49 CFR Part 180 — Continuing Qualification and Maintenance of Packagings

PART 180—CONTINUING QUALIFICATION AND MAINTENANCE OF PACKAGINGS Authority: 49 U.S.C. 5101-5128; 49 CFR 1.81 and 1.97. Source: Amdt. 180-2, 54 FR 25032, June 12, 1989, unless otherwise noted. Subpart A—General § 180.1 Purpose and scope. This part prescribes requirements pertaining to the maintenance, reconditioning, repair, inspection and testing of packagings, and any other function having an effect on the continuing qualification and use of a packaging under the requirements of this subchapter. § 180.2 Applicability. (a) Any person who performs a function prescribed in this part shall perform that function in accordance with this part. (b) Any person who performs a function prescribed in this part is considered subject to the regulations of this subchapter when that person— (1) Makes any representation indicating compliance with one or more of the requirements of this part; or (2) Reintroduces into commerce a packaging that bears markings indicating compliance with this part. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended by Amdt. 180-2, 56 FR 27877, June 17, 1991] § 180.3 General requirements. (a) No person may represent, mark, certify, sell, or offer a packaging or container as meeting the requirements of this part, or a special permit pertaining to this part issued under subchapter A of this chapter, whether or not the packaging or container is intended to be used for the transportation of a hazardous material, unless it is marked, maintained, reconditioned, repaired, or retested, as appropriate, in accordance with this part, an approval issued thereunder, or a special permit issued under subchapter A of this chapter. (b) The representations, markings, and certifications subject to the prohibitions of paragraph (a) of this section include: (1) Identifications that include the letters “DOT”, “MC”, “ICC”, or “UN”; (2) Special permit, approval, and registration numbers that include the letters “DOT”; (3) Test dates displayed in association with specification, registration, approval, or exemption markings indicating conformance to a test or retest requirement of this subchapter, an approval issued thereunder, or a special permit issued under subchapter A of this chapter; (4) Documents indicating conformance to the testing, inspection, maintenance or other continuing qualification requirements of this part; and (5) Sales literature, including advertising, indicating that the packaging or container represented therein conforms to requirements contained in subchapter A or C of this chapter. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended by Amdt. 180-3, 58 FR 33306, June 16, 1993; 70 FR 73166, Dec. 9, 2005] Subpart B [Reserved] Subpart C—Qualification, Maintenance and Use of Cylinders Source: 67 FR 51660, Aug. 8, 2002, unless otherwise noted. § 180.201 Applicability. This subpart prescribes requirements, in addition to those contained in parts 107, 171, 172, 173, and 178 of this chapter, for the continuing qualification, maintenance, or periodic requalification of DOT specification and exemption cylinders and UN pressure receptacles. [71 FR 33894, June 12, 2006] § 180.203 Definitions. As used in this section, the word “cylinder” includes UN pressure receptacles. In addition to the definitions contained in § 171.8 of this subchapter, the following definitions apply to this subpart: Commercially free of corrosive components e.g., Condemn Filled charged Mobile unit Non-corrosive service Over-heated Over-pressurized Permanent expansion Proof pressure test Rebuild Repair Requalification Requalification identification number or RIN [67 FR 51660, Aug. 8, 2002, as amended at 71 FR 33894, June 12, 2006; 85 FR 85432, Dec. 28, 2020] § 180.205 General requirements for requalification of specification cylinders. (a) General. (b) Persons performing requalification functions. (c) Periodic requalification of cylinders. (1) Each cylinder that is requalified in accordance with the requirements specified in this section must be marked in accordance with § 180.213 or the requirements of the Transport Canada TDG Regulations, or in the case of a TC cylinder requalified in the United States by a DOT RIN holder, in accordance with the requirements of the Transport Canada TDG Regulations except that registration with Transport Canada is not required and cylinders must be marked with the requalifiers DOT issued requalifier identification number. (2) Each cylinder that fails requalification must be: (i) Rejected and may be repaired or rebuilt in accordance with § 180.211 or § 180.212, as appropriate; or (ii) Condemned in accordance with paragraph (i) of this section. (3) For DOT specification cylinders, the marked service pressure may be changed upon approval of the Associate Administrator and in accordance with written procedures specified in the approval. (4) For a specification 3, 3A, 3AA, 3AL, 3AX, 3AAX, 3B, 3BN, or 3T cylinder filled with gases in other than Division 2.2, from the first requalification due on or after December 31, 2003, the burst pressure of a CG-1, CG-4, or CG-5 pressure relief device must be at test pressure with a tolerance of plus zero to minus 10%. An additional 5% tolerance is allowed when a combined rupture disc is placed inside a holder. This requirement does not apply if a CG-2, CG-3 or CG-9 thermally activated relief device or a CG-7 reclosing pressure valve is used on the cylinder. (5) Each 3-series specification cylinder that is horizontally mounted on a motor vehicle or in a framework and that is: 12 feet or longer; has an outside diameter greater than or equal to 18 inches; and is supported by the neck mounting surface during transportation in commerce must be inspected at the time of requalification in accordance with CGA C-23 (IBR, see § 171.7 of this subchapter). (d) Conditions requiring test and inspection of cylinders. (1) The cylinder shows evidence of dents, corrosion, cracked or abraded areas, leakage, or any other condition that might render it unsafe for use in transportation; (2) The cylinder has been in an accident and has been damaged to an extent that may adversely affect its lading retention capability; (3) The cylinder shows evidence of or is known to have thermal damage, or have been over-heated; (4) Except in association with an authorized repair, evidence of removal of wall thickness via grinding, sanding or other means; (5) For a cylinder subject to paragraph (c)(5) of this section, if there is visible corrosion around the neck or under the flange/sleeve, as outlined in Section 4.2 of CGA C-23, it must be removed and examined in accordance with CGA C-23 before being returned to service; or (6) The Associate Administrator determines that the cylinder may be in an unsafe condition. (e) Cylinders containing Class 8 (corrosive) liquids. (1) Visually inspected, internally and externally, in accordance with paragraph (f) of this section and the inspection is recorded as prescribed in § 180.215; (2) Requalified in accordance with this section, regardless of the date of the previous requalification. When requalification is performed using ultrasonic examination, the cylinder must be visually inspected in accordance with paragraph (e)(1) of this section; (3) Marked in accordance with § 180.213; and (4) Decontaminated to remove all significant residue or impregnation of the Class 8 material. (f) Visual inspection. (1) The visual inspection must be performed in accordance with the following standards (all IBR, see § 171.7 of this subchapter): CGA C-6 for steel and nickel cylinders; CGA C-6.1 for seamless aluminum cylinders; CGA C-6.2 for fiber reinforced composite special permit cylinders; CGA C-6.3 for low pressure aluminum cylinders; CGA C-8 for DOT 3HT cylinders; and CGA C-13 for DOT 8 series cylinders. (2) If a cylinder or tube is requalified by ultrasonic examination, only an external visual inspection is required. (3) For each cylinder with a coating or attachments that would inhibit inspection of the cylinder, the coating or attachments must be removed before performing the visual inspection. (4) Each cylinder subject to visual inspection must be approved, rejected, or condemned according to the criteria in the applicable CGA standard. (5) In addition to other requirements prescribed in this paragraph (f), each specification cylinder manufactured of aluminum alloy 6351-T6 and used in self-contained underwater breathing apparatus (SCUBA), self-contained breathing apparatus (SCBA), or oxygen service must be inspected for sustained load cracking in accordance with appendix C to this part at the first scheduled five-year requalification period after January 1, 2007, and every five years thereafter. (6) Except in association with an authorized repair, removal of wall thickness via grinding, sanding, or other means is not permitted. Removal of paint or loose material to prepare the cylinder for inspection is permitted ( i.e., (7) Chasing of cylinder threads to clean them is permitted, but removal of metal must not occur. Re-tapping of cylinder threads is not permitted, except by the original manufacturer, as provided in § 180.212. (g) Pressure test. (2) The pressure indicating device and expansion indicating device must meet the resolution requirements of CGA C-1. Midpoint visual interpolation is allowed. (3) Each day before retesting, the retester shall confirm, by using a calibrated cylinder or other method authorized in writing by the Associate Administrator, that: (i) The pressure-indicating device, as part of the retest apparatus, is accurate within ±1.0% of the prescribed test pressure of any cylinder tested that day. The pressure indicating device, itself, must be certified as having an accuracy of ±0.5%, or better, of its full range, and must permit readings of pressure from 90%-110% of the minimum prescribed test pressure of the cylinder to be tested. The accuracy of the pressure indicating device within the test system can be demonstrated at any point within 500 psig of the actual test pressure for test pressures at or above 3000 psig, or 10% of the actual test pressure for test pressures below 3000 psig. (ii) The expansion-indicating device, as part of the retest apparatus, meets the accuracy requirements of CGA C-1. (4) Test equipment must be verified each day before retesting as required in CGA C-1. (i) The retester must demonstrate calibration in conformance with this paragraph (g) to an authorized inspector on any day that it retests cylinders. (ii) A retester must maintain calibrated cylinder certificates in conformance with § 180.215(b)(4). (5) A system check may be performed at or below 90% of test pressure prior to the retest. In the case of a malfunction of the test equipment or operator error, the test may be repeated in accordance with CGA C-1, section 5.7.1. This paragraph (g) does not authorize retest of a cylinder otherwise required to be condemned under paragraph (i) of this section. (h) Ultrasonic examination (UE). (i) Cylinder rejection. (1) Except as provided in paragraphs (i)(3) and (4) of this section, a cylinder that is rejected may not be marked as meeting the requirements of this section. (2) The requalifier must notify the cylinder owner, in writing, that the cylinder has been rejected. (3) Unless the cylinder is repaired or rebuilt in conformance with requirements in § 180.211, it may not be filled with a hazardous material and offered for transportation where use of a specification packaging is required. (4) A rejected cylinder with a service pressure of less than 900 psig may be requalified and marked if the cylinder is repaired or rebuilt and subsequently inspected and tested in conformance with— (i) The visual inspection requirements of paragraph (f) of this section; (ii) Part 178 of this subchapter and this part; (iii) Any special permit covering the manufacture, requalification, and/or use of that cylinder; and (iv) Any approval required under § 180.211. (j) Cylinder condemnation. (i) The cylinder meets a condition for condemnation under the visual inspection requirements of paragraph (f) of this section. (ii) The cylinder leaks through its wall. (iii) Evidence of cracking exists to the extent that the cylinder is likely to be weakened appreciably. (iv) For a DOT specification cylinder, other than a DOT 4E aluminum cylinder or a special permit cylinder, permanent expansion exceeds 10 percent of total expansion. (v) For a DOT 3HT cylinder— (A) The pressure test yields an elastic expansion exceeding the marked rejection elastic expansion (REE) value. (B) The cylinder shows evidence of denting or bulging. (C) The cylinder bears a manufacture or an original test date older than twenty-four years or after 4380 pressurizations, whichever occurs first. If a cylinder is refilled, on average, more than once every other day, an accurate record of the number of rechargings must be maintained by the cylinder owner or the owner's agent. (vi) For a DOT 4E aluminum cylinder, permanent expansion exceeds 12 percent of total expansion. (vii) For a DOT special permit cylinder, permanent expansion exceeds the limit in the applicable special permit, or the cylinder meets another criterion for condemnation in the applicable special permit. (viii) For an aluminum or an aluminum-lined composite special permit cylinder, the cylinder is known to have been or shows evidence of having been overheated. Arc burns must be considered evidence of overheating. (ix) The cylinder is known to have been or shows evidence of having been over-pressurized. (x) For a cylinder with a specified service life, its authorized service life has expired. (xi) The cylinder has been stamped on the sidewall, except as provided in part 178 of this subchapter. (2) When a cylinder must be condemned, the requalifier must— (i) Communicate condemnation of the cylinder as follows: (A) Stamp a series of Xs over the DOT-specification number and the marked pressure or stamp “CONDEMNED” on the shoulder, top head, or neck using a steel stamp; (B) For composite cylinders, securely affix to the cylinder a label with the word “CONDEMNED” overcoated with epoxy near, but not obscuring, the original cylinder manufacturer's label; or (C) As an alternative to the stamping or labeling as described in this paragraph (j)(2), at the direction of the owner, the requalifier may render the cylinder incapable of holding pressure. If a condemned cylinder contains hazardous materials, the requalifier must stamp the cylinder “CONDEMNED” and affix a readily visible label on the cylinder stating: “UN REJECTED, RETURNING TO ORIGIN FOR PROPER DISPOSITION.” The requalifier may only transport the condemned cylinder by private motor vehicle carriage to a facility capable of safely removing the contents of the cylinder. (ii) Notify the cylinder owner, in writing, that the cylinder is condemned and may not be filled with hazardous material and offered for transportation in commerce where use of a specification packaging is required. (3) No person may remove, obliterate, or alter the required condemnation communication of paragraph (j)(2) of this section. (k) Training materials. [67 FR 51660, Aug. 8, 2002, as amended at 68 FR 24662, May 8, 2003; 68 FR 75764, Dec. 31, 2003; 70 FR 34077, June 13, 2005; 70 FR 73166, Dec. 9, 2005; 71 FR 51128, Aug. 29, 2006; 73 FR 4720, Jan. 28, 2008; 75 FR 53597, Sept. 1, 2010; 82 FR 15896, Mar. 30, 2017; 85 FR 85433, Dec. 28, 2020; 89 FR 15666, Mar. 4, 2024] § 180.207 Requirements for requalification of UN pressure receptacles. (a) General. (2) No pressure receptacle due for requalification may be filled with a hazardous material and offered for transportation in commerce unless that pressure receptacle has been successfully requalified and marked in accordance with this subpart or requalified and marked by a facility registered by Transport Canada in accordance with the Transport Canada TDG Regulations (IBR, see (3) A pressure receptacle with a specified service life may not be requalified after its authorized service life has expired. A pressure receptacle with a specified service life may not be refilled and offered for transportation after its authorized service life has expired unless approval has been obtained in writing from the Associate Administrator. (b) Periodic requalification of UN pressure receptacles. (2) Each pressure receptacle that fails requalification must be rejected or condemned in accordance with the applicable ISO requalification standard. (c) Requalification interval. 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: UN1043, Fertilizer ammoniating solution with free ammonia. UN1746, Bromine trifluoride. 5 Pressure receptacles used for adsorbed gases. (d) Requalification procedures. e.g., (1) Seamless steel. (ii) Each seamless steel UN pressure receptacle that is horizontally mounted on a motor vehicle or in a framework and that: is 12 feet or longer; has an outside diameter greater than or equal to 18 inches; and is supported by a neck mounting surface during transportation must be inspected at the time of requalification in accordance with CGA C-23 (IBR, see § 171.7 of this subchapter). Notwithstanding the periodic inspection, if the seamless steel UN pressure receptacle shows visible corrosion, as outlined in Section 4.2 of CGA C-23, around the neck or under the flange/sleeve, then it must be removed and examined in accordance with Section 6 of CGA C-23 prior to returning to service. (2) Seamless UN aluminum: (3) Dissolved acetylene UN cylinders: Each dissolved acetylene cylinder must be requalified in accordance with ISO 10462:2013(E)/Amd 1:2019 (IBR, see § 171.7 of this subchapter). However, a cylinder may continue to be requalified in accordance with ISO 10462:2013(E) (IBR, see § 171.7 of this subchapter) without the supplemental amendment until December 31, 2024. Further, a cylinder requalified in accordance with ISO 10462:2013(E) until December 31, 2018, may continue to be used until its next required requalification. The porous mass and the shell must be requalified no sooner than three (3) years, six (6) months, from the date of manufacture. Thereafter, subsequent requalifications of the porous mass and shell must be performed at least once every 10 years. (4) Composite UN cylinders: see see (5) UN cylinders for adsorbed gases: Each UN cylinder for adsorbed gases must be inspected and tested in accordance with § 173.302c of this subchapter and ISO 11513:2019(E) (IBR, see § 171.7 of this subchapter). However, a UN cylinder may continue to be requalified in accordance with ISO 11513:2011(E) (IBR, see § 171.7 of this subchapter) until December 31, 2024. (6) Valves: see (7) UN cylinder bundles: see (8) UN pressure drums: UN pressure drums must be inspected and tested in accordance with ISO 23088:2020 (IBR, see § 171.7 of this subchapter). [71 FR 33894, June 12, 2006, as amended at 71 FR 54397, Sept. 14, 2006; 76 FR 3389, Jan. 19, 2011; 80 FR 1168, Jan. 8, 2015; 82 FR 15897, Mar. 30, 2017; 85 FR 27901, May 11, 2020; 85 FR 85434, Dec. 28, 2020; 86 FR 45000, July 26, 2022; 89 FR 15667, Mar. 4, 2024; 89 FR 25490, Apr. 10, 2024] § 180.209 Requirements for requalification of specification cylinders. (a) Periodic qualification of cylinders. Table 1 to Paragraph ( a 1 Specification under which cylinder was made Minimum test pressure 2 Requalification period 3 3000 psig 5. 3A, 3AA 5/3 times service pressure, except non-corrosive service ( see 3 5, 10, or 12 ( see 3AL 5/3 times service pressure 5 or 12 ( see 4 3AX, 3AAX 5/3 times service pressure 5. 3B, 3BN 2 times service pressure ( see 5 or 10 ( see 3E Test not required 3HT 5/3 times service pressure 3 ( see 3T 5/3 times service pressure or UE 3 5. 4AA480 2 times service pressure ( see 5 or 10 ( see 4B, 4BA, 4BW, 4B-240ET 2 times service pressure, except non-corrosive service ( see 5, 7, 10, or 12 ( see 4D, 4DA, 4DS 2 times service pressure 5. 