the
and installed to prevent any single in- pipeline or distribution system in ex-
cident such as an explosion in a vault cess of those for which it was designed,
or damage by a vehicle from affecting or against which it was protected,

the operation of both the overpressure whichever is lower.
protective device and the district regu- (c) Relief valves or other pressure
lator; and limiting devices must be installed at or
451
§ 192.203 49 CFR Ch. I (10–1–18 Edition)
near each regulator station in a low- suitable for the anticipated pressure
pressure distribution system, with a and temperature condition. Slip type
capacity to limit the maximum pres- expansion joints may not be used. Ex-
sure in the main to a pressure that will pansion must be allowed for by pro-
not exceed the safe operating pressure viding flexibility within the system
for any connected and properly ad- itself.
justed gas utilization equipment. (9) Each control line must be pro-
[35 FR 13257, Aug. 19, 1970, as amended by tected from anticipated causes of dam-
Amdt. 192–9, 37 FR 20827, Oct. 4, 1972; Amdt. age and must be designed and installed
192–85, 63 FR 37503, July 13, 1998] to prevent damage to any one control
line from making both the regulator
§ 192.203 Instrument, control, and sam-
pling pipe and components. and the over-pressure protective device
inoperative.
(a) Applicability. This section applies
to the design of instrument, control, [35 FR 13257, Aug. 19, 1970, as amended by
and sampling pipe and components. It Amdt. 192–78, 61 FR 28784, June 6, 1996; Amdt.
does not apply to permanently closed 192–85, 63 FR 37503, July 13, 1998]
systems, such as fluid-filled tempera-
ture-responsive devices. Subpart E—Welding of Steel in
(b) Materials and design. All materials Pipelines
employed for pipe and components
must be designed to meet the par- § 192.221 Scope.
ticular conditions of service and the
following: (a) This subpart prescribes minimum
(1) Each takeoff connection and at- requirements for welding steel mate-
taching boss, fitting, or adapter must rials in pipelines.
be made of suitable material, be able to (b) This subpart does not apply to
withstand the maximum service pres- welding that occurs during the manu-
sure and temperature of the pipe or facture of steel pipe or steel pipeline
equipment to which it is attached, and components.
be designed to satisfactorily withstand
all stresses without failure by fatigue. § 192.225 Welding procedures.
(2) Except for takeoff lines that can (a) Welding must be performed by a
be isolated from sources of pressure by qualified welder or welding operator in
other valving, a shutoff valve must be accordance with welding procedures
installed in each takeoff line as near as qualified under section 5, section 12,
practicable to the point of takeoff. Appendix A or Appendix B of API Std
Blowdown valves must be installed
1104 (incorporated by reference, see
where necessary.
§ 192.7), or section IX of the ASME Boil-
(3) Brass or copper material may not
be used for metal temperatures greater er and Pressure Vessel Code (ASME
than 400 °F (204 °C). BPVC) (incorporated by reference, see
(4) Pipe or components that may con- § 192.7) to produce welds meeting the re-
tain liquids must be protected by heat- quirements of this subpart. The quality
ing or other means from damage due to of the test welds used to qualify weld-
freezing. ing procedures must be determined by
(5) Pipe or components in which liq- destructive testing in accordance with
uids may accumulate must have drains the applicable welding standard(s).
or drips. (b) Each welding procedure must be
(6) Pipe or components subject to recorded in detail, including the results
clogging from solids or deposits must of the qualifying tests. This record
have suitable connections for cleaning. must be retained and followed when-
(7) The arrangement of pipe, compo- ever the procedure is used.
nents, and supports must provide safe-
ty under anticipated operating [Amdt. 192–52, 51 FR 20297, June 4, 1986;
Amdt. 192–94, 69 FR 32894, June 14, 2004;
stresses.
(8) Each joint between sections of Amdt. 192–119, 80 FR 181, Jan. 5, 2015; Amdt.
192–120, 80 FR 12778, Mar. 11, 2015; Amdt. 192–
pipe, and between pipe and valves or
123, 82 FR 7997, Jan. 23, 2017]
fittings, must be made in a manner
452
§ 192.227 Qualification of welders and welds tested and found acceptable

welding operators. under the above acceptance criteria at
(a) Except as provided in paragraph least twice each calendar year, but at
(b) of this section, each welder or weld- intervals not exceeding 71⁄2 months. A
ing operator must be qualified in ac- welder or welding operator qualified
cordance with section 6, section 12, Ap- under an earlier edition of a standard
pendix A or Appendix B of API Std 1104 listed in § 192.7 of this part may weld,
(incorporated by reference, see § 192.7), but may not re-qualify under that ear-
or section IX of the ASME Boiler and lier edition; and,
Pressure Vessel Code (ASME BPVC) (2) May not weld on pipe to be oper-
(incorporated by reference, see § 192.7). ated at a pressure that produces a hoop
However, a welder or welding operator stress of less than 20 percent of SMYS
qualified under an earlier edition than unless the welder or welding operator
the listed in § 192.7 of this part may is tested in accordance with paragraph
weld but may not requalify under that (c)(1) of this section or re-qualifies
earlier edition. under paragraph (d)(1) or (d)(2) of this
(b) A welder may qualify to perform section.
welding on pipe to be operated at a (d) A welder or welding operator
pressure that produces a hoop stress of qualified under § 192.227(b) may not
less than 20 percent of SMYS by per- weld unless—
forming an acceptable test weld, for (1) Within the preceding 15 calendar
the process to be used, under the test months, but at least once each cal-
set forth in section I of Appendix C of endar year, the welder or welding oper-
this part. Each welder who is to make ator has re-qualified under § 192.227(b);
a welded service line connection to a or
main must first perform an acceptable (2) Within the preceding 71⁄2 calendar
test weld under section II of Appendix months, but at least twice each cal-
C of this part as a requirement of the endar year, the welder or welding oper-
qualifying test. ator has had—
[Amdt. 192–120, 80 FR 12778, Mar. 11, 2015, as (i) A production weld cut out, tested,
amended by Amdt. 192–123, 82 FR 7997, Jan. and found acceptable in accordance
23, 2017] with the qualifying test; or
(ii) For a welder who works only on
§ 192.229 Limitations on welders and service lines 2 inches (51 millimeters)
welding operators. or smaller in diameter, the welder has
(a) No welder or welding operator had two sample welds tested and found
whose qualification is based on non- acceptable in accordance with the test
destructive testing may weld com- in section III of Appendix C of this
pressor station pipe and components. part.
(b) A welder or welding operator may
not weld with a particular welding [Amdt. 192–120, 80 FR 12778, Mar. 11, 2015]
process unless, within the preceding 6 § 192.231 Protection from weather.
calendar months, the welder or welding
operator was engaged in welding with The welding operation must be pro-
that process. tected from weather conditions that
(c) A welder or welding operator would impair the quality of the com-
qualified under § 192.227(a)— pleted weld.
(1) May not weld on pipe to be oper-
ated at a pressure that produces a hoop § 192.233 Miter joints.
stress of 20 percent or more of SMYS (a) A miter joint on steel pipe to be
unless within the preceding 6 calendar operated at a pressure that produces a
months the welder or welding operator hoop stress of 30 percent or more of
has had one weld tested and found ac- SMYS may not deflect the pipe more
ceptable under either section 6, section than 3°.
9, section 12 or Appendix A of API Std (b) A miter joint on steel pipe to be
1104 (incorporated by reference, see operated at a pressure that produces a

§ 192.7). Alternatively, welders or weld- hoop stress of less than 30 percent, but
ing operators may maintain an ongoing more than 10 percent, of SMYS may
qualification status by performing not deflect the pipe more than 121⁄2° and
453
§ 192.235 49 CFR Ch. I (10–1–18 Edition)
must be a distance equal to one pipe di- Std 1104 may not be used to accept
ameter or more away from any other cracks.
miter joint, as measured from the [35 FR 13257, Aug. 19, 1970, as amended by
crotch of each joint. Amdt. 192–37, 46 FR 10160, Feb. 2, 1981; Amdt.
(c) A miter joint on steel pipe to be 192–78, 61 FR 28784, June 6, 1996; Amdt. 192–85,
operated at a pressure that produces a 63 FR 37503, July 13, 1998; Amdt. 192–94, 69 FR
hoop stress of 10 percent or less of 32894, June 14, 2004; Amdt. 192–119, 80 FR 181,
SMYS may not deflect the pipe more Jan. 5, 2015; Amdt. 192–120, 80 FR 12778, Mar.
11, 2015]
than 90°.
§ 192.243 Nondestructive testing.
§ 192.235 Preparation for welding.
(a) Nondestructive testing of welds
Before beginning any welding, the
must be performed by any process,
welding surfaces must be clean and free other than trepanning, that will clear-
of any material that may be detri- ly indicate defects that may affect the
mental to the weld, and the pipe or integrity of the weld.
component must be aligned to provide (b) Nondestructive testing of welds
the most favorable condition for depos- must be performed:
iting the root bead. This alignment (1) In accordance with written proce-
must be preserved while the root bead dures; and
is being deposited. (2) By persons who have been trained
and qualified in the established proce-
§ 192.241 Inspection and test of welds.
dures and with the equipment em-
(a) Visual inspection of welding must ployed in testing.
be conducted by an individual qualified (c) Procedures must be established
by appropriate training and experience for the proper interpretation of each
to ensure that: nondestructive test of a weld to ensure
(1) The welding is performed in ac- the acceptability of the weld under
cordance with the welding procedure; § 192.241(c).
and (d) When nondestructive testing is re-
(2) The weld is acceptable under para- quired under § 192.241(b), the following
graph (c) of this section. percentages of each day’s field butt
(b) The welds on a pipeline to be op- welds, selected at random by the oper-
erated at a pressure that produces a ator, must be nondestructively tested
hoop stress of 20 percent or more of over their entire circumference:
SMYS must be nondestructively tested (1) In Class 1 locations, except off-
in accordance with § 192.243, except that shore, at least 10 percent.
welds that are visually inspected and (2) In Class 2 locations, at least 15
approved by a qualified welding inspec- percent.
tor need not be nondestructively tested (3) In Class 3 and Class 4 locations, at
if: crossings of major or navigable rivers,
offshore, and within railroad or public
(1) The pipe has a nominal diameter
highway rights-of-way, including tun-
of less than 6 inches (152 millimeters);
nels, bridges, and overhead road cross-
or
ings, 100 percent unless impracticable,
(2) The pipeline is to be operated at a in which case at least 90 percent. Non-
pressure that produces a hoop stress of destructive testing must be impracti-
less than 40 percent of SMYS and the cable for each girth weld not tested.
welds are so limited in number that (4) At pipeline tie-ins, including tie-
nondestructive testing is impractical. ins of replacement sections, 100 per-
(c) The acceptability of a weld that is cent.
nondestructively tested or visually in- (e) Except for a welder or welding op-
spected is determined according to the erator whose work is isolated from the
standards in section 9 or Appendix A of principal welding activity, a sample of
API Std 1104 (incorporated by ref- each welder or welding operator’s work
erence, see § 192.7). Appendix A of API for each day must be nondestructively
tested, when nondestructive testing is
required under § 192.241(b).
454
(f) When nondestructive testing is re- the longitudinal pullout or thrust

quired under § 192.241(b), each operator forces caused by contraction or expan-
must retain, for the life of the pipeline, sion of the piping or by anticipated ex-
a record showing by milepost, engi- ternal or internal loading.
neering station, or by geographic fea- (b) Each joint must be made in ac-
ture, the number of girth welds made, cordance with written procedures that
the number nondestructively tested, have been proven by test or experience
the number rejected, and the disposi- to produce strong gastight joints.
tion of the rejects. (c) Each joint must be inspected to
insure compliance with this subpart.
Amdt. 192–27, 41 FR 34606, Aug. 16, 1976; § 192.275 Cast iron pipe.
Amdt. 192–50, 50 FR 37192, Sept. 12, 1985;
Amdt. 192–78, 61 FR 28784, June 6, 1996; Amdt. (a) Each caulked bell and spigot joint
192–120, 80 FR 12779, Mar. 11, 2015] in cast iron pipe must be sealed with
mechanical leak clamps.
§ 192.245 Repair or removal of defects. (b) Each mechanical joint in cast
(a) Each weld that is unacceptable iron pipe must have a gasket made of a
under § 192.241(c) must be removed or resilient material as the sealing me-
repaired. Except for welds on an off- dium. Each gasket must be suitably
shore pipeline being installed from a confined and retained under compres-
pipeline vessel, a weld must be re- sion by a separate gland or follower
moved if it has a crack that is more ring.
than 8 percent of the weld length. (c) Cast iron pipe may not be joined
(b) Each weld that is repaired must by threaded joints.
have the defect removed down to sound (d) Cast iron pipe may not be joined
metal and the segment to be repaired by brazing.
must be preheated if conditions exist [35 FR 13257, Aug. 19, 1970, as amended by
which would adversely affect the qual- Amdt. 192–62, 54 FR 5628, Feb. 6, 1989]
ity of the weld repair. After repair, the
segment of the weld that was repaired § 192.277 Ductile iron pipe.
must be inspected to ensure its accept- (a) Ductile iron pipe may not be
ability. joined by threaded joints.
(c) Repair of a crack, or of any defect (b) Ductile iron pipe may not be
in a previously repaired area must be joined by brazing.
in accordance with written weld repair
procedures that have been qualified [35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 192–62, 54 FR 5628, Feb. 6, 1989]
under § 192.225. Repair procedures must
provide that the minimum mechanical § 192.279 Copper pipe.
properties specified for the welding
procedure used to make the original Copper pipe may not be threaded ex-
weld are met upon completion of the cept that copper pipe used for joining
final weld repair. screw fittings or valves may be thread-
ed if the wall thickness is equivalent to
[Amdt. 192–46, 48 FR 48674, Oct. 20, 1983] the comparable size of Schedule 40 or
heavier wall pipe listed in Table C1 of
Subpart F—Joining of Materials ASME/ANSI B16.5.
Other Than by Welding [Amdt. 192–62, 54 FR 5628, Feb. 6, 1989, as
amended at 58 FR 14521, Mar. 18, 1993]
§ 192.271 Scope.
(a) This subpart prescribes minimum § 192.281 Plastic pipe.
requirements for joining materials in (a) General. A plastic pipe joint that
pipelines, other than by welding. is joined by solvent cement, adhesive,
(b) This subpart does not apply to or heat fusion may not be disturbed
joining during the manufacture of pipe until it has properly set. Plastic pipe
or pipeline components. may not be joined by a threaded joint
or miter joint.
§ 192.273 General. (b) Solvent cement joints. Each solvent
(a) The pipeline must be designed and cement joint on plastic pipe must com-
installed so that each joint will sustain ply with the following:
455
§ 192.283 49 CFR Ch. I (10–1–18 Edition)
(1) The mating surfaces of the joint § 192.283 Plastic pipe: Qualifying join-
must be clean, dry, and free of material ing procedures.
which might be detrimental to the (a) Heat fusion, solvent cement, and ad-
joint. hesive joints. Before any written proce-
(2) The solvent cement must conform dure established under § 192.273(b) is
to ASTM D2513–99, (incorporated by used for making plastic pipe joints by a
reference, see § 192.7). heat fusion, solvent cement, or adhe-
(3) The joint may not be heated to ac- sive method, the procedure must be
celerate the setting of the cement. qualified by subjecting specimen joints
(c) Heat-fusion joints. Each heat-fu- made according to the procedure to the
sion joint on plastic pipe must comply following tests:
with the following: (1) The burst test requirements of—
(1) A butt heat-fusion joint must be (i) In the case of thermoplastic pipe,
joined by a device that holds the heater paragraph 6.6 (Sustained Pressure Test)
element square to the ends of the pip- or paragraph 6.7 (Minimum Hydrostatic
ing, compresses the heated ends to- Burst Test) of ASTM D2513–99 for plas-
gether, and holds the pipe in proper tic materials other than polyethylene
alignment while the plastic hardens. or ASTM D2513–09a (incorporated by
(2) A socket heat-fusion joint must be reference, see § 192.7) for polyethylene
joined by a device that heats the mat- plastic materials;
ing surfaces of the joint uniformly and (ii) In the case of thermosetting plas-
simultaneously to essentially the same tic pipe, paragraph 8.5 (Minimum Hy-
temperature. drostatic Burst Pressure) or paragraph
(3) An electrofusion joint must be 8.9 (Sustained Static Pressure Test) of
joined utilizing the equipment and ASTM D2517 (incorporated by ref-
techniques of the fittings manufacturer erence, see § 192.7); or
or equipment and techniques shown, by (iii) In the case of electrofusion fit-
testing joints to the requirements of tings for polyethylene (PE) pipe and
§ 192.283(a)(1)(iii), to be at least equiva- tubing, paragraph 9.1 (Minimum Hy-
lent to those of the fittings manufac- draulic Burst Pressure Test), para-
turer. graph 9.2 (Sustained Pressure Test),
(4) Heat may not be applied with a paragraph 9.3 (Tensile Strength Test),
torch or other open flame. or paragraph 9.4 (Joint Integrity Tests)
(d) Adhesive joints. Each adhesive of ASTM F1055 (incorporated by ref-
joint on plastic pipe must comply with erence, see § 192.7).
the following: (2) For procedures intended for lat-
(1) The adhesive must conform to eral pipe connections, subject a speci-
ASTM D 2517 (incorporated by ref- men joint made from pipe sections
erence, see § 192.7). joined at right angles according to the
(2) The materials and adhesive must procedure to a force on the lateral pipe
be compatible with each other. until failure occurs in the specimen. If
(e) Mechanical joints. Each compres- failure initiates outside the joint area,
sion type mechanical joint on plastic the procedure qualifies for use; and
pipe must comply with the following: (3) For procedures intended for non-
(1) The gasket material in the cou- lateral pipe connections, follow the
pling must be compatible with the tensile test requirements of ASTM
plastic. D638 (incorporated by reference, see
(2) A rigid internal tubular stiffener, § 192.7), except that the test may be
other than a split tubular stiffener, conducted at ambient temperature and
must be used in conjunction with the humidity If the specimen elongates no
coupling. less than 25 percent or failure initiates
outside the joint area, the procedure
[35 FR 13257, Aug. 19, 1970, as amended by qualifies for use.
Amdt. 192–34, 44 FR 42973, July 23, 1979;
(b) Mechanical joints. Before any writ-
Amdt. 192–58, 53 FR 1635, Jan. 21, 1988; Amdt.
192–61, 53 FR 36793, Sept. 22, 1988; 58 FR 14521, ten procedure established under
Mar. 18, 1993; Amdt. 192–78, 61 FR 28784, June § 192.273(b) is used for making mechan-
6, 1996; Amdt. 192–114, 75 FR 48603, Aug. 11, ical plastic pipe joints that are de-
2010; Amdt. 192–119, 80 FR 181, Jan. 5, 2015] signed to withstand tensile forces, the
456
procedure must be qualified by sub- § 192.285 Plastic pipe: Qualifying per-

jecting 5 specimen joints made accord- sons to make joints.
ing to the procedure to the following (a) No person may make a plastic
tensile test: pipe joint unless that person has been
(1) Use an apparatus for the test as qualified under the applicable joining
specified in ASTM D 638 (except for procedure by:
conditioning), (incorporated by ref-
(1) Appropriate training or experi-
erence, see § 192.7).
ence in the use of the procedure; and
(2) The specimen must be of such
length that the distance between the (2) Making a specimen joint from
grips of the apparatus and the end of pipe sections joined according to the
the stiffener does not affect the joint procedure that passes the inspection
strength. and test set forth in paragraph (b) of
(3) The speed of testing is 0.20 in (5.0 this section.
mm) per minute, plus or minus 25 per- (b) The specimen joint must be:
cent. (1) Visually examined during and
(4) Pipe specimens less than 4 inches after assembly or joining and found to
(102 mm) in diameter are qualified if have the same appearance as a joint or
the pipe yields to an elongation of no photographs of a joint that is accept-
less than 25 percent or failure initiates able under the procedure; and
outside the joint area. (2) In the case of a heat fusion, sol-
(5) Pipe specimens 4 inches (102 mm) vent cement, or adhesive joint:
and larger in diameter shall be pulled (i) Tested under any one of the test
until the pipe is subjected to a tensile methods listed under § 192.283(a) appli-
stress equal to or greater than the cable to the type of joint and material
maximum thermal stress that would be being tested;
produced by a temperature change of (ii) Examined by ultrasonic inspec-
100 °F (38 °C) or until the pipe is pulled tion and found not to contain flaws
from the fitting. If the pipe pulls from that would cause failure; or
the fitting, the lowest value of the five (iii) Cut into at least 3 longitudinal
test results or the manufacturer’s rat- straps, each of which is:
ing, whichever is lower must be used in (A) Visually examined and found not
the design calculations for stress. to contain voids or discontinuities on
(6) Each specimen that fails at the the cut surfaces of the joint area; and
grips must be retested using new pipe. (B) Deformed by bending, torque, or
(7) Results obtained pertain only to impact, and if failure occurs, it must
the specific outside diameter, and ma- not initiate in the joint area.
terial of the pipe tested, except that (c) A person must be re-qualified
testing of a heavier wall pipe may be under an applicable procedure once
used to qualify pipe of the same mate- each calendar year at intervals not ex-
rial but with a lesser wall thickness. ceeding 15 months, or after any produc-
(c) A copy of each written procedure tion joint is found unacceptable by
being used for joining plastic pipe must testing under § 192.513.
be available to the persons making and (d) Each operator shall establish a
inspecting joints. method to determine that each person
(d) Pipe or fittings manufactured be- making joints in plastic pipelines in
fore July 1, 1980, may be used in ac- the operator’s system is qualified in ac-
cordance with procedures that the cordance with this section.
manufacturer certifies will produce a
joint as strong as the pipe. [Amdt. 192–34A, 45 FR 9935, Feb. 14, 1980, as
amended by Amdt. 192–34B, 46 FR 39, Jan. 2,
[Amdt. 192–34A, 45 FR 9935, Feb. 14, 1980, as 1981; Amdt. 192–93, 68 FR 53900, Sept. 15, 2003;
amended by Amdt. 192–34B, 46 FR 39, Jan. 2, Amdt. 192–120, 80 FR 12779, Mar. 11, 2015]
1981; 47 FR 32720, July 29, 1982; 47 FR 49973,
Nov. 4, 1982; 58 FR 14521, Mar. 18, 1993; Amdt. § 192.287 Plastic pipe: Inspection of
192–78, 61 FR 28784, June 6, 1996; Amdt. 192–85, joints.
63 FR 37503, July 13, 1998; Amdt. 192–94, 69 FR

