[Code of Federal Regulations]
[Title 49, Volume 2]
[Revised as of October 1, 2003]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR180.509]
[Page 1094-1097]
TITLE 49--TRANSPORTATION
CHAPTER I--RESEARCH AND SPECIAL PROGRAMS ADMINISTRATION, DEPARTMENT OF
TRANSPORTATION
PART 180_CONTINUING QUALIFICATION AND MAINTENANCE OF PACKAGINGS--Table of
Contents
Subpart F_Qualification and Maintenance of Tank Cars
Sec. 180.509 Requirements for inspection and test of specification tank
cars.
(a) General. (1) Each tank car facility shall evaluate a tank car
according to the requirements specified in Sec. 180.511.
(2) Each tank car that successfully passes a periodic inspection and
test must be marked as prescribed in Sec. 180.515.
(3) A written report as specified in Sec. 180.517(b) must be
prepared for each tank car that is inspected and tested under this
section.
(b) Conditions requiring inspection and test of tank cars. Without
regard to any other periodic inspection and test requirements, a tank
car must have an appropriate inspection and test according to the type
of defect and the type of maintenance or repair performed if:
(1) The tank car shows evidence of abrasion, corrosion, cracks,
dents, distortions, defects in welds, or any other condition that makes
the tank car unsafe for transportation. An example is if maintenance is
performed to replace a fitting, then only a leakage pressure test needs
to be performed.
(2) The tank car was in an accident and damaged to an extent that
may adversely affect its capability to retain its contents.
(3) The tank bears evidence of damage caused by fire.
(4) The Associate Administrator for Safety, FRA, requires it based
on the existence of probable cause that a tank car or a class or design
of tank cars may be in an unsafe operating condition.
(c) Frequency of inspection and tests. Each tank car shall have an
inspection and test according to the requirements of this paragraph.
(1) For Class 107 tank cars and tank cars of riveted construction,
the tank car must have a hydrostatic pressure test and visual inspection
conforming to the requirements in effect prior to July 1, 1996, for the
tank specification.
(2) For Class DOT 113 tank cars, see Sec. 173.319(e) of this
subchapter.
(3) For fusion welded tank cars, each tank car must have an
inspection and
[[Page 1095]]
test in accordance with paragraphs (d) through (k) of this section.
(i) For cars transporting materials not corrosive to the tank, every
10 years for the tank and service equipment (i.e., filling and
discharge, venting, safety, heating, and measuring devices).
(ii) For non-lined or non-coated tank cars transporting materials
corrosive to the tank, an interval based on the following formula, but
in no case shall the interval exceed 10 years for the tank and 5 years
for service equipment:
[GRAPHIC] [TIFF OMITTED] TC13NO91.039
Where:
i is the inspection and test interval.
t1 is the actual thickness.
t2 is the allowable minimum thickness under paragraph (g) of
this section.
r is the corrosion rate per year.
(iii) For lined or coated tank cars transporting a material
corrosive to the tank, every 10 years for the tank, 5 years for the
service equipment.
(A) When a lining or coating is applied to protect the tank shell
from the lading, the owner of the lining or coating shall determine the
periodic inspection interval, test technique, and acceptance criteria
for the lining or coating. The owner must maintain at its principal
place of business all supporting documentation used to make such a
determination, such as the lining or coating manufacturer's recommended
inspection interval, test technique, and acceptance criteria. The
supporting documentation must be made available to FRA upon request.
(B) The owner of the lining or coating shall provide the periodic
inspection interval, test technique, and acceptance criteria for the
lining or coating to the person responsible for qualifying the lining
and coating.
(d) Visual inspection. At a minimum, each tank car facility must
visually inspect the tank externally and internally as follows:
(1) An internal inspection of the tank shell and heads for abrasion,
corrosion, cracks, dents, distortions, defects in welds, or any other
condition that makes the tank car unsafe for transportation, and except
in the areas where insulation or a thermal protection system precludes
it, an external inspection of the tank shell and heads for abrasion,
corrosion, cracks, dents, distortions, defects in welds, or any other
condition that makes the tank car unsafe for transportation;
(2) An inspection of the piping, valves, fittings, and gaskets for
indications of corrosion and other conditions that make the tank car
unsafe for transportation;
(3) An inspection for missing or loose bolts, nuts, or elements that
make the tank car unsafe for transportation;
(4) An inspection of all closures on the tank car for proper
securement in a tool tight condition and an inspection of the protective
housings for proper securement;
(5) An inspection of excess flow valves having threaded seats for
tightness; and
(6) An inspection of the required markings on the tank car for
legibility.
(e) Structural integrity inspections and tests. At a minimum, each
tank car facility shall inspect the tank car for structural integrity as
specified in this section. The structural integrity inspection and test
shall include all transverse fillet welds greater than 0.64 cm (0.25
inch) within 121.92 cm (4 feet) of the bottom longitudinal center line;
the termination of longitudinal fillet welds greater than 0.64 cm (0.25
inch) within 121.92 cm (4 feet) of the bottom longitudinal center line;
and all tank shell butt welds within 60.96 cm (2 feet) of the bottom
longitudinal center line by one or more of the following inspection and
test methods to determine that the welds are in proper condition:
(1) Dye penetrant test;
(2) Radiography test;
(3) Magnetic particle test;
(4) Ultrasonic test; or
(5) Optically-aided visual inspection (e.g., magnifiers,
fiberscopes, borescopes, and machine vision technology).
(f) Thickness tests. (1) Each tank car facility shall measure the
thickness of the tank car shell, heads, sumps, domes, and nozzles on
each tank car by using a device capable of accurately measuring the
thickness to within +-0.05 mm (+-0.002 inch).