4E 2 times service pressure, except non-corrosive service ( see 5, 10, or 12 ( see 4L Test not required 8, 8AL 10 or 20 ( see Exemption or special permit cylinder See current exemption or special permit, or UE 3 See current exemption or special permit. Foreign cylinder ( see As marked on cylinder, but not less than 53 of any service or working pressure marking 5 ( see 1 2 3 4 (b) DOT 3A or 3AA cylinders. (i) The cylinder was manufactured after December 31, 1945. (ii) The cylinder is used exclusively for air; argon; cyclopropane; ethylene; helium; hydrogen; krypton; neon; nitrogen; nitrous oxide; oxygen; sulfur hexafluoride; xenon; chlorinated hydrocarbons, fluorinated hydrocarbons, liquefied hydrocarbons, and mixtures thereof that are commercially free from corroding components; permitted mixtures of these gases ( see (iii) [Reserved] (iv) The cylinder is dried immediately after hydrostatic testing to remove all traces of water. (v) The cylinder is not used for underwater breathing. (vi) Each cylinder is stamped with a five-pointed star at least one-fourth of an inch high immediately following the test date. (2) A cylinder conforming to specification DOT 3A or 3AA with a water capacity of 56.7 kg (125 lb.) or less that is not removed from any cluster, bank, group, rack, or vehicle each time it is filled, may be requalified by either hydrostatic testing and visual inspection described in § 180.205 or by ultrasonic examination (UE) every ten years instead of every five years, provided the cylinder conforms to all of the following conditions: (i) The cylinder was manufactured after December 31, 1945. (ii) The cylinder is used exclusively for air; argon; helium; oxygen; nitrogen; neon; tetrafluoromethane (CF4); hydrogen; deuterium; mixtures of hydrogen, argon, helium, oxygen, and/or nitrogen; mixtures of argon, xenon, and/or neon; mixtures of krypton and neon; mixtures of hydrogen, argon, helium, and/or nitrogen; and mixtures containing deuterium, provided all gas mixtures have a dew point at or below minus (52 °F) at 1 atmosphere. (iii) Carbon dioxide in any concentration cannot be added to cylinders in the bundle. (iv) Gases that are toxic and/or corrosive cannot be added to cylinders in the bundle. (v) If requalified by hydrostatic pressure testing, the cylinder is dried immediately after testing to remove all traces of water. (vi) The cylinder is not used for underwater breathing. (vii) Each cylinder is stamped with a five-pointed star at least one-fourth of an inch high immediately following the test date. (3) If, since the last required requalification, a cylinder has not been used exclusively for the gases specifically identified in paragraph (b)(1)(ii) of this section, but currently conforms with all other provisions of paragraph (b)(1) of this section, it may be requalified every 10 years instead of every five years, provided it is first requalified and examined as prescribed by § 173.302a(b)(2), (3) and (4) of this subchapter. (4) Except as specified in paragraph (b)(3) of this section, if a cylinder, marked with a star, is filled with a compressed gas other than as specified in paragraph (b)(1)(ii) of this section, the star following the most recent test date must be obliterated. The cylinder must be requalified five years from the marked test date, or prior to the first filling with a compressed gas, if the required five-year requalification period has passed. (c) DOT 4-series cylinders. (d) Cylinders 5.44 kg (12 lb) or less with service pressures of 300 psig or less. (e) Cylinders in non-corrosive gas service. (f) Poisonous materials. (g) Visual inspections. e.g., Table 2 to Paragraph ( g 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 4BA, DOT 4BW Butadiene, inhibited, that is commercially free from corroding components. DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B. DOT 4AA480, DOT 4B, DOT 4BA, DOT 4BW Cyclopropane that is commercially free from corroding components. DOT 3A, DOT 3AA, DOT 3A480X, DOT 4B, DOT 4BA, DOT 4BW, DOT 4E Chlorinated hydrocarbons and mixtures thereof that are commercially free from corroding components. DOT 3A, DOT 3AA, DOT 3A480X, DOT 4B, DOT 4BA, DOT 4BW, DOT 4E Fluorinated hydrocarbons and mixtures thereof that are commercially free from corroding components. DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT 4BA, DOT 4BW, DOT 4E Liquefied hydrocarbon gas that is commercially free of corroding components. DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, DOT 4B, DOT 4BA, DOT 4BW, DOT 4E Liquefied petroleum gas that meets the detail requirements limits in Table 1 of ASTM 1835, Standard Specification for Liquefied 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, DOT 4E Methylacetylene-propadiene, stabilized, that is commercially free from corroding components. DOT 3A, DOT 3AA, DOT 3B, DOT 4B, DOT 4BA, DOT 4BW, DOT 4E Propylene that is commercially 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 Alkaline earth metal dispersions, Potassium, Potassium Sodium alloys and Sodium that are commercially free of corroding components. (h) Cylinders containing anhydrous ammonia. (i) Requalification of DOT-8 series cylinders. Date of cylinder manufacture Shell (visual inspection) requalification Porous filler requalification 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, 1991 10 years 1 10 years 5 to 20 years 2 Not required. 1 2 (2) Unless requalified and marked in accordance with CGA Pamphlet C-13 before October 1, 1994, an acetylene cylinder must be requalified by a person who holds a current RIN. (3) If a cylinder valve is replaced, a cylinder valve of the same weight must be used or the tare weight of the cylinder must be adjusted to compensate for valve weight differential. (4) The person performing a visual inspection or requalification must record the results as specified in § 180.215. (5) The person performing a visual inspection or requalification must mark the cylinder as specified in § 180.213. (j) Cylinder used as a fire extinguisher. (1) A DOT 4B, 4BA, 4B240ET or 4BW cylinder used as a fire extinguisher may be tested as follows: (i) For a cylinder with a water capacity of 5.44 kg (12 pounds) or less, by the water-jacket, direct expansion or proof pressure test methods as prescribed in CGA C-1. A requalification must be performed by the end of 12 years after the original test date and at 12-year intervals thereafter. (A) Each cylinder must be tested to a minimum of two (2) times service pressure. (B) When testing using the water-jacket or direct expansion test method, the permanent volumetric expansion may not exceed 10 percent of total volumetric expansion at test pressure. (C) When testing using the proof pressure test method, the cylinder must be carefully examined under test pressure and removed from service if a leak or defect is found. (ii) For a cylinder having a water capacity over 5.44 kg (12 pounds), by the water-jacket, direct expansion or proof pressure test methods as prescribed in CGA C-1. For the water-jacket or direct expansion test, the requalification must be performed by the end of 12 years after the original test date and at 12-year intervals theafter. For the proof-pressure test, a requalification must be performed by the end of 12 years after the original test date and at seven (7) year intervals. (A) Each cylinder must be tested to a minimum of two (2) times service pressure. (B) When testing using the water-jacket or direct expansion test method, the permanent volumetric expansion may not exceed 10 percent of total volumetric expansion at test pressure. (C) When testing using the proof pressure test method, the cylinder must be carefully examined under test pressure and removed from service if a leak or defect is found. (2) A DOT 3A, 3AA, or 3AL cylinder must be requalified by: (i) The water-jacket or direct expansion method. A requalification must be performed 12 years after the original test date and at 12-year intervals thereafter. (ii) Each cylinder must be tested to a minimum of 5/3 (iii) When testing using the water-jacket or direct expansion test method, the permanent volumetric expansion may not exceed 10 percent of total volumetric expansion at test pressure. (k) 3HT cylinders. (l) Requalification of foreign cylinders filled for export. (1) It has been inspected, tested and marked in conformance with the procedures and requirements of this subpart or the Associate Administrator has authorized the filling company to fill foreign cylinders under an alternative method of qualification; and (2) It is offered for transportation in conformance with the requirements of §§ 171.12(a)(4) or 171.23(a)(5) of this subchapter. (m) DOT-3AL cylinders manufactured of 6351-T6 aluminum alloy. Table 4 to Paragraph (m)—Requalification and Inspection of DOT-3AL Cylinders Made of Aluminum Alloy 6351-T6 Requalification requirement Examination procedure 1 Sustained Load Cracking Condemnation Criteria 2 Requalification period (years) Eddy current examination combined with visual inspection Eddy current—In accordance with Appendix C of this part Any crack in the neck or shoulder of 2 thread lengths or more 5 1 2 [67 FR 51660, Aug. 8, 2002, as amended at 68 FR 24662, May 8, 2003; 68 FR 55544, Sept. 26, 2003; 68 FR 48572, Aug. 14, 2003; 68 FR 75764, Dec. 31, 2003; 70 FR 73166, Dec. 9, 2005; 71 FR 51128, Aug. 29, 2005; 72 FR 55696, Oct. 1, 2007; 74 FR 53189, Oct. 16, 2009; 81 FR 3685, Jan. 21, 2016; 81 FR 35545, June 2, 2016; 85 FR 68797, Oct. 30, 2020; 85 FR 75716, Nov. 25, 2020; 85 FR 85434, Dec. 28, 2020; 89 FR 15667, Mar. 4, 2024; 91 FR 49357, Aug. 4, 2026] § 180.211 Repair, rebuilding and reheat treatment of DOT-4 series specification cylinders. (a) General requirements for repair and rebuilding. (b) General repair requirements. (1) The repair and the inspection of the work performed must be made in accordance with the requirements of the cylinder specification. (2) The person performing the repair must use the procedure, equipment, and filler metal or brazing material as authorized by the approval issued under § 107.805 of this chapter. (3) Welding and brazing must be performed on an area free from contaminants. (4) A weld defect, such as porosity in a pressure retaining seam, must be completely removed before re-welding. Puddling may be used to remove a weld defect only by the tungsten inert gas shielded arc process. (5) After removal of a non-pressure attachment and before its replacement, the cylinder must be given a visual inspection in accordance with § 180.205(f). (6) Reheat treatment of DOT 4B, 4BA or 4BW specification cylinders after replacement of non-pressure attachments is not required when the total weld material does not exceed 20.3 cm (8 inches). Individual welds must be at least 7.6 cm (3 inches) apart. (7) After repair of a DOT 4B, 4BA or 4BW cylinder, the weld area must be leak tested at the service pressure of the cylinder. (8) Repair of weld defects must be free of cracks. (9) When a non-pressure attachment with the original cylinder specification markings is replaced, all markings must be transferred to the attachment on the repaired cylinder. (10) Walls, heads or bottoms of cylinders with defects or leaks in base metal may not be repaired, but may be replaced as provided for in paragraph (d) of this section. (c) Additional repair requirements for 4L cylinders. (i) The removal of either end of the insulation jacket to permit access to the cylinder, piping system, or neck tube. (ii) The replacement of the neck tube. At least a 13 mm (0.51 inch) piece of the original neck tube must be protruding above the cylinder's top end. The original weld attaching the neck tube to the cylinder must be sound and the replacement neck tube must be welded to this remaining piece of the original neck tube. (iii) The replacement of material such as, but not limited to, the insulating material and the piping system within the insulation space is authorized. The replacement material must be equivalent to that used at the time of original manufacture. (iv) Other welding procedures that are permitted by CGA Pamphlet C-3 (IBR, see § 171.7 of this subchapter), and not excluded by the definition of “rebuild,” are authorized. (2) After repair, the cylinder must be— (i) Pressure tested in accordance with the specifications under which the cylinder was originally manufactured; (ii) Leak tested before and after assembly of the insulation jacket using a mass spectrometer detection system; and (iii) Tested for heat conductivity requirements. (d) General rebuilding requirements. (i) The person rebuilding the cylinder must use the procedures and equipment as authorized by the approval issued under § 107.805 of this chapter. (ii) After removal of a non-pressure component and before replacement of any non-pressure component, the cylinder must be visually inspected in accordance with CGA Pamphlet C-6 (IBR, see § 171.7 of this subchapter). (iii) The rebuilder may rebuild a DOT 4B, 4BA or 4BW cylinder having a water capacity of 9.07 kg (20 lb) or greater by replacing a head of the cylinder using a circumferential joint. When this weld joint is located at other than an original welded joint, a notation of this modification must be shown on the Manufacturer's Report of Rebuilding in § 180.215(c)(2). The weld joint must be on the cylindrical section of the cylinder. (iv) Any welding and the inspection of the rebuilt cylinder must be in accordance with the requirements of the applicable cylinder specification and the following requirements: (A) Rebuilding of any cylinder involving a joint subject to internal pressure may only be performed by fusion welding; (B) Welding must be performed on an area free from contaminants; and (C) A weld defect, such as porosity in a pressure retaining seam, must be completely removed before re-welding. Puddling may be used to remove a weld defect only by using the tungsten inert gas shielded arc process. (2) Any rebuilt cylinder must be— (i) Heat treated in accordance with paragraph (f) of this section; (ii) Subjected to a volumetric expansion test on each cylinder. The results of the tests must conform to the applicable cylinder specification; (iii) Inspected and have test data reviewed to determine conformance with the applicable cylinder specification; and (iv) Made of material conforming to the specification. Determination of conformance shall include chemical analysis, verification, inspection and tensile testing of the replaced part. Tensile tests must be performed on the replaced part after heat treatment by lots defined in the applicable specification. (3) For each rebuilt cylinder, an inspector's report must be prepared to include the information listed in § 180.215(c). (4) Rebuilding a cylinder with brazed seams is prohibited. (5) When an end with the original cylinder specification markings is replaced, all markings must be transferred to the rebuilt cylinder. (e) Additional rebuilding requirements for DOT 4L cylinders. (i) Substituting or adding material in the insulation space not identical to that used in the original manufacture of that cylinder; (ii) Making a weld repair not to exceed 150 mm (5.9 inches) in length on the longitudinal seam of the cylinder or 300 mm (11.8 inches) in length on a circumferential weld joint of the cylinder; or (iii) Replacing the outer jacket. (2) Reheat treatment of cylinders is prohibited. (3) After rebuilding, each inner containment vessel must be proof pressure tested at 2 times its service pressure. Each completed assembly must be leak-tested using a mass spectrometer detection system. (f) Reheat treatment. (2) Cylinders must be segregated in lots for reheat treatment. The reheat treatment and visual inspection must be performed in accordance with the specification for the cylinders except as provided in paragraph (f)(4) of this section. (3) After reheat treatment, each cylinder in the lot must be subjected to a volumetric expansion test and meet the acceptance criteria in the applicable specification or be scrapped. (4) After all welding and heat treatment, a test of the new weld must be performed as required by the original specification. The test results must be recorded in accordance with § 180.215. (g) Repair, rebuilding and reheat treatment in Canada. see [67 FR 51660, Aug. 8, 2002, as amended at 68 FR 24664, May 8, 2003; 68 FR 75764, Dec. 31, 2003; 71 FR 54398, Sept. 14, 2006; 82 FR 15897, Mar. 30, 2017] § 180.212 Repair of seamless DOT 3-series specification cylinders and seamless UN pressure receptacles. (a) General requirements for repair of DOT 3-series cylinders and UN pressure receptacles. (i) The repair facility holds an approval issued under the provisions in § 107.805 of this chapter; and (ii) Except as provided in paragraph (b) of this section, the repair and the inspection is performed under the provisions of an approval issued under subpart H of part 107 of this chapter or by a facility registered by Transport Canada in accordance with the Transport Canada TDG Regulations (IBR; see § 171.7 of this subchapter) and conform to the applicable cylinder specification or ISO standard contained in part 178 of this subchapter. (2) The person performing the repair must prepare a report containing, at a minimum, the results prescribed in § 180.215. (3) If grinding is performed on a DOT 3-series cylinder or a seamless UN pressure receptacle, the following conditions apply after grinding has been completed. Grinding must not be used to remove arc burns from a cylinder, as such a cylinder must be condemned: (i) Ultrasonic examination must be conducted to ensure that the wall thickness is not less than the minimum design requirement. The wall thickness must be measured in at least 3 different areas for every 10 square inches of grinding area. (ii) The cylinder must be requalified in conformance with § 180.205. (iii) The cylinder must be marked in accordance with § 180.213(f)(10) to indicate compliance with this paragraph (a)(3). (4) DOT 3-series seamless steel tubes with an outside diameter greater than 9 5/8 (b) Repairs not requiring prior approval. (1) The removal and replacement of a neck ring or foot ring on a DOT 3A, 3AA or 3B cylinder or a UN pressure receptacle that does not affect a pressure part of the cylinder when the repair is performed by a repair facility or a cylinder manufacturer of these types of cylinders. The repair may be made by welding or brazing in conformance with the original specification. After removal and before replacement, the cylinder must be visually inspected and any defective cylinder must be rejected. The heat treatment, testing and inspection of the repair must be performed under the supervision of an inspector and must be performed in accordance with the original specification. (2) External rethreading of a DOT 3AX, 3AAX, or 3T specification cylinder or a UN pressure receptacle, and external threading of a seamless DOT 3AX, 3AAX, or 3T specification cylinder or seamless UN pressure receptacle originally manufactured without external threads; or the internal rethreading of a DOT-3 series cylinder or a seamless UN pressure receptacle when performed by a cylinder manufacturer of these types of cylinders. The repair work must be performed under the supervision of an independent inspection agency. Upon completion of the rethreading or post-manufacture threading, the threads must be gauged in accordance with Federal Standard H-28 or an equivalent standard containing the same specification limits. The rethreaded cylinder or UN pressure receptacle must be stamped clearly and legibly with the words “RETHREAD” and a post-manufacture threaded cylinder or UN pressure receptacle must be stamped clearly and legibly with the words “POST-THREAD”, on the shoulder, top head, or neck. No DOT specification cylinder or UN pressure receptacle may be rethreaded more than one time without approval of the Associate Administrator. [71 FR 33895, June 12, 2006, as amended at 71 FR 54398, Sept. 14, 2006; 72 FR 55697, Oct. 1, 2007; 82 FR 15897, Mar. 30, 2017; 85 FR 85435, Dec. 28, 2020; 89 FR 15668, Mar. 4, 2024] § 180.213 Requalification markings. (a) General. (b) Placement of markings. (1) Requalification and required specification markings must be legible so as to be readily visible at all times. Illegible specification markings may be remarked on the cylinder as provided by the original specification. Requalification markings may be placed on any portion of the upper end of the cylinder excluding the sidewall, as provided in this section. Requalification and required specification markings that are illegible may be reproduced on a metal plate and attached as provided by the original specification. (2) Previous requalification markings may not be obliterated, except that, when the space originally provided for requalification dates becomes filled, additional dates may be added as follows: (i) All preceding requalification dates may be removed by peening provided that— (A) Permission is obtained from the cylinder owner; (B) The minimum wall thickness is maintained in accordance with manufacturing specifications for the cylinder; and (C) The original manufacturing test date is not removed. (ii) When the cylinder is fitted with a footring, additional dates may be marked on the external surface of the footring. (c) Requalification marking method. (1) A cylinder used as a fire extinguisher (see § 180.209(j)) may be marked by using a pressure sensitive label. (2) For a DOT 3HT cylinder, when stamped, the test date and RIN must be applied by low-stress steel stamps to a depth no greater than that prescribed at the time of manufacture. Stamping on the sidewall is not authorized. (3) For a composite cylinder, the requalification markings must be applied on a pressure sensitive label, securely affixed and overcoated with epoxy in a manner prescribed by the cylinder manufacturer, near the original manufacturer's label. Stamping of the composite surface is not authorized. (d) Requalification markings. A1 9 06 X 32 Where: “9” is the month of requalification “A123” is the RIN “06” is the year of requalification, and “X” represents the symbols described in paragraphs (f)(2) through (f)(8) of this section. (1) Upon written request, variation from the marking requirement may be approved by the Associate Administrator. (2) A cylinder subject to the requirements of § 171.23(a)(5) of this subchapter must be marked with the date and RIN in accordance with this paragraph (d) and paragraph (f)(11) of this section, or marked in accordance with the requalification authorized by the Associate Administrator in accordance with § 171.23(a)(5)(i) of this subchapter. (e) Size of markings. 