32895, June 14, 2004; Amdt. 192–94, 69 FR 54592, No person may carry out the inspec-
Sept. 9, 2004; Amdt. 192–114, 75 FR 48603, Aug. tion of joints in plastic pipes required
11, 2010; Amdt. 192–119, 80 FR 181, Jan. 5, 2015] by §§ 192.273(c) and 192.285(b) unless that
457
§ 192.301 49 CFR Ch. I (10–1–18 Edition)
person has been qualified by appro- moved. If a repair is made by grinding,

priate training or experience in evalu- the remaining wall thickness must at
ating the acceptability of plastic pipe least be equal to either:
joints made under the applicable join- (1) The minimum thickness required
ing procedure. by the tolerances in the specification
[Amdt. 192–34, 44 FR 42974, July 23, 1979] to which the pipe was manufactured; or
(2) The nominal wall thickness re-
Subpart G—General Construction quired for the design pressure of the
pipeline.
Requirements for Transmission
(b) Each of the following dents must
Lines and Mains be removed from steel pipe to be oper-
§ 192.301 Scope. ated at a pressure that produces a hoop
stress of 20 percent, or more, of SMYS,
This subpart prescribes minimum re- unless the dent is repaired by a method
quirements for constructing trans-
that reliable engineering tests and
mission lines and mains.
analyses show can permanently restore
§ 192.303 Compliance with specifica- the serviceability of the pipe:
tions or standards. (1) A dent that contains a stress con-
Each transmission line or main must centrator such as a scratch, gouge,
be constructed in accordance with com- groove, or arc burn.
prehensive written specifications or (2) A dent that affects the longitu-
standards that are consistent with this dinal weld or a circumferential weld.
part. (3) In pipe to be operated at a pres-
sure that produces a hoop stress of 40
§ 192.305 Inspection: General. percent or more of SMYS, a dent that
Each transmission line or main must has a depth of:
be inspected to ensure that it is con- (i) More than 1⁄4 inch (6.4 millimeters)
structed in accordance with this part. in pipe 123⁄4 inches (324 millimeters) or
less in outer diameter; or
EFFECTIVE DATE NOTE: At 80 FR 12779, Mar.
11, 2015, § 192.305 was revised, effective Oct. 1, (ii) More than 2 percent of the nomi-
2015. At 80 FR 58633, Sept. 30, 2015, this nal pipe diameter in pipe over 123⁄4
amendment was delayed indefinitely. For inches (324 millimeters) in outer di-
the convenience of the user, the revised text ameter.
is set forth as follows:
For the purpose of this section a
§ 192.305 Inspection: General. ‘‘dent’’ is a depression that produces a
Each transmission line and main must be gross disturbance in the curvature of
inspected to ensure that it is constructed in the pipe wall without reducing the
accordance with this subpart. An operator pipe-wall thickness. The depth of a
must not use operator personnel to perform dent is measured as the gap between
a required inspection if the operator per- the lowest point of the dent and a pro-
sonnel performed the construction task re- longation of the original contour of the
quiring inspection. Nothing in this section
prohibits the operator from inspecting con-
pipe.
struction tasks with operator personnel who (c) Each arc burn on steel pipe to be
are involved in other construction tasks. operated at a pressure that produces a
hoop stress of 40 percent, or more, of
§ 192.307 Inspection of materials. SMYS must be repaired or removed. If
Each length of pipe and each other a repair is made by grinding, the arc
component must be visually inspected burn must be completely removed and
at the site of installation to ensure the remaining wall thickness must be
that it has not sustained any visually at least equal to either:
determinable damage that could im- (1) The minimum wall thickness re-
pair its serviceability. quired by the tolerances in the speci-
fication to which the pipe was manu-
§ 192.309 Repair of steel pipe.
factured; or
(a) Each imperfection or damage that (2) The nominal wall thickness re-
impairs the serviceability of a length quired for the design pressure of the
of steel pipe must be repaired or re- pipeline.
458
(d) A gouge, groove, arc burn, or dent § 192.315 Wrinkle bends in steel pipe.
may not be repaired by insert patching (a) A wrinkle bend may not be made
or by pounding out. on steel pipe to be operated at a pres-
(e) Each gouge, groove, arc burn, or sure that produces a hoop stress of 30
dent that is removed from a length of percent, or more, of SMYS.
pipe must be removed by cutting out (b) Each wrinkle bend on steel pipe
the damaged portion as a cylinder. must comply with the following:
[35 FR 13257, Aug. 19, 1970, as amended by (1) The bend must not have any sharp
Amdt. 192–1, 35 FR 17660, Nov. 17, 1970; Amdt. kinks.
192–85, 63 FR 37503, July 13, 1998; Amdt. 192– (2) When measured along the crotch
88, 64 FR 69664, Dec. 14, 1999] of the bend, the wrinkles must be a dis-
tance of at least one pipe diameter.
§ 192.311 Repair of plastic pipe. (3) On pipe 16 inches (406 millimeters)
Each imperfection or damage that or larger in diameter, the bend may
would impair the serviceability of plas- not have a deflection of more than 11⁄2°
tic pipe must be repaired or removed. for each wrinkle.
[Amdt. 192–93, 68 FR 53900, Sept. 15, 2003]
(4) On pipe containing a longitudinal
weld the longitudinal seam must be as
§ 192.313 Bends and elbows. near as practicable to the neutral axis
of the bend.
(a) Each field bend in steel pipe,
other than a wrinkle bend made in ac- [35 FR 13257, Aug. 19, 1970, as amended by
cordance with § 192.315, must comply Amdt. 192–85, 63 FR 37503, July 13, 1998]
with the following:
§ 192.317 Protection from hazards.
(1) A bend must not impair the serv-
iceability of the pipe. (a) The operator must take all prac-
(2) Each bend must have a smooth ticable steps to protect each trans-
contour and be free from buckling, mission line or main from washouts,
cracks, or any other mechanical dam- floods, unstable soil, landslides, or
age. other hazards that may cause the pipe-
(3) On pipe containing a longitudinal line to move or to sustain abnormal
weld, the longitudinal weld must be as loads. In addition, the operator must
near as practicable to the neutral axis take all practicable steps to protect
of the bend unless: offshore pipelines from damage by mud
(i) The bend is made with an internal slides, water currents, hurricanes, ship
bending mandrel; or anchors, and fishing operations.
(ii) The pipe is 12 inches (305 millime- (b) Each aboveground transmission
ters) or less in outside diameter or has line or main, not located offshore or in
a diameter to wall thickness ratio less inland navigable water areas, must be
than 70. protected from accidental damage by
(b) Each circumferential weld of steel vehicular traffic or other similar
pipe which is located where the stress causes, either by being placed at a safe
during bending causes a permanent de- distance from the traffic or by install-
formation in the pipe must be non- ing barricades.
destructively tested either before or (c) Pipelines, including pipe risers, on
after the bending process. each platform located offshore or in in-
(c) Wrought-steel welding elbows and land navigable waters must be pro-
transverse segments of these elbows tected from accidental damage by ves-
may not be used for changes in direc- sels.
tion on steel pipe that is 2 inches (51 [Amdt. 192–27, 41 FR 34606, Aug. 16, 1976, as
millimeters) or more in diameter un- amended by Amdt. 192–78, 61 FR 28784, June
less the arc length, as measured along 6, 1996]
the crotch, is at least 1 inch (25 milli-
meters). § 192.319 Installation of pipe in a
ditch.
[Amdt. 192–26, 41 FR 26018, June 24, 1976, as
amended by Amdt. 192–29, 42 FR 42866, Aug. (a) When installed in a ditch, each
25, 1977; Amdt. 192–29, 42 FR 60148, Nov. 25, transmission line that is to be operated
1977; Amdt. 192–49, 50 FR 13225, Apr. 3, 1985; at a pressure producing a hoop stress of
Amdt. 192–85, 63 FR 37503, July 13, 1998] 20 percent or more of SMYS must be
459
§ 192.321 49 CFR Ch. I (10–1–18 Edition)
installed so that the pipe fits the ditch pipe while it is underground. Tracer
so as to minimize stresses and protect wire may not be wrapped around the
the pipe coating from damage. pipe and contact with the pipe must be
(b) When a ditch for a transmission minimized but is not prohibited. Tracer
line or main is backfilled, it must be wire or other metallic elements in-
backfilled in a manner that: stalled for pipe locating purposes must
(1) Provides firm support under the be resistant to corrosion damage, ei-
pipe; and ther by use of coated copper wire or by
(2) Prevents damage to the pipe and other means.
pipe coating from equipment or from (f) Plastic pipe that is being encased
the backfill material. must be inserted into the casing pipe in
(c) All offshore pipe in water at least a manner that will protect the plastic.
12 feet (3.7 meters) deep but not more The leading end of the plastic must be
than 200 feet (61 meters) deep, as meas- closed before insertion.
ured from the mean low tide, except (g) Uncased plastic pipe may be tem-
pipe in the Gulf of Mexico and its inlets porarily installed above ground level
under 15 feet (4.6 meters) of water, under the following conditions:
must be installed so that the top of the (1) The operator must be able to dem-
pipe is below the natural bottom unless onstrate that the cumulative above-
the pipe is supported by stanchions, ground exposure of the pipe does not
held in place by anchors or heavy con- exceed the manufacturer’s rec-
crete coating, or protected by an equiv- ommended maximum period of expo-
alent means. Pipe in the Gulf of Mexico sure or 2 years, whichever is less.
and its inlets under 15 feet (4.6 meters) (2) The pipe either is located where
of water must be installed so that the damage by external forces is unlikely
top of the pipe is 36 inches (914 milli- or is otherwise protected against such
meters) below the seabed for normal damage.
excavation or 18 inches (457 millime- (3) The pipe adequately resists expo-
ters) for rock excavation. sure to ultraviolet light and high and
[35 FR 13257, Aug. 19, 1970, as amended by low temperatures.
Amdt. 192–27, 41 FR 34606, Aug. 16, 1976; (h) Plastic pipe may be installed on
Amdt. 192–78, 61 FR 28784, June 6, 1996; Amdt. bridges provided that it is:
192–85, 63 FR 37503, July 13, 1998] (1) Installed with protection from
mechanical damage, such as installa-
§ 192.321 Installation of plastic pipe. tion in a metallic casing;
(a) Plastic pipe must be installed (2) Protected from ultraviolet radi-
below ground level except as provided ation; and
by paragraphs (g) and (h) of this sec- (3) Not allowed to exceed the pipe
tion. temperature limits specified in
(b) Plastic pipe that is installed in a § 192.123.
vault or any other below grade enclo- [35 FR 13257, Aug. 19, 1970, as amended by
sure must be completely encased in Amdt. 192–78, 61 FR 28784, June 6, 1996; Amdt.
gas-tight metal pipe and fittings that 192–85, 63 FR 37503, July 13, 1998; Amdt. 192–
are adequately protected from corro- 93, 68 FR 53900, Sept. 15, 2003; Amdt. 192–94, 69
sion. FR 32895, June 14, 2004]
(c) Plastic pipe must be installed so
as to minimize shear or tensile § 192.323 Casing.
stresses. Each casing used on a transmission
(d) Thermoplastic pipe that is not en- line or main under a railroad or high-
cased must have a minimum wall way must comply with the following:
thickness of 0.090 inch (2.29 millime- (a) The casing must be designed to
ters), except that pipe with an outside withstand the superimposed loads.
diameter of 0.875 inch (22.3 millimeters) (b) If there is a possibility of water
or less may have a minimum wall entering the casing, the ends must be
thickness of 0.062 inch (1.58 millime- sealed.
ters). (c) If the ends of an unvented casing

(e) Plastic pipe that is not encased are sealed and the sealing is strong
must have an electrically conducting enough to retain the maximum allow-
wire or other means of locating the able operating pressure of the pipe, the
460
casing must be designed to hold this mission line or main with the min-
pressure at a stress level of not more imum cover, the transmission line or
than 72 percent of SMYS. main may be installed with less cover
(d) If vents are installed on a casing, if it is provided with additional protec-
the vents must be protected from the tion to withstand anticipated external
weather to prevent water from enter- loads.
ing the casing. (d) A main may be installed with less
than 24 inches (610 millimeters) of
§ 192.325 Underground clearance. cover if the law of the State or munici-
(a) Each transmission line must be pality:
installed with at least 12 inches (305 (1) Establishes a minimum cover of
millimeters) of clearance from any less than 24 inches (610 millimeters);
other underground structure not asso- (2) Requires that mains be installed
ciated with the transmission line. If in a common trench with other utility
this clearance cannot be attained, the lines; and
transmission line must be protected (3) Provides adequately for preven-
from damage that might result from tion of damage to the pipe by external
the proximity of the other structure. forces.
(b) Each main must be installed with (e) Except as provided in paragraph
enough clearance from any other un- (c) of this section, all pipe installed in
derground structure to allow proper a navigable river, stream, or harbor
maintenance and to protect against must be installed with a minimum
damage that might result from prox- cover of 48 inches (1,219 millimeters) in
imity to other structures. soil or 24 inches (610 millimeters) in
(c) In addition to meeting the re- consolidated rock between the top of
quirements of paragraph (a) or (b) of the pipe and the underwater natural
this section, each plastic transmission bottom (as determined by recognized
line or main must be installed with suf- and generally accepted practices).
ficient clearance, or must be insulated, (f) All pipe installed offshore, except
from any source of heat so as to pre- in the Gulf of Mexico and its inlets,
vent the heat from impairing the serv- under water not more than 200 feet (60
iceability of the pipe. meters) deep, as measured from the
(d) Each pipe-type or bottle-type mean low tide, must be installed as fol-
holder must be installed with a min- lows:
imum clearance from any other holder (1) Except as provided in paragraph
as prescribed in § 192.175(b). (c) of this section, pipe under water
less than 12 feet (3.66 meters) deep,
Amdt. 192–85, 63 FR 37503, July 13, 1998] must be installed with a minimum
cover of 36 inches (914 millimeters) in
§ 192.327 Cover. soil or 18 inches (457 millimeters) in
(a) Except as provided in paragraphs consolidated rock between the top of
(c), (e), (f), and (g) of this section, each the pipe and the natural bottom.
buried transmission line must be in- (2) Pipe under water at least 12 feet
stalled with a minimum cover as fol- (3.66 meters) deep must be installed so
lows: that the top of the pipe is below the
natural bottom, unless the pipe is sup-
Location Normal soil Consoli- ported by stanchions, held in place by
dated rock
anchors or heavy concrete coating, or
Inches (Millimeters). protected by an equivalent means.
Class 1 locations ........................... 30 (762) 18 (457) (g) All pipelines installed under
Class 2, 3, and 4 locations ........... 36 (914) 24 (610)
Drainage ditches of public roads water in the Gulf of Mexico and its in-
and railroad crossings ............... 36 (914) 24 (610) lets, as defined in § 192.3, must be in-
stalled in accordance with
(b) Except as provided in paragraphs § 192.612(b)(3).
(c) and (d) of this section, each buried
main must be installed with at least 24 Amdt. 192–27, 41 FR 34606, Aug. 16, 1976;
inches (610 millimeters) of cover. Amdt. 192–78, 61 FR 28785, June 6, 1996; Amdt.
(c) Where an underground structure 192–85, 63 FR 37503, July 13, 1998; Amdt. 192–
prevents the installation of a trans- 98, 69 FR 48406, Aug. 10, 2004]
461
§ 192.328 49 CFR Ch. I (10–1–18 Edition)
§ 192.328 Additional construction re- ating pressure calculated under

quirements for steel pipe using al- § 192.620, a segment must meet the fol-
ternative maximum allowable oper- lowing additional construction require-
ating pressure. ments. Records must be maintained,
For a new or existing pipeline seg- for the useful life of the pipeline, dem-
ment to be eligible for operation at the onstrating compliance with these re-
alternative maximum allowable oper- quirements:
To address this construction The pipeline segment must meet this additional construction requirement:
issue:
(a) Quality assurance ............... (1) The construction of the pipeline segment must be done under a quality assurance plan ad-
dressing pipe inspection, hauling and stringing, field bending, welding, non-destructive ex-
amination of girth welds, applying and testing field applied coating, lowering of the pipeline
into the ditch, padding and backfilling, and hydrostatic testing.
(2) The quality assurance plan for applying and testing field applied coating to girth welds
must be:
(i) Equivalent to that required under § 192.112(f)(3) for pipe; and
(ii) Performed by an individual with the knowledge, skills, and ability to assure effective coating
application.
(b) Girth welds .......................... (1) All girth welds on a new pipeline segment must be non-destructively examined in accord-
ance with § 192.243(b) and (c).
(c) Depth of cover ..................... (1) Notwithstanding any lesser depth of cover otherwise allowed in § 192.327, there must be at
least 36 inches (914 millimeters) of cover or equivalent means to protect the pipeline from
outside force damage.
(2) In areas where deep tilling or other activities could threaten the pipeline, the top of the
pipeline must be installed at least one foot below the deepest expected penetration of the
soil.
(d) Initial strength testing .......... (1) The pipeline segment must not have experienced failures indicative of systemic material
defects during strength testing, including initial hydrostatic testing. A root cause analysis, in-
cluding metallurgical examination of the failed pipe, must be performed for any failure expe-
rienced to verify that it is not indicative of a systemic concern. The results of this root cause
analysis must be reported to each PHMSA pipeline safety regional office where the pipe is
in service at least 60 days prior to operating at the alternative MAOP. An operator must also
notify a State pipeline safety authority when the pipeline is located in a State where PHMSA
has an interstate agent agreement, or an intrastate pipeline is regulated by that State.
(e) Interference currents ........... (1) For a new pipeline segment, the construction must address the impacts of induced alter-
nating current from parallel electric transmission lines and other known sources of potential
interference with corrosion control.
[72 FR 62176, Oct. 17, 2008] (b) Each service regulator installed
within a building must be located as
Subpart H—Customer Meters, near as practical to the point of service
Service Regulators, and Serv- line entrance.
ice Lines (c) Each meter installed within a
building must be located in a venti-
§ 192.351 Scope. lated place and not less than 3 feet (914
millimeters) from any source of igni-
This subpart prescribes minimum re-
tion or any source of heat which might
quirements for installing customer me-
damage the meter.
ters, service regulators, service lines,
service line valves, and service line (d) Where feasible, the upstream reg-
connections to mains. ulator in a series must be located out-
side the building, unless it is located in
§ 192.353 Customer meters and regu- a separate metering or regulating
lators: Location. building.
(a) Each meter and service regulator, [35 FR 13257, Aug. 19, 1970, as amended by
whether inside or outside a building, Amdt. 192–85, 63 FR 37503, July 13, 1998;
must be installed in a readily acces- Amdt. 192–93, 68 FR 53900, Sept. 15, 2003]
sible location and be protected from
corrosion and other damage, including, § 192.355 Customer meters and regu-
lators: Protection from damage.
if installed outside a building, vehic-

ular damage that may be anticipated. (a) Protection from vacuum or back
However, the upstream regulator in a pressure. If the customer’s equipment
series may be buried. might create either a vacuum or a back
462
pressure, a device must be installed to § 192.361 Service lines: Installation.