(2) After repairs, alterations, conversions or modifications of a
tank car
[[Page 1096]]
that result in a reduction to the tank car shell thickness, the tank car
facility shall measure the thickness of the tank car shell in the area
of reduced shell thickness to ensure that the shell thickness conforms
to paragraph (g) of this section.
(g) Service life shell thickness allowance. (1) A tank car found
with a shell thickness below the required minimum thickness after
forming for its specification, as stated in part 179 of this subchapter,
may continue in service if:
(i) Construction of the tank car shell and heads is from carbon
steel, stainless steel, aluminum, nickel, or manganese-molybdenum steel;
and
(ii) Any reduction in the required minimum thickness of the tank
shell or head is not more than that provided in the following table:
Allowable Shell Thickness Reductions
----------------------------------------------------------------------------------------------------------------
Class DOT 103, 104, 111, and 115 tank Class DOT 105, 109, 112, and 114 tank
cars cars
Damage type -------------------------------------------------------------------------------
Top shell and tank Top shell and tank
head Bottom shell head Bottom shell
----------------------------------------------------------------------------------------------------------------
Corrosion....................... 3.17 mm (0.125 1.58 mm (0.063 0.79 mm (0.031 0.79 mm (0.031
inch). inch). inch). inch).
Corrosion and mechanical........ 3.17 mm (0.125 1.58 mm (0.063 0.79 mm (0.031 0.79 mm (0.031
inch). inch). inch). inch).
Corrosion, local................ 4.76 mm (0.188 3.17 mm (0.125 1.58 mm (0.063 1.58 mm (0.063
inch). inch). inch). inch).
Mechanical, local............... 3.17 mm (0.125 1.58 mm (0.063 1.58 mm (0.063 1.58 mm (0.063
inch). inch). inch). inch).
Corrosion and mechanical, local. 4.76 mm (0.188 3.17 mm (0.125 1.58 mm (0.063 1.58 mm (0.063
inch). inch). inch). inch).
----------------------------------------------------------------------------------------------------------------
Notes:
1. The perimeter for a local reduction may not exceed a 60.96 cm (24 inch) perimeter. Local reductions in the
top shell must be separated from other reductions in the top shell by at least 40.64 cm (16 inches). The
cumulative perimeter for local reductions in the bottom shell may not exceed 182.88 cm (72 inches).
2. Any reduction in the tank car shell may not affect the structural strength of the tank car so that the tank
car shell no longer conforms to Section 6.2 of the AAR Specifications for Tank Cars.
3. Any reduction applies only to the outer shell for Class DOT 115 tank cars.
4. For Class DOT 103 and 104 tank cars, the inside diameter may not exceed 243.84 cm (96 inches).
(h) Safety system inspections. At a minimum, each tank car facility
must inspect:
(1) Tank car thermal protection systems, tank head puncture
resistance systems, coupler vertical restraint systems, and systems used
to protect discontinuities (i.e., skid protection and protective
housings) to ensure their integrity.
(2) Reclosing pressure relief devices by:
(i) Removing the reclosing pressure relief device from the tank car
for inspection; and
(ii) Testing the reclosing pressure relief device with air or
another gas to ensure that it conforms to the start-to-discharge
pressure for the specification or hazardous material in this subchapter.
(i) Lining and coating inspection and test. When this subchapter
requires a lining or coating, at a minimum, each tank car facility must
inspect the lining or coating installed on the tank car according to the
inspection interval test technique, and acceptance criteria established
by the owner of the lining or coating in accordance with paragraph
(c)(3)(iii) of this section.
(j) Leakage pressure test. (1) After reassembly of a tank car or
service equipment, a tank car facility must perform a leak test on the
tank or service equipment to detect leakage, if any, between manway
covers, cover plates, and service equipment. The test may be conducted
with the hazardous material in the tank. When the test pressure exceeds
the start-to-discharge or burst pressure of a pressure relief device,
the device must be rendered inoperative. The written procedures and test
method for leak testing must ensure for the sensitivity and reliability
of the test method and for the serviceability of components to prevent
premature failure.
(2) Interior heater systems must be tested hydrostatically at 13.87
Bar (200 psig) and must show no signs of leakage.
(k) Alternative inspection and test procedures. In lieu of the other
requirements of this section, a person may use an alternative inspection
and test procedure or interval based on a damage-
[[Page 1097]]
tolerance fatigue evaluation (that includes a determination of the
probable locations and modes of damage due to fatigue, corrosion, or
accidental damage), when the evaluation is examined by the Association
of American Railroads Tank Car Committee and approved by the Associate
Administrator for Safety, FRA.
(l) Inspection and test compliance date for tank cars. After July 1,
2000, each tank car with a metal jacket or with a thermal protection
system shall have an inspection and test conforming to this section no
later than the date the tank car requires a periodic hydrostatic
pressure test (i.e., the marked due date on the tank car for the
hydrostatic test).
(2) After July 1, 1998, each tank car without a metal jacket shall
have an inspection and test conforming to this section no later than the
date the tank car requires a periodic hydrostatic pressure test (i.e.,
the marked due date on the tank car for the hydrostatic test).
(3) For tank cars on a 20-year periodic hydrostatic pressure test
interval (i.e., Class DOT 103W, 104W, 111A60W1, 111A100W1, and 111A100W3
tank cars), the next inspection and test date is the midpoint between
the compliance date in paragraph (l)(1) or (2) of this section and the
remaining years until the tank would have had a hydrostatic pressure
test.
[Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as amended by Amdt. 179-50,
61 FR 33256, June 26, 1996; 62 FR 51561, Oct. 1, 1997; 63 FR 52851, Oct.
1, 1998; 66 FR 45391, Aug. 28, 2001]