1/4 1/8 (f) Marking illustrations. (1) For designation of the 5-year volumetric expansion test, 10-year volumetric expansion test for UN cylinders and cylinders conforming to § 180.209(f) and (h), or 12-year volumetric expansion test for fire extinguishers conforming to § 173.309(a) of this subchapter and cylinders conforming to § 180.209(e) and (g), the marking is as illustrated in paragraph (d) of this section. (2) For designation of the 10-year volumetric expansion test for cylinders conforming to § 180.209(b), the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with a five-point star. (3) For designation of special filling limits up to 10% in excess of the marked service pressure for cylinders conforming to § 173.302a(b) of this subchapter, the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with a plus sign “ + ”. (4) For designation of the proof pressure test, the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with the letter “S”. (5) For designation of the 5-year external visual inspection for cylinders conforming to § 180.209(g), the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with the letter “E”. (6) For designation of DOT 8 series cylinder shell requalification only, the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with the letter “S”. (7) For designation of DOT 8 series and UN cylinder shell and porous filler requalification, the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with the letters “FS.” (8) For designation of a nondestructive examination combined with a visual inspection, the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with the type of test performed, for example the letters “AE” for acoustic emission or “UE” for ultrasonic examination. (9) For designation of the eddy current examination combined with a visual inspection, the marking is as illustrated in paragraph (d) of this section, except the “X” is replaced with the letters “VE.” (10) For designation of grinding with ultrasonic wall thickness examination, the marking is as illustrated in paragraph (d) of this section, except the “X” is replaced with the letter “R”. (11) For designation of requalification of a foreign cylinder requalified in conformance with §§ 171.23(a)(5) of this subchapter and 180.209(l), the marking is as illustrated in paragraph (d) of this section, except that the “X” is replaced with the letters “EX” to indicate that the cylinder is for export only. (g) Visual inspection requalification markings. e.g., (2) Where: (i) “03” is the month of requalification (the additional numeral “0” is optional”); (ii) “V123456” is the RIN; (iii) “14” is the year of requalification; and (iv) “E” to indicate visual inspection. [67 FR 51660, Aug. 8, 2002, as amended at 70 FR 73166, Dec. 9, 2005; 71 FR 33896, June 12, 2006; 71 FR 51128, Aug. 29, 2006; 71 FR 78635, Dec. 29, 2006; 75 FR 53597, Sept. 1, 2010; 80 FR 72929, Nov. 23, 2015; 81 FR 3686, Jan. 21, 2016; 85 FR 75716, Nov. 25, 2020; 85 FR 85435, Dec. 28, 2020] § 180.215 Reporting and record retention requirements. (a) Facility records. (1) Current RIN issuance letter; (2) If the RIN has expired and renewal is pending, a copy of the renewal request; (3) Copies of notifications to Associate Administrator required under § 107.805 of this chapter; (4) Current copies of those portions of this subchapter applicable to its cylinder requalification and marking activities at that location; (5) Current copies of all special permits governing exemption cylinders requalified or marked by the requalifier at that location; and (6) The information contained in each applicable CGA or ASTM standard incorporated by reference in § 171.7 of this subchapter applicable to the requalifier's activities. (b) Requalification records. (1) Calibration test records. (2) Pressure test and visual inspection records. (3) Wall stress. (4) Calibration certificates. (c) Repair, rebuilding or reheat treatment records. (2) A record of rebuilding, in accordance with § 180.211(d), must be completed for each cylinder rebuilt. The record must be clear, legible, and contain the following information: (i) Name and address of test facility, date of test report, and name of original manufacturer; (ii) Marks stamped on cylinder to include specification number, service pressure, serial number, symbol of manufacturer, inspector's mark, and other marks, if any; (iii) Cylinder outside diameter and length in inches; (iv) Rebuild process (welded, brazed, type seams, etc.); (v) Description of assembly and any attachments replaced (e.g., neckrings, footrings); (vi) Chemical analysis of material for the cylinder, including seat and Code No., type of analysis (ladle, check), chemical components (Carbon (C), Phosphorous (P), Sulfur (S), Silicon (Si), Manganese (Mn), Nickel (Ni), Chromium (Cr), Molybdenum (Mo), Copper (Cu), Aluminum (Al), Zinc (Zn)), material manufacturer, name of person performing the analysis, results of physical tests of material for cylinder (yield strength (psi), tensile strength (psi), elongation percentage (inches), reduction in area percentage, weld bend, tensile bend, name of inspector); (vii) Results of a test on a cylinder, including test method, test pressure, total expansion, permanent expansion, elastic expansion, percent permanent expansion (permanent expansion may not exceed ten percent (10 percent) of total expansion), and volumetric capacity (volumetric capacity of a rebuilt cylinder must be within ±3 percent of the calculated capacity); (viii) Each report must include the following certification statement: “I certify that this rebuilt cylinder is accurately represented by the data above and conforms to all of the requirements in Subchapter C of Chapter I of Title 49 of the Code of Federal Regulations.”. The certification must be signed by the rebuild technician and principal, officer, or partner of the rebuild facility. (3) A record of grinding and ultrasonic examination in conformance with § 180.212(a)(3) must be completed for each cylinder on which grinding is performed. The record must be clear, legible, and contain the following information: (i) Name and address of the test facility, date of test report, and name or original manufacturer; (ii) Marks stamped on cylinder to include specification number, service pressure, serial number, symbol of manufacturer, and date of manufacture; (iii) Cylinder outside diameter and length in inches; (iv) Detailed map of where the grinding was performed on the cylinder; and (v) Wall thickness measurements in grind area in conformance with § 180.212(a)(3)(i). [67 FR 51660, Aug. 8, 2002, as amended at 68 FR 24664, May 8, 2003; 70 FR 73166, Dec. 9, 2005; 71 FR 54398, Sept. 14, 2006; 72 FR 55697, Oct. 1, 2007; 85 FR 85436, Dec. 28, 2020] § 180.217 Requalification requirements for MEGCs. (a) Periodic inspections. see (b) Exceptional inspection and test. (c) Correction of unsafe condition. (d) Repairs and modifications to MEGCs. (e) Requalification markings. (f) Records. [71 FR 33896, June 12, 2006, as amended at 85 FR 27901, May 11, 2020] Subpart D—Qualification and Maintenance of IBCs § 180.350 Applicability and definitions. This subpart prescribes requirements, in addition to those contained in parts 107, 171, 172, 173 and 178 of this subchapter, applicable to any person responsible for the continuing qualification, maintenance, or periodic retesting of an IBC. The following definitions apply: (a) Remanufactured IBCs (b) Repaired IBCs (c) Routine maintenance of IBCs is the routine performance on: (1) Metal, rigid plastic or composite IBCs of operations such as: (i) Cleaning; (ii) Removal and reinstallation or replacement of body closures (including associated gaskets), or of service equipment conforming to the original manufacturer's specifications provided that the leaktightness of the IBC is verified; or (iii) Restoration of structural equipment not directly performing a hazardous material containment or discharge pressure retention function so as to conform to the design type (for example, the straightening of legs or lifting attachments), provided the containment function of the IBC is not affected. (2) Plastics or textile flexible IBCs of operations, such as: (i) Cleaning; or (ii) Replacement of non-integral components, such as non-integral liners and closure ties, with components conforming to the original manufacturer's specification; provided that these operations do not adversely affect the containment function of the flexible IBC or alter the design type. [68 FR 45042, July 31, 2003, as amended at 69 FR 76186, Dec. 20, 2004; 76 FR 3389, Jan. 19, 2011] § 180.351 Qualification of IBCs. (a) General. (b) IBC specifications. [Amdt. 180-5, 59 FR 38079, July 26, 1994, as amended at 66 FR 45391, Aug. 28, 2001] § 180.352 Requirements for retest and inspection of IBCs. (a) General. (b) Test and inspections for metal, rigid plastic, and composite IBCs. (1) Each IBC intended to contain solids that are loaded or discharged under pressure or intended to contain liquids must be tested in accordance with the leakproofness test prescribed in § 178.813 of this subchapter prior to its first use in transportation and every 2.5 years thereafter, starting from the date of manufacture or the date of a repair conforming to paragraph (d)(1) of this section. For this test, the IBC is not required to have its closures fitted. (2) An external visual inspection must be conducted initially after production and every 2.5 years starting from the date of manufacture or the date of a repair conforming to paragraph (d)(1) of this section to ensure that: (i) The IBC is marked in accordance with requirements in § 178.703 of this subchapter. Missing or damaged markings, or markings difficult to read must be restored or returned to original condition. (ii) Service equipment is fully functional and free from damage which may cause failure. Missing, broken, or damaged parts must be repaired or replaced. (iii) The IBC is capable of withstanding the applicable design qualification tests. The IBC must be externally inspected for cracks, warpage, corrosion or any other damage which might render the IBC unsafe for transportation. An IBC found with such defects must be removed from service or repaired in accordance with paragraph (d) of this section. The inner receptacle of a composite IBC must be removed from the outer IBC body for inspection unless the inner receptacle is bonded to the outer body or unless the outer body is constructed in such a way (e.g., a welded or riveted cage) that removal of the inner receptacle is not possible without impairing the integrity of the outer body. Defective inner receptacles must be replaced in accordance with paragraph (d) of this section or the entire IBC must be removed from service. For metal IBCs, thermal insulation must be removed to the extent necessary for proper examination of the IBC body. (3) Each metal, rigid plastic and composite IBC must be internally inspected at least every five years to ensure that the IBC is free from damage and to ensure that the IBC is capable of withstanding the applicable design qualification tests. (i) The IBC must be internally inspected for cracks, warpage, and corrosion or any other defect that might render the IBC unsafe for transportation. An IBC found with such defects must be removed from hazardous materials service until restored to the original design type of the IBC. (ii) Metal IBCs must be inspected to ensure the minimum wall thickness requirements in § 178.705(c)(1)(iv) of this subchapter are met. Metal IBCs not conforming to minimum wall thickness requirements must be removed from hazardous materials service. (c) Visual inspection for flexible, fiberboard, or wooden IBCs. (1) The IBC is marked in accordance with requirements in § 178.703 of this subchapter. Additional marking allowed for each design type may be present. Required markings that are missing, damaged or difficult to read must be restored or returned to original condition. (2) Proper construction and design specifications have been met. (i) Each flexible IBC must be inspected to ensure that: (A) Lifting straps if used, are securely fastened to the IBC in accordance with the design type. (B) Seams are free from defects in stitching, heat sealing or gluing which would render the IBC unsafe for transportation of hazardous materials. All stitched seam-ends must be secure. (C) Fabric used to construct the IBC is free from cuts, tears and punctures. Additionally, fabric must be free from scoring which may render the IBC unsafe for transport. (ii) Each fiberboard IBC must be inspected to ensure that: (A) Fluting or corrugated fiberboard is firmly glued to facings. (B) Seams are creased and free from scoring, cuts, and scratches. (C) Joints are appropriately overlapped and glued, stitched, taped or stapled as prescribed by the design. Where staples are used, the joints must be inspected for protruding staple-ends which could puncture or abrade the inner liner. All such ends must be protected before the IBC is authorized for hazardous materials service. (iii) Each wooden IBC must be inspected to ensure that: (A) End joints are secured in the manner prescribed by the design. (B) IBC walls are free from defects in wood. Inner protrusions which could puncture or abrade the liner must be covered. (d) Requirements applicable to repair of IBCs. (i) The repaired IBC conforms to the original design type, is capable of withstanding the applicable design qualification tests, and is retested and inspected in accordance with the applicable requirements of this section; (ii) An IBC intended to contain liquids or solids that are loaded or discharged under pressure is subjected to a leakproofness test as specified in § 178.813 of this subchapter and is marked with the date of the test; and (iii) The IBC is subjected to the internal and external inspection requirements as specified in paragraph (b) of this section. (iv) The person performing the tests and inspections after the repair must durably mark the IBC near the manfacturer's UN design type marking to show the following: (A) The country in which the tests and inspections were performed; (B) The name or authorized symbol of the person performing the tests and inspections; and (C) The date (month, year) of the tests and inspections. (v) Retests and inspections performed in accordance with paragraphs (d)(1)(i) and (ii) of this section may be used to satisfy the requirements for the 2.5 and five year periodic tests and inspections required by paragraph (b) of this section, as applicable. (2) Except for flexible and fiberboard IBCs, the structural equipment of an IBC may be repaired and returned to service provided: (i) The repaired IBC conforms to the original design type and is capable of withstanding the applicable design qualification tests; and (ii) The IBC is subjected to the internal and external inspection requirements as specified in paragraph (b) of this section. (3) Service equipment may be replaced provided: (i) The repaired IBC conforms to the original design type and is capable of withstanding the applicable design qualification tests; (ii) The IBC is subjected to the external visual inspection requirements as specified in paragraph (b) of this section; and (iii) The proper functioning and leak tightness of the service equipment, if applicable, is verified. (e) Requirements applicable to routine maintenance of IBCs. (1) The country in which the routine maintenance was carried out; and (2) The name or authorized symbol of the party performing the routine maintenance. (f) Retest date. (g) Record retention. (2) Records must include design types and packaging specifications, test and inspection dates, name and address of test and inspection facilities, names or name of any persons conducting test or inspections, and test or inspection specifics and results. (3) Records must be kept for each packaging at each location where periodic tests are conducted, until such tests are successfully performed again or for at least 2.5 years from the date of the last test. These records must be made available for inspection by a representative of the Department on request. [Amdt. 180-5, 59 FR 38079, July 26, 1994, as amended at 64 FR 10782, Mar. 5, 1999; 65 FR 58632, Sept. 29, 2000; 66 FR 45186, 45391, Aug. 28, 2001; 68 FR 45042, July 31, 2003; 69 FR 76186, Dec. 20, 2004; 70 FR 34399, June 14, 2005; 70 FR 56099, Sept. 23, 2005; 71 FR 78635, Dec. 29, 2006] Subpart E—Qualification and Maintenance of Cargo Tanks § 180.401 Applicability. This subpart prescribes requirements, in addition to those contained in parts 107, 171, 172, 173 and 178 of this subchapter, applicable to any person responsible for the continuing qualification, maintenance or periodic testing of a cargo tank. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended at 55 FR 37065, Sept. 7, 1990] § 180.403 Definitions. In addition to the definitions contained in §§ 171.8, 178.320(a) and 178.345-1 of this subchapter, the following definitions apply to this subpart: Corroded or abraded Corrosive to the tank or valve Delivery hose assembly Modification (1) A change to motor vehicle equipment such as lights, truck or tractor power train components, steering and brake systems, and suspension parts, and changes to appurtenances, such as fender attachments, lighting brackets, ladder brackets; and (2) Replacement of components such as valves, vents, and fittings with a component of a similar design and of the same size. Owner Piping system Rebarrelling Repair (1) A change to motor vehicle equipment such as lights, truck or tractor power train components, steering and brake systems, and suspension parts, and changes to appurtenances, such as fender attachments, lighting brackets, ladder brackets; and (2) Replacement of components such as valves, vents, and fittings with a component of a similar design and of the same size. (3) Replacement of an appurtenance by welding to a mounting pad. Replacement of a barrel tank. tank, Stretching [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended at 55 FR 37065, Sept. 7, 1990; Amdt. 180-3, 57 FR 45466, Oct. 1, 1992; Amdt. 180-7, 59 FR 55177, Nov. 3, 1994; 60 FR 17402, Apr. 5, 1995; Amdt. 180-10, 61 FR 51342, Oct. 1, 1996; 63 FR 52850, Oct. 1, 1998; 64 FR 28050, May 24, 1999; 68 FR 19286, Apr. 18, 2003; 69 FR 54047, Sept. 7, 2004] § 180.405 Qualification of cargo tanks. (a) General. (b) Cargo tank specifications. (2) Exception. (i) Records are available verifying the cargo tank was originally manufactured to the specification; (ii) If the cargo tank was stretched, rebarrelled, or modified, records are available verifying that the stretching, rebarrelling, or modification was performed in accordance with the National Board Inspection Code and this part; (iii) A Design Certifying Engineer or Registered Inspector verifies the cargo tank conforms to all applicable requirements of the original specification and furnishes to the owner written documentation that verifies the tank conforms to the original structural design requirements in effect at the time the tank was originally constructed; (iv) The cargo tank meets all applicable tests and inspections required by § 180.407(c); and (v) The cargo tank is recertified to the original specification in accordance with the reporting and record retention provisions of § 180.417. The certification documents required by § 180.417(a)(3) must include both the date the cargo tank was originally certified to the specification and the date it was recertified. The specification plate on the cargo tank or the cargo tank motor vehicle must display the date the cargo tank was originally certified to the specification. (c) Cargo tank specifications no longer authorized for construction. (i) The cargo tank initial construction began on or before the date listed in table 1, column 2, as follows: Table 1 Column 1 Column 2 MC 300 Sept. 2, 1967 MC 301 June 12, 1961 MC 302, MC 303, MC 304, MC 305, MC 310, MC 311 Sept. 2, 1967 MC 330 May 15, 1967 (ii) The cargo tank was marked or certified before the date listed in table 2, column 2, as follows: Table 2 Column 1 Column 2 MC 306, MC 307, MC 312 Sept. 1, 1995 (2) A cargo tank of a specification listed in paragraph (c)(1) of this section may have its pressure relief devices and outlets modified as follows: (i) A Specification MC 300, MC 301, MC 302, MC 303, or MC 305 cargo tank, to conform with a Specification MC 306 or DOT 406 cargo tank (See §§ 178.346-3 and 178.346-4 of this subchapter). (ii) A Specification MC 306 cargo