protect the system.
(a) Depth. Each buried service line
(b) Service regulator vents and relief
must be installed with at least 12
vents. Service regulator vents and re-
inches (305 millimeters) of cover in pri-
lief vents must terminate outdoors,
and the outdoor terminal must— vate property and at least 18 inches
(1) Be rain and insect resistant; (457 millimeters) of cover in streets and
(2) Be located at a place where gas roads. However, where an underground
from the vent can escape freely into structure prevents installation at
the atmosphere and away from any those depths, the service line must be
opening into the building; and able to withstand any anticipated ex-
(3) Be protected from damage caused ternal load.
by submergence in areas where flood- (b) Support and backfill. Each service
ing may occur. line must be properly supported on un-
(c) Pits and vaults. Each pit or vault disturbed or well-compacted soil, and
that houses a customer meter or regu- material used for backfill must be free
lator at a place where vehicular traffic of materials that could damage the
is anticipated, must be able to support pipe or its coating.
that traffic. (c) Grading for drainage. Where con-
densate in the gas might cause inter-
ruption in the gas supply to the cus-
Amdt. 192–58, 53 FR 1635, Jan. 21, 1988]
tomer, the service line must be graded
§ 192.357 Customer meters and regu- so as to drain into the main or into
lators: Installation. drips at the low points in the service
(a) Each meter and each regulator line.
must be installed so as to minimize an- (d) Protection against piping strain and
ticipated stresses upon the connecting external loading. Each service line must
piping and the meter. be installed so as to minimize antici-
(b) When close all-thread nipples are pated piping strain and external load-
used, the wall thickness remaining ing.
after the threads are cut must meet (e) Installation of service lines into
the minimum wall thickness require- buildings. Each underground service
ments of this part. line installed below grade through the
(c) Connections made of lead or other outer foundation wall of a building
easily damaged material may not be must:
used in the installation of meters or (1) In the case of a metal service line,
regulators. be protected against corrosion;
(d) Each regulator that might release (2) In the case of a plastic service
gas in its operation must be vented to line, be protected from shearing action
the outside atmosphere. and backfill settlement; and
(3) Be sealed at the foundation wall
§ 192.359 Customer meter installations: to prevent leakage into the building.
Operating pressure. (f) Installation of service lines under
(a) A meter may not be used at a buildings. Where an underground serv-
pressure that is more than 67 percent ice line is installed under a building:
of the manufacturer’s shell test pres- (1) It must be encased in a gas tight
sure. conduit;
(b) Each newly installed meter manu- (2) The conduit and the service line
factured after November 12, 1970, must must, if the service line supplies the
have been tested to a minimum of 10 building it underlies, extend into a nor-
p.s.i. (69 kPa) gage. mally usable and accessible part of the
(c) A rebuilt or repaired tinned steel building; and
case meter may not be used at a pres- (3) The space between the conduit
sure that is more than 50 percent of the and the service line must be sealed to
pressure used to test the meter after prevent gas leakage into the building
rebuilding or repairing. and, if the conduit is sealed at both

[35 FR 13257, Aug. 19, 1970, as amended by ends, a vent line from the annular
Amdt. 192–1, 35 FR 17660, Nov. 17, 1970; Amdt. space must extend to a point where gas
192–85, 63 FR 37503, July 13, 1998] would not be a hazard, and extend
463
§ 192.363 49 CFR Ch. I (10–1–18 Edition)
above grade, terminating in a rain and stalled to minimize the possibility of

insect resistant fitting. dust and moisture being carried from
(g) Locating underground service lines. the main into the service line.
Each underground nonmetallic service (b) Compression-type connection to
line that is not encased must have a main. Each compression-type service
means of locating the pipe that com- line to main connection must:
plies with § 192.321(e). (1) Be designed and installed to effec-
[35 FR 13257, Aug. 19, 1970, as amended by tively sustain the longitudinal pull-out
Amdt. 192–75, 61 FR 18517, Apr. 26, 1996; Amdt. or thrust forces caused by contraction
192–85, 63 FR 37503, July 13, 1998; Amdt. 192– or expansion of the piping, or by antici-
93, 68 FR 53900, Sept. 15, 2003]
pated external or internal loading; and
§ 192.363 Service lines: Valve require- (2) If gaskets are used in connecting
ments. the service line to the main connection
(a) Each service line must have a fitting, have gaskets that are compat-
service-line valve that meets the appli- ible with the kind of gas in the system.
cable requirements of subparts B and D [35 FR 13257, Aug. 19, 1970, as amended by
of this part. A valve incorporated in a Amdt. 192–75, 61 FR 18517, Apr. 26, 1996]
meter bar, that allows the meter to be
bypassed, may not be used as a service- § 192.369 Service lines: Connections to
line valve. cast iron or ductile iron mains.
(b) A soft seat service line valve may (a) Each service line connected to a
not be used if its ability to control the cast iron or ductile iron main must be
flow of gas could be adversely affected connected by a mechanical clamp, by
by exposure to anticipated heat.
drilling and tapping the main, or by
(c) Each service-line valve on a high-
another method meeting the require-
pressure service line, installed above
ments of § 192.273.
ground or in an area where the blowing
of gas would be hazardous, must be de- (b) If a threaded tap is being inserted,
signed and constructed to minimize the the requirements of § 192.151 (b) and (c)
possibility of the removal of the core of must also be met.
the valve with other than specialized
tools. § 192.371 Service lines: Steel.
Each steel service line to be operated
§ 192.365 Service lines: Location of at less than 100 p.s.i. (689 kPa) gage
valves. must be constructed of pipe designed
(a) Relation to regulator or meter. Each for a minimum of 100 p.s.i. (689 kPa)
service-line valve must be installed up- gage.
stream of the regulator or, if there is
no regulator, upstream of the meter. [Amdt. 192–1, 35 FR 17660, Nov. 17, 1970, as
(b) Outside valves. Each service line amended by Amdt. 192–85, 63 FR 37503, July
13, 1998]
must have a shut-off valve in a readily
accessible location that, if feasible, is
§ 192.373 Service lines: Cast iron and
outside of the building. ductile iron.
(c) Underground valves. Each under-
ground service-line valve must be lo- (a) Cast or ductile iron pipe less than
cated in a covered durable curb box or 6 inches (152 millimeters) in diameter
standpipe that allows ready operation may not be installed for service lines.
of the valve and is supported independ- (b) If cast iron pipe or ductile iron
ently of the service lines. pipe is installed for use as a service
line, the part of the service line which
§ 192.367 Service lines: General re- extends through the building wall must
quirements for connections to main
piping. be of steel pipe.
(c) A cast iron or ductile iron service
(a) Location. Each service line con- line may not be installed in unstable
nection to a main must be located at

soil or under a building.
the top of the main or, if that is not
practical, at the side of the main, un- [35 FR 13257, Aug. 19, 1970, as amended by
less a suitable protective device is in- Amdt. 192–85, 63 FR 37503, July 13, 1998]
464
§ 192.375 Service lines: Plastic. (1) Function properly up to the max-

imum operating pressure at which the
(a) Each plastic service line outside a
valve is rated;
building must be installed below
(2) Function properly at all tempera-
ground level, except that—
tures reasonably expected in the oper-
(1) It may be installed in accordance ating environment of the service line;
with § 192.321(g); and
(3) At 10 p.s.i. (69 kPa) gage:
(2) It may terminate above ground
(i) Close at, or not more than 50 per-
level and outside the building, if—
cent above, the rated closure flow rate
(i) The above ground level part of the specified by the manufacturer; and
plastic service line is protected against (ii) Upon closure, reduce gas flow—
deterioration and external damage; and
(A) For an excess flow valve designed
(ii) The plastic service line is not to allow pressure to equalize across the
used to support external loads. valve, to no more than 5 percent of the
(b) Each plastic service line inside a manufacturer’s specified closure flow
building must be protected against ex- rate, up to a maximum of 20 cubic feet
ternal damage. per hour (0.57 cubic meters per hour);
[35 FR 13257, Aug. 19, 1970, as amended by or
Amdt. 192–78, 61 FR 28785, June 6, 1996] (B) For an excess flow valve designed
to prevent equalization of pressure
§ 192.377 Service lines: Copper. across the valve, to no more than 0.4
Each copper service line installed cubic feet per hour (.01 cubic meters
within a building must be protected per hour); and
against external damage. (4) Not close when the pressure is less
than the manufacturer’s minimum
§ 192.379 New service lines not in use. specified operating pressure and the
flow rate is below the manufacturer’s
Each service line that is not placed
minimum specified closure flow rate.
in service upon completion of installa-
(b) An excess flow valve must meet
tion must comply with one of the fol-
the applicable requirements of Sub-
lowing until the customer is supplied
parts B and D of this part.
with gas:
(c) An operator must mark or other-
(a) The valve that is closed to pre-
wise identify the presence of an excess
vent the flow of gas to the customer
flow valve in the service line.
must be provided with a locking device
or other means designed to prevent the (d) An operator shall locate an excess
opening of the valve by persons other flow valve as near as practical to the
than those authorized by the operator. fitting connecting the service line to
its source of gas supply.
(b) A mechanical device or fitting
(e) An operator should not install an
that will prevent the flow of gas must
excess flow valve on a service line
be installed in the service line or in the
where the operator has prior experi-
meter assembly.
ence with contaminants in the gas
(c) The customer’s piping must be stream, where these contaminants
physically disconnected from the gas could be expected to cause the excess
supply and the open pipe ends sealed. flow valve to malfunction or where the
[Amdt. 192–8, 37 FR 20694, Oct. 3, 1972] excess flow valve would interfere with
necessary operation and maintenance
§ 192.381 Service lines: Excess flow activities on the service, such as blow-
valve performance standards. ing liquids from the line.
(a) Excess flow valves (EFVs) to be [Amdt. 192–79, 61 FR 31459, June 20, 1996, as
used on service lines that operate con- amended by Amdt. 192–80, 62 FR 2619, Jan. 17,
tinuously throughout the year at a 1997; Amdt. 192–85, 63 FR 37504, July 13, 1998;
pressure not less than 10 p.s.i. (69 kPa) Amdt. 192–121, 81 FR 71001, Oct. 14, 2016]
gage must be manufactured and tested
§ 192.383 Excess flow valve installa-
by the manufacturer according to an

industry specification, or the manufac- tion.
turer’s written specification, to ensure (a) Definitions. As used in this sec-
that each valve will: tion:
465
§ 192.383 49 CFR Ch. I (10–1–18 Edition)
Branched service line means a gas tivities, such as blowing liquids from
service line that begins at the existing the line; or
service line or is installed concurrently (4) An EFV meeting the performance
with the primary service line but standards in § 192.381 is not commer-
serves a separate residence. cially available to the operator.
Replaced service line means a gas serv- (d) Customer’s right to request an EFV.
ice line where the fitting that connects Existing service line customers who de-
the service line to the main is replaced sire an EFV on service lines not ex-
or the piping connected to this fitting ceeding 1,000 SCFH and who do not
is replaced. qualify for one of the exceptions in
Service line serving single-family resi- paragraph (c) of this section may re-
dence means a gas service line that be- quest an EFV to be installed on their
gins at the fitting that connects the service lines. If an eligible service line
service line to the main and serves customer requests an EFV installation,
only one single-family residence (SFR). an operator must install the EFV at a
(b) Installation required. An EFV in- mutually agreeable date. The opera-
stallation must comply with the per- tor’s rate-setter determines how and to
formance standards in § 192.381. After whom the costs of the requested EFVs
April 14, 2017, each operator must in- are distributed.
stall an EFV on any new or replaced (e) Operator notification of customers
service line serving the following types concerning EFV installation. Operators
of services before the line is activated: must notify customers of their right to
(1) A single service line to one SFR; request an EFV in the following man-
(2) A branched service line to a SFR ner:
installed concurrently with the pri- (1) Except as specified in paragraphs
mary SFR service line (i.e., a single (c) and (e)(5) of this section, each oper-
EFV may be installed to protect both ator must provide written or electronic
service lines); notification to customers of their right
(3) A branched service line to a SFR to request the installation of an EFV.
installed off a previously installed SFR Electronic notification can include
service line that does not contain an emails, Web site postings, and e-billing
EFV; notices.
(4) Multifamily residences with (2) The notification must include an
known customer loads not exceeding explanation for the service line cus-
1,000 SCFH per service, at time of serv- tomer of the potential safety benefits
ice installation based on installed that may be derived from installing an
meter capacity, and EFV. The explanation must include in-
(5) A single, small commercial cus- formation that an EFV is designed to
tomer served by a single service line shut off the flow of natural gas auto-
with a known customer load not ex- matically if the service line breaks.
ceeding 1,000 SCFH, at the time of (3) The notification must include a
meter installation, based on installed description of EFV installation and re-
meter capacity. placement costs. The notice must alert
(c) Exceptions to excess flow valve in- the customer that the costs for main-
stallation requirement. An operator need taining and replacing an EFV may
not install an excess flow valve if one later be incurred, and what those costs
or more of the following conditions are will be to the extent known.
present: (4) The notification must indicate
(1) The service line does not operate that if a service line customer requests
at a pressure of 10 psig or greater installation of an EFV and the load
throughout the year; does not exceed 1,000 SCFH and the
(2) The operator has prior experience conditions of paragraph (c) are not
with contaminants in the gas stream present, the operator must install an
that could interfere with the EFV’s op- EFV at a mutually agreeable date.
eration or cause loss of service to a (5) Operators of master-meter sys-

customer; tems and liquefied petroleum gas
(3) An EFV could interfere with nec- (LPG) operators with fewer than 100
essary operation or maintenance ac- customers may continuously post a
466
general notification in a prominent lo- § 192.451 Scope.

cation frequented by customers.
(a) This subpart prescribes minimum
(f) Operator evidence of customer notifi- requirements for the protection of me-
cation. An operator must make a copy tallic pipelines from external, internal,
of the notice or notices currently in and atmospheric corrosion.
use available during PHMSA inspec-
(b) [Reserved]
tions or State inspections conducted
under a pipeline safety program cer- [Amdt. 192–4, 36 FR 12302, June 30, 1971, as
tified or approved by PHMSA under 49 amended by Amdt. 192–27, 41 FR 34606, Aug.
U.S.C. 60105 or 60106. 16, 1976; Amdt. 192–33, 43 FR 39389, Sept. 5,
1978]
(g) Reporting. Except for operators of
master-meter systems and LPG opera- § 192.452 How does this subpart apply
tors with fewer than 100 customers, to converted pipelines and regu-
each operator must report the EFV lated onshore gathering lines?
measures detailed in the annual report
(a) Converted pipelines. Notwith-
required by § 191.11.
standing the date the pipeline was in-
[Amdt. 192–121, 81 FR 71001, Oct. 14, 2016; 81 stalled or any earlier deadlines for
FR 72739, Oct. 21, 2016] compliance, each pipeline which quali-
fies for use under this part in accord-
§ 192.385 Manual service line shut-off ance with § 192.14 must meet the re-
valve installation. quirements of this subpart specifically
(a) Definitions. As used in this sec- applicable to pipelines installed before
tion: August 1, 1971, and all other applicable
Manual service line shut-off valve requirements within 1 year after the
means a curb valve or other manually pipeline is readied for service. How-
operated valve located near the service ever, the requirements of this subpart
line that is safely accessible to oper- specifically applicable to pipelines in-
ator personnel or other personnel au- stalled after July 31, 1971, apply if the
thorized by the operator to manually pipeline substantially meets those re-
shut off gas flow to the service line, if quirements before it is readied for serv-
needed. ice or it is a segment which is replaced,
(b) Installation requirement. The oper- relocated, or substantially altered.
ator must install either a manual serv- (b) Regulated onshore gathering lines.
ice line shut-off valve or, if possible, For any regulated onshore gathering
based on sound engineering analysis line under § 192.9 existing on April 14,
and availability, an EFV for any new 2006, that was not previously subject to
or replaced service line with installed this part, and for any onshore gath-
meter capacity exceeding 1,000 SCFH. ering line that becomes a regulated on-
(c) Accessibility and maintenance. Man- shore gathering line under § 192.9 after
ual service line shut-off valves for any April 14, 2006, because of a change in
new or replaced service line must be in- class location or increase in dwelling
stalled in such a way as to allow acces- density:
sibility during emergencies. Manual (1) The requirements of this subpart
service shut-off valves installed under specifically applicable to pipelines in-
this section are subject to regular stalled before August 1, 1971, apply to
scheduled maintenance, as documented the gathering line regardless of the
by the operator and consistent with date the pipeline was actually in-
the valve manufacturer’s specification. stalled; and
(2) The requirements of this subpart
[Amdt. 192–121, 81 FR 71002, Oct. 14, 2016] specifically applicable to pipelines in-
stalled after July 31, 1971, apply only if
Subpart I—Requirements for the pipeline substantially meets those
Corrosion Control requirements.
[Amdt. 192–30, 42 FR 60148, Nov. 25, 1977, as

SOURCE: Amdt. 192–4, 36 FR 12302, June 30, amended by Amdt. 192–102, 71 FR 13303, Mar.
1971, unless otherwise noted. 15, 2006]
467
§ 192.453 49 CFR Ch. I (10–1–18 Edition)
§ 192.453 General. (1) For a copper pipeline, a corrosive

environment does not exist; or
The corrosion control procedures re-
quired by § 192.605(b)(2), including those (2) For a temporary pipeline with an
for the design, installation, operation, operating period of service not to ex-
and maintenance of cathodic protec- ceed 5 years beyond installation, corro-
tion systems, must be carried out by, sion during the 5-year period of service
or under the direction of, a person of the pipeline will not be detrimental
qualified in pipeline corrosion control to public safety.
methods. (d) Notwithstanding the provisions of
paragraph (b) or (c) of this section, if a
[Amdt. 192–71, 59 FR 6584, Feb. 11, 1994] pipeline is externally coated, it must
be cathodically protected in accord-
§ 192.455 External corrosion control: ance with paragraph (a)(2) of this sec-
Buried or submerged pipelines in- tion.
stalled after July 31, 1971.
(e) Aluminum may not be installed in
(a) Except as provided in paragraphs a buried or submerged pipeline if that
(b), (c), and (f) of this section, each bur- aluminum is exposed to an environ-
ied or submerged pipeline installed ment with a natural pH in excess of 8,
after July 31, 1971, must be protected unless tests or experience indicate its
against external corrosion, including suitability in the particular environ-
the following: ment involved.
(1) It must have an external protec- (f) This section does not apply to
tive coating meeting the requirements electrically isolated, metal alloy fit-
of § 192.461. tings in plastic pipelines, if:
(2) It must have a cathodic protec- (1) For the size fitting to be used, an
tion system designed to protect the operator can show by test, investiga-
pipeline in accordance with this sub- tion, or experience in the area of appli-
part, installed and placed in operation cation that adequate corrosion control
within 1 year after completion of con- is provided by the alloy composition;
struction. and
(b) An operator need not comply with (2) The fitting is designed to prevent
paragraph (a) of this section, if the op- leakage caused by localized corrosion
erator can demonstrate by tests, inves- pitting.
tigation, or experience in the area of
application, including, as a minimum, [Amdt. 192–4, 36 FR 12302, June 30, 1971, as
amended at Amdt. 192–28, 42 FR 35654, July
soil resistivity measurements and tests
11, 1977; Amdt. 192–39, 47 FR 9844, Mar. 8, 1982;
for corrosion accelerating bacteria, Amdt. 192–78, 61 FR 28785, June 6, 1996; Amdt.
that a corrosive environment does not 192–85, 63 FR 37504, July 13, 1998]
exist. However, within 6 months after
an installation made pursuant to the § 192.457 External corrosion control:
preceding sentence, the operator shall Buried or submerged pipelines in-
conduct tests, including pipe-to-soil stalled before August 1, 1971.
potential measurements with respect (a) Except for buried piping at com-
to either a continuous reference elec- pressor, regulator, and measuring sta-
trode or an electrode using close spac- tions, each buried or submerged trans-
ing, not to exceed 20 feet (6 meters), mission line installed before August 1,
and soil resistivity measurements at 1971, that has an effective external
potential profile peak locations, to coating must be cathodically protected
adequately evaluate the potential pro- along the entire area that is effectively
file along the entire pipeline. If the coated, in accordance with this sub-
tests made indicate that a corrosive part. For the purposes of this subpart,
condition exists, the pipeline must be a pipeline does not have an effective
cathodically protected in accordance external coating if its cathodic protec-
with paragraph (a)(2) of this section. tion current requirements are substan-
(c) An operator need not comply with tially the same as if it were bare. The
paragraph (a) of this section, if the op- operator shall make tests to determine
erator can demonstrate by tests, inves- the cathodic protection current re-
tigation, or experience that— quirements.
468
(b) Except for cast iron or ductile must also have low moisture absorp-
iron, each of the following buried or tion and high electrical resistance.
submerged pipelines installed before (c) Each external protective coating
August 1, 1971, must be cathodically must be inspected just prior to low-
protected in accordance with this sub- ering the pipe into the ditch and back-
part in areas in which active corrosion filling, and any damage detrimental to
is found: effective corrosion control must be re-
(1) Bare or ineffectively coated trans- paired.
mission lines. (d) Each external protective coating
(2) Bare or coated pipes at com- must be protected from damage result-
pressor, regulator, and measuring sta- ing from adverse ditch conditions or
tions. damage from supporting blocks.
(3) Bare or coated distribution lines. (e) If coated pipe is installed by bor-
ing, driving, or other similar method,
[Amdt. 192–4, 36 FR 12302, June 30, 1971, as precautions must be taken to minimize
amended by Amdt. 192–33, 43 FR 39390, Sept.
5, 1978; Amdt. 192–93, 68 FR 53900, Sept. 15,
damage to the coating during installa-
2003] tion.
§ 192.459 External corrosion control: § 192.463 External corrosion control:

Examination of buried pipeline Cathodic protection.
when exposed. (a) Each cathodic protection system
Whenever an operator has knowledge required by this subpart must provide a
that any portion of a buried pipeline is level of cathodic protection that com-
exposed, the exposed portion must be plies with one or more of the applicable
examined for evidence of external cor- criteria contained in appendix D of this
rosion if the pipe is bare, or if the coat- part. If none of these criteria is appli-
ing is deteriorated. If external corro- cable, the cathodic protection system
sion requiring remedial action under must provide a level of cathodic pro-
§§ 192.483 through 192.489 is found, the tection at least equal to that provided
operator shall investigate circumferen- by compliance with one or more of
tially and longitudinally beyond the these criteria.
exposed portion (by visual examina- (b) If amphoteric metals are included
tion, indirect method, or both) to de- in a buried or submerged pipeline con-
termine whether additional corrosion taining a metal of different anodic po-
requiring remedial action exists in the tential—
vicinity of the exposed portion. (1) The amphoteric metals must be
electrically isolated from the remain-
[Amdt. 192–87, 64 FR 56981, Oct. 22, 1999] der of the pipeline and cathodically
protected; or
§ 192.461 External corrosion control:
Protective coating. (2) The entire buried or submerged
pipeline must be cathodically pro-
(a) Each external protective coating, tected at a cathodic potential that
whether conductive or insulating, ap- meets the requirements of appendix D
plied for the purpose of external corro- of this part for amphoteric metals.
sion control must— (c) The amount of cathodic protec-
(1) Be applied on a properly prepared tion must be controlled so as not to
surface; damage the protective coating or the
(2) Have sufficient adhesion to the pipe.
metal surface to effectively resist
underfilm migration of moisture; § 192.465 External corrosion control:
(3) Be sufficiently ductile to resist Monitoring.
cracking; (a) Each pipeline that is under ca-
(4) Have sufficient strength to resist thodic protection must be tested at
damage due to handling and soil stress; least once each calendar year, but with
and intervals not exceeding 15 months, to
(5) Have properties compatible with determine whether the cathodic protec-
any supplemental cathodic protection. tion meets the requirements of
(b) Each external protective coating § 192.463. However, if tests at those in-
which is an electrically insulating type tervals are impractical for separately
469
§ 192.467 49 CFR Ch. I (10–1–18 Edition)
protected short sections of mains or § 192.467 External corrosion control:

transmission lines, not in excess of 100 Electrical isolation.
feet (30 meters), or separately pro- (a) Each buried or submerged pipe-
tected service lines, these pipelines line must be electrically isolated from
may be surveyed on a sampling basis.
other underground metallic structures,
At least 10 percent of these protected
unless the pipeline and the other struc-
structures, distributed over the entire
tures are electrically interconnected
system must be surveyed each calendar
and cathodically protected as a single
year, with a different 10 percent
unit.
checked each subsequent year, so that
the entire system is tested in each 10– (b) One or more insulating devices
year period. must be installed where electrical iso-
(b) Each cathodic protection rectifier lation of a portion of a pipeline is nec-
or other impressed current power essary to facilitate the application of
source must be inspected six times corrosion control.
each calendar year, but with intervals (c) Except for unprotected copper in-
not exceeding 21⁄2 months, to insure serted in ferrous pipe, each pipeline
that it is operating. must be electrically isolated from me-
(c) Each reverse current switch, each tallic casings that are a part of the un-
diode, and each interference bond derground system. However, if isola-
whose failure would jeopardize struction is not achieved because it is im-
ture protection must be electrically practical, other measures must be
checked for proper performance six taken to minimize corrosion of the
times each calendar year, but with in- pipeline inside the casing.
tervals not exceeding 21⁄2 months. Each (d) Inspection and electrical tests
other interference bond must be must be made to assure that electrical
checked at least once each calendar isolation is adequate.
year, but with intervals not exceeding (e) An insulating device may not be
15 months. installed in an area where a combus-
(d) Each operator shall take prompt tible atmosphere is anticipated unless
remedial action to correct any defi- precautions are taken to prevent arc-
ciencies indicated by the monitoring. ing.
(e) After the initial evaluation re- (f) Where a pipeline is located in
quired by §§ 192.455(b) and (c) and close proximity to electrical trans-
192.457(b), each operator must, not less mission tower footings, ground cables
than every 3 years at intervals not ex- or counterpoise, or in other areas
ceeding 39 months, reevaluate its un- where fault currents or unusual risk of
protected pipelines and cathodically lightning may be anticipated, it must
protect them in accordance with this be provided with protection against
subpart in areas in which active corro-
damage due to fault currents or light-
sion is found. The operator must deter-
ning, and protective measures must
mine the areas of active corrosion by
also be taken at insulating devices.
electrical survey. However, on distribu-
tion lines and where an electrical sur- [Amdt. 192–4, 36 FR 12302, June 30, 1971, as
vey is impractical on transmission amended by Amdt. 192–33, 43 FR 39390, Sept.
lines, areas of active corrosion may be 5, 1978]
determined by other means that in-
clude review and analysis of leak re- § 192.469 External corrosion control:
pair and inspection records, corrosion Test stations.
monitoring records, exposed pipe in- Each pipeline under cathodic protec-
spection records, and the pipeline envi- tion required by this subpart must
ronment. have sufficient test stations or other
[Amdt. 192–4, 36 FR 12302, June 30, 1971, as contact points for electrical measure-
amended by Amdt. 192–33, 43 FR 39390, Sept. ment to determine the adequacy of ca-
5, 1978; Amdt. 192–35A, 45 FR 23441, Apr. 7, thodic protection.

1980; Amdt. 192–85, 63 FR 37504, July 13, 1998;
Amdt. 192–93, 68 FR 53900, Sept. 15, 2003; [Amdt. 192–27, 41 FR 34606, Aug. 16, 1976]
Amdt. 192–114, 75 FR 48603, Aug. 11, 2010]
470
§ 192.471 External corrosion control: not be stored in pipe-type or bottle-

Test leads. type holders.
(a) Each test lead wire must be con- [Amdt. 192–4, 36 FR 12302, June 30, 1971, as
nected to the pipeline so as to remain amended by Amdt. 192–33, 43 FR 39390, Sept.
mechanically secure and electrically 5, 1978; Amdt. 192–78, 61 FR 28785, June 6, 1996;
conductive. Amdt. 192–85, 63 FR 37504, July 13, 1998]
(b) Each test lead wire must be at-
§ 192.476 Internal corrosion control:
tached to the pipeline so as to mini- Design and construction of trans-
mize stress concentration on the pipe. mission line.
(c) Each bared test lead wire and
bared metallic area at point of connec- (a) Design and construction. Except as
tion to the pipeline must be coated provided in paragraph (b) of this sec-
with an electrical insulating material tion, each new transmission line and
compatible with the pipe coating and each replacement of line pipe, valve,
the insulation on the wire. fitting, or other line component in a
transmission line must have features
§ 192.473 External corrosion control: incorporated into its design and con-
Interference currents. struction to reduce the risk of internal
corrosion. At a minimum, unless it is
(a) Each operator whose pipeline sys-
impracticable or unnecessary to do so,
tem is subjected to stray currents shall
each new transmission line or replace-
have in effect a continuing program to
ment of line pipe, valve, fitting, or
minimize the detrimental effects of
other line component in a transmission
such currents.
line must:
(b) Each impressed current type ca-
(1) Be configured to reduce the risk
thodic protection system or galvanic
that liquids will collect in the line;
anode system must be designed and in-
(2) Have effective liquid removal fea-
stalled so as to minimize any adverse
tures whenever the configuration
effects on existing adjacent under-
would allow liquids to collect; and
ground metallic structures.
(3) Allow use of devices for moni-
[Amdt. 192–4, 36 FR 12302, June 30, 1971, as toring internal corrosion at locations
amended by Amdt. 192–33, 43 FR 39390, Sept. with significant potential for internal
5, 1978] corrosion.
(b) Exceptions to applicability. The de-
§ 192.475 Internal corrosion control: sign and construction requirements of
General.
paragraph (a) of this section do not
(a) Corrosive gas may not be trans- apply to the following:
ported by pipeline, unless the corrosive (1) Offshore pipeline; and
effect of the gas on the pipeline has (2) Pipeline installed or line pipe,
been investigated and steps have been valve, fitting or other line component
taken to minimize internal corrosion. replaced before May 23, 2007.
(b) Whenever any pipe is removed (c) Change to existing transmission line.
from a pipeline for any reason, the in- When an operator changes the configu-
ternal surface must be inspected for ration of a transmission line, the oper-
evidence of corrosion. If internal corro- ator must evaluate the impact of the
sion is found— change on internal corrosion risk to
(1) The adjacent pipe must be inves- the downstream portion of an existing
tigated to determine the extent of in- onshore transmission line and provide
ternal corrosion; for removal of liquids and monitoring
(2) Replacement must be made to the of internal corrosion as appropriate.
extent required by the applicable para- (d) Records. An operator must main-
graphs of §§ 192.485, 192.487, or 192.489; tain records demonstrating compliance
and with this section. Provided the records
(3) Steps must be taken to minimize show why incorporating design fea-
the internal corrosion. tures addressing paragraph (a)(1),
(c) Gas containing more than 0.25 (a)(2), or (a)(3) of this section is im-
grain of hydrogen sulfide per 100 cubic practicable or unnecessary, an operator
feet (5.8 milligrams/m.3) at standard may fulfill this requirement through
conditions (4 parts per million) may written procedures supported by as-
471
§ 192.477 49 CFR Ch. I (10–1–18 Edition)
built drawings or other construction (b) During inspections the operator

records. must give particular attention to pipe
at soil-to-air interfaces, under thermal
[72 FR 20059, Apr. 23, 2007]
insulation, under disbonded coatings,
at pipe supports, in splash zones, at
§ 192.477 Internal corrosion control:
Monitoring. deck penetrations, and in spans over
water.
If corrosive gas is being transported, (c) If atmospheric corrosion is found
coupons or other suitable means must during an inspection, the operator
be used to determine the effectiveness must provide protection against the
of the steps taken to minimize internal corrosion as required by § 192.479.
corrosion. Each coupon or other means
[Amdt. 192–93, 68 FR 53901, Sept. 15, 2003]
of monitoring internal corrosion must
be checked two times each calendar § 192.483 Remedial measures: General.
year, but with intervals not exceeding
(a) Each segment of metallic pipe
71⁄2 months.
that replaces pipe removed from a bur-
[Amdt. 192–33, 43 FR 39390, Sept. 5, 1978] ied or submerged pipeline because of
external corrosion must have a prop-
§ 192.479 Atmospheric corrosion con- erly prepared surface and must be pro-
trol: General. vided with an external protective coat-
(a) Each operator must clean and ing that meets the requirements of
coat each pipeline or portion of pipe- § 192.461.
line that is exposed to the atmosphere, (b) Each segment of metallic pipe
except pipelines under paragraph (c) of that replaces pipe removed from a bur-
this section. ied or submerged pipeline because of
(b) Coating material must be suitable external corrosion must be cathodi-
for the prevention of atmospheric cor- cally protected in accordance with this
rosion. subpart.
(c) Except for cast iron or ductile
(c) Except portions of pipelines in off- iron pipe, each segment of buried or
shore splash zones or soil-to-air inter- submerged pipe that is required to be
faces, the operator need not protect repaired because of external corrosion
from atmospheric corrosion any pipe- must be cathodically protected in ac-
line for which the operator dem- cordance with this subpart.
onstrates by test, investigation, or ex-
perience appropriate to the environ- § 192.485 Remedial measures: Trans-
ment of the pipeline that corrosion mission lines.
will— (a) General corrosion. Each segment of
(1) Only be a light surface oxide; or transmission line with general corro-
(2) Not affect the safe operation of sion and with a remaining wall thick-
the pipeline before the next scheduled ness less than that required for the
inspection. MAOP of the pipeline must be replaced
[Amdt. 192–93, 68 FR 53901, Sept. 15, 2003]
or the operating pressure reduced com-
mensurate with the strength of the
§ 192.481 Atmospheric corrosion con- pipe based on actual remaining wall
trol: Monitoring. thickness. However, corroded pipe may
be repaired by a method that reliable
(a) Each operator must inspect each engineering tests and analyses show
pipeline or portion of pipeline that is can permanently restore the service-
exposed to the atmosphere for evidence ability of the pipe. Corrosion pitting so
of atmospheric corrosion, as follows: closely grouped as to affect the overall
If the pipeline is lo- strength of the pipe is considered gen-
Then the frequency of inspection is:
cated: eral corrosion for the purpose of this
paragraph.
Onshore ................. At least once every 3 calendar years,
but with intervals not exceeding 39 (b) Localized corrosion pitting. Each
months segment of transmission line pipe with

Offshore ................. At least once each calendar year, but localized corrosion pitting to a degree
with intervals not exceeding 15 where leakage might result must be re-
months
placed or repaired, or the operating
472
pressure must be reduced commensu- any leakage might result, must be re-
rate with the strength of the pipe, placed.
based on the actual remaining wall (b) Localized graphitization. Each seg-
thickness in the pits. ment of cast iron or ductile iron pipe
(c) Under paragraphs (a) and (b) of on which localized graphitization is
this section, the strength of pipe based found to a degree where any leakage
on actual remaining wall thickness might result, must be replaced or re-
may be determined by the procedure in paired, or sealed by internal sealing
ASME/ANSI B31G (incorporated by ref- methods adequate to prevent or arrest
erence, see § 192.7) or the procedure in any leakage.
PRCI PR 3–805 (R–STRENG) (incor-
§ 192.490 Direct assessment.
porated by reference, see § 192.7). Both
procedures apply to corroded regions Each operator that uses direct as-
that do not penetrate the pipe wall, sessment as defined in § 192.903 on an
subject to the limitations prescribed in onshore transmission line made pri-
the procedures. marily of steel or iron to evaluate the
effects of a threat in the first column
[Amdt. 192–4, 36 FR 12302, June 30, 1971, as must carry out the direct assessment
amended by Amdt. 192–33, 43 FR 39390, Sept. according to the standard listed in the
5, 1978; Amdt. 192–78, 61 FR 28785, June 6, 1996; second column. These standards do not
Amdt. 192–88, 64 FR 69664, Dec. 14, 1999; Amdt.
apply to methods associated with di-
192–119, 80 FR 181, Jan. 5, 2015]
rect assessment, such as close interval
§ 192.487 Remedial measures: Distribu- surveys, voltage gradient surveys, or
tion lines other than cast iron or examination of exposed pipelines, when
ductile iron lines. used separately from the direct assess-
ment process.
(a) General corrosion. Except for cast
iron or ductile iron pipe, each segment Threat Standard 1
of generally corroded distribution line External corrosion ..................................... § 192.925 2
pipe with a remaining wall thickness Internal corrosion in pipelines that trans- § 192.927
less than that required for the MAOP port dry gas.
of the pipeline, or a remaining wall Stress corrosion cracking ......................... § 192.929
thickness less than 30 percent of the 1 For lines not subject to subpart O of this part, the terms
‘‘covered segment’’ and ‘‘covered pipeline segment’’ in
nominal wall thickness, must be re- §§ 192.925, 192.927, and 192.929 refer to the pipeline seg-
placed. However, corroded pipe may be ment on which direct assessment is performed.
2 In § 192.925(b), the provision regarding detection of coat-
repaired by a method that reliable ening damage applies only to pipelines subject to subpart O of
gineering tests and analyses show can this part.
permanently restore the serviceability
of the pipe. Corrosion pitting so closely [Amdt. 192–101, 70 FR 61575, Oct. 25, 2005]
grouped as to affect the overall § 192.491 Corrosion control records.
strength of the pipe is considered gen-
eral corrosion for the purpose of this (a) Each operator shall maintain
paragraph. records or maps to show the location of
(b) Localized corrosion pitting. Except cathodically protected piping, cathodic
for cast iron or ductile iron pipe, each protection facilities, galvanic anodes,
and neighboring structures bonded to
segment of distribution line pipe with
the cathodic protection system.
localized corrosion pitting to a degree
Records or maps showing a stated num-
where leakage might result must be re-
ber of anodes, installed in a stated
placed or repaired.
manner or spacing, need not show spe-
[Amdt. 192–4, 36 FR 12302, June 30, 1971, as cific distances to each buried anode.
amended by Amdt. 192–88, 64 FR 69665, Dec. (b) Each record or map required by
14, 1999] paragraph (a) of this section must be
retained for as long as the pipeline re-
§ 192.489 Remedial measures: Cast mains in service.
iron and ductile iron pipelines. (c) Each operator shall maintain a
(a) General graphitization. Each seg- record of each test, survey, or inspec-
ment of cast iron or ductile iron pipe tion required by this subpart in suffi-
on which general graphitization is cient detail to demonstrate the ade-
found to a degree where a fracture or quacy of corrosion control measures or
473
§ 192.501 49 CFR Ch. I (10–1–18 Edition)
that a corrosive condition does not (1) The component was tested to at
exist. These records must be retained least the pressure required for the pipe-
for at least 5 years, except that records line to which it is being added;
related to §§ 192.465 (a) and (e) and (2) The component was manufactured
192.475(b) must be retained for as long under a quality control system that en-
as the pipeline remains in service. sures that each item manufactured is
[Amdt. 192–78, 61 FR 28785, June 6, 1996]
at least equal in strength to a proto-
type and that the prototype was tested
to at least the pressure required for the
Subpart J—Test Requirements pipeline to which it is being added; or
§ 192.501 Scope. (3) The component carries a pressure
rating established through applicable
This subpart prescribes minimum ASME/ANSI, Manufacturers Standard-
leak-test and strength-test require- ization Society of the Valve and Fit-
ments for pipelines. tings Industry, Inc. (MSS) specifica-
§ 192.503 General requirements. tions, or by unit strength calculations
as described in § 192.143.
(a) No person may operate a new seg-
ment of pipeline, or return to service a [35 FR 13257, Aug. 19, 1970, as amended by
segment of pipeline that has been relo- Amdt. 192–58, 53 FR 1635, Jan. 21, 1988; Amdt.
192–60, 53 FR 36029, Sept. 16, 1988; Amdt. 192–
cated or replaced, until— 60A, 54 FR 5485, Feb. 3, 1989; Amdt. 192–120, 80
(1) It has been tested in accordance FR 12779, Mar. 11, 2015]
with this subpart and § 192.619 to sub-
stantiate the maximum allowable oper- § 192.505 Strength test requirements
ating pressure; and for steel pipeline to operate at a
(2) Each potentially hazardous leak hoop stress of 30 percent or more of
has been located and eliminated. SMYS.
(b) The test medium must be liquid, (a) Except for service lines, each seg-
air, natural gas, or inert gas that is— ment of a steel pipeline that is to oper-
(1) Compatible with the material of ate at a hoop stress of 30 percent or
which the pipeline is constructed; more of SMYS must be strength tested
(2) Relatively free of sedimentary in accordance with this section to sub-
materials; and stantiate the proposed maximum al-
(3) Except for natural gas, nonflam- lowable operating pressure. In addi-
mable. tion, in a Class 1 or Class 2 location, if
(c) Except as provided in § 192.505(a), there is a building intended for human
if air, natural gas, or inert gas is used occupancy within 300 feet (91 meters) of
as the test medium, the following max- a pipeline, a hydrostatic test must be
imum hoop stress limitations apply: conducted to a test pressure of at least
Maximum hoop stress allowed as per-
125 percent of maximum operating
Class location centage of SMYS pressure on that segment of the pipe-
Natural gas Air or inert gas
line within 300 feet (91 meters) of such
a building, but in no event may the
1 ......................... 80 80 test section be less than 600 feet (183
2 ......................... 30 75
3 ......................... 30 50
meters) unless the length of the newly
4 ......................... 30 40 installed or relocated pipe is less than
600 feet (183 meters). However, if the
(d) Each joint used to tie in a test buildings are evacuated while the hoop
segment of pipeline is excepted from stress exceeds 50 percent of SMYS, air
the specific test requirements of this or inert gas may be used as the test
subpart, but each non-welded joint medium.
must be leak tested at not less than its (b) In a Class 1 or Class 2 location,
operating pressure. each compressor station regulator sta-
(e) If a component other than pipe is tion, and measuring station, must be
the only item being replaced or added tested to at least Class 3 location test
to a pipeline, a strength test after in- requirements.

