Attachment_3_180.605_pages_822_thru_824.pdf

§ 180.601

Subpart G-Qualification and Maintenance of Portable

Tanks

Source: 66 FR 33453, June 21,2001, unless otherwise not ed.

§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 retest ing of a portable tank.

§180.603 Qualification of portable tanks.

(a) Each portable tank used for the tmnsportation of haz ardous materials must be an authorized packaging.

(b) To qualify as an authorized packaging, each portable tank must conform to the requirements of this subchap ter and the applicable design specification to which the portable tank was constructed.

(c) The following portable tanks are authorized for use pro vided they conform to all applicable safety requirements of this subchapter: 51, 56, 57, 60, 1M 101, 1M 102 and UN portable tanks.

(d) A portable tank that also meets the definition of "con tainer" in 49 CFR 450.3(a)(3) must conform to the re quirements 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. The owner of a portable tank constructed in accor dance with and used under an exemption issued prior to August 31, 1996, which was in conformance with the re quirements for Specification DOT 51 portable tanks with the exception of the location of fill and discharge outlets, shall examine the portable tank and its design to determine if it meets the outlet requirements in effect on October 1, 1996. If the owner determines that the por table tank is in compliance with all requirements of the DOT 51 specification, the exemption number stenciled on the portable tank shall be removed and the specifica tion plate (or a plate placed adjacent to the specification plate) shall be durably marked "DOT 51-E*****" (where ***** is to be replaced by the exemption number). Dur ing the period the portable tank is in service, and for one year thereafter, the owner of the portable tank must re tain on file, at its principal place of business, a copy of the last exemption in effect.

§180.605 Requirements for periodic testing, inspec tion 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 inspect ed prior to being returned for transportation.

(b) Conditions requiring test and inspection of portable tanks. Without regard to any other test or inspection re quirements, a Specification or UN portable tank must be tested and inspected in accordance with this section pri or to further use if any of the following conditions exist:

(1) The portable tank shows evidence of dents, corroded or abraded areas, leakage, or any other condition that might render it unsafe for transportation ser vice.

(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 materi als transportation service for a period of one year or more.

(4) The portable tank has been modified from its original design specification.

49 CFR Ch. 1 (11-10 Edition)

(5) The portable tank is in an unsafe operating condition based on the existence of probable cause.

(