tank to conform to a Specification DOT 406 cargo tank (See §§ 178.346-3 and 178.346-4 of this subchapter). (iii) A Specification MC 304 cargo tank, to conform with a Specification MC 307 or DOT 407 cargo tank (See §§ 178.347-4 and 178.345-11 of this subchapter). (iv) A Specification MC 307 cargo tank, to conform with a Specification DOT 407 cargo tank (See §§ 178.347-4 and 178.345-11 of this subchapter). (v) A Specification MC 310 or MC 311 cargo tank, to conform with a Specification MC 312 or DOT 412 cargo tank (See §§ 178.348-4 and 178.345-11 of this subchapter). (vi) A Specification MC 312 cargo tank, to conform with a Specification DOT 412 cargo tank (See §§ 178.348-4 and 178.345-11 of this subchapter). (vii) A Specification MC 330 cargo tank, to conform with a Specification MC 331 cargo tank, except as specifically required by § 173.315 of this subchapter (see §§ 178.337-8 and 178.337-9 of this subchapter). (d) MC 338 cargo tank. (1) The holding time must be determined, as required in § 178.338-9 of this subchapter, on each cargo tank or on at least one cargo tank of each design. Any subsequent cargo tank manufactured to the same design type (see § 178.320), if not individually tested, must have the optional test regimen performed during the first shipment (see § 178.338-9 (b) and (c) of this subchapter). (2) The holding time determined by test for one authorized cryogenic liquid may be used as the basis for establishing the holding time for other authorized cryogenic liquids. (e) MC 331 cargo tanks. (f) MC 306, MC 307, MC 312 cargo tanks. (1) A cargo tank motor vehicle constructed after August 1, 1981, or the date specified in the applicable exemption, in conformance with the following conditions that apply, may be remarked and certified in accordance with paragraphs (f) (5) and (6) of this section: (i) A vacuum-loaded cargo tank must have an ASME Code stamped specification plate marked with a minimum internal design pressure of 25 psig, and be designed for a minimum external design pressure of 15 psig. (ii) An outlet equipped with a self-closing system which includes an external stop-valve must have the stop valve and associated piping protected within the vehicle's rear-end tank protection device, vehicle frame or an equally adequate accident damage protection device (See § 178.345-8 of this subchapter.) The self-closing system (See § 178.345-11 of this subchapter) must be equipped with a remotely actuated means of closure as follows: (A) For a cargo tank used in other than corrosive service, the remote means of closure must be activated for closure by manual or mechanical means and, in case of fire, by an automatic heat activated means. (B) For a cargo tank used in corrosive service, the remote means of closure may be actuated by manual or mechanical means only. (iii) A cargo tank having an unreinforced portion of the shell exceeding 60 inches must have the circumferential reinforcement located so that the thickness and tensile strength of shell material in combination with the frame and circumferential reinforcement produces a structural integrity at least equal to that prescribed in § 178.345-3 of this subchapter or the specification in effect at time of manufacture. (iv) A cargo tank having a projection from the tank shell or head that may contain lading in any tank position is authorized, provided such projection is as strong as the tank shell or head and is located within the motor vehicle's rear-end tank protection or other appropriate accident damage protection device. (v) A cargo tank may be constructed of nickel, titanium, or other ASME sheet or plate materials in accordance with an exemption. (2) A vacuum-loaded cargo tank constructed after August 1, 1981, or the date specified in the applicable exemption, in conformance with paragraph (f)(1) of this section, except that an outlet equipped with an external valve which is not part of a self-closing system: (i) Must be equipped with a self-closing system prior to September 1, 1993. (ii) May be remarked and certified in accordance with paragraphs (f)(5) and (6) of this section after the cargo tank motor vehicle has been equipped with the self-closing system. (3) A vacuum-loaded cargo tank constructed prior to August 1, 1981, in conformance with paragraph (f)(1) of this section, except for paragraph (f)(1)(i), may be remarked and certified in accordance with paragraphs (f) (5) and (6) of this section. (4) A vacuum-loaded cargo tank constructed prior to August 1, 1981, in conformance with paragraph (f)(1) of this section, except for paragraph (f)(1)(i) of this section, and except that an outlet is equipped with an external valve which is not part of a self-closing system: (i) Must be equipped with a self-closing system prior to September 1, 1993. (ii) May be remarked and certified in accordance with paragraphs (f)(5) and (6) of this section after the cargo tank motor vehicle has been equipped with the self-closing system. (5) The owner of a cargo tank for which a determination has been made that the cargo tank is in conformance with paragraph (f) (1), (2), (3), or (4) of this section shall complete a written certification, in English, signed by the owner and containing at least the following information: (i) A statement certifying that each cargo tank conforms to § 180.405 (f) (1), (2), (3), or (4); (ii) The applicable DOT exemption number, the applicable specification number and the owner's and manufacturer's serial number for the cargo tank; (iii) A statement setting forth any modifications made to bring the cargo tank into conformance with § 180.405(f) (1), (2), (3), or (4), or the applicable specification; (iv) A statement identifying the person certifying the cargo tank and the date of certification. (6) The owner of a certified cargo tank shall remove the exemption number stenciled on the cargo tank and shall durably mark the specification plate (or a plate placed adjacent to the specification plate) “MC + + + -E ****####” (where “ + + + ” is to be replaced by the applicable specification number, “* * * *” by the exemption number and “# # # #” by the alloy.) (7) A cargo tank remarked and certified in conformance with this paragraph (f) is excepted from the provisions of § 180.405(c). (8) During the period the cargo tank is in service, and for one year thereafter, the owner of a cargo tank that is certified and remarked in this manner must retain on file at its principal place of business a copy of the certificate and the last exemption in effect. (g) Cargo tank manhole assemblies. (2) On or before August 31, 1995, each owner of a cargo tank marked or certified before December 31, 1990, authorized for the transportation of a hazardous material, must have the cargo tank equipped with manhole assemblies conforming with § 178.345-5, except for the dimensional requirements in § 178.345-5(a), the hydrostatic testing requirements in § 178.345-5(b), and the marking requirements in § 178.345-5(e) of this subchapter. A manhole assembly meeting one of the following provisions is considered to be in compliance with this paragraph: (i) Manhole assemblies on MC 300, MC 301, MC 302, MC 303, MC 305, MC 306, MC 310, MC 311, and MC 312 cargo tanks that are marked or certified in writing as conforming to § 178.345-5 of this subchapter or TTMA RP No. 61-98 (incorporated by reference; see § 171.7 of this subchapter), or are tested and certified in accordance with TTMA TB No. 107 (incorporated by reference; see § 171.7 of this subchapter). (ii) Manhole assemblies on MC 304 and MC 307 cargo tanks. (iii) Manhole assemblies on MC 310, MC 311, and MC 312 cargo tanks with a test pressure of 36 psig or greater. (3) [Reserved] (h) Pressure relief system. (1) Until August 31, 1998, the owner of a cargo tank may replace a reclosing pressure relief device with a device which is in compliance with the requirements for pressure relief devices in effect at the time the cargo tank specification became superseded. If the pressure relief device is installed as an integral part of a manhole cover assembly, the manhole cover must comply with the requirements of paragraph (g) of this section. (2) After August 31, 1998, replacement for any reclosing pressure relief valve must be capable of reseating to a leak-tight condition after a pressure surge, and the volume of lading released may not exceed 1 L. Specific performance requirements for these pressure relief valves are set forth in § 178.345-10(b)(3) of this subchapter. (3) As provided in paragraph (c)(2) of this section, the owner of a cargo tank may elect to modify reclosing pressure relief devices to more recent cargo tank specifications. However, replacement devices constructed to the requirements of § 178.345-10 of this subchapter must provide the minimum venting capacity required by the original specification to which the cargo tank was designed and constructed. (i) Flammable cryogenic liquids. (j) Withdrawal of certification. (k) DOT-specification cargo tank with no marked design pressure or a marked design pressure of less than 3 psig. (l) MC 300, MC 301, MC 302, MC 303, MC 305, MC 306 cargo tank—Rear accident damage protection. (i) Was manufactured before July 1, 1989; (ii) Is used to transport gasoline or any other petroleum distillate product; and (iii) Is operated in combination with a cargo tank full trailer. However, an empty cargo tank truck, without a cargo tank full trailer attached, may be operated without the required rear bumper or rear-end tank protection device on a one-time basis while being transported to a repair facility for installation of a rear bumper or rear-end protection device. (2) Each cargo tank shall be provided with a rear accident damage protection device to protect the tank and piping in the event of a rear-end collision and reduce the likelihood of damage which could result in the loss of lading. The rear-end protection device must be in the form of a rear-end tank protection device meeting the requirements of § 178.345-8(d) or a rear bumper meeting the following: (i) The bumper shall be located at least 6 inches to the rear of any vehicle component used for loading or unloading or that may contain lading while the vehicle is in transit. (ii) The dimensions of the bumper shall conform to § 393.86 of this title. (iii) The structure of the bumper must be designed in accordance with § 178.345-8(d)(3) of this subchapter. (m) Specification MC 330, MC 331 cargo tank motor vehicles, and nonspecification cargo tank motor vehicles conforming to § 173.315(k) of this subchapter, intended for use in the transportation of liquefied compressed gases. (2) The requirement in paragraph (m)(1) of this section does not apply to a cargo tank equal to or less than 13,247.5 L (3,500 gallons) water capacity transporting in metered delivery service a Division 2.1 material, a Division 2.2 material with a subsidiary hazard, or anhydrous ammonia equipped with an off-truck remote shut-off device that was installed prior to July 1, 2000. The device must be capable of stopping the transfer of lading by operation of a transmitter carried by a qualified person attending unloading of the cargo tank. The device is subject to the requirement in § 177.840(o) of this subchapter for a daily test at 45.72 meters (150 feet). (3) Each specification MC 330 and MC 331 cargo tank in metered delivery service of greater than 13,247.5 L (3,500 gallons) water capacity transporting a Division 2.1 material, a Division 2.2 material with a subsidiary hazard, or anhydrous ammonia, marked and certified before July 1, 1999, must have an emergency discharge control capability as specified in §§ 173.315(n) and 177.840 of this subchapter no later than the date of its first scheduled pressure test after July 1, 2001, or July 1, 2003, whichever is earlier. (n) Thermal activation. (o) On-truck remote control of self-closing stop valves—MC 330, MC 331, and MC 338. (1) Each owner of an MC 330 or MC 331 cargo tank motor vehicle marked or certified before January 1, 1995, must equip the cargo tank with an on-vehicle remote means of closure of the internal self-closing stop valve in conformance with § 178.337-8(a)(4) of this subchapter. This requirement does not apply to cargo tanks used only for carbon dioxide and marked “For carbon dioxide only” or intended for use in chlorine service only. (2) Each owner of an MC 338 cargo tank motor vehicle marked or certified before January 1, 1995, must equip each remotely controlled shutoff valve with an on-vehicle remote means of automatic closure in conformance with § 178.338-11(c) of this subchapter. This requirement does not apply to cargo tanks used for the transportation of argon, carbon dioxide, helium, krypton, neon, nitrogen, or xenon, or mixtures thereof. [Amdt. 180-2, 54 FR 25032, June 12, 1989] Editorial Note: For Federal Register www.govinfo.gov. § 180.407 Requirements for test and inspection of specification cargo tanks. (a) General. (2) Except during a pressure test, a cargo tank may not be subjected to a pressure greater than its design pressure or MAWP. (3) A person witnessing or performing a test or inspection specified in this section must meet the minimum qualifications prescribed in § 180.409. (4) Each cargo tank must be evaluated in accordance with the acceptable results of tests and inspections prescribed in § 180.411. (5) Each cargo tank which has successfully passed a test or inspection specified in this section must be marked in accordance with § 180.415. (6) A cargo tank which fails a prescribed test or inspection must: (i) Be repaired and retested in accordance with § 180.413; or (ii) Be removed from hazardous materials service and the specification plate removed, obliterated or covered in a secure manner. (7) The use of video cameras or fiber optic equipment is authorized for any test or inspection, or portion thereof, provided all the required areas and elements can be viewed and evaluated in accordance with this subpart. (b) Conditions requiring test and inspection of cargo tanks. (1) The cargo tank shows evidence of dents, cuts, gouges, corroded or abraded areas, leakage, or any other condition that might render it unsafe for hazardous materials service. At a minimum, any area of a cargo tank showing evidence of dents, cuts, digs, gouges, or corroded or abraded areas must be thickness tested in accordance with the procedures set forth in paragraphs (i)(2), (i)(3), (i)(5), (i)(6), (i)(9), and (i)(10) of this section and evaluated in accordance with the criteria prescribed in § 180.411. Any signs of leakage must be repaired in accordance with § 180.413. The suitability of any repair affecting the structural integrity of the cargo tank must be determined either by the testing required in the applicable manufacturing specification or in paragraph (g)(1)(iv) of this section. (2) The cargo tank has sustained damage to an extent that may adversely affect its lading retention capability. A damaged cargo tank must be pressure tested in accordance with the procedures set forth in paragraph (g) of this section. (3) The cargo tank has been out of hazardous materials transportation service for a period of one year or more. Each cargo tank that has been out of hazardous materials transportation service for a period of one year or more must be pressure tested in accordance with § 180.407(g) prior to further use. (4) [Reserved] (5) The Department so requires based on the existence of probable cause that the cargo tank is in an unsafe operating condition. (c) Periodic test and inspection. Compliance Dates—Inspections and Test Under § 180.407( c Test or inspection Date by which first test Interval External Visual Inspection: All cargo tanks designed to be loaded by vacuum with full opening rear heads September 1, 1991 6 months. All other cargo tanks September 1, 1991 1 year. Internal Visual Inspection: All insulated cargo tanks, except MC 330, MC 331, MC 338 (see Note 4) September 1, 1991 1 year. 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 dedicated propane service constructed of nonquenched and tempered NQT SA-612 steel (see Note 5) 10 years. 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 and lined, except MC 338 September 1, 1991 1 year. All cargo tanks designed to be loaded by vacuum with full opening rear heads September 1, 1992 2 years. 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 dedicated propane service constructed of nonquenched and tempered NQT SA-612 steel (See Note 5) 10 years. All other cargo tanks September 1, 1995 5 years. Thickness Test: All unlined cargo tanks transporting material corrosive to the tank, except MC 338 September 1, 1992 2 years. Note 1: Note 2: Note 3: Note 4: Note 5: (d) External visual inspection and testing. (1) Where insulation precludes a complete external visual inspection as required by paragraphs (d)(2) through (d)(6) of this section, the cargo tank also must be given an internal visual inspection in accordance with paragraph (e) of this section. If external visual inspection is precluded because any part of the cargo tank wall is externally lined, coated, or designed to prevent an external visual inspection, those areas of the cargo tank must be internally inspected. If internal visual inspection is precluded because the cargo tank is lined, coated, or designed so as to prevent access for internal inspection, the tank must be hydrostatically or pneumatically tested in accordance with paragraph (g)(1)(iv) of this section. Those items able to be externally inspected must be externally inspected and noted in the inspection report. (2) The external visual inspection and testing must include as a minimum the following: (i) The tank shell and heads must be inspected for corroded or abraded areas, dents, distortions, defects in welds and any other conditions, including leakage, that might render the tank unsafe for transportation service; (ii) The piping, valves, and gaskets must be carefully inspected for corroded areas, defects in welds, and other conditions, including leakage, that might render the tank unsafe for transportation service; (iii) All devices for tightening manhole covers must be operative and there must be no evidence of leakage at manhole covers or gaskets; (iv) All emergency devices and valves including self-closing stop valves, excess flow valves and remote closure devices must be free from corrosion, distortion, erosion and any external damage that will prevent safe operation. Remote closure devices and self-closing stop valves must be functioned to demonstrate proper operation; (v) Missing bolts, nuts and fusible links or elements must be replaced, and loose bolts and nuts must be tightened; (vi) All markings on the cargo tank required by parts 172, 178 and 180 of this subchapter must be legible; (vii) [Reserved] (viii) All major appurtenances and structural attachments on the cargo tank including, but not limited to, suspension system attachments, connecting structures, and those elements of the upper coupler (fifth wheel) assembly that can be inspected without dismantling the upper coupler (fifth wheel) assembly must be inspected for any corrosion or damage which might prevent safe operation; (ix) For cargo tanks transporting lading corrosive to the tank, areas covered by the upper coupler (fifth wheel) assembly must be inspected at least once in each two year period for corroded and abraded areas, dents, distortions, defects in welds, and any other condition that might render the tank unsafe for transportation service. The upper coupler (fifth wheel) assembly must be removed from the cargo tank for this inspection. (3) All reclosing pressure relief valves must be externally inspected for any corrosion or damage which might prevent safe operation. All reclosing pressure relief valves on cargo tanks carrying lading corrosive to the valve must be removed from the cargo tank for inspection and testing. Each reclosing pressure relief valve required to be removed and tested must be tested according to the requirements set forth in paragraph (j) of this section. (4) Ring stiffeners or other appurtenances, installed on cargo tanks constructed of mild steel or high-strength, low-alloy steel, that create air cavities adjacent to the tank shell that do not allow for external visual inspection must be thickness tested in accordance with paragraphs (i)(2) and (i)(3) of this section, at least once every 2 years. At least four symmetrically distributed readings must be taken to establish an average thickness for the ring stiffener or appurtenance. If any thickness reading is less than the average thickness by more than 10%, thickness testing in accordance with paragraphs (i)(2) and (i)(3) of this section must be conducted from the inside of the cargo tank on the area of the tank wall covered by the appurtenance or ring stiffener. (5) Corroded or abraded areas of the cargo tank wall must be thickness tested in accordance with the procedures set forth in paragraphs (i)(2), (i)(3), (i)(5), (i)(6), (i)(9), and (i)(10) of this section. (6) The