stallation is not required, if the manu- (c) Except as provided in paragraph
facturer of the component certifies (e) of this section, the strength test
that: must be conducted by maintaining the
474
pressure at or above the test pressure ardous leaks in the segment being test-
for at least 8 hours. ed.
(d) For fabricated units and short (b) Each main that is to be operated
sections of pipe, for which a post in- at less than 1 p.s.i. (6.9 kPa) gage must
stallation test is impractical, a pre- be tested to at least 10 p.s.i. (69 kPa)
installation strength test must be con- gage and each main to be operated at
ducted by maintaining the pressure at or above 1 p.s.i. (6.9 kPa) gage must be
or above the test pressure for at least tested to at least 90 p.s.i. (621 kPa)
4 hours. gage.
[35 FR 13257, Aug. 19, 1970, as amended by [35 FR 13257, Aug. 19, 1970, as amended by
Amdt. 192–85, 63 FR 37504, July 13, 1998; Amdt. 192–58, 53 FR 1635, Jan. 21, 1988; Amdt.
Amdt. 192–94, 69 FR 32895, June 14, 2004; 192–85, 63 FR 37504, July 13, 1998]
Amdt. 195–94, 69 FR 54592, Sept. 9, 2004; Amdt.
192–120, 80 FR 12779, Mar. 11, 2015]
§ 192.511 Test requirements for service
lines.
§ 192.507 Test requirements for pipe-
lines to operate at a hoop stress less (a) Each segment of a service line
than 30 percent of SMYS and at or (other than plastic) must be leak test-
above 100 p.s.i. (689 kPa) gage. ed in accordance with this section be-
Except for service lines and plastic fore being placed in service. If feasible,
pipelines, each segment of a pipeline the service line connection to the main
that is to be operated at a hoop stress must be included in the test; if not fea-
less than 30 percent of SMYS and at or sible, it must be given a leakage test at
above 100 p.s.i. (689 kPa) gage must be the operating pressure when placed in
tested in accordance with the fol- service.
lowing: (b) Each segment of a service line
(a) The pipeline operator must use a (other than plastic) intended to be op-
test procedure that will ensure dis- erated at a pressure of at least 1 p.s.i.
covery of all potentially hazardous (6.9 kPa) gage but not more than 40
leaks in the segment being tested. p.s.i. (276 kPa) gage must be given a
(b) If, during the test, the segment is leak test at a pressure of not less than
to be stressed to 20 percent or more of 50 p.s.i. (345 kPa) gage.
SMYS and natural gas, inert gas, or air (c) Each segment of a service line
is the test medium— (other than plastic) intended to be op-
(1) A leak test must be made at a erated at pressures of more than 40
pressure between 100 p.s.i. (689 kPa) p.s.i. (276 kPa) gage must be tested to
gage and the pressure required to at least 90 p.s.i. (621 kPa) gage, except
produce a hoop stress of 20 percent of that each segment of a steel service
SMYS; or line stressed to 20 percent or more of
(2) The line must be walked to check SMYS must be tested in accordance
for leaks while the hoop stress is held with § 192.507 of this subpart.
at approximately 20 percent of SMYS.
(c) The pressure must be maintained [35 FR 13257, Aug. 19, 1970, as amended by
at or above the test pressure for at Amdt. 192–74, 61 FR 18517, Apr. 26, 1996; Amdt.
least 1 hour. 192–85, 63 FR 37504, July 13, 1998]
[35 FR 13257, Aug. 19, 1970, as amended by § 192.513 Test requirements for plastic
Amdt. 192–58, 53 FR 1635, Jan. 21, 1988; Amdt. pipelines.
192–85, 63 FR 37504, July 13, 1998]
(a) Each segment of a plastic pipeline
§ 192.509 Test requirements for pipe- must be tested in accordance with this
lines to operate below 100 p.s.i. (689 section.
kPa) gage. (b) The test procedure must insure
Except for service lines and plastic discovery of all potentially hazardous
pipelines, each segment of a pipeline leaks in the segment being tested.
that is to be operated below 100 p.s.i. (c) The test pressure must be at least
(689 kPa) gage must be leak tested in 150 percent of the maximum operating
accordance with the following: pressure or 50 p.s.i. (345 kPa) gage,
(a) The test procedure used must en- whichever is greater. However, the
sure discovery of all potentially haz- maximum test pressure may not be
475
§ 192.515 49 CFR Ch. I (10–1–18 Edition)
more than three times the pressure de- §§ 192.509, 192.511, and 192.513 for at least
termined under § 192.121, at a tempera- 5 years.
ture not less than the pipe temperature
during the test. Amdt. 192–93, 68 FR 53901, Sept. 15, 2003]
(d) During the test, the temperature
of thermoplastic material may not be
more than 100 °F (38 °C), or the tem- Subpart K—Uprating
perature at which the material’s long- § 192.551 Scope.
term hydrostatic strength has been de-
termined under the listed specification, This subpart prescribes minimum re-
whichever is greater. quirements for increasing maximum
allowable operating pressures
[35 FR 13257, Aug. 19, 1970, as amended by (uprating) for pipelines.
Amdt. 192–77, 61 FR 27793, June 3, 1996; 61 FR
45905, Aug. 30, 1996; Amdt. 192–85, 63 FR 37504, § 192.553 General requirements.
July 13, 1998]
(a) Pressure increases. Whenever the
§ 192.515 Environmental protection requirements of this subpart require
and safety requirements. that an increase in operating pressure
(a) In conducting tests under this be made in increments, the pressure
subpart, each operator shall insure must be increased gradually, at a rate
that every reasonable precaution is that can be controlled, and in accord-
taken to protect its employees and the ance with the following:
general public during the testing. (1) At the end of each incremental in-
Whenever the hoop stress of the seg- crease, the pressure must be held con-
ment of the pipeline being tested will stant while the entire segment of pipe-
exceed 50 percent of SMYS, the oper- line that is affected is checked for
ator shall take all practicable steps to leaks.
keep persons not working on the test- (2) Each leak detected must be re-
ing operation outside of the testing paired before a further pressure in-
area until the pressure is reduced to or crease is made, except that a leak de-
below the proposed maximum allow- termined not to be potentially haz-
able operating pressure. ardous need not be repaired, if it is
(b) The operator shall insure that the monitored during the pressure increase
test medium is disposed of in a manner and it does not become potentially haz-
that will minimize damage to the envi- ardous.
ronment. (b) Records. Each operator who
uprates a segment of pipeline shall re-
§ 192.517 Records. tain for the life of the segment a record
(a) Each operator shall make, and re- of each investigation required by this
tain for the useful life of the pipeline, subpart, of all work performed, and of
a record of each test performed under each pressure test conducted, in con-
§§ 192.505 and 192.507. The record must nection with the uprating.
contain at least the following informa- (c) Written plan. Each operator who
tion: uprates a segment of pipeline shall es-
(1) The operator’s name, the name of tablish a written procedure that will
the operator’s employee responsible for ensure that each applicable require-
making the test, and the name of any ment of this subpart is complied with.
test company used. (d) Limitation on increase in maximum
(2) Test medium used. allowable operating pressure. Except as
(3) Test pressure. provided in § 192.555(c), a new maximum
(4) Test duration. allowable operating pressure estab-
(5) Pressure recording charts, or lished under this subpart may not ex-
other record of pressure readings. ceed the maximum that would be al-
(6) Elevation variations, whenever lowed under §§ 192.619 and 192.621 for a
significant for the particular test. new segment of pipeline constructed of
(7) Leaks and failures noted and their the same materials in the same loca-
disposition. tion. However, when uprating a steel
(b) Each operator must maintain a pipeline, if any variable necessary to
record of each test required by determine the design pressure under
476
the design formula (§ 192.105) is un- location if the line has not previously
known, the MAOP may be increased as been tested, and if:
provided in § 192.619(a)(1). (i) It is impractical to test it in ac-
[35 FR 13257, Aug. 10, 1970, as amended by cordance with the requirements of this
Amdt. 192–78, 61 FR 28785, June 6, 1996; Amdt. part;
192–93, 68 FR 53901, Sept. 15, 2003] (ii) The new maximum operating
pressure does not exceed 80 percent of
§ 192.555 Uprating to a pressure that that allowed for a new line of the same
will produce a hoop stress of 30 per- design in the same location; and
cent or more of SMYS in steel pipe-
lines. (iii) The operator determines that
the new maximum allowable operating
(a) Unless the requirements of this pressure is consistent with the condi-
section have been met, no person may
tion of the segment of pipeline and the
subject any segment of a steel pipeline
design requirements of this part.
to an operating pressure that will
produce a hoop stress of 30 percent or (e) Where a segment of pipeline is
more of SMYS and that is above the es- uprated in accordance with paragraph
tablished maximum allowable oper- (c) or (d)(2) of this section, the increase
ating pressure. in pressure must be made in incre-
(b) Before increasing operating pres- ments that are equal to:
sure above the previously established (1) 10 percent of the pressure before
maximum allowable operating pressure the uprating; or
the operator shall: (2) 25 percent of the total pressure in-
(1) Review the design, operating, and crease,
maintenance history and previous test- whichever produces the fewer number
ing of the segment of pipeline and de- of increments.
termine whether the proposed increase
is safe and consistent with the require- § 192.557 Uprating: Steel pipelines to a
ments of this part; and pressure that will produce a hoop
(2) Make any repairs, replacements, stress less than 30 percent of SMYS:
or alterations in the segment of pipe- plastic, cast iron, and ductile iron
line that are necessary for safe oper- pipelines.
ation at the increased pressure. (a) Unless the requirements of this
(c) After complying with paragraph section have been met, no person may
(b) of this section, an operator may in- subject:
crease the maximum allowable oper- (1) A segment of steel pipeline to an
ating pressure of a segment of pipeline operating pressure that will produce a
constructed before September 12, 1970, hoop stress less than 30 percent of
to the highest pressure that is per- SMYS and that is above the previously
mitted under § 192.619, using as test established maximum allowable oper-
pressure the highest pressure to which ating pressure; or
the segment of pipeline was previously
(2) A plastic, cast iron, or ductile
subjected (either in a strength test or
iron pipeline segment to an operating
in actual operation).
pressure that is above the previously
(d) After complying with paragraph
established maximum allowable oper-
(b) of this section, an operator that
does not qualify under paragraph (c) of ating pressure.
this section may increase the pre- (b) Before increasing operating pres-
viously established maximum allow- sure above the previously established
able operating pressure if at least one maximum allowable operating pres-
of the following requirements is met: sure, the operator shall:
(1) The segment of pipeline is suc- (1) Review the design, operating, and
cessfully tested in accordance with the maintenance history of the segment of
requirements of this part for a new line pipeline;
of the same material in the same loca- (2) Make a leakage survey (if it has
tion. been more than 1 year since the last

(2) An increased maximum allowable survey) and repair any leaks that are
operating pressure may be established found, except that a leak determined
for a segment of pipeline in a Class 1 not to be potentially hazardous need
477
§ 192.557 49 CFR Ch. I (10–1–18 Edition)
not be repaired, if it is monitored dur- tion apply, there must be at least two
ing the pressure increase and it does approximately equal incremental in-
not become potentially hazardous; creases.
(3) Make any repairs, replacements, (d) If records for cast iron or ductile
or alterations in the segment of pipe- iron pipeline facilities are not com-
line that are necessary for safe oper- plete enough to determine stresses pro-
ation at the increased pressure; duced by internal pressure, trench
(4) Reinforce or anchor offsets, bends loading, rolling loads, beam stresses,
and dead ends in pipe joined by com- and other bending loads, in evaluating
pression couplings or bell and spigot the level of safety of the pipeline when
joints to prevent failure of the pipe operating at the proposed increased
joint, if the offset, bend, or dead end is pressure, the following procedures
exposed in an excavation; must be followed:
(5) Isolate the segment of pipeline in (1) In estimating the stresses, if the
which the pressure is to be increased original laying conditions cannot be
from any adjacent segment that will ascertained, the operator shall assume
continue to be operated at a lower that cast iron pipe was supported on
pressure; and blocks with tamped backfill and that
(6) If the pressure in mains or service ductile iron pipe was laid without
lines, or both, is to be higher than the blocks with tamped backfill.
pressure delivered to the customer, in- (2) Unless the actual maximum cover
stall a service regulator on each serv- depth is known, the operator shall
ice line and test each regulator to de- measure the actual cover in at least
termine that it is functioning. Pressure three places where the cover is most
may be increased as necessary to test likely to be greatest and shall use the
each regulator, after a regulator has greatest cover measured.
been installed on each pipeline subject (3) Unless the actual nominal wall
to the increased pressure. thickness is known, the operator shall
(c) After complying with paragraph determine the wall thickness by cut-
(b) of this section, the increase in max- ting and measuring coupons from at
imum allowable operating pressure least three separate pipe lengths. The
must be made in increments that are coupons must be cut from pipe lengths
equal to 10 p.s.i. (69 kPa) gage or 25 per- in areas where the cover depth is most
cent of the total pressure increase, likely to be the greatest. The average
whichever produces the fewer number of all measurements taken must be in-
of increments. Whenever the require- creased by the allowance indicated in
ments of paragraph (b)(6) of this sec- the following table:
Allowance inches (millimeters)
Cast iron pipe

Pipe size inches (millimeters)
Ductile iron pipe
Centrifugally cast
Pit cast pipe pipe
3 to 8 (76 to 203) ............................................................................ 0.075 (1.91) 0.065 (1.65) 0.065 (1.65)

10 to 12 (254 to 305) ...................................................................... 0.08 (2.03) 0.07 (1.78) 0.07 (1.78)
14 to 24 (356 to 610) ...................................................................... 0.08 (2.03) 0.08 (2.03) 0.075 (1.91)
30 to 42 (762 to 1067) .................................................................... 0.09 (2.29) 0.09 (2.29) 0.075 (1.91)
48 (1219) ......................................................................................... 0.09 (2.29) 0.09 (2.29) 0.08 (2.03)
54 to 60 (1372 to 1524) .................................................................. 0.09 (2.29) .............................. ..............................
(4) For cast iron pipe, unless the pipe and a modulus of rupture of 31,000 p.s.i.
manufacturing process is known, the (214 MPa) gage.
operator shall assume that the pipe is
pit cast pipe with a bursting tensile Amdt. 192–37, 46 FR 10160, Feb. 2, 1981; Amdt.
strength of 11,000 p.s.i. (76 MPa) gage 192–62, 54 FR 5628, Feb. 6, 1989; Amdt. 195–85,
63 FR 37504, July 13, 1998]
478
Subpart L—Operations (1) Operating, maintaining, and re-

pairing the pipeline in accordance with
§ 192.601 Scope. each of the requirements of this sub-
part and subpart M of this part.
This subpart prescribes minimum re-
(2) Controlling corrosion in accord-
quirements for the operation of pipe-
ance with the operations and mainte-
line facilities.
nance requirements of subpart I of this
§ 192.603 General provisions. part.
(3) Making construction records,
(a) No person may operate a segment maps, and operating history available
of pipeline unless it is operated in ac- to appropriate operating personnel.
cordance with this subpart. (4) Gathering of data needed for re-
(b) Each operator shall keep records porting incidents under Part 191 of this
necessary to administer the procedures chapter in a timely and effective man-
established under § 192.605. ner.
(c) The Associate Administrator or (5) Starting up and shutting down
the State Agency that has submitted a any part of the pipeline in a manner
current certification under the pipeline designed to assure operation within the
safety laws, (49 U.S.C. 60101 et seq.) with MAOP limits prescribed by this part,
respect to the pipeline facility gov- plus the build-up allowed for operation
erned by an operator’s plans and proce- of pressure-limiting and control de-
dures may, after notice and oppor- vices.
tunity for hearing as provided in 49 (6) Maintaining compressor stations,
CFR 190.206 or the relevant State pro- including provisions for isolating units
cedures, require the operator to amend or sections of pipe and for purging be-
its plans and procedures as necessary fore returning to service.
to provide a reasonable level of safety. (7) Starting, operating and shutting
[35 FR 13257, Aug. 19, 1970, as amended by down gas compressor units.
Amdt. 192–66, 56 FR 31090, July 9, 1991; Amdt. (8) Periodically reviewing the work
192–71, 59 FR 6584, Feb. 11, 1994; Amdt. 192–75, done by operator personnel to deter-
61 FR 18517, Apr. 26, 1996; Amdt. 192–118, 78 mine the effectiveness, and adequacy of
FR 58915, Sept. 25, 2013] the procedures used in normal oper-
ation and maintenance and modifying
§ 192.605 Procedural manual for oper- the procedures when deficiencies are
ations, maintenance, and emer- found.
gencies.
(9) Taking adequate precautions in
(a) General. Each operator shall pre- excavated trenches to protect per-
pare and follow for each pipeline, a sonnel from the hazards of unsafe accu-
manual of written procedures for con- mulations of vapor or gas, and making
ducting operations and maintenance available when needed at the exca-
activities and for emergency response. vation, emergency rescue equipment,
For transmission lines, the manual including a breathing apparatus and, a
must also include procedures for han- rescue harness and line.
dling abnormal operations. This man- (10) Systematic and routine testing
ual must be reviewed and updated by and inspection of pipe-type or bottle-
the operator at intervals not exceeding type holders including—
15 months, but at least once each cal- (i) Provision for detecting external
endar year. This manual must be pre- corrosion before the strength of the
pared before operations of a pipeline container has been impaired;
system commence. Appropriate parts (ii) Periodic sampling and testing of
of the manual must be kept at loca- gas in storage to determine the dew
tions where operations and mainte- point of vapors contained in the stored
nance activities are conducted. gas which, if condensed, might cause
(b) Maintenance and normal oper- internal corrosion or interfere with the
ations. The manual required by para- safe operation of the storage plant; and
graph (a) of this section must include (iii) Periodic inspection and testing
procedures for the following, if applica- of pressure limiting equipment to de-
ble, to provide safety during mainte- termine that it is in safe operating
nance and operations. condition and has adequate capacity.
479
§ 192.607 49 CFR Ch. I (10–1–18 Edition)
(11) Responding promptly to a report (e) Surveillance, emergency response,

of a gas odor inside or near a building, and accident investigation. The proce-
unless the operator’s emergency procedures required by §§ 192.613(a), 192.615,
dures under § 192.615(a)(3) specifically and 192.617 must be included in the
apply to these reports. manual required by paragraph (a) of
(12) Implementing the applicable con- this section.
trol room management procedures re- [Amdt. 192–71, 59 FR 6584, Feb. 11, 1994, as
quired by § 192.631. amended by Amdt. 192–71A, 60 FR 14381, Mar.
(c) Abnormal operation. For trans- 17, 1995; Amdt. 192–93, 68 FR 53901, Sept. 15,
mission lines, the manual required by 2003; Amdt. 192–112, 74 FR 63327, Dec. 3, 2009]
paragraph (a) of this section must in-
clude procedures for the following to § 192.607 [Reserved]
provide safety when operating design
limits have been exceeded: § 192.609 Change in class location: Re-
quired study.
(1) Responding to, investigating, and
correcting the cause of: Whenever an increase in population
(i) Unintended closure of valves or density indicates a change in class lo-
shutdowns; cation for a segment of an existing
(ii) Increase or decrease in pressure steel pipeline operating at hoop stress
or flow rate outside normal operating that is more than 40 percent of SMYS,
limits; or indicates that the hoop stress cor-
responding to the established max-
(iii) Loss of communications;
imum allowable operating pressure for
(iv) Operation of any safety device; a segment of existing pipeline is not
and commensurate with the present class
(v) Any other foreseeable malfunc- location, the operator shall imme-
tion of a component, deviation from diately make a study to determine:
normal operation, or personnel error, (a) The present class location for the
which may result in a hazard to per- segment involved.
sons or property. (b) The design, construction, and
(2) Checking variations from normal testing procedures followed in the
operation after abnormal operation has original construction, and a compari-
ended at sufficient critical locations in son of these procedures with those re-
the system to determine continued in- quired for the present class location by
tegrity and safe operation. the applicable provisions of this part.
(3) Notifying responsible operator (c) The physical condition of the seg-
personnel when notice of an abnormal ment to the extent it can be
operation is received. ascertained from available records;
(4) Periodically reviewing the re- (d) The operating and maintenance
sponse of operator personnel to deter- history of the segment;
mine the effectiveness of the proce- (e) The maximum actual operating
dures controlling abnormal operation pressure and the corresponding oper-
and taking corrective action where de- ating hoop stress, taking pressure gra-
ficiencies are found. dient into account, for the segment of
(5) The requirements of this para- pipeline involved; and
graph (c) do not apply to natural gas (f) The actual area affected by the
distribution operators that are oper- population density increase, and phys-
ating transmission lines in connection ical barriers or other factors which
with their distribution system. may limit further expansion of the
(d) Safety-related condition reports. more densely populated area.
The manual required by paragraph (a)
of this section must include instruc- § 192.611 Change in class location:
tions enabling personnel who perform Confirmation or revision of max-
operation and maintenance activities imum allowable operating pressure.
to recognize conditions that poten- (a) If the hoop stress corresponding
tially may be safety-related conditions to the established maximum allowable

that are subject to the reporting re- operating pressure of a segment of
quirements of § 191.23 of this sub- pipeline is not commensurate with the
chapter. present class location, and the segment
480
is in satisfactory physical condition, pressure after the requalification test

the maximum allowable operating is 0.8 times the test pressure for Class
pressure of that segment of pipeline 2 locations and 0.667 times the test
must be confirmed or revised according pressure for Class 3 locations. The cor-
to one of the following requirements: responding hoop stress may not exceed
(1) If the segment involved has been 80 percent of the SMYS of the pipe in
previously tested in place for a period Class 2 locations and 67 percent of
of not less than 8 hours: SMYS in Class 3 locations.
(i) The maximum allowable operating (b) The maximum allowable oper-
pressure is 0.8 times the test pressure ating pressure confirmed or revised in
in Class 2 locations, 0.667 times the test accordance with this section, may not
pressure in Class 3 locations, or 0.555 exceed the maximum allowable oper-
times the test pressure in Class 4 loca- ating pressure established before the
tions. The corresponding hoop stress confirmation or revision.
may not exceed 72 percent of the SMYS (c) Confirmation or revision of the
of the pipe in Class 2 locations, 60 per- maximum allowable operating pressure
cent of SMYS in Class 3 locations, or 50 of a segment of pipeline in accordance
percent of SMYS in Class 4 locations. with this section does not preclude the
(ii) The alternative maximum allow- application of §§ 192.553 and 192.555.
able operating pressure is 0.8 times the (d) Confirmation or revision of the
test pressure in Class 2 locations and maximum allowable operating pressure
0.667 times the test pressure in Class 3 that is required as a result of a study
locations. For pipelines operating at under § 192.609 must be completed with-
alternative maximum allowable pres- in 24 months of the change in class lo-
sure per § 192.620, the corresponding cation. Pressure reduction under para-
hoop stress may not exceed 80 percent graph (a) (1) or (2) of this section with-
of the SMYS of the pipe in Class 2 loca- in the 24-month period does not pre-
tions and 67 percent of SMYS in Class clude establishing a maximum allow-
3 locations. able operating pressure under para-
(2) The maximum allowable oper- graph (a)(3) of this section at a later
ating pressure of the segment involved date.
must be reduced so that the cor- [Amdt. 192–63A, 54 FR 24174, June 6, 1989, as
responding hoop stress is not more amended by Amdt. 192–78, 61 FR 28785, June
than that allowed by this part for new 6, 1996; Amdt. 192–94, 69 FR 32895, June 14,
segments of pipelines in the existing 2004; 73 FR 62177, Oct. 17, 2008]
class location.
(3) The segment involved must be § 192.612 Underwater inspection and
tested in accordance with the applica- reburial of pipelines in the Gulf of
ble requirements of subpart J of this Mexico and its inlets.
part, and its maximum allowable oper- (a) Each operator shall prepare and
ating pressure must then be estab- follow a procedure to identify its pipe-
lished according to the following cri- lines in the Gulf of Mexico and its in-
teria: lets in waters less than 15 feet (4.6 me-
(i) The maximum allowable operating ters) deep as measured from mean low
pressure after the requalification test water that are at risk of being an ex-
is 0.8 times the test pressure for Class posed underwater pipeline or a hazard
2 locations, 0.667 times the test pres- to navigation. The procedures must be
sure for Class 3 locations, and 0.555 in effect August 10, 2005.
times the test pressure for Class 4 loca- (b) Each operator shall conduct ap-
tions. propriate periodic underwater inspec-
(ii) The corresponding hoop stress tions of its pipelines in the Gulf of
may not exceed 72 percent of the SMYS Mexico and its inlets in waters less
of the pipe in Class 2 locations, 60 per- than 15 feet (4.6 meters) deep as meas-
cent of SMYS in Class 3 locations, or 50 ured from mean low water based on the
percent of SMYS in Class 4 locations. identified risk.
(iii) For pipeline operating at an al- (c) If an operator discovers that its
ternative maximum allowable oper- pipeline is an exposed underwater pipe-
ating pressure per § 192.620, the alter- line or poses a hazard to navigation,
native maximum allowable operating the operator shall—
481
§ 192.613 49 CFR Ch. I (10–1–18 Edition)
(1) Promptly, but not later than 24 § 192.614 Damage prevention program.
hours after discovery, notify the Na-
(a) Except as provided in paragraphs
tional Response Center, telephone: 1–
(d) and (e) of this section, each oper-
800–424–8802, of the location and, if
ator of a buried pipeline must carry
available, the geographic coordinates out, in accordance with this section, a
of that pipeline. written program to prevent damage to
(2) Promptly, but not later than 7 that pipeline from excavation activi-
days after discovery, mark the location ties. For the purposes of this section,
of the pipeline in accordance with 33 the term ‘‘excavation activities’’ in-
CFR part 64 at the ends of the pipeline cludes excavation, blasting, boring,
segment and at intervals of not over tunneling, backfilling, the removal of
500 yards (457 meters) long, except that aboveground structures by either ex-
a pipeline segment less than 200 yards plosive or mechanical means, and other
(183 meters) long need only be marked earthmoving operations.
at the center; and (b) An operator may comply with any
(3) Within 6 months after discovery, of the requirements of paragraph (c) of
or not later than November 1 of the fol- this section through participation in a
lowing year if the 6 month period is public service program, such as a one-
later than November 1 of the year of call system, but such participation
discovery, bury the pipeline so that the does not relieve the operator of respon-
top of the pipe is 36 inches (914 milli- sibility for compliance with this sec-
meters) below the underwater natural tion. However, an operator must per-
bottom (as determined by recognized form the duties of paragraph (c)(3) of
and generally accepted practices) for this section through participation in a
normal excavation or 18 inches (457 one-call system, if that one-call system
millimeters) for rock excavation. is a qualified one-call system. In areas
(i) An operator may employ engi- that are covered by more than one
neered alternatives to burial that meet qualified one-call system, an operator
or exceed the level of protection pro- need only join one of the qualified one-
vided by burial. call systems if there is a central tele-
(ii) If an operator cannot obtain re- phone number for excavators to call for
quired state or Federal permits in time excavation activities, or if the one-call
to comply with this section, it must systems in those areas communicate
notify OPS; specify whether the re- with one another. An operator’s pipe-
quired permit is State or Federal; and, line system must be covered by a quali-
justify the delay. fied one-call system where there is one
in place. For the purpose of this sec-
[Amdt. 192–98, 69 FR 48406, Aug. 10, 2004] tion, a one-call system is considered a
‘‘qualified one-call system’’ if it meets
§ 192.613 Continuing surveillance. the requirements of section (b)(1) or
(a) Each operator shall have a proce- (b)(2) of this section.
dure for continuing surveillance of its (1) The state has adopted a one-call
facilities to determine and take appro- damage prevention program under
priate action concerning changes in § 198.37 of this chapter; or
class location, failures, leakage his- (2) The one-call system:
tory, corrosion, substantial changes in (i) Is operated in accordance with
cathodic protection requirements, and § 198.39 of this chapter;
other unusual operating and mainte- (ii) Provides a pipeline operator an
nance conditions. opportunity similar to a voluntary par-
(b) If a segment of pipeline is deter- ticipant to have a part in management
mined to be in unsatisfactory condition responsibilities; and
but no immediate hazard exists, the op- (iii) Assesses a participating pipeline
erator shall initiate a program to re- operator a fee that is proportionate to
condition or phase out the segment in- the costs of the one-call system’s cov-
volved, or, if the segment cannot be re- erage of the operator’s pipeline.
conditioned or phased out, reduce the (c) The damage prevention program
maximum allowable operating pressure required by paragraph (a) of this sec-
in accordance with § 192.619 (a) and (b). tion must, at a minimum:
482
(1) Include the identity, on a current (2) The requirements of paragraphs

basis, of persons who normally engage (c)(1) and (c)(2) of this section.
in excavation activities in the area in
[Amdt. 192–40, 47 FR 13824, Apr. 1, 1982, as
which the pipeline is located. amended by Amdt. 192–57, 52 FR 32800, Aug.
(2) Provides for notification of the 31, 1987; Amdt. 192–73, 60 FR 14650, Mar. 20,
public in the vicinity of the pipeline 1995; Amdt. 192–78, 61 FR 28785, June 6, 1996;
and actual notification of the persons Amdt.192–82, 62 FR 61699, Nov. 19, 1997; Amdt.
identified in paragraph (c)(1) of this 192–84, 63 FR 38758, July 20, 1998]
section of the following as often as
needed to make them aware of the § 192.615 Emergency plans.
damage prevention program: (a) Each operator shall establish
(i) The program’s existence and pur- written procedures to minimize the
pose; and hazard resulting from a gas pipeline
(ii) How to learn the location of un- emergency. At a minimum, the proce-
derground pipelines before excavation dures must provide for the following:
activities are begun. (1) Receiving, identifying, and
(3) Provide a means of receiving and classifying notices of events which re-
recording notification of planned exca- quire immediate response by the oper-
vation activities. ator.
(4) If the operator has buried pipe- (2) Establishing and maintaining ade-
lines in the area of excavation activity, quate means of communication with
provide for actual notification of per- appropriate fire, police, and other pub-
sons who give notice of their intent to lic officials.
excavate of the type of temporary (3) Prompt and effective response to a
marking to be provided and how to notice of each type of emergency, in-
identify the markings. cluding the following:
(5) Provide for temporary marking of (i) Gas detected inside or near a
buried pipelines in the area of exca- building.
vation activity before, as far as prac- (ii) Fire located near or directly in-
tical, the activity begins. volving a pipeline facility.
(6) Provide as follows for inspection (iii) Explosion occurring near or di-
of pipelines that an operator has rea- rectly involving a pipeline facility.
son to believe could be damaged by ex- (iv) Natural disaster.
cavation activities: (4) The availability of personnel,
(i) The inspection must be done as equipment, tools, and materials, as
frequently as necessary during and needed at the scene of an emergency.
after the activities to verify the integ- (5) Actions directed toward pro-
rity of the pipeline; and tecting people first and then property.
(ii) In the case of blasting, any in- (6) Emergency shutdown and pressure
spection must include leakage surveys. reduction in any section of the opera-
(d) A damage prevention program tor’s pipeline system necessary to min-
under this section is not required for imize hazards to life or property.
the following pipelines: (7) Making safe any actual or poten-
(1) Pipelines located offshore. tial hazard to life or property.
(2) Pipelines, other than those lo- (8) Notifying appropriate fire, police,
cated offshore, in Class 1 or 2 locations and other public officials of gas pipe-
until September 20, 1995. line emergencies and coordinating with
(3) Pipelines to which access is phys- them both planned responses and ac-
ically controlled by the operator. tual responses during an emergency.
(e) Pipelines operated by persons (9) Safely restoring any service out-
other than municipalities (including age.
operators of master meters) whose pri- (10) Beginning action under § 192.617,
mary activity does not include the if applicable, as soon after the end of
transportation of gas need not comply the emergency as possible.
with the following: (11) Actions required to be taken by a

(1) The requirement of paragraph (a) controller during an emergency in ac-
of this section that the damage preven- cordance with § 192.631.
tion program be written; and (b) Each operator shall:
483
§ 192.616 49 CFR Ch. I (10–1–18 Edition)
(1) Furnish its supervisors who are not practicable and not necessary for
responsible for emergency action a safety.
copy of that portion of the latest edi- (d) The operator’s program must spe-
tion of the emergency procedures es- cifically include provisions to educate
tablished under paragraph (a) of this the public, appropriate government or-
section as necessary for compliance ganizations, and persons engaged in ex-
with those procedures. cavation related activities on:
(2) Train the appropriate operating (1) Use of a one-call notification sys-
personnel to assure that they are tem prior to excavation and other dam-
knowledgeable of the emergency proce- age prevention activities;
dures and verify that the training is ef- (2) Possible hazards associated with
fective. unintended releases from a gas pipeline
(3) Review employee activities to de- facility;
termine whether the procedures were (3) Physical indications that such a
effectively followed in each emergency. release may have occurred;
(c) Each operator shall establish and (4) Steps that should be taken for
maintain liaison with appropriate fire, public safety in the event of a gas pipe-
police, and other public officials to: line release; and
(1) Learn the responsibility and re- (5) Procedures for reporting such an
sources of each government organiza- event.
tion that may respond to a gas pipeline (e) The program must include activi-
emergency; ties to advise affected municipalities,
(2) Acquaint the officials with the op- school districts, businesses, and resi-
erator’s ability in responding to a gas dents of pipeline facility locations.
pipeline emergency; (f) The program and the media used
(3) Identify the types of gas pipeline must be as comprehensive as necessary
emergencies of which the operator no- to reach all areas in which the operator
tifies the officials; and transports gas.
(4) Plan how the operator and offi- (g) The program must be conducted
cials can engage in mutual assistance in English and in other languages com-
to minimize hazards to life or property. monly understood by a significant
[Amdt. 192–24, 41 FR 13587, Mar. 31, 1976, as number and concentration of the non-
amended by Amdt. 192–71, 59 FR 6585, Feb. 11, English speaking population in the op-
1994; Amdt. 192–112, 74 FR 63327, Dec. 3, 2009] erator’s area.
(h) Operators in existence on June 20,
§ 192.616 Public awareness. 2005, must have completed their writ-
(a) Except for an operator of a master ten programs no later than June 20,
meter or petroleum gas system covered 2006. The operator of a master meter or
under paragraph (j) of this section, petroleum gas system covered under
each pipeline operator must develop paragraph (j) of this section must com-
and implement a written continuing plete development of its written proce-
public education program that follows dure by June 13, 2008. Upon request, op-
the guidance provided in the American erators must submit their completed
Petroleum Institute’s (API) Rec- programs to PHMSA or, in the case of
ommended Practice (RP) 1162 (incor- an intrastate pipeline facility operator,
porated by reference, see § 192.7). the appropriate State agency.
(b) The operator’s program must fol- (i) The operator’s program docu-
low the general program recommenda- mentation and evaluation results must
tions of API RP 1162 and assess the be available for periodic review by ap-
unique attributes and characteristics propriate regulatory agencies.
of the operator’s pipeline and facilities. (j) Unless the operator transports gas
(c) The operator must follow the gen- as a primary activity, the operator of a
eral program recommendations, includ- master meter or petroleum gas system
ing baseline and supplemental require- is not required to develop a public
ments of API RP 1162, unless the oper- awareness program as prescribed in
ator provides justification in its pro- paragraphs (a) through (g) of this sec-
gram or procedural manual as to why tion. Instead the operator must develop
compliance with all or certain provi- and implement a written procedure to
sions of the recommended practice is provide its customers public awareness
484
messages twice annually. If the master the design formula (§ 192.105) is un-
meter or petroleum gas system is lo- known, one of the following pressures
cated on property the operator does is to be used as design pressure:
not control, the operator must provide (i) Eighty percent of the first test
similar messages twice annually to pressure that produces yield under sec-
persons controlling the property. The tion N5 of Appendix N of ASME B31.8
public awareness message must in- (incorporated by reference, see § 192.7),
clude: reduced by the appropriate factor in
(1) A description of the purpose and paragraph (a)(2)(ii) of this section; or
reliability of the pipeline; (ii) If the pipe is 123⁄4 inches (324 mm)
(2) An overview of the hazards of the or less in outside diameter and is not
pipeline and prevention measures used; tested to yield under this paragraph,
(3) Information about damage preven- 200 p.s.i. (1379 kPa).
tion; (2) The pressure obtained by dividing
(4) How to recognize and respond to a the pressure to which the segment was
leak; and tested after construction as follows:
(5) How to get additional informa- (i) For plastic pipe in all locations,
tion. the test pressure is divided by a factor
[Amdt. 192–100, 70 FR 28842, May 19, 2005; 70 of 1.5.
FR 35041, June 16, 2005; 72 FR 70810, Dec. 13, (ii) For steel pipe operated at 100
2007] p.s.i. (689 kPa) gage or more, the test
pressure is divided by a factor deter-
§ 192.617 Investigation of failures. mined in accordance with the following
Each operator shall establish proce- table:
dures for analyzing accidents and fail-
Factors 1, segment—
ures, including the selection of samples
of the failed facility or equipment for Class location Installed Installed Converted
before
laboratory examination, where appro- (Nov. 12, after (Nov. under
11, 1970) § 192.14
priate, for the purpose of determining 1970)
the causes of the failure and mini-
1 ............................... 1.1 1.1 1.25
mizing the possibility of a recurrence. 2 ............................... 1.25 1.25 1.25
3 ............................... 1.4 1.5 1.5
§ 192.619 Maximum allowable oper- 4 ............................... 1.4 1.5 1.5
ating pressure: Steel or plastic pipe- 1 For offshore segments installed, uprated or converted after
lines. July 31, 1977, that are not located on an offshore platform,
the factor is 1.25. For segments installed, uprated or con-
(a) No person may operate a segment verted after July 31, 1977, that are located on an offshore
of steel or plastic pipeline at a pressure platform or on a platform in inland navigable waters, including
a pipe riser, the factor is 1.5.
that exceeds a maximum allowable op-
erating pressure determined under (3) The highest actual operating pres-
paragraph (c) or (d) of this section, or sure to which the segment was sub-
the lowest of the following: jected during the 5 years preceding the
(1) The design pressure of the weak- applicable date in the second column.
est element in the segment, deter- This pressure restriction applies unless
mined in accordance with subparts C the segment was tested according to
and D of this part. However, for steel the requirements in paragraph (a)(2) of
pipe in pipelines being converted under this section after the applicable date in
§ 192.14 or uprated under subpart K of the third column or the segment was
this part, if any variable necessary to uprated according to the requirements
determine the design pressure under in subpart K of this part:
Pipeline segment Pressure date Test date
—Onshore gathering line that first be- March 15, 2006, or date line becomes 5 years preceding applicable date in sec-
came subject to this part (other than subject to this part, whichever is later. ond column.
§ 192.612) after April 13, 2006.
—Onshore transmission line that was a
gathering line not subject to this part
before March 15, 2006.