gaskets on any full opening rear head must be: (i) Visually inspected for cracks or splits caused by weather or wear; and (ii) Replaced if cuts or cracks which are likely to cause leakage, or are of a depth one-half inch or more, are found. (7) The inspector must record the results of the external visual examination as specified in § 180.417(b). (e) Internal visual inspection. (2) The internal visual inspection must include as a minimum the following: (i) The tank shell and heads must be inspected for corroded and abraded areas, dents, distortions, defects in welds, and any other condition that might render the tank unsafe for transportation service. (ii) Tank liners must be inspected as specified in § 180.407(f). (3) Corroded or abraded areas of the cargo tank wall must be thickness tested in accordance with paragraphs (i)(2), (i)(3), (i)(5), (i)(6), (i)(9), and (i)(10) of this section. (4) The inspector must record the results of the internal visual inspection as specified in § 180.417(b). (f) Lining inspection. (1) Rubber (elastomeric) lining must be tested for holes as follows: (i) Equipment must consist of: (A) A high frequency spark tester capable of producing sufficient voltage to ensure proper calibration; (B) A probe with an “L” shaped 2.4 mm (0.09 inch) diameter wire with up to a 30.5 cm (12-inch) bottom leg (end bent to a 12.7 mm (0.5 inch) radius), or equally sensitive probe; and (C) A steel calibration coupon 30.5 cm × 30.5 cm (12 inches × 12 inches) covered with the same material and thickness as that to be tested. The material on the coupon shall have a test hole to the metal substrate made by puncturing the material with a 22 gauge hypodermic needle or comparable piercing tool. (ii) The probe must be passed over the surface of the calibration coupon in a constant uninterrupted manner until the hole is found. The hole is detected by the white or light blue spark formed. (A sound lining causes a dark blue or purple spark.) The voltage must be adjusted to the lowest setting that will produce a minimum 12.7 mm (0.5 inch) spark measured from the top of the lining to the probe. To assure that the setting on the probe has not changed, the spark tester must be calibrated periodically using the test calibration coupon, and the same power source, probe, and cable length. (iii) After calibration, the probe must be passed over the lining in an uninterrupted stroke. (iv) Holes that are found must be repaired using equipment and procedures prescribed by the lining manufacturer or lining installer. (2) Linings made of other than rubber (elastomeric material) must be tested using equipment and procedures prescribed by the lining manufacturer or lining installer. (3) Degraded or defective areas of the cargo tank liner must be removed and the cargo tank wall below the defect must be inspected. Corroded areas of the tank wall must be thickness tested in accordance with paragraphs (i)(2), (i)(3), (i)(5) and (i)(6) of this section. (4) The inspector must record the results of the lining inspection as specified in § 180.417(b). (g) Pressure test. (1) Test Procedure (ii) All self-closing pressure relief valves, including emergency relief vents and normal vents, must be removed from the cargo tank for inspection and testing according to the requirements in paragraph (j) of this section. (iii) Except for cargo tanks carrying lading corrosive to the tank, areas covered by the upper coupler (fifth wheel) assembly must be inspected for corroded and abraded areas, dents, distortions, defects in welds, and any other condition that might render the tank unsafe for transportation service. The upper coupler (fifth wheel) assembly must be removed from the cargo tank for this inspection. (iv) Each cargo tank must be tested hydrostatically or pneumatically to the internal pressure specified in the following table. At no time during the pressure test may a cargo tank be subject to pressures that exceed those identified in the following table: Table 1 to Paragraph (g)(1)(iv) Specification Test pressure MC 300, 301, 302, 303, 305, 306 The test pressure on the name plate or specification plate, 20.7 kPa (3 psig) or design pressure, whichever is greater. MC 304, 307 The test pressure on the name plate or specification plate, 275.8 kPa (40 psig) or 1.5 times the design pressure, whichever is greater. MC 310, 311, 312 The test pressure on the name plate or specification plate, 20.7 kPa (3 psig) or 1.5 times the design pressure, whichever is greater. MC 330, 331 The test pressure on the name plate or specification plate, 1.5 times either the MAWP or the re-rated pressure, whichever is applicable. MC 338 The test pressure on the name plate or specification plate, 1.25 times either the MAWP or the re-rated pressure, whichever is applicable. DOT 406 The test pressure on the name plate or specification plate, 34.5 kPa (5 psig) or 1.5 times the MAWP, whichever is greater. DOT 407 The test pressure on the name plate or specification plate, 275.8 kPa (40 psig) or 1.5 times the MAWP, whichever is greater. DOT 412 The test pressure on the name plate or specification plate, or 1.5 times the MAWP, whichever is greater. (v) [Reserved] (vi) Each cargo tank of a multi-tank cargo tank motor vehicle must be tested with the adjacent cargo tanks empty and at atmospheric pressure. (vii) All closures except pressure relief devices must be in place during the test. All prescribed loading and unloading venting devices rated at less than test pressure may be removed during the test. If retained, the devices must be rendered inoperative by clamps, plugs, or other equally effective restraining devices. Restraining devices may not prevent detection of leaks or damage the venting devices and must be removed immediately after the test is completed. (viii) Hydrostatic test method. (ix) Pneumatic test method. (2) When testing an insulated cargo tank, the insulation and jacketing need not be removed unless it is otherwise impossible to reach test pressure and maintain a condition of pressure equilibrium after test pressure is reached, or the vacuum integrity cannot be maintained in the insulation space. If an MC 338 cargo tank used for the transportation of a flammable gas or oxygen, refrigerated liquid is opened for any reason, the cleanliness must be verified prior to closure using the procedures contained in § 178.338-15 of this subchapter. (3) Each MC 330 and MC 331 cargo tank constructed of quenched and tempered steel in accordance with Part UHT in Section VIII of the ASME Code (IBR, see § 171.7 of this subchapter), or constructed of other than quenched and tempered steel but without postweld heat treatment, used for the transportation of anhydrous ammonia or any other hazardous materials that may cause corrosion stress cracking, must be internally inspected by the wet fluorescent magnetic particle method immediately prior to and in conjunction with the performance of the pressure test prescribed in this section. Each MC 330 and MC 331 cargo tank constructed of quenched and tempered steel in accordance with Part UHT in Section VIII of the ASME Code and used for the transportation of liquefied petroleum gas must be internally inspected by the wet fluorescent magnetic particle method immediately prior to and in conjunction with the performance of the pressure test prescribed in this section. The wet fluorescent magnetic particle inspection must be in accordance with Section V of the ASME Code and CGA Technical Bulletin TB-2 (IBR, see § 171.7 of this subchapter). This paragraph does not apply to cargo tanks that do not have manholes. (See § 180.417(c) for reporting requirements.) (4) All pressure bearing portions of a cargo tank heating system employing a medium such as, but not limited to, steam or hot water for heating the lading must be hydrostatically pressure tested at least once every 5 years. The test pressure must be at least the maximum system design operating pressure and must be maintained for five minutes. A heating system employing flues for heating the lading must be tested to ensure against lading leakage into the flues or into the atmosphere. (5) Exceptions. (ii) Pressure testing is not required for uninsulated lined cargo tanks, with a design pressure or MAWP of 15 psig or less, which receive an external visual inspection and a lining inspection at least once each year. (6) Acceptance criteria. (i) The heating system remains in place and is structurally sound and no lading may leak into the heating system, and (ii) The specification plate heating system information is changed to indicate that the cargo tank has no working heating system. (7) The inspector must record the results of the pressure test as specified in § 180.417(b). (h) Leakage test. (1) Each cargo tank must be tested for leaks in accordance with paragraph (c) of this section. The leakage test must include testing product piping with all valves and accessories in place and operative, except that any venting devices set to discharge at less than the leakage test pressure must be removed or rendered inoperative during the test. All internal or external self-closing stop valves must be tested for leak tightness. Each cargo tank of a multi-cargo tank motor vehicle must be tested with adjacent cargo tanks empty and at atmospheric pressure. Test pressure must be maintained for at least 5 minutes. Cargo tanks in liquefied compressed gas service must be externally inspected for leaks during the leakage test. Suitable safeguards must be provided to protect personnel should a failure occur. Cargo tanks may be leakage tested with hazardous materials contained in the cargo tank during the test. Leakage test pressure must be no less than 80% of MAWP marked on the specification plate except as follows: (i) A cargo tank with an MAWP of 690 kPa (100 psig) or more may be leakage tested at its maximum normal operating pressure provided it is in dedicated service or services; or (ii) An MC 330 or MC 331 cargo tank in dedicated liquified petroleum gas service may be leakage tested at not less than 414 kPa (60 psig). (iii) An operator of a specification MC 330 or MC 331 cargo tank, and a nonspecification cargo tank authorized under § 173.315(k) of this subchapter, equipped with a meter may check leak tightness of the internal self-closing stop valve by conducting a meter creep test. (See appendix B to this part.) (iv) An MC 330 or MC 331 cargo tank in dedicated service for anhydrous ammonia may be leakage tested at not less than 414 kPa (60 psig). (v) A non-specification cargo tank required by § 173.8(d) of this subchapter to be leakage tested, must be leakage tested at not less than 16.6 kPa (2.4 psig), or as specified in paragraph (h)(2) of this section. (2) Cargo tanks used to transport petroleum distillate fuels that are equipped with vapor collection equipment may be leak tested in accordance with the Environmental Protection Agency's “Method 27—Determination of Vapor Tightness of Gasoline Delivery Tank Using Pressure-Vacuum Test,” as set forth in Appendix A to 40 CFR part 60. Test methods and procedures and maximum allowable pressure and vacuum changes are in 40 CFR 63.425(e). The hydrostatic test alternative, using liquid in Environmental Protection Agency's “Method 27—Determination of Vapor Tightness of Gasoline Delivery Tank Using Pressure-Vacuum Test,” may not be used to satisfy the leak testing requirements of this paragraph. The test must be conducted using air. (3) A cargo tank that fails to retain leakage test pressure may not be returned to service as a specification cargo tank, except under conditions specified in § 180.411(d). (4) After July 1, 2000, Registered Inspectors of specification MC 330 and MC 331 cargo tanks, and nonspecification cargo tanks authorized under § 173.315(k) of this subchapter must visually inspect the delivery hose assembly and piping system while the assembly is under leakage test pressure utilizing the rejection criteria listed in § 180.416(g). Delivery hose assemblies not permanently attached to the cargo tank motor vehicle may be inspected separately from the cargo tank motor vehicle. In addition to a written record of the inspection prepared in accordance with § 180.417(b), the Registered Inspector conducting the test must note the hose identification number, the date of the test, and the condition of the hose assembly and piping system tested. (5) The inspector must record the results of the leakage test as specified in § 180.417(b). (i) Thickness testing. (2) Measurements must be made using a device capable of accurately measuring thickness to within ±0.002 of an inch. (3) Any person performing thickness testing must be trained in the proper use of the thickness testing device used in accordance with the manufacturer's instruction. (4) Thickness testing must be performed in the following areas of the cargo tank wall, as a minimum: (i) Areas of the tank shell and heads and shell and head area around any piping that retains lading; (ii) Areas of high shell stress such as the bottom center of the tank; (iii) Areas near openings; (iv) Areas around weld joints; (v) Areas around shell reinforcements; (vi) Areas around appurtenance attachments; (vii) Areas near upper coupler (fifth wheel) assembly attachments; (viii) Areas near suspension system attachments and connecting structures; (ix) Known thin areas in the tank shell and nominal liquid level lines; and (x) Connecting structures joining multiple cargo tanks of carbon steel in a self-supporting cargo tank motor vehicle. (5) Minimum thicknesses for MC 300, MC 301, MC 302, MC 303, MC 304, MC 305, MC 306, MC 307, MC 310, MC 311, and MC 312 cargo tanks are determined based on the definition of minimum thickness found in § 178.320(a) of this subchapter. The following Tables I and II identify the “In-Service Minimum Thickness” values to be used to determine the minimum thickness for the referenced cargo tanks. The column headed “Minimum Manufactured Thickness” indicates the minimum values required for new construction of DOT 400 series cargo tanks, found in Tables I and II of §§ 178.346-2, 178.347-2, and 178.348-2 of this subchapter. In-Service Minimum Thicknesses for MC 300, MC 301, MC 302, MC 303, MC 304, MC 305, MC 306, MC 307, MC 310, MC 311, and MC 312 cargo tanks are based on 90 percent of the manufactured thickness specified in the DOT specification, rounded to three places. Table I—In-Service Minimum Thickness for MC 300, MC 303, MC 304, MC 306, MC 307, MC 310, MC 311, and MC 312 Specification Cargo Tanks Constructed of Steel and Steel Alloys Minimum manufactured thickness (US gauge or inches) Nominal decimal equivalent for (inches) In-service minimum thickness reference (inches) 19 0.0418 0.038 18 0.0478 0.043 17 0.0538 0.048 16 0.0598 0.054 15 0.0673 0.061 14 0.0747 0.067 13 0.0897 0.081 12 0.1046 0.094 11 0.1196 0.108 10 0.1345 0.121 9 0.1495 0.135 8 0.1644 0.148 7 0.1793 0.161 3/16 0.1875 0.169 1/4 0.2500 0.225 5/16 0.3125 0.281 3/8 0.3750 0.338 Table II—In-Service Minimum Thickness for MC 301, MC 302, MC 304, MC 305, MC 306, MC 307, MC 311, and MC 312 Specification Cargo Tanks Constructed of Aluminum and Aluminum Alloys Minimum manufactured thickness In-service minimum thickness (inches) 0.078 0.070 0.087 0.078 0.096 0.086 0.109 0.098 0.130 0.117 0.141 0.127 0.151 0.136 0.172 0.155 0.173 0.156 0.194 0.175 0.216 0.194 0.237 0.213 0.270 0.243 0.360 0.324 0.450 0.405 0.540 0.486 (6) An owner of a cargo tank that no longer conforms to the minimum thickness prescribed for the design as manufactured may use the cargo tank to transport authorized materials at reduced maximum weight of lading or reduced maximum working pressure, or combinations thereof, provided the following conditions are met: (i) A Design Certifying Engineer must certify that the cargo tank design and thickness are appropriate for the reduced loading conditions by issuance of a revised manufacturer's certificate, and (ii) The cargo tank motor vehicle's nameplate must reflect the revised service limits. (7) An owner of a cargo tank that no longer conforms with the minimum thickness prescribed for the specification may not return the cargo tank to hazardous materials service. The tank's specification plate must be removed, obliterated or covered in a secure manner. (8) The inspector must record the results of the thickness test as specified in § 180.417(b). (9) For MC 331 cargo tanks constructed before October 1, 2003, minimum thickness shall be determined by the thickness indicated on the U1A form minus any corrosion allowance. For MC 331 cargo tanks constructed after October 1, 2003, the minimum thickness will be the value indicated on the specification plate. If no corrosion allowance is indicated on the U1A form then the thickness of the tank shall be the thickness of the material of construction indicated on the UIA form with no corrosion allowance. (10) For 400-series cargo tanks, minimum thickness is calculated according to tables in each applicable section of this subchapter for that specification: § 178.346-2 for DOT 406 cargo tanks, § 178.347-2 for DOT 407 cargo tanks, and § 178.348-2 for DOT 412 cargo tanks. (j) Pressure vent bench test. (1) Each self-closing pressure relief valve must open and reseat to a leaktight condition at the pressures prescribed for the applicable cargo tank specification or at the following pressures: (i) For MC 306 cargo tanks: (A) With MC 306 reclosing pressure relief valves, it must open at not less than 3 psi and not more than 4.4 psi and must reseat to a leak tight-condition at no less than 2.7 psi. (B) With reclosing pressure relief valves modified as provided in § 180.405(c) to conform with DOT 406 specifications, according to the pressures set forth for a DOT 406 cargo tank in § 178.346-3 of this subchapter. (ii) For MC 307 cargo tanks: (A) With MC 307 reclosing pressure relief valves, it must open at not less than the cargo tank MAWP and not more than 110% of the cargo tank MAWP and must reseat to a leak tight-condition at no less than 90% of the cargo tank MAWP. (B) With reclosing pressure relief valves modified as provided in § 180.405(c) to conform with DOT 407 specifications, according to the pressures set forth for a DOT 407 cargo tank in § 178.347-4 of this subchapter. (iii) For MC 312 cargo tanks: (A) With MC 312 reclosing pressure relief valves, it must open at not less than the cargo tank MAWP and not more than 110% of the cargo tank MAWP and must reseat to a leak tight-condition at no less than 90% of the cargo tank MAWP. (B) With reclosing pressure relief valves modified as provided in § 180.405(c) to conform with DOT 412 specifications, according to the pressures set forth for a DOT 412 cargo tank in § 178.348-4 of this subchapter. (iv) For MC 330 or MC 331 cargo tanks, it must open at not less than the required set pressure and not more than 110% of the required set pressure and must reseat to a leak-tight condition at no less than 90% of the required set pressure. (v) For DOT 400-series cargo tanks, according to the pressures set forth for the applicable cargo tank specification in §§ 178.346-3, 178.347-4, and 178.348-4, respectively, of this subchapter. (vi) For cargo tanks not specified in this paragraph, it must open at not less than the required set pressure and not more than 110% of the required set pressure and must reseat to a leak-tight condition at no less than 90% of the required set pressure or the pressure prescribed for the applicable cargo tank specification. (2) Normal vents (1 psig vents) must be tested according to the testing criteria established by the valve manufacturer. (3) Self-closing pressure relief devices not tested or failing the tests in paragraph (j)(1) of this section must be repaired or replaced. [Amdt. 180-2, 54 FR 25032, June 12, 1989] Editorial Note: For Federal Register www.govinfo.gov. § 180.409 Minimum qualifications for inspectors and testers. (a) Except as otherwise provided in this section, any person performing or witnessing the inspections and tests specified in § 180.407(c) must— (1) Be registered with the Federal Motor Carrier Safety Administration in accordance with part 107, subpart F of this chapter, (2) Be familiar with DOT-specification cargo tanks and trained and experienced in use of the inspection and testing equipment needed, and (3) Have the training and experience required to meet the definition of “Registered Inspector” in § 171.8 of this chapter. (b) A person who only performs annual external visual inspections and leakage tests on a cargo tank motor vehicle, owned or operated by that person, with a capacity of less than 13,250 L (3,500 gallons) used exclusively for flammable liquid petroleum fuels, is not required to meet the educational and years of experience requirements set forth in the definition of “Registered Inspector” in § 171.8 of this subchapter. Although not required to meet the educational and years of experience requirements, a person who performs visual inspections or leakage tests or signs the inspection reports must have the knowledge and ability to perform such inspections and tests and must perform them as required by this subchapter, and must register with the Department as required by subpart F of part 107 of this chapter. (c) A person who performs only annual external visual inspections and leakage tests on a permanently mounted non-bulk tank, owned or operated by that person, for petroleum products as authorized by § 173.8(c) of this subchapter, is not required to be registered in accordance with subpart F of part 107 of this chapter. In addition the person who signs the inspection report required by § 180.417(b) of this subpart for such non-bulk tanks is not required to be registered. Although not required to register, a person who performs visual inspections or leakage tests or signs the inspection reports must have the knowledge and ability to perform such inspections and tests and must perform them as required by this subchapter. (d) A motor carrier or cargo tank owner who meets the requirements of paragraph (a) of this section may use an employee who is not a Registered Inspector to perform a portion of the pressure retest required by § 180.407(g). External and internal visual inspections must be accomplished by a Registered Inspector, but the hydrostatic or pneumatic pressure test, as set forth in § 180.407(g)(1)(viii) and (ix), respectively, may be done by an employee who is not a Registered Inspector provided that— (1) The employee is familiar with the cargo tank and is trained and experienced in the use of the inspection and testing equipment used; (2) The employer submits certification that such employee meets the qualification requirements to the Associate Administrator, Attn: (PHH-32), Pipeline and Hazardous Materials Safety Administration, Department of Transportation, East Building, 1200 New Jersey Avenue, SE., Washington, DC 20590; and (3) The employer retains a copy of the tester's qualifications with the documents required by § 180.417(b). [Amdt. 180-2, 55 FR 37069, Sept. 7, 1990, as amended by Amdt. 180-3, 56 FR 66287, Dec. 20, 1991; 57 FR 45466, Oct. 1, 1992; Amdt. 180-11, 62 FR 1217, Jan. 8, 1997; 66 FR 45391, Aug. 28, 2001; 68 FR 19288, Apr. 18, 2003; 70 FR 56100, Sept. 23, 2005; 72 FR 55697, Oct. 1, 2007] § 180.411 Acceptable results of tests and inspections. (a) Corroded or abraded areas. (b) Dents, cuts, digs and gouges. (1) For dents at welds or that include a weld, the maximum allowable depth is 1/2 1/10 (2) The minimum thickness remaining beneath a cut, dig, or gouge may not be less than that prescribed in the applicable specification. (c) Weld or structural defects. (d) Leakage. (e) Relief valves. (f) Liner integrity. (g) Pressure test. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended at 68 FR 75764, Dec. 31, 2003] § 180.413 Repair, modification, stretching, rebarrelling, or mounting of specification cargo tanks. (a) General. (1) Except as otherwise provided in this section, each repair, modification, stretching, or rebarrelling of a specification cargo tank must be performed by a repair facility holding a valid National Board Certificate of Authorization for use of the National Board “R” stamp and must be made in accordance with the edition of the National Board Inspection Code in effect at the time the work is performed. (i) Repairs, modifications, stretchings, and rebarrellings performed on non-ASME stamped specification cargo tanks may be performed by: (A) A cargo tank manufacturer holding a valid ASME Certificate of Authorization for the use of the ASME “U” stamp using the quality control procedures used to obtain the Certificate of Authorization; or (B) A repair facility holding a valid National Board Certificate of Authorization for use of the National Board “R” stamp using the quality control procedures used to obtain the Certificate of Authorization. (ii) A repair, modification, stretching, or rebarrelling of a non-ASME stamped cargo tank may be done without certification by an Authorized Inspector, completion of the R-1 form, or being stamped with the “R” stamp. (iii) A repair, as defined in § 180.403, of a DOT specification cargo tank used for the transportation of hazardous materials in the United States may be performed by a facility in Canada in accordance with the Transport Canada TDG Regulations (IBR, see § 171.7 of this subchapter) provided: (A) The facility holds a valid Certificate of Authorization from a provincial pressure vessel jurisdiction for repair; (B) The facility is registered in accordance with the Transport Canada TDG Regulations to repair the corresponding TC specification; and (C) All repairs are performed using the quality control procedures used to obtain the Certificate of Authorization. (2) Prior to each repair, modification, stretching, rebarrelling, or mounting, the cargo tank motor vehicle must be emptied of any hazardous material lading. In addition, cargo tank motor vehicles used to transport flammable or toxic lading must be sufficiently cleaned of residue and purged of vapors so any potential hazard is removed, including void spaces between double bulkheads, piping and vapor recovery systems. (3) Each person performing a repair, modification, stretching, rebarrelling or mounting of a DOT specification cargo tank must be registered in accordance with subpart F of part 107 of this chapter. (b) Repair. (1) DOT 406, DOT 407, and DOT 412 cargo tanks must be repaired in accordance with the specification requirements in effect at the time of repair; (2) MC 300, MC 301, MC 302, MC 303, MC 305, and MC 306 cargo tanks must be repaired in accordance with either the most recent revision of the original specification or with the DOT 406 specification in effect at the time of repair; (3) MC 304 and MC 307 cargo tanks must be repaired in accordance with either the most recent revision of the original specification or with the DOT 407 specification in effect at the time of repair; (4) MC 310, MC 311, and MC 312 cargo tanks must be repaired in accordance with either the most recent revision of the original specification or with the DOT 412 specification in effect at the time of repair; (5) MC 338 cargo tanks must be repaired in accordance with the specification requirements in effect at the time of repair; and (6) MC 330 and MC 331 cargo tanks must be repaired in accordance with the repair procedures described in CGA Technical Bulletin TB-2 (IBR, see § 171.7 of this subchapter) and the National Board Inspection Code (IBR, see § 171.7 of this subchapter). Each cargo tank having cracks or other defects requiring welded repairs must meet all inspection, test, and heat treatment requirements in § 178.337-16 of this subchapter in effect at the time of the repair, except that postweld heat treatment after minor weld repairs is not required. When a repair is made of defects revealed by the wet fluorescent magnetic particle inspection, including those repaired by grinding, the affected area of the cargo tank must again be examined by the wet fluorescent magnetic particle method after hydrostatic testing to assure that all defects have been removed. (c) Maintenance or replacement of piping, valves, hoses, or fittings. (1) After maintenance or replacement that does not involve welding on the cargo tank wall, the repaired or replaced piping, valve, hose, or fitting must be tested for leaks. This requirement is met when the piping, valve, hose, or fitting is tested after installation in accordance with § 180.407(h)(1). A hose may be tested before or after installation on the cargo tank. (2) After repair or replacement of piping, valves, or fittings that involves welding on the cargo tank wall, the cargo tank must be pressure tested in accordance with the applicable manufacturing specification or § 180.407(g)(1)(iv). In addition, the affected piping, valve, or fitting must be tested in accordance with paragraph (c)(1) of this section. (3) Hoses on cargo tanks in dedicated liquefied compressed gas, except carbon dioxide, service are excepted from these testing requirements, but must be tested in accordance with § 180.416(f). (d) Modification, stretching, or rebarrelling. (1) The design of the modified, stretched, or rebarrelled cargo tank motor vehicle must be certified in writing by a Design Certifying Engineer as meeting the structural integrity and accident damage protection requirements of the applicable specification. (2) Except as provided in paragraph (d)(2)(v) of this section, all new material and equipment affected by modification, stretching, or rebarrelling must meet the requirements of the specification in effect at the time such work is performed, and all applicable structural integrity requirements (§ 178.337-3, § 178.338-3, or § 178.345-3 of this subchapter). The work must conform to the requirements of the applicable specification as follows: (i) For specification MC 300, MC 301, MC 302, MC 303, MC 305 and MC 306 cargo tanks, the provisions of either specification MC 306 or DOT 406 until August 31, 1995 and, thereafter to specification DOT 406 only; (ii) For specification MC 304 and MC 307 cargo tanks, the provisions of either specification MC 307 or DOT 407 until August 31, 1995 and, thereafter to specification DOT 407 only; (iii) For specification MC 310, MC 311, and MC 312 cargo tanks, the provisions of either specification MC 312 or DOT 412 until August 31, 1995 and, thereafter to specification DOT 412 only; (iv) For specification MC 330 cargo tanks, the provisions of specification MC 331; and (v) For specification MC 338 cargo tanks, the provisions of specification MC 338. However, structural modifications to MC 338 cargo tanks authorized under § 180.405(d) may conform to applicable provisions of the ASME Code instead of specification MC 338, provided the structural integrity of the modified cargo tank is at least equivalent to that of the original cargo tank. (3) The person performing the modification, stretching, or rebarrelling must: (i) Have knowledge of the original design concept, particularly with respect to structural design analysis, material and welding procedures. (ii) Assure compliance of the rebuilt cargo tank's structural integrity, venting, and accident damage protection with the applicable specification requirements. (iii) Assure compliance with all applicable Federal Motor Carrier Safety Regulations for all newly installed safety equipment. (iv) Assure the suitability of each modification, stretching and rebarrelling that affects the lading retention capability of the cargo tank by performing the tests required in the applicable specification or § 180.407(g)(1)(iv). (v) Any modification that changes information displayed on the specification plate requires the installation of a supplemental specification plate, nameplate, or both containing the information that reflects the cargo tank as modified, stretched or rebarrelled. The plate must include the name of the person or facility doing the work, DOT registration number, date work is completed, retest information, and any other information that differs from the original plate. The supplemental plates must be installed immediately adjacent to the existing plate or plates. (vi) On a variable specification cargo tank, install a supplemental or new variable specification plate, and replace the specification listed on the original specification plate with the words “see variable specification plate.” (4) A Registered Inspector must certify that the modified, stretched, or rebarrelled cargo tank conforms to the requirements of this section and the applicable specification by issuing a supplemental certificate of compliance. The registration number of the Registered Inspector must be entered on the certificate. (e) Mounting of cargo tanks. (1) Performed as required by paragraph (d)(2) of this section and certified by a Design Certifying Engineer if the mounting of a cargo tank on a motor vehicle chassis involves welding on the cargo tank head or shell or any change or modification of the methods of attachment; or (2) In accordance with the original specification for attachment to the chassis or the specification for attachment to the chassis in effect at the time of the mounting, and performed under the supervision of a Registered Inspector if the mounting of a cargo tank on a motor vehicle chassis does not involve welding on the cargo tank head or shell or a change or modification of the methods of attachment. (f) Records. [68 FR 19288, Apr. 18, 2003; 68 FR 52372, Sept. 3, 2003, as amended at 68 FR 75764, Dec. 31, 2003; 82 FR 15897, Mar. 30, 2017] § 180.415 Test and inspection markings. (a) Each cargo tank successfully completing the test and inspection requirements contained in § 180.407 must be marked as specified in this section. (b) Each cargo tank must be durably and legibly marked, in English, with the date (month and year) and the type of test or inspection performed, subject to the following provisions: (1) The date must be readily identifiable with the applicable test or inspection. (2) The markings must be in letters and numbers at least 32 mm (1.25 inches) high, near the specification plate or anywhere on the front head. (3) The type of test or inspection may be abbreviated as follows: (i) V for external visual inspection and test; (ii) I for internal visual inspection; (iii) P for pressure test; (iv) L for lining inspection; (v) T for thickness test; and (vi) K for leakage test for a cargo tank tested under § 180.407, except § 180.407(h)(2); and (vii) K-EPA27 for a cargo tank tested under § 180.407(h)(2) after October 1, 2004. Examples to paragraph (b). The markings “10-99 P, V, L” represent that in October 1999 a cargo tank passed the prescribed pressure test, external visual inspection and test, and the lining inspection. The markings “2-00 K-EPA27” represent that in February 2000 a cargo tank passed the leakage test under § 180.407(h)(2). The markings “2-00 K, K-EPA27” represent that in February 2000 a cargo tank passed the leakage test under both § 180.407(h)(1) and under EPA Method 27 in § 180.407(h)(2). (c) For a cargo tank motor vehicle composed of multiple cargo tanks constructed to the same specification, which are tested and inspected at the same time, one set of test and inspection markings may be used to satisfy the requirements of this section. For a cargo tank motor vehicle composed of multiple cargo tanks constructed to different specifications, which are tested and inspected at different intervals, the test and inspection markings must appear in the order of the cargo tank's corresponding location, from front to rear. [Amdt. 180-2, 56 FR 27879, June 17, 1991, as amended by Amdt. 180-3, 56 FR 66287, Dec. 20, 1991; 57 FR 45466, Oct. 1, 1992; Amdt. 180-6, 59 FR 49135, Sept. 26, 1994; Amdt. 180-10, 61 FR 51343, Oct. 1, 1996; 68 FR 19290, Apr. 18, 2003; 68 FR 52372, Sept. 3, 2003] § 180.416 Discharge system inspection and maintenance program for cargo tanks transporting liquefied compressed gases. (a) Applicability. (b) Hose identification. (c) Post-delivery hose check. (d) Monthly inspections and tests. (2) The operator must visually inspect the piping system at least once each calendar month the cargo tank is in service. The inspection must include fusible elements and all components of the piping system, including bolts, connections, and seals. (3) At least once each calendar month a cargo tank is in service, the operator must actuate all emergency discharge control devices designed to close the internal self-closing stop valve to assure that all linkages operate as designed. appendix A to this part outlines acceptable procedures that may be used for this test. (4) The operator of a cargo tank must check the internal self-closing stop valve in the liquid discharge opening for leakage through the valve at least once each calendar month the cargo tank is in service. On cargo tanks equipped with a meter, the meter creep test as outlined in appendix B to this part or a test providing equivalent accuracy is acceptable. For cargo tanks that are not equipped with a meter, appendix B to this part outlines one acceptable method that may be used to check internal self-closing stop valves for closure. (5) The operator must note each inspection in a record. That record must include the inspection date, the name of the person performing the inspection, the hose assembly identification number, the manufacturer of the hose assembly, the date the hose was assembled and tested, and an indication that the delivery hose assembly and piping system passed or failed the tests and inspections. The operator must retain a copy of each test and inspection record at its principal place of business or where the vehicle is housed or maintained until the next test of the same type is successfully completed. (e) Annual hose leakage test. (f) New or repaired delivery hose assemblies. (1) The operator must visually examine the delivery hose assembly while it is under pressure. (2) Upon successful completion of the pressure test and inspection, the operator must assure that the delivery hose assembly is permanently marked with the month and year of the test. (3) After July 1, 2000, the operator must complete a record documenting the test and inspection, including the date, the signature of the inspector, the hose owner, the hose identification number, the date of original delivery hose assembly and test, notes of any defects observed and repairs made, and an indication that the delivery hose assembly passed or failed the tests and inspections. A copy of each test and inspection record must be retained by the operator at its principal place of business or where the vehicle is housed or maintained until the next test of the same type is successfully completed. (g) Rejection criteria. (i) Damage to the hose cover that exposes the reinforcement. (ii) Wire braid reinforcement that has been kinked or flattened so as to permanently deform the wire braid. (iii) Soft spots when not under pressure, bulging under pressure, or loose outer covering. (iv) Damaged, slipping, or excessively worn hose couplings. (v) Loose or missing bolts or fastenings on bolted hose coupling assemblies. (2) No operator may use a cargo tank with a piping system found to have any condition identified in this paragraph (g)(2) for unloading liquefied compressed gases. (i) Any external leak identifiable without the use of instruments. (ii) Bolts that are loose, missing, or severely corroded. (iii) Manual stop valves that will not actuate. (iv) Rubber hose flexible connectors with any condition outlined in paragraph (g)(1) of this section. (v) Stainless steel flexible connectors with damaged reinforcement braid. (vi) Internal self-closing stop valves that fail to close or that permit leakage through the valve detectable without the use of instruments. (vii) Pipes or joints that are severely corroded. [64 FR 28051, May 24, 1999, as amended at 78 FR 15330, Mar. 11, 2013] § 180.417 Reporting and record retention requirements. (a) Vehicle certification. (2) Each motor carrier who uses a specification cargo tank motor vehicle must obtain a copy of the manufacturer's certificate and related papers or the alternative report authorized by paragraph (a)(3)(i) or (ii) of this section and retain the documents as specified in this paragraph (a)(2). A motor carrier who is not the owner of a cargo tank motor vehicle must also retain a copy of the vehicle certification report for as long as the cargo tank motor vehicle is used by that carrier and for one year thereafter. The information required by this section must be maintained at the company's principal place of business or at the location where the vehicle is housed or maintained. The provisions of this section do not apply to a motor carrier who leases a cargo tank for less than 30 days. (3) DOT Specification cargo tanks Non-ASME Code stamped cargo tanks (ii) ASME Code Stamped cargo tanks. (b) Test or inspection reporting. (1) Each test or inspection report must include the following information: (i) Owner's and manufacturer's unique serial number for the cargo tank; (ii) Name of cargo tank manufacturer; (iii) Cargo tank DOT or MC specification number; (iv) MAWP of the cargo tank; (v) Minimum thickness of the cargo tank shell and heads when the cargo tank is thickness tested in accordance with § 180.407(d)(5), § 180.407(e)(3), § 180.407(f)(3), or § 180.407(i); (vi) Indication of whether the cargo tank is lined, insulated, or both; and (vii) Indication of special service of the cargo tank (e.g., transports material corrosive to the tank, dedicated service, etc.) (2) Each test or inspection report must include the following specific information as appropriate for each individual type of test or inspection: (i) Type of test or inspection performed; (ii) Date of test or inspection (month and year); (iii) Listing of all items tested or inspected, including information about pressure relief devices that are removed, inspected and tested or replaced, when applicable (type of device, set to discharge