Offshore gathering lines ........................... July 1, 1976 ............................................. July 1, 1971.
All other pipelines ..................................... July 1, 1970 ............................................. July 1, 1965.
485
§ 192.620 49 CFR Ch. I (10–1–18 Edition)
(4) The pressure determined by the Class location Alternative de-

sign factor (F)
operator to be the maximum safe pres-
sure after considering the history of 1 ..................................................................... 0.80
the segment, particularly known corro- 2 ..................................................................... 0.67
3 ..................................................................... 0.56
sion and the actual operating pressure.
(b) No person may operate a segment (i) For facilities installed prior to De-
to which paragraph (a)(4) of this sec- cember 22, 2008, for which § 192.111(b),
tion is applicable, unless over-pressure (c), or (d) applies, use the following de-
protective devices are installed on the sign factors as alternatives for the fac-
segment in a manner that will prevent tors specified in those paragraphs:
the maximum allowable operating § 192.111(b)¥0.67 or less; 192.111(c) and
pressure from being exceeded, in ac- (d)¥0.56 or less.
cordance with § 192.195. (ii) [Reserved]
(c) The requirements on pressure re- (2) The alternative maximum allow-
strictions in this section do not apply able operating pressure is the lower of
in the following instance. An operator the following:
may operate a segment of pipeline (i) The design pressure of the weakest
found to be in satisfactory condition, element in the pipeline segment, deter-
considering its operating and mainte- mined under subparts C and D of this
nance history, at the highest actual op- part.
erating pressure to which the segment (ii) The pressure obtained by dividing
was subjected during the 5 years pre- the pressure to which the pipeline seg-
ceding the applicable date in the sec- ment was tested after construction by
a factor determined in the following
ond column of the table in paragraph
table:
(a)(3) of this section. An operator must
still comply with § 192.611. Class location Alternative test
factor
(d) The operator of a pipeline seg-
ment of steel pipeline meeting the con- 1 ..................................................................... 1.25
2 ..................................................................... 1 1.50
ditions prescribed in § 192.620(b) may
3 ..................................................................... 1.50
elect to operate the segment at a max-
1 For Class 2 alternative maximum allowable operating
imum allowable operating pressure de- pressure segments installed prior to December 22, 2008 the
termined under § 192.620(a). alternative test factor is 1.25.
[35 FR 13257, Aug. 19, 1970] (b) When may an operator use the alter-
native maximum allowable operating pres-
sure calculated under paragraph (a) of
tations affecting § 192.619, see the List of CFR
Sections Affected, which appears in the
this section? An operator may use an al-
Finding Aids section of the printed volume ternative maximum allowable oper-
and at www.fdsys.gov. ating pressure calculated under para-
graph (a) of this section if the fol-
§ 192.620 Alternative maximum allow- lowing conditions are met:
able operating pressure for certain (1) The pipeline segment is in a Class
steel pipelines. 1, 2, or 3 location;
(a) How does an operator calculate the (2) The pipeline segment is con-
structed of steel pipe meeting the addi-
alternative maximum allowable operating
tional design requirements in § 192.112;
pressure? An operator calculates the al-
(3) A supervisory control and data ac-
ternative maximum allowable oper-
quisition system provides remote mon-
ating pressure by using different fac- itoring and control of the pipeline seg-
tors in the same formulas used for cal- ment. The control provided must in-
culating maximum allowable operating clude monitoring of pressures and
pressure under § 192.619(a) as follows: flows, monitoring compressor start-ups
(1) In determining the alternative de- and shut-downs, and remote closure of
sign pressure under § 192.105, use a de- valves per paragraph (d)(3) of this sec-
sign factor determined in accordance tion;

with § 192.111(b), (c), or (d) or, if none of (4) The pipeline segment meets the
these paragraphs apply, in accordance additional construction requirements
with the following table: described in § 192.328;
486
(5) The pipeline segment does not (ii) The operating and maintenance
contain any mechanical couplings used procedures include the additional oper-
in place of girth welds; ating and maintenance requirements of
(6) If a pipeline segment has been pre- paragraph (d) of this section; and
viously operated, the segment has not (iii) The review and any needed pro-
experienced any failure during normal gram upgrade of the damage preven-
operations indicative of a systemic tion program required by paragraph
fault in material as determined by a (d)(4)(v) of this section has been com-
root cause analysis, including met- pleted.
allurgical examination of the failed (3) Send a copy of the certification
pipe. The results of this root cause required by paragraph (c)(2) of this sec-
analysis must be reported to each tion to each PHMSA pipeline safety re-
PHMSA pipeline safety regional office gional office where the pipeline is in
where the pipeline is in service at least service 30 days prior to operating at
60 days prior to operation at the alter- the alternative MAOP. An operator
native MAOP. An operator must also must also send a copy to a State pipe-
notify a State pipeline safety authority line safety authority when the pipeline
when the pipeline is located in a State is located in a State where PHMSA has
where PHMSA has an interstate agent an interstate agent agreement, or an
agreement, or an intrastate pipeline is intrastate pipeline is regulated by that
regulated by that State; and State.
(7) At least 95 percent of girth welds (4) For each pipeline segment, do one
on a segment that was constructed of the following:
prior to December 22, 2008, must have (i) Perform a strength test as de-
been non-destructively examined in ac- scribed in § 192.505 at a test pressure
cordance with § 192.243(b) and (c). calculated under paragraph (a) of this
(c) What is an operator electing to use section or
the alternative maximum allowable oper- (ii) For a pipeline segment in exist-
ating pressure required to do? If an oper- ence prior to December 22, 2008, certify,
ator elects to use the alternative max- under paragraph (c)(2) of this section,
imum allowable operating pressure cal- that the strength test performed under
culated under paragraph (a) of this sec- § 192.505 was conducted at test pressure
tion for a pipeline segment, the oper- calculated under paragraph (a) of this
ator must do each of the following: section, or conduct a new strength test
(1) For pipelines already in service, in accordance with paragraph (c)(4)(i)
notify the PHMSA pipeline safety re- of this section.
gional office where the pipeline is in (5) Comply with the additional oper-
service of the intention to use the al- ation and maintenance requirements
ternative pressure at least 180 days be- described in paragraph (d) of this sec-
fore operating at the alternative tion.
MAOP. For new pipelines, notify the (6) If the performance of a construc-
PHMSA pipeline safety regional office tion task associated with imple-
of planned alternative MAOP design menting alternative MAOP that occurs
and operation at least 60 days prior to after December 22, 2008, can affect the
the earliest start date of either pipe integrity of the pipeline segment, treat
manufacturing or construction activi- that task as a ‘‘covered task’’, notwith-
ties. An operator must also notify the standing the definition in § 192.801(b)
state pipeline safety authority when and implement the requirements of
the pipeline is located in a state where subpart N as appropriate.
PHMSA has an interstate agent agree- (7) Maintain, for the useful life of the
ment or where an intrastate pipeline is pipeline, records demonstrating com-
regulated by that state. pliance with paragraphs (b), (c)(6), and
(2) Certify, by signature of a senior (d) of this section.
executive officer of the company, as (8) A Class 1 and Class 2 location can
follows: be upgraded one class due to class

(i) The pipeline segment meets the changes per § 192.611(a). All class loca-
conditions described in paragraph (b) of tion changes from Class 1 to Class 2
this section; and and from Class 2 to Class 3 must have
487
§ 192.620 49 CFR Ch. I (10–1–18 Edition)
all anomalies evaluated and remediation at the alternative maximum allow-
ated per: The ‘‘original pipeline class able operating pressure? In addition to
grade’’ § 192.620(d)(11) anomaly repair compliance with other applicable safe-
requirements; and all anomalies with a ty standards in this part, if an operator
wall loss equal to or greater than 40 establishes a maximum allowable oper-
percent must be excavated and remedi- ating pressure for a pipeline segment
ated. Pipelines in Class 4 may not oper- under paragraph (a) of this section, an
ate at an alternative MAOP. operator must comply with the addi-
(d) What additional operation and tional operation and maintenance re-
maintenance requirements apply to oper- quirements as follows:
To address increased risk of a
maximum allowable operating
pressure based on higher Take the following additional step:
stress levels in the following
areas:
(1) Identifying and evaluating Develop a threat matrix consistent with § 192.917 to do the following:
threats. (i) Identify and compare the increased risk of operating the pipeline at the increased stress
level under this section with conventional operation; and
(ii) Describe and implement procedures used to mitigate the risk.
(2) Notifying the public ............. (i) Recalculate the potential impact circle as defined in § 192.903 to reflect use of the alter-
native maximum operating pressure calculated under paragraph (a) of this section and pipe-
line operating conditions; and
(ii) In implementing the public education program required under § 192.616, perform the fol-
lowing:
(A) Include persons occupying property within 220 yards of the centerline and within the po-
tential impact circle within the targeted audience; and
(B) Include information about the integrity management activities performed under this section
within the message provided to the audience.
(3) Responding to an emer- (i) Ensure that the identification of high consequence areas reflects the larger potential impact
gency in an area defined as circle recalculated under paragraph (d)(2)(i) of this section.
a high consequence area in
§ 192.903.
(ii) If personnel response time to mainline valves on either side of the high consequence area
exceeds one hour (under normal driving conditions and speed limits) from the time the event
is identified in the control room, provide remote valve control through a supervisory control
and data acquisition (SCADA) system, other leak detection system, or an alternative method
of control.
(iii) Remote valve control must include the ability to close and monitor the valve position (open
or closed), and monitor pressure upstream and downstream.
(iv) A line break valve control system using differential pressure, rate of pressure drop or other
widely-accepted method is an acceptable alternative to remote valve control.
(4) Protecting the right-of-way .. (i) Patrol the right-of-way at intervals not exceeding 45 days, but at least 12 times each cal-
endar year, to inspect for excavation activities, ground movement, wash outs, leakage, or
other activities or conditions affecting the safety operation of the pipeline.
(ii) Develop and implement a plan to monitor for and mitigate occurrences of unstable soil and
ground movement.
(iii) If observed conditions indicate the possible loss of cover, perform a depth of cover study
and replace cover as necessary to restore the depth of cover or apply alternative means to
provide protection equivalent to the originally-required depth of cover.
(iv) Use line-of-sight line markers satisfying the requirements of § 192.707(d) except in agricul-
tural areas, large water crossings or swamp, steep terrain, or where prohibited by Federal
Energy Regulatory Commission orders, permits, or local law.
(v) Review the damage prevention program under § 192.614(a) in light of national consensus
practices, to ensure the program provides adequate protection of the right-of-way. Identify
the standards or practices considered in the review, and meet or exceed those standards or
practices by incorporating appropriate changes into the program.
(vi) Develop and implement a right-of-way management plan to protect the pipeline segment
from damage due to excavation activities.
(5) Controlling internal corro- (i) Develop and implement a program to monitor for and mitigate the presence of, deleterious
sion. gas stream constituents.
(ii) At points where gas with potentially deleterious contaminants enters the pipeline, use filter
separators or separators and gas quality monitoring equipment.
(iii) Use gas quality monitoring equipment that includes a moisture analyzer, chromatograph,
and periodic hydrogen sulfide sampling.
(iv) Use cleaning pigs and sample accumulated liquids. Use inhibitors when corrosive gas or
liquids are present.

(v) Address deleterious gas stream constituents as follows:
(A) Limit carbon dioxide to 3 percent by volume;
(B) Allow no free water and otherwise limit water to seven pounds per million cubic feet of
gas; and
488

areas:
(C) Limit hydrogen sulfide to 1.0 grain per hundred cubic feet (16 ppm) of gas, where the hy-
drogen sulfide is greater than 0.5 grain per hundred cubic feet (8 ppm) of gas, implement a
pigging and inhibitor injection program to address deleterious gas stream constituents, in-
cluding follow-up sampling and quality testing of liquids at receipt points.
(vi) Review the program at least quarterly based on the gas stream experience and implement
adjustments to monitor for, and mitigate the presence of, deleterious gas stream constitu-
ents.
(6) Controlling interference that (i) Prior to operating an existing pipeline segment at an alternate maximum allowable oper-
can impact external corrosion. ating pressure calculated under this section, or within six months after placing a new pipe-
line segment in service at an alternate maximum allowable operating pressure calculated
under this section, address any interference currents on the pipeline segment.
(ii) To address interference currents, perform the following:
(A) Conduct an interference survey to detect the presence and level of any electrical current
that could impact external corrosion where interference is suspected;
(B) Analyze the results of the survey; and
(C) Take any remedial action needed within 6 months after completing the survey to protect
the pipeline segment from deleterious current.
(7) Confirming external corro- (i) Within six months after placing the cathodic protection of a new pipeline segment in oper-
sion control through indirect ation, or within six months after certifying a segment under § 192.620(c)(1) of an existing
assessment. pipeline segment under this section, assess the adequacy of the cathodic protection through
an indirect method such as close-interval survey, and the integrity of the coating using direct
current voltage gradient (DCVG) or alternating current voltage gradient (ACVG).
(ii) Remediate any construction damaged coating with a voltage drop classified as moderate or
severe (IR drop greater than 35% for DCVG or 50 dBμv for ACVG) under section 4 of
NACE RP–0502–2002 (incorporated by reference, see § 192.7).
(iii) Within six months after completing the baseline internal inspection required under para-
graph (d)(9) of this section, integrate the results of the indirect assessment required under
paragraph (d)(7)(i) of this section with the results of the baseline internal inspection and take
any needed remedial actions.
(iv) For all pipeline segments in high consequence areas, perform periodic assessments as
follows:
(A) Conduct periodic close interval surveys with current interrupted to confirm voltage drops in
association with periodic assessments under subpart O of this part.
(B) Locate pipe-to-soil test stations at half-mile intervals within each high consequence area
ensuring at least one station is within each high consequence area, if practicable.
(C) Integrate the results with those of the baseline and periodic assessments for integrity done
under paragraphs (d)(9) and (d)(10) of this section.
(8) Controlling external corro- (i) If an annual test station reading indicates cathodic protection below the level of protection
sion through cathodic protec- required in subpart I of this part, complete remedial action within six months of the failed
tion. reading or notify each PHMSA pipeline safety regional office where the pipeline is in service
demonstrating that the integrity of the pipeline is not compromised if the repair takes longer
than 6 months. An operator must also notify a State pipeline safety authority when the pipe-
line is located in a State where PHMSA has an interstate agent agreement, or an intrastate
pipeline is regulated by that State; and
(ii) After remedial action to address a failed reading, confirm restoration of adequate corrosion
control by a close interval survey on either side of the affected test station to the next test
station unless the reason for the failed reading is determined to be a rectifier connection or
power input problem that can be remediated and otherwise verified.
(iii) If the pipeline segment has been in operation, the cathodic protection system on the pipe-
line segment must have been operational within 12 months of the completion of construc-
tion.
(9) Conducting a baseline as- (i) Except as provided in paragraph (d)(9)(iii) of this section, for a new pipeline segment oper-
sessment of integrity. ating at the new alternative maximum allowable operating pressure, perform a baseline in-
ternal inspection of the entire pipeline segment as follows:
(A) Assess using a geometry tool after the initial hydrostatic test and backfill and within six
months after placing the new pipeline segment in service; and
(B) Assess using a high resolution magnetic flux tool within three years after placing the new
pipeline segment in service at the alternative maximum allowable operating pressure.
(ii) Except as provided in paragraph (d)(9)(iii) of this section, for an existing pipeline segment,
perform a baseline internal assessment using a geometry tool and a high resolution mag-
netic flux tool before, but within two years prior to, raising pressure to the alternative max-
imum allowable operating pressure as allowed under this section.
(iii) If headers, mainline valve by-passes, compressor station piping, meter station piping, or
other short portion of a pipeline segment operating at alternative maximum allowable oper-
ating pressure cannot accommodate a geometry tool and a high resolution magnetic flux
tool, use direct assessment (per § 192.925, § 192.927 and/or § 192.929) or pressure testing
(per subpart J of this part) to assess that portion.
(10) Conducting periodic as- (i) Determine a frequency for subsequent periodic integrity assessments as if all the alternative
sessments of integrity. maximum allowable operating pressure pipeline segments were covered by subpart O of
this part and
489
§ 192.621 49 CFR Ch. I (10–1–18 Edition)

areas:
(ii) Conduct periodic internal inspections using a high resolution magnetic flux tool on the fre-
quency determined under paragraph (d)(10)(i) of this section, or
(iii) Use direct assessment (per § 192.925, § 192.927 and/or § 192.929) or pressure testing
(per subpart J of this part) for periodic assessment of a portion of a segment to the extent
permitted for a baseline assessment under paragraph (d)(9)(iii) of this section.
(11) Making repairs .................. (i) Perform the following when evaluating an anomaly:
(A) Use the most conservative calculation for determining remaining strength or an alternative
validated calculation based on pipe diameter, wall thickness, grade, operating pressure, op-
erating stress level, and operating temperature: and
(B) Take into account the tolerances of the tools used for the inspection.
(ii) Repair a defect immediately if any of the following apply:
(A) The defect is a dent discovered during the baseline assessment for integrity under para-
graph (d)(9) of this section and the defect meets the criteria for immediate repair in
§ 192.309(b).
(B) The defect meets the criteria for immediate repair in § 192.933(d).
(C) The alternative maximum allowable operating pressure was based on a design factor of
0.67 under paragraph (a) of this section and the failure pressure is less than 1.25 times the
alternative maximum allowable operating pressure.
(D) The alternative maximum allowable operating pressure was based on a design factor of
0.56 under paragraph (a) of this section and the failure pressure is less than or equal to 1.4
times the alternative maximum allowable operating pressure.
(iii) If paragraph (d)(11)(ii) of this section does not require immediate repair, repair a defect
within one year if any of the following apply:
(A) The defect meets the criteria for repair within one year in § 192.933(d).
(B) The alternative maximum allowable operating pressure was based on a design factor of
(C) The alternative maximum allowable operating pressure was based on a design factor of
(D) The alternative maximum allowable operating pressure was based on a design factor of
0.56 under paragraph (a) of this section and the failure pressure is less than or equal to
1.80 times the alternative maximum allowable operating pressure.
(iv) Evaluate any defect not required to be repaired under paragraph (d)(11)(ii) or (iii) of this
section to determine its growth rate, set the maximum interval for repair or re-inspection,
and repair or re-inspect within that interval.
(e) Is there any change in overpressure § 192.621 Maximum allowable oper-

protection associated with operating at ating pressure: High-pressure dis-
the alternative maximum allowable oper- tribution systems.
ating pressure? Notwithstanding the re- (a) No person may operate a segment
quired capacity of pressure relieving of a high pressure distribution system
and limiting stations otherwise re- at a pressure that exceeds the lowest of
quired by § 192.201, if an operator estab- the following pressures, as applicable:
lishes a maximum allowable operating (1) The design pressure of the weak-
pressure for a pipeline segment in ac- est element in the segment, deter-
cordance with paragraph (a) of this sec- mined in accordance with subparts C
tion, an operator must: and D of this part.
(1) Provide overpressure protection (2) 60 p.s.i. (414 kPa) gage, for a seg-
that limits mainline pressure to a max- ment of a distribution system other-
imum of 104 percent of the maximum wise designed to operate at over 60
allowable operating pressure; and p.s.i. (414 kPa) gage, unless the service
(2) Develop and follow a procedure for lines in the segment are equipped with
establishing and maintaining accurate service regulators or other pressure
set points for the supervisory control limiting devices in series that meet the
and data acquisition system. requirements of § 192.197(c).
[73 FR 62177, Oct. 17, 2008, as amended by (3) 25 p.s.i. (172 kPa) gage in segments
Amdt. 192–111, 74 FR 62505, Nov. 30, 2009; of cast iron pipe in which there are
Amdt. 192–120, 80 FR 12779, Mar. 11, 2015] unreinforced bell and spigot joints.
490
(4) The pressure limits to which a (iii) A gas dehydration plant; or