pressure, pressure at which device opened, pressure at which device re-seated, and a statement of disposition of the device (e.g., reinstalled, repaired, or replaced)); information regarding the inspection of upper coupler assemblies, when applicable (visually examined in place, or removed for examination); and, information regarding leakage and pressure testing, when applicable (pneumatic or hydrostatic testing method, identification of the fluid used for the test, test pressure, and holding time of test); (iv) Location of defects found and method of repair; (v) ASME or National Board Certificate of Authorization number of facility performing repairs, if applicable; (vi) Name and address of person performing test; (vii) Registration number of the facility or person performing the test; (viii) Continued qualification statement, such as “cargo tank meets the requirements of the DOT specification identified on this report” or “cargo tank fails to meet the requirements of the DOT specification identified on this report”; (ix) DOT registration number of the registered inspector; and (x) Dated signature of the registered inspector and the cargo tank owner. (3) The owner and the motor carrier, if not the owner, must each retain a copy of the test and inspection reports until the next test or inspection of the same type is successfully completed. This requirement does not apply to a motor carrier leasing a cargo tank for fewer than 30 days. (c) Additional requirements for Specification MC 330 and MC 331 cargo tanks. (i) Carrier's name, address of principal place of business, and telephone number; (ii) Complete identification plate data required by Specification MC 330 or MC 331, including data required by ASME Code; (iii) Carrier's equipment number; (iv) A statement indicating whether or not the tank was stress relieved after fabrication; (v) Name and address of the person performing the test and the date of the test; (vi) A statement of the nature and severity of any defects found. In particular, information must be furnished to indicate the location of defects detected, such as in weld, heat-affected zone, the liquid phase, the vapor phase, or the head-to-shell seam. If no defect or damage was discovered, that fact must be reported; (vii) A statement indicating the methods employed to make repairs, who made the repairs, and the date they were completed. Also, a statement of whether or not the tank was stress relieved after repairs and, if so, whether full or local stress relieving was performed; (viii) A statement of the disposition of the cargo tank, such as “cargo tank scrapped” or “cargo tank returned to service”; and (ix) A statement of whether or not the cargo tank is used in anhydrous ammonia, liquefied petroleum gas, or any other service that may cause stress corrosion cracking. Also, if the cargo tank has been used in anhydrous ammonia service since the last report, a statement indicating whether each shipment of ammonia was certified by its shipper as containing 0.2 percent water by weight. (2) A copy of the report must be retained by the carrier at its principal place of business during the period the cargo tank is in the carrier's service and for one year thereafter. Upon a written request to, and with the approval of, the Field Administrator, Regional Service Center, Federal Motor Carrier Safety Administration for the region in which a motor carrier has its principal place of business, the carrier may maintain the reports at a regional or terminal office. (3) The requirement in paragraph (c)(1) of this section does not apply to a motor carrier leasing a cargo tank for less than 30 days. (d) Supplying certificates and reports. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended at 55 FR 21038, May 22, 1990; 55 FR 37069, Sept. 7, 1990; 56 FR 27879, June 17, 1991; 58 FR 12905, Mar. 8, 1993; Amdt. 180-2, 59 FR 1786, Jan. 12, 1994; Amdt. 180-10, 61 FR 51343, Oct. 1, 1996; 63 FR 52850, Oct. 1, 1998; 64 FR 28052, May 24, 1999; 65 FR 50463, Aug. 18, 2000; 67 FR 61016, Sept. 27, 2002; 68 FR 19290, Apr. 18, 2003; 68 FR 52372, Sept. 3, 2003; 69 FR 54047, Sept. 7, 2004; 70 FR 34077, June 13, 2005; 76 FR 43532, July 20, 2011; 85 FR 75717, Nov. 25, 2020] Subpart F—Qualification and Maintenance of Tank Cars Source: Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, unless otherwise noted. § 180.501 Applicability. (a) This subpart prescribes requirements, in addition to those contained in parts 107, 171, 172, 173, 174, and 179 of this subchapter, applicable to any person who manufactures, fabricates, marks, maintains, repairs, inspects, or services tank cars to ensure continuing qualification. (b) This subpart also establishes the minimum acceptable framework for an owner's qualification program for tank cars and components. Owners should follow this subpart in developing their written procedures (work instructions), as required under § 179.7(d), for use by tank car facility employees. The owner's qualification program for each tank car, or a fleet of tank cars, must identify where to inspect, how to inspect, and the acceptance criteria. Alternative inspection and test procedures or intervals based on a damage-tolerance analysis or service reliability assessment must be approved by the Associate Administrator for Railroad Safety in accordance with 180.509(l). Tank car facilities must incorporate the owner's qualification program in their quality assurance program, as required under § 179.7(a)(2), (b)(3), (b)(5), and (d). (c) Any person who performs a function prescribed in this part shall perform that function in accordance with this part. (d) Where, in this subpart, a person is required to make documents available to FRA upon request, such request means that credentialed FRA personnel or an authorized representative of the Department may view the documents and make copies of them. The document owner's may seek confidential treatment of the documents presented. See § 105.30. [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as amended by Amdt. 179-50, 61 FR 33256, June 26, 1996; 77 FR 37986, June 25, 2012] § 180.503 Definitions. The following definitions and those contained in §§ 171.8 and 179.2 of this subchapter apply: Coating/lining owner Corrosive to the tank or service equipment Defects Design level of reliability and safety Inspection and test Interior heater system Maintenance Modification Objectively reasonable and articulable belief Qualification, Qualification of Tests and inspections § 180.509 (*) Tank Visual Inspection d Structural Integrity Inspection e Thickness Test: Note 1 f Safety System Inspection h Service Equipment Service Equipment k Coating/lining Internal Coatings and Linings i Note 1: Subparagraph (f)(2) may require thickness tests at an interval different from the other items for qualification of the tank. Railworthy, Railworthiness Reactive to the tank or service equipment Reinforced tank shell butt weld Reinforcing pad Reliability Representation Safety system Service equipment Service equipment owner Tank car owner Tank car tank [77 FR 37986, June 25, 2012, as amended at 81 FR 35546, June 2, 2016; 89 FR 52994, June 24, 2024] § 180.505 Quality assurance program. The quality assurance program requirements of § 179.7 of this subchapter apply. § 180.507 Qualification of tank cars. (a) Each tank car marked as meeting a “DOT” specification or any other tank car used for the transportation of a hazardous material must meet the requirements of this subchapter or the applicable specification to which the tank was constructed. (b)(1) Tank cars prescribed in the following table are no longer authorized for construction but may remain in hazardous materials service provided they conform to all applicable safety requirements of this subchapter: Table 1 to Paragraph ( b Specification prescribed in the current regulations Other specifications permitted Notes 105A200W 105A100W 1 105A200ALW 105A100ALW 1 Note 1 to Table 1 to paragraph (b)(1): Tanks built as Specification DOT 105A100W or DOT 105A100ALW may be altered and converted to DOT 105A200W and DOT 105A200ALW, respectively. (2) [Reserved] (3) Specification DOT-113A175W, DOT-113C60W, DOT-113D60W, and DOT-113D120W tank cars may continue in use, but new construction is not authorized. (4) Class DOT 105A and 105S tank cars used to transport hydrogen chloride, refrigerated liquid under the terms of DOT-E 3992 may continue in service, but new construction is not authorized. (5) Specification DOT-103A-ALW, 103AW, 103ALW, 103ANW, 103BW, 103CW, 103DW, 103EW, and 104W tank cars may continue in use, but new construction is not authorized. [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as amended at 68 FR 48572, Aug. 14, 2003; 77 FR 37987, June 25, 2012; 87 FR 79785, Dec. 27, 2022] § 180.509 Requirements for inspection and test of specification tank cars. (a) General. (1) Inspects and tests each item according to the requirements specified in this section; (2) Evaluates each item according to the acceptable results of inspections and tests specified in § 180.511; (3) Marks each tank car as specified in § 180.515 that is qualified to transport hazardous materials; (4) Prepares the documentation as required by § 180.517 for each item qualified under this section. A copy of the documentation required by § 180.517 must be sent to the owner as appropriate and according to the owner's instructions. (b) Conditions requiring qualification of tank cars. (1) The tank car shows evidence of abrasion, corrosion, cracks, dents, distortions, defects in welds, or any other condition that may make the tank car unsafe for transportation, (2) The tank car was in an accident and shows evidence of damage to an extent that may adversely affect its capability to retain its contents or to otherwise remain railworthy. (3) The tank bears evidence of damage caused by fire. (4) The Associate Administrator for Railroad Safety, FRA, requires it based on the existence of an objectively reasonable and articulable belief 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. (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 § 173.319(e) of this subchapter. (3) Fusion welded tank cars must be inspected and tested to be qualified and maintained in accordance with the following table. All qualification requirements need not be done at the same 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 definitions at § 180.503) See § 180.509(i). J Leakage pressure test After reassembly. K Service equipment (including pressure relief device) See § 180.509(k). (d) Visual inspection. (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, and for DOT 115 class tank cars, an internal inspection of the inner container and external inspection of the outer shell and heads for defects in welds, or any other condition that may make the tank car unsafe for transportation; (2) When an internal coating or lining, head protection, insulation, or thermal protection is removed in part or in whole, the internal and external exposed surface of the tank must be visually inspected for defects in welds or any other condition that may make the tank car unsafe for transportation, and this inspection must precede any application or reapplication of a coating or lining; (3) An inspection of the service equipment, including gaskets, for indications of corrosion and other conditions that may make the tank car unsafe for transportation; (4) An inspection for missing or loose bolts, nuts, or elements that may make the tank car unsafe for transportation; (5) An inspection of all closures on the tank car for conditions that may make the tank car unsafe for transportation, including an inspection of the protective housings for proper condition; (6) An inspection of excess flow valves with threaded seats for tightness; and (7) An inspection of the required markings on the tank car for legibility. (e) Structural integrity inspections and tests. (i) All transverse fillet welds greater than 0.64 cm (0.25 inch) within 121.92 cm (4 feet) of the bottom longitudinal centerline except body bolster pad attachment welds; (ii) The termination of longitudinal fillet welds greater than 0.64 cm (0.25 inch) within 121.92 cm (4 feet) of the bottom longitudinal centerline; and (iii) The tank shell butt welds within 60.96 cm (2 feet) of the bottom longitudinal centerline, unless the tank car owner can determine by analysis (e.g., finite element analysis, damage-tolerance analysis, or service reliability assessment) that the structure will not develop defects that reduce the design level of safety and reliability or fail within its operational life or prior to the next required inspection. The owner must maintain all documentation used to make such determination at its principal place of business and make the data available to FRA or an authorized representative of the Department upon request. (2) For DOT 115 class tanks, paragraphs (e)(1)(i) through (iii) of this section apply only to the outer shell fillet welds and to the non-reinforced exposed outer shell butt welds. (3) The inspection requirements of paragraph (e)(1)(iii) of this section do not apply to reinforced tank shell butt welds until the time of lining removal or application for tank cars with an internal lead, glass, or rubber lining. (4) Each tank car facility must inspect and test the elements identified in paragraph (e)(1) of this section by one or more of the following methods: (i) Dye penetrant testing (PT); (ii) Radiographic examination (RT); (iii) Magnetic particle testing (MT); (iv) Ultrasonic testing (UT); and (v) Direct, remote, or enhanced visual inspection, using, for example, magnifiers, fiberscopes, borescopes, and/or machine vision technology (VT). (f) Thickness tests. i.e. (2) The tank car owner must ensure that each tank car has a thickness test measurement: (i) At the time of an internal coating or lining application or replacement, or (ii) At least once every ten (10) years for a tank that does not have an internal coating or lining, or (iii) At least once every five (5) years for a tank that does not have an internal coating or lining when: (A) The tank is used to transport a material that is corrosive or reactive to the tank (see Appendix D of this part) or service equipment as defined § 180.503, and (B) The remaining shell and head thickness is tested and determined to be at or below line C in Figure A of this paragraph. Where: A. As-built tank shell or head thickness with additional thickness. B. Required minimum tank shell or head thickness after forming per part 179. C. Inspection frequency adjustment point (design minimum shell or head thickness, minus 1/2 D. Condemning limit for general corrosion (required minimum shell or head thickness, minus the value in paragraph (g) of this section). E. Condemning limit for localized corrosion (required minimum shell or head thickness, minus the table value in paragraph (g) of this section, minus 1.58 mm ( 1/16 F. Allowable shell or head thickness reduction (table value in paragraph (g) of this section). G. Additional thickness reduction for localized areas in paragraph (g) of this section. (3) For a localized repair of an internal coating or lining where a material corrosive to the tank or service equipment as defined § 180.503 has contacted the tank, a qualified individual must verify the coating or lining's conformance with paragraph (g) of this section by measuring the shell or head in the area of the repair. The thickness test applies only to the non-lined or coated repaired area, and is not a qualification event. Modification of the tank stencil is not required. (4) Operation of a tank car below the condemning limit for general corrosion or the condemning limit for localized corrosion (as shown in Figure A of this section) is prohibited. (5) For sumps, protective housing ( i.e. (6) After repairs, alterations, conversions, modifications, or blasting of tank car that results in a reduction of the tank's thickness, and anytime a tank car coating or lining is removed, a qualified individual must measure the thickness of the tank in the area of reduced thickness to ensure that the thickness of the tank conforms to paragraph (g) of this section. (g) Service life thickness allowance. Allowable Shell Thickness Reductions Marked tank test pressure Top shell and tank head Bottom shell 60 psig <200 psig 3.17 mm 1 8 1.58 mm. 1 16 ≥200 psig 0.79 mm 1 32 0.79 mm. 1 32 Note 1. A tank car owner may add an extra 1.58 mm ( 1/16 Note 2. Any reduction in the tank car shell thickness may not affect the structural strength of the tank car to the extent that the tank car no longer conforms to the applicable provisions of Section 6.2 of the AAR Specifications for Tank Cars (IBR, see § 171.7 of this subchapter). Note 3. For DOT 115 class tank cars, shell thickness reductions apply only to the outer shell of the tank car. There is no shell or head thickness reduction authorized for the inner tank. (2) [Reserved] (h) Safety system inspections. (i) Internal coating and lining inspection and test. (2) The owner of the internal coating or lining must establish and maintain a record of the service life of the coating or lining and commodity combination, that is, the specific hazardous materials that were loaded into a tank and the coating or lining in place at the time of loading. The owner of the internal coating or lining must use its knowledge of the service life of each coating or lining and commodity combination to establish an appropriate inspection interval for that coating or lining and commodity combination. This interval must not exceed eight (8) years, unless the coating or lining owner can establish, document, and show that the service history or scientific analysis of the coating or lining and commodity pairing supports a longer inspection interval. The owner must maintain at its principal place of business a written procedure for collecting and documenting the performance of the coating or lining applied within the tank car for its service life. The internal coating or lining owner must provide this documentation, including inspection and test, repair, removal, and application procedures, to the FRA or car owner upon request. Further, the offeror must provide commodity information to the car owner and the owner of the internal coating or lining upon request. (3) The owner of the internal coating or lining must provide the test method and acceptance criteria to the tank car owner and to the person responsible for qualifying the coating or lining. The tank car facility inspecting and testing the internal coating or lining must follow the inspection and test procedure, including the acceptance requirements, established by the internal coating or lining owner. (j) Leakage pressure test. (k) Service equipment inspection and test. (2) Each tank car facility must qualify service equipment, including reclosing pressure relief devices and interior heater systems in accordance with the applicable provisions of Appendix D of the AAR Specifications for Tank Cars (IBR, see § 171.7 of this subchapter). (l) Alternative inspection and test procedures. (m) Inspection and test compliance date for tank cars. i.e. (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. (3) For tank cars on a 20-year periodic hydrostatic pressure test interval ( i.e. [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; 68 FR 75765, Dec. 31, 2003; 71 FR 54398, Sept. 14, 2006; 77 FR 37987, June 25, 2012] § 180.511 Acceptable results of inspections and tests. Provided it conforms to other applicable requirements of this subchapter, a tank car is qualified for use if it successfully passes the inspections and tests set forth below conducted in accordance with this subpart. A representation of that qualification must consist of marking the tank in accordance with § 180.515. (a) Visual inspection. (b) Structural integrity inspection and test. (c) Service life shell thickness. (d) Safety system inspection. (e) Lining and coating inspection. (f) Leakage pressure test. (g) Hydrostatic test. (h) Service equipment. [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as amended by Amdt. 179-50, 61 FR 33256, June 26, 1996; 66 FR 45187, Aug. 28, 2001; 77 FR 37990, June 25, 2012] § 180.513 Repairs, alterations, conversions, and modifications. (a) To work on tank cars, a tank car facility must comply with the applicable requirements of this subpart, the AAR Specifications for Tank Cars (IBR, see § 171.7 of this subchapter), and the owner's requirements. (b) Responsibilities of Tank Car Facility. (c) Unless the exterior tank car shell or interior tank car jacket has a protective coating, after a repair that requires the complete removal of the tank car jacket, the exterior tank car shell and the interior tank car jacket must have a protective coating applied to prevent the deterioration of the tank shell and tank jacket. Previously applied coatings that still provide effective protection need not be covered over. (d) After repair, replacement, or qualification of tank car service equipment, the tank service equipment must successfully pass the leak test prescribed in § 180.509(j). [77 FR 37990, June 25, 2012] § 180.515 Markings. (a) When a tank car passes the required inspection and test with acceptable results, the tank car facility must mark the date of the inspection and test and due date of the next inspection and test qualified on the tank car in accordance with the applicable provisions of Appendix C of the AAR Specifications for Tank Cars (IBR, see § 171.7 of this subchapter). When a tank car facility performs multiple inspections and tests at the same time, one date may be used to satisfy the requirements of this section. One date also may be shown when multiple inspections and tests have the same due date. Dates displayed on the “consolidated stencil” (see the applicable provisions of Appendix C of the AAR Specifications for Tank Cars) take precedence over dates modified, and not stenciled, pursuant to interval adjustments for service equipment, linings, and granted alternative inspection intervals. (b) Converted DOT 105, 109, 112, 114, or 120 class tank cars must have the new specification and conversion date permanently marked in letters and figures at least 0.95 cm (0.375 inch) high on the outside of the manway nozzle or the edge of the manway nozzle flange on the left side of the car. The marking may have the last numeral of the specification number omitted (e.g., “DOT 111A100W” instead of “DOT 111A100W1”). (c) When qualified within six months of installation and protected from deterioration, the test date marking of a reclosing pressure relief device is the installation date on the tank car. [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as amended by Amdt. 179-50, 61 FR 33256, June 26, 1996; 63 FR 52851, Oct. 1, 1998; 66 FR 45391, Aug. 28, 2001; 68 FR 75765, Dec. 31, 2003; 77 FR 37991, June 25, 2012; 85 FR 45030, July 24, 2020; 90 FR 26459, June 23, 2025] § 180.517 Reporting and record retention requirements. (a) Certification and representation. (b) Inspection and test reporting. (1) Type of inspection and test performed (a checklist is acceptable); (2) The results of each inspection and test performed; (3) Tank car reporting mark and number; (4) Tank car specification; (5) Inspection and test date (month and year); (6) Location and description of defects found and method used to repair each defect; (7) The name and address of the tank car facility and the name and signature of inspector; and (8) The unique code (station stencil) identifying the facility. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended at 68 FR 75765, Dec. 31, 2003; 77 FR 37991, June 25, 2012] § 180.519 Periodic retest and inspection of tank cars other than single-unit tank car tanks. (a) General. (b) Pressure test. (2) Each tank, except tanks built to specification DOT 107A, must also be subjected to interior air pressure test of at least 100 psig under conditions favorable to detection of any leakage. No leaks may appear. (3) Safety relief valves must be retested by air or gas, must start-to-discharge at or below the prescribed pressure and must be vapor tight at or above the prescribed pressure. (4) Rupture discs and fusible plugs must be removed from the tank and visually inspected. (5) Tanks must be retested as specified in Retest Table 1 of this paragraph (b)(5), and before returning to service after repairs involving welding or heat treatment: Retest Table 1 Specification Retest interval—years Minimum Retest Pressure relief valve Tank Pressure relief devices d Tank hydrostatic c Tank air test Start-to- Vapor tight 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 * * * * d a ( 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 b c d (6) The month and year of test, followed by a “V” if visually inspected as described in paragraph (c) of this section, must be plainly and permanently stamped into the metal of one head or chime of each tank with successful test results; for example, 01-90 for January 1990. On DOT 107A**** tanks, the date must be stamped into the metal of the marked end, except that if all tanks mounted on a car have been tested, the date may be stamped into the metal of a plate permanently applied to the bulkhead on the “A” end of the car. Dates of previous tests and all prescribed markings must be kept legible. (c) Visual inspection. (d) Written records. [Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as amended by Amdt. 179-50, 61 FR 33257, June 26, 1996; 65 FR 58633, Sept. 29, 2000; 66 FR 45187, 45392, Aug. 28, 2001; 68 FR 75765, Dec. 31, 2003] Subpart G—Qualification and Maintenance of Portable Tanks Source: 66 FR 33453, June 21, 2001, unless otherwise noted. § 180.601 Applicability. This subpart prescribes requirements, in addition to those contained in parts 107, 171, 172, 173, and 178 of this subchapter, applicable to any person responsible for the continuing qualification, maintenance or periodic retesting of a portable tank. § 180.603 Qualification of portable tanks. (a) Each portable tank used for the transportation of hazardous materials must be an authorized packaging. (b) To qualify as an authorized packaging, each portable tank must conform to the requirements of this subchapter and the applicable design specification to which the portable tank was constructed. (c) The following portable tanks are authorized for use provided they conform to all applicable safety requirements of this subchapter: 51, 56, 57, 60, IM 101, IM 102 and UN portable tanks. (d) A portable tank that also meets the definition of “container” in 49 CFR 450.3(a)(3) must conform to the requirements in parts 450 through 453 of this title for compliance with Annex II of the Convention for Safe Containers (CSC). (e) Exemption portable tanks based on DOT 51 portable tanks. § 180.605 Requirements for periodic testing, inspection, and repair of portable tanks. (a) A portable tank constructed in accordance with a DOT specification for which a test or inspection specified in this subpart has become due, must be tested or inspected prior to being returned for transportation. (b) Conditions requiring test and inspection of portable tanks. (1) The portable tank shows evidence of dents, corroded or abraded areas, leakage, or any other condition that might render it unsafe for transportation service. (2) The portable tank has been in an accident and has been damaged to an extent that may adversely affect its ability to retain the hazardous material. (3) The portable tank has been out of hazardous materials transportation service for a period of one year or more. (4) The portable tank has been modified from its original design specification. (5) The portable tank is in an unsafe operating condition. (c) Schedule for periodic inspections and tests. (1) Each IM or UN portable tank must be given an initial inspection and test before being placed into service, a periodic inspection and test at least once every 5 years, and an intermediate periodic inspection and test at least every 2.5 years following the initial inspection and the last 5 year periodic inspection and test. (2) Each Specification 51 portable tank must be given a periodic inspection and test at least once every five years. (3) Each Specification 56 or 57 portable tank must be given a periodic inspection and test at least once every 2.5 years. (4) Each Specification 60 portable tank must be given a periodic inspection and test at the end of the first 4-year period after the original test; at least once every 2 years thereafter up to a total of 12 years of service; and at least once annually thereafter. Retesting is not required on a rubber-lined tank except before each relining. (d) Intermediate periodic inspection and test. (e) Periodic inspection and test. (f) Exceptional inspection and test. (g) Internal and external examination. (1) The shell is inspected for pitting, corrosion, or abrasions, dents, distortions, defects in welds or any other conditions, including leakage, that might render the portable tank unsafe for transportation. The wall thickness must be verified by appropriate measurement if this inspection indicates a reduction of wall thickness; (2) The piping, valves, and gaskets are inspected for corroded areas, defects, and other conditions, including leakage, that might render the portable tank unsafe for filling, discharge or transportation; (3) Devices for tightening manhole covers are operative and there is no leakage at manhole covers or gaskets; (4) Missing or loose bolts or nuts on any flanged connection or blank flange are replaced or tightened; (5) All emergency devices and valves are free from corrosion, distortion and any damage or defect that could prevent their normal operation. Remote closure devices and self-closing stop-valves must be operated to demonstrate proper operation; (6) Required markings on the portable tank are legible and in accordance with the applicable requirements; and (7) The framework, the supports and the arrangements for lifting the portable tank are in satisfactory condition. (h) Pressure test procedures for specification 51, 56, 57, 60, IM or UN portable tanks. (2) Each Specification 60 portable tank must be retested by completely filling the tank with water or other liquid having a similar viscosity, the temperature of the liquid must not exceed 37.7 °C (100 °F) during the test, and applying a pressure of 60 psig. The portable tank must be capable of holding the prescribed pressure for at least 10 minutes without leakage, evidence of impending failure, or failure. All closures shall be in place while the test is made and the pressure shall be gauged at the top of the tank. Safety devices and/or vents shall be plugged during this test. (3) Each Specification IM or UN portable tank, except for UN portable tanks used for non-refrigerated and refrigerated liquefied gases, and all piping, valves and accessories, except pressure relief devices, must be hydrostatically tested with water, or other liquid of similar density and viscosity, to a pressure not less than 150% of its maximum allowable working pressure. UN portable tanks used for the transportation of non-refrigerated liquefied gases must be hydrostatically tested with water, or other liquid of similar density and viscosity, to a pressure not less than 130% of its maximum allowable working pressure. UN portable tanks used for the transportation of refrigerated liquefied gases may be tested hydrostatically or pneumatically using an inert gas to a pressure not less than 1.3 times the design pressure. For pneumatic testing, due regard for protection of all personnel must be taken because of the potential hazard involved in such a test. The pneumatic test pressure in the portable tank must be reached by gradually increasing the pressure to one-half of the test pressure. Thereafter, the test pressure must be increased in steps of approximately one-tenth of the test pressure until the required test pressure has been reached. The pressure must then be reduced to a value equal to four-fifths of the test pressure and held for a sufficient time to permit inspection of the portable tank for leaks. The minimum test pressure for a portable tank is determined on the basis of the hazardous materials that are intended to be transported in the portable tanks. For liquid, solid and non-refrigerated liquefied gases, the minimum test pressure for specific hazardous materials are specified in the applicable T Codes assigned to a particular hazardous material in the § 172.101 Table of this subchapter. While under pressure the tank shall be inspected for leakage, distortion, or any other condition which might render the tank unsafe for service. A portable tank fails to meet the requirements of the pressure test if, during the test, there is permanent distortion of the tank exceeding that permitted by the applicable specification; if there is any leakage; or if there are any deficiencies that would render the portable tank unsafe for transportation. Any portable tank that fails must be rejected and may not be used again for the transportation of a hazardous material unless the tank is adequately repaired, and, thereafter, a successful test is conducted in accordance with the requirements of this paragraph. An approval agency shall witness the hydrostatic or pneumatic test. Any damage or deficiency that might render the portable tank unsafe for service shall be repaired to the satisfaction of the witnessing approval agency. The repaired tank must be retested to the original pressure test requirements. Upon successful completion of the hydrostatic or pneumatic test, as applicable, the witnessing approval agency shall apply its name, identifying mark or identifying number in accordance with paragraph (k) of this section. (i) Rejection criteria. (j) Repair. (k) Inspection and test markings. (2) Each Specification DOT 51, 56, 57 or 60 portable tank must be durably and legibly marked, in English, with the date (month and year) of the most recent periodic retest. The marking must be placed on or near the metal certification plate and must be in accordance with § 178.3 of this subchapter. The letters and numerals must not be less than 3 mm (0.118 inches) high when on the metal certification plate, and 12 mm (0.47 inches) high when on the portable tank, except that a portable tank manufactured under a previously authorized specification may continue to be marked with smaller markings if originally authorized under that specification (for example, DOT Specification 57 portable tanks). (l) Record retention. (2) If the owner does not have the manufacturer's certificate required by the specification and the manufacturer's data report required by the ASME, the owner may contact the National Board for a copy of the manufacturer's data report, if the portable tank was registered with the National Board, or copy the information contained on the portable tanks specification plate and ASME Code data plates. [Amdt. 180-2, 54 FR 25032, June 12, 1989, as amended at 67 FR 15744, Apr. 3, 2002; 68 FR 45042, July 31, 2003; 74 FR 53189, Oct. 16, 2009; 82 FR 15897, Mar. 30, 2017; 83 FR 55811, Nov. 7, 2018; 87 FR 79785, Dec. 27, 2022] Appendix A to Part 180—Internal Self-closing Stop Valve Emergency Closure Test for Liquefied Compressed Gases 1. In performing this test, all internal self-closing stop valves must be opened. Each emergency discharge control remote actuator (on-truck and off-truck) must be operated to ensure that each internal self-closing stop valve's lever, piston, or other valve indicator has moved to the closed position. 2. On pump-actuated pressure differential internal valves, the three-way toggle valve handle or its cable attachment must be activated to verify that the toggle handle moves to the closed position. [64 FR 28052, May 24, 1999, as amended at 67 FR 15744, Apr. 3, 2002] Appendix B to Part 180—Acceptable Internal Self-closing Stop Valve Leakage Tests for Cargo Tanks Transporting Liquefied Compressed Gases For internal self-closing stop valve leakage testing, leakage is defined as any leakage through the internal self-closing valve or to the atmosphere that is detectable when the valve is in the closed position. On some valves this will require the closure of the pressure by-pass port. (a) Meter Creep Test. 1. An operator of a cargo tank equipped with a calibrated meter may check the internal self-closing stop valve for leakage through the valve seat using the meter as a flow measurement indicator. The test is initiated by starting the delivery process or returning product to the cargo tank through the delivery system. This may be performed at an idle. After the flow is established, the operator closes the internal self-closing stop valve and monitors the meter flow. The meter flow must stop within 30 seconds with no meter creep within 5 seconds after the meter stops. 2. On pump-actuated pressure differential internal self-closing stop valves, the valve must be closed with the remote actuator to assure that it is functioning. On other types of internal self-closing stop valves, the valve(s) may be closed using either the normal valve control or the discharge control system (e.g., remote). 3. Rejection criteria: Any detectable meter creep within the first five seconds after initial meter stoppage. (b) Internal Self-Closing Stop Valve Test. An operator of a cargo tank that is not equipped with a meter may check the internal self-closing stop valve(s) for leakage as follows: 1. The internal self-closing stop valve must be in the closed position. 2. All of the material in the downstream piping must be evacuated, and the piping must be returned to atmospheric temperature and pressure. 3. The outlet must be monitored for 30 seconds for detectable leakage. 4. Rejection criteria. Any detectable leakage is considered unacceptable. [64 FR 28052, May 24, 1999] Appendix C to Part 180—Eddy Current Examination With Visual Inspection for DOT 3AL Cylinders Manufactured of Aluminum Alloy 6351-T6 1. Examination Procedure. 2. Visual examinations. 3. Eddy Current Equipment. 4. Eddy Current Reference Ring. 1/3 5. Condemnation Criteria. 6. Examination equipment records. (i) Equipment manufacturer, model number and serial number. (ii) Probe description and unique identification (e.g., serial number, part number, etc.). 7. Eddy current examination reporting and record retention requirements. (i) Specification of each standard reference ring used to perform the eddy current examination. (ii) DOT specification or exemption number of the cylinder; manufacturer's name or symbol; owner's name or symbol, if present; serial number; and, date of manufacture. (iii) Name of test operator performing the eddy current examination. (iv) Date of eddy current examination. (vi) Acceptance/condemnation results (e.g., pass or fail). (vii) Retester identification number. 8. Personnel Qualification Requirements. 9. Training Records. [71 FR 51129, Aug. 29, 2006] Appendix D to Part 180—Hazardous Materials Corrosive to Tanks or Service Equipment This list contains materials identified either by proper shipping name in 49 CFR 172.101 or shipped under an “n.o.s.” shipping description that, under certain conditions, can corrode carbon steel tanks or service equipment at a rate that may reduce the design level of reliability and safety of the tank or equipment to an unsafe level before the next qualification. Materials identified on this list are considered corrosive to the tank or service equipment. While every effort was made to identify materials deemed corrosive to the tank or service equipment, owners and operators are cautioned that this list may not be inclusive. Tank car owners and operators are reminded of their duty to ensure that no in-service tank will deteriorate below the specified minimum thickness requirements in this subchapter. See § 180.509(f)(3). In addition, FRA states a tank car owner must designate an internal coating or lining appropriately based on its knowledge of the chemical and not rely simply on this list. Regarding future thickness tests, this list may also be modified based on an analysis of the test results by the car owner, the Department of Transportation, or the Association of American Railroads' Tank Car Committee. Hazardous Materials Table Proper Shipping Names (See § 172.101) Acetic acid, glacial or Acetic acid solution Aluminum chloride, solution Arsenic acid, liquid Arsenic acid, solid Butyric acid Ferric chloride, solution Fertilizer ammoniating solution ( Nitrogen fertilizer solution Fluoroboric acid Fluorosilicic acid Formaldehyde, solutions, flammable Formaldehyde, solutions Hydrobromic acid Hydrochloric acid Hydrochloric acid solution Hydrofluoric acid and Sulfuric acid mixtures Hydrofluoric acid Hydrogen peroxide and peroxyacetic acid mixtures, stabilized Hydrogen, peroxide, aqueous solutions Hydrogen peroxide, stabilized or Hypochlorite solutions Nitric acid Phenyl phosphorus dichloride Phenyl phosphorus thiodichloride Phosphoric acid solution Phosphoric acid, solid Phosphorus trichloride ( Phosphorus chloride Sodium chlorate Sodium chlorate, aqueous solution Sodium hydrosulfide Sulfur, molten Sulfuric acid Sulfuric acid, fuming Sulfuric acid, spent Zinc chloride, anhydrous Zinc chloride, solution Materials Transported Under an “N.O.S.” Description Benzoic acid (Environmentally hazardous substance, liquid, n.o.s., (RQ 5,000 pounds) Bisulphites, aqueous solution, n.o.s. (Ammonium bisulfide) Black liquor (Corrosive liquids, n.o.s. (contains sulfuric acid)) Calcium lignosulfonate (not regulated under this subchapter) Hexanoic acid (Corrosive liquids, n.o.s. (contains hexanoic acid)) Lignin liquor (not regulated under this subchapter) Lithium chloride (not regulated under this subchapter) Sodium polyacrylate (not regulated under this subchapter) Titanium sulfate solution (Corrosive liquids, n.o.s. (contains sulfuric acid)) White liquor (not regulated under this subchapter) [77 FR 37991, June 25, 2012]

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