joint could be subjected without the (iv) An industrial plant using gas in a
possibility of its parting. process where the presence of an odor-
(5) The pressure determined by the ant:
operator to be the maximum safe pres- (A) Makes the end product unfit for
sure after considering the history of the purpose for which it is intended;
the segment, particularly known corro- (B) Reduces the activity of a cata-
sion and the actual operating pres- lyst; or
sures. (C) Reduces the percentage comple-
(b) No person may operate a segment tion of a chemical reaction;
of pipeline to which paragraph (a)(5) of (3) In the case of a lateral line which
this section applies, unless over- transports gas to a distribution center,
pressure protective devices are in- at least 50 percent of the length of that
stalled on the segment in a manner line is in a Class 1 or Class 2 location;
that will prevent the maximum allow- or
able operating pressure from being ex- (4) The combustible gas is hydrogen
ceeded, in accordance with § 192.195. intended for use as a feedstock in a
[35 FR 13257, Aug. 19, 1970, as amended by manufacturing process.
Amdt. 192–85, 63 FR 37504, July 13, 1998] (c) In the concentrations in which it
is used, the odorant in combustible
§ 192.623 Maximum and minimum al- gases must comply with the following:
lowable operating pressure; Low-
pressure distribution systems. (1) The odorant may not be delete-
rious to persons, materials, or pipe.
(a) No person may operate a low-pres- (2) The products of combustion from
sure distribution system at a pressure the odorant may not be toxic when
high enough to make unsafe the oper- breathed nor may they be corrosive or
ation of any connected and properly harmful to those materials to which
adjusted low-pressure gas burning the products of combustion will be ex-
equipment. posed.
(b) No person may operate a low pres- (d) The odorant may not be soluble in
sure distribution system at a pressure water to an extent greater than 2.5
lower than the minimum pressure at parts to 100 parts by weight.
which the safe and continuing oper-
(e) Equipment for odorization must
ation of any connected and properly
introduce the odorant without wide
adjusted low-pressure gas burning
variations in the level of odorant.
equipment can be assured.
(f) To assure the proper concentra-
§ 192.625 Odorization of gas. tion of odorant in accordance with this
section, each operator must conduct
(a) A combustible gas in a distribu- periodic sampling of combustible gases
tion line must contain a natural odor- using an instrument capable of deter-
ant or be odorized so that at a con- mining the percentage of gas in air at
centration in air of one-fifth of the which the odor becomes readily detect-
lower explosive limit, the gas is readily able. Operators of master meter sys-
detectable by a person with a normal tems may comply with this require-
sense of smell. ment by—
(b) After December 31, 1976, a com-
(1) Receiving written verification
bustible gas in a transmission line in a
from their gas source that the gas has
Class 3 or Class 4 location must comply
the proper concentration of odorant;
with the requirements of paragraph (a)
and
of this section unless:
(2) Conducting periodic ‘‘sniff’’ tests
(1) At least 50 percent of the length of
at the extremities of the system to
the line downstream from that location
confirm that the gas contains odorant.
is in a Class 1 or Class 2 location;
(2) The line transports gas to any of [35 FR 13257, Aug. 19, 1970]
the following facilities which received EDITORIAL NOTE: For FEDERAL REGISTER ci-
gas without an odorant from that line tations affecting § 192.625, see the List of CFR
before May 5, 1975; Sections Affected, which appears in the
(i) An underground storage field; Finding Aids section of the printed volume
(ii) A gas processing plant; and at www.fdsys.gov.
491
§ 192.627 49 CFR Ch. I (10–1–18 Edition)
§ 192.627 Tapping pipelines under than October 1, 2011. The procedures re-
pressure. quired by paragraphs (c)(1) through (4),
Each tap made on a pipeline under (d)(1), (d)(4), and (e) must be imple-
pressure must be performed by a crew mented no later than August 1, 2012.
qualified to make hot taps. The training procedures required by
paragraph (h) must be implemented no
§ 192.629 Purging of pipelines. later than August 1, 2012, except that
(a) When a pipeline is being purged of any training required by another para-
air by use of gas, the gas must be re- graph of this section must be imple-
leased into one end of the line in a mented no later than the deadline for
moderately rapid and continuous flow. that paragraph.
If gas cannot be supplied in sufficient (b) Roles and responsibilities. Each op-
quantity to prevent the formation of a erator must define the roles and re-
hazardous mixture of gas and air, a sponsibilities of a controller during
slug of inert gas must be released into normal, abnormal, and emergency op-
the line before the gas. erating conditions. To provide for a
(b) When a pipeline is being purged of controller’s prompt and appropriate re-
gas by use of air, the air must be response to operating conditions, an op-
leased into one end of the line in a erator must define each of the fol-
moderately rapid and continuous flow. lowing:
If air cannot be supplied in sufficient (1) A controller’s authority and re-
quantity to prevent the formation of a sponsibility to make decisions and
hazardous mixture of gas and air, a take actions during normal operations;
slug of inert gas must be released into (2) A controller’s role when an abnor-
the line before the air. mal operating condition is detected,
even if the controller is not the first to
§ 192.631 Control room management. detect the condition, including the con-
(a) General. (1) This section applies to troller’s responsibility to take specific
each operator of a pipeline facility actions and to communicate with oth-
with a controller working in a control ers;
room who monitors and controls all or (3) A controller’s role during an
part of a pipeline facility through a emergency, even if the controller is not
SCADA system. Each operator must the first to detect the emergency, in-
have and follow written control room cluding the controller’s responsibility
management procedures that imple- to take specific actions and to commu-
ment the requirements of this section, nicate with others;
except that for each control room (4) A method of recording controller
where an operator’s activities are lim- shift-changes and any hand-over of re-
ited to either or both of: sponsibility between controllers; and
(i) Distribution with less than 250,000 (5) The roles, responsibilities and
services, or qualifications of others with the au-
(ii) Transmission without a com- thority to direct or supersede the spe-
pressor station, the operator must have cific technical actions of a controller.
and follow written procedures that im- (c) Provide adequate information. Each
plement only paragraphs (d) (regarding operator must provide its controllers
fatigue), (i) (regarding compliance vali- with the information, tools, processes
dation), and (j) (regarding compliance and procedures necessary for the con-
and deviations) of this section. trollers to carry out the roles and re-
(2) The procedures required by this sponsibilities the operator has defined
section must be integrated, as appro- by performing each of the following:
priate, with operating and emergency (1) Implement sections 1, 4, 8, 9, 11.1,
procedures required by §§ 192.605 and and 11.3 of API RP 1165 (incorporated
192.615. An operator must develop the by reference, see § 192.7) whenever a
procedures no later than August 1, 2011, SCADA system is added, expanded or
and must implement the procedures ac- replaced, unless the operator dem-
cording to the following schedule. The onstrates that certain provisions of

procedures required by paragraphs (b), sections 1, 4, 8, 9, 11.1, and 11.3 of API
(c)(5), (d)(2) and (d)(3), (f) and (g) of this RP 1165 are not practical for the
section must be implemented no later SCADA system used;
492
(2) Conduct a point-to-point have had forced or manual values for

verification between SCADA displays periods of time exceeding that required
and related field equipment when field for associated maintenance or oper-
equipment is added or moved and when ating activities;
other changes that affect pipeline safe- (3) Verify the correct safety-related
ty are made to field equipment or alarm set-point values and alarm de-
SCADA displays; scriptions at least once each calendar
(3) Test and verify an internal com- year, but at intervals not to exceed 15
munication plan to provide adequate months;
means for manual operation of the
(4) Review the alarm management
pipeline safely, at least once each cal-
plan required by this paragraph at
endar year, but at intervals not to ex-
ceed 15 months; least once each calendar year, but at
(4) Test any backup SCADA systems intervals not exceeding 15 months, to
at least once each calendar year, but at determine the effectiveness of the plan;
intervals not to exceed 15 months; and (5) Monitor the content and volume
(5) Establish and implement proce- of general activity being directed to
dures for when a different controller and required of each controller at least
assumes responsibility, including the once each calendar year, but at inter-
content of information to be ex- vals not to exceed 15 months, that will
changed. assure controllers have sufficient time
(d) Fatigue mitigation. Each operator to analyze and react to incoming
must implement the following methods alarms; and
to reduce the risk associated with con- (6) Address deficiencies identified
troller fatigue that could inhibit a con- through the implementation of para-
troller’s ability to carry out the roles graphs (e)(1) through (e)(5) of this sec-
and responsibilities the operator has tion.
defined: (f) Change management. Each operator
(1) Establish shift lengths and sched- must assure that changes that could
ule rotations that provide controllers
affect control room operations are co-
off-duty time sufficient to achieve
ordinated with the control room per-
eight hours of continuous sleep;
(2) Educate controllers and super- sonnel by performing each of the fol-
visors in fatigue mitigation strategies lowing:
and how off-duty activities contribute (1) Establish communications be-
to fatigue; tween control room representatives,
(3) Train controllers and supervisors operator’s management, and associated
to recognize the effects of fatigue; and field personnel when planning and im-
(4) Establish a maximum limit on plementing physical changes to pipe-
controller hours-of-service, which may line equipment or configuration;
provide for an emergency deviation (2) Require its field personnel to con-
from the maximum limit if necessary tact the control room when emergency
for the safe operation of a pipeline fa- conditions exist and when making field
cility. changes that affect control room oper-
(e) Alarm management. Each operator ations; and
using a SCADA system must have a (3) Seek control room or control
written alarm management plan to room management participation in
provide for effective controller re- planning prior to implementation of
sponse to alarms. An operator’s plan significant pipeline hydraulic or con-
must include provisions to: figuration changes.
(1) Review SCADA safety-related
(g) Operating experience. Each oper-
alarm operations using a process that
ensures alarms are accurate and sup- ator must assure that lessons learned
port safe pipeline operations; from its operating experience are in-
(2) Identify at least once each cal- corporated, as appropriate, into its
control room management procedures
endar month points affecting safety

that have been taken off scan in the by performing each of the following:
SCADA host, have had alarms inhib- (1) Review incidents that must be re-
ited, generated false alarms, or that ported pursuant to 49 CFR part 191 to
493
§ 192.701 49 CFR Ch. I (10–1–18 Edition)
determine if control room actions con- (i) Compliance validation. Upon re-
tributed to the event and, if so, cor- quest, operators must submit their pro-
rect, where necessary, deficiencies re- cedures to PHMSA or, in the case of an
lated to: intrastate pipeline facility regulated
(i) Controller fatigue; by a State, to the appropriate State
(ii) Field equipment; agency.
(iii) The operation of any relief de- (j) Compliance and deviations. An oper-
vice; ator must maintain for review during
(iv) Procedures; inspection:
(v) SCADA system configuration; and (1) Records that demonstrate compli-
(vi) SCADA system performance. ance with the requirements of this sec-
(2) Include lessons learned from the tion; and
operator’s experience in the training (2) Documentation to demonstrate
program required by this section. that any deviation from the procedures
(h) Training. Each operator must es- required by this section was necessary
tablish a controller training program for the safe operation of a pipeline fa-
and review the training program con- cility.
tent to identify potential improve-
ments at least once each calendar year, [Amdt. 192–112, 74 FR 63327, Dec. 3, 2009, as
but at intervals not to exceed 15 amended at 75 FR 5537, Feb. 3, 2010; 76 FR
months. An operator’s program must 35135, June 16, 2011; Amdt. 192–123, 82 FR 7997,
Jan. 23, 2017]
provide for training each controller to
carry out the roles and responsibilities
defined by the operator. In addition, Subpart M—Maintenance
the training program must include the
following elements: § 192.701 Scope.
(1) Responding to abnormal operating This subpart prescribes minimum re-
conditions likely to occur simulta- quirements for maintenance of pipeline
neously or in sequence; facilities.
(2) Use of a computerized simulator
or non-computerized (tabletop) method § 192.703 General.
for training controllers to recognize (a) No person may operate a segment
abnormal operating conditions;
of pipeline, unless it is maintained in
(3) Training controllers on their re- accordance with this subpart.
sponsibilities for communication under
(b) Each segment of pipeline that be-
the operator’s emergency response pro-
cedures; comes unsafe must be replaced, re-
paired, or removed from service.
(4) Training that will provide a con-
troller a working knowledge of the (c) Hazardous leaks must be repaired
pipeline system, especially during the promptly.
development of abnormal operating
§ 192.705 Transmission lines: Patrol-
conditions;
ling.
(5) For pipeline operating setups that
are periodically, but infrequently used, (a) Each operator shall have a patrol
providing an opportunity for control- program to observe surface conditions
lers to review relevant procedures in on and adjacent to the transmission
advance of their application; and line right-of-way for indications of
(6) Control room team training and leaks, construction activity, and other
exercises that include both controllers factors affecting safety and operation.
and other individuals, defined by the (b) The frequency of patrols is deter-
operator, who would reasonably be ex- mined by the size of the line, the oper-
pected to operationally collaborate ating pressures, the class location, ter-
with controllers (control room per- rain, weather, and other relevant fac-
sonnel) during normal, abnormal or tors, but intervals between patrols may
emergency situations. Operators must not be longer than prescribed in the

comply with the team training require- following table:
ments under this paragraph by no later
than January 23, 2018.
494
Maximum interval between patrols (1) Mains and transmission lines lo-
Class loca- At highway and rail-
cated offshore, or at crossings of or
At all other places
tion of line road crossings under waterways and other bodies of
water.
1, 2 ........... 71⁄2 months; but at 15 months; but at
least twice each cal- least once each cal- (2) Mains in Class 3 or Class 4 loca-
endar year. endar year. tions where a damage prevention pro-
3 ................ 4 ⁄2 months; but at
1 7 ⁄2 months; but at
1
gram is in effect under § 192.614.
least four times least twice each cal-
each calendar year. endar year. (3) Transmission lines in Class 3 or 4
4 ................ 4 ⁄2 months; but at
1 4 ⁄2 months; but at
1
locations until March 20, 1996.
least four times least four times
each calendar year. each calendar year.
(4) Transmission lines in Class 3 or 4
locations where placement of a line
(c) Methods of patrolling include marker is impractical.
walking, driving, flying or other appro- (c) Pipelines aboveground. Line mark-
priate means of traversing the right-of- ers must be placed and maintained
way. along each section of a main and trans-
mission line that is located above-
[Amdt. 192–21, 40 FR 20283, May 9, 1975, as ground in an area accessible to the
amended by Amdt. 192–43, 47 FR 46851, Oct. public.
21, 1982; Amdt. 192–78, 61 FR 28786, June 6,
1996] (d) Marker warning. The following
must be written legibly on a back-
§ 192.706 Transmission lines: Leakage ground of sharply contrasting color on
surveys. each line marker:
Leakage surveys of a transmission (1) The word ‘‘Warning,’’ ‘‘Caution,’’
line must be conducted at intervals not or ‘‘Danger’’ followed by the words
exceeding 15 months, but at least once ‘‘Gas (or name of gas transported)
each calendar year. However, in the Pipeline’’ all of which, except for
case of a transmission line which markers in heavily developed urban
transports gas in conformity with areas, must be in letters at least 1 inch
§ 192.625 without an odor or odorant, (25 millimeters) high with 1⁄4 inch (6.4
leakage surveys using leak detector millimeters) stroke.
equipment must be conducted— (2) The name of the operator and the
(a) In Class 3 locations, at intervals telephone number (including area code)
not exceeding 71⁄2 months, but at least where the operator can be reached at
twice each calendar year; and all times.
(b) In Class 4 locations, at intervals [Amdt. 192–20, 40 FR 13505, Mar. 27, 1975;
not exceeding 41⁄2 months, but at least Amdt. 192–27, 41 FR 39752, Sept. 16, 1976, as
four times each calendar year. amended by Amdt. 192–20A, 41 FR 56808, Dec.
30, 1976; Amdt. 192–44, 48 FR 25208, June 6,
[Amdt. 192–21, 40 FR 20283, May 9, 1975, as
1983; Amdt. 192–73, 60 FR 14650, Mar. 20, 1995;
amended by Amdt. 192–43, 47 FR 46851, Oct.
Amdt. 192–85, 63 FR 37504, July 13, 1998]
21, 1982; Amdt. 192–71, 59 FR 6585, Feb. 11,
1994]
§ 192.709 Transmission lines: Record
§ 192.707 Line markers for mains and keeping.
transmission lines. Each operator shall maintain the fol-
(a) Buried pipelines. Except as pro- lowing records for transmission lines
vided in paragraph (b) of this section, a for the periods specified:
line marker must be placed and main-

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Title 49

Revised as of October 1, 2018

Containing a codification of documents

Published by the Office of the Federal Register

Legal Status and Use of Seals and Logos

Use of ISBN Prefix

U.S. GOVERNMENT PUBLISHING OFFICE

U.S. Superintendent of Documents • Washington, DC 20402–0001

SUBTITLE B—OTHER REGULATIONS RELATING TO TRANSPORTATION

Chapter I—Pipeline and Hazardous Materials Safety Administra-

Table of CFR Titles and Chapters ....................................................... 665

Alphabetical List of Agencies Appearing in the CFR ......................... 685

List of CFR Sections Affected ............................................................. 695

To cite the regulations in

OMB CONTROL NUMBERS

Title 49—TRANSPORTATION is composed of nine volumes. The parts in these vol-

EDITORIAL NOTE: Other regulations issued by the Department of Transportation appear in

SUBTITLE B—OTHER REGULATIONS RELATING TO TRANSPORTATION

CHAPTER I—Pipeline and Hazardous Materials Safety Ad-

SUBCHAPTER C—HAZARDOUS MATERIALS REGULATIONS (CONTINUED)

178.37 Specification 3AA and 3AAX seamless sories.

178.338–4 Joints. for Class 7 (Radioactive) Materials

Subpart L—Non-bulk Performance- Subpart O—Testing of IBCs

178.708 Standards for fiberboard IBCs. Containers

If a manufacturer or subsequent dis- of the packaging manufacturer or the

§ 178.33–2 Type and size.

§ 178.33–7 Wall thickness. § 178.33a–2 Type and size.

(a) By means of printing, § 178.33b–6 Manufacture.

§ 178.33b–7 Design qualification test. (1) DOT–2S.

tainers shall be complete with ends as-

(1) A cylinder may not be constructed 1234 = serial number

AB 5–95 (nominal) not over 1,000 pounds and a

manufactured using equipment and inder must be uniformly and properly

openings. Threads are required on open- and reduction of area of material as

the finished cylinder. and adding thereto 0.2 percent of the

(ii) To calculate the maximum ten- P = hydrostatic test pressure-psig.

TABLE 2—CHECK ANALYSIS TOLERANCES

Carbon ...................................................... To 0.15 incl .................................................................... 0.02 0.03

Molybdenum ............................................. To 0.20 incl .................................................................... .01 .01

cracks must have cracks removed to inder must be at a 90-degree angle to

or less, by placing the cylinder between must be the stress corresponding to a

subjected to same heat treatment as gauge length under appropriate load

cylinder. Gaskets, adequate to prevent (i) A gauge length of 8 inches with a

bounded by a line representing the pressure, must be applied to one side of

§ 178.35 must be stamped plainly and phosphorus.

representative samples without failure duced section. When size of cylinder

ment is authorized for rejected cyl-

of this section. A wall stress of more S = Tensile stress in psi;

requirements of NBS Handbook H–28. ed in a batch furnace, two tension

tion. Size of specimen for acceptance (1 specimen only

TABLE 2—MECHANICAL PROPERTY LIMITS

6061–T6 .................................................................................. 38,000 35,000 214

all cylinders must be subjected to a so-

mens may be taken in any location or (ii) Obtaining a certified chemical

(iii) Obtaining a certified check anal- (v) Conditions of time, temperature

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

Carbon (max) ....................................................... 0.08 0.08 0.08

Titanium ............................................................... (1)

TABLE 2—CHECK ANALYSIS TOLERANCES

Carbon ..................................................... To 0.15 incl ...................................................................... 0.01 0.01

age. Threads must comply with the fol-

(ii) Taper threads to be of length not jection. Radiographic inspection must

container diameter need not be sub-

must be tested as outlined in para- spector’s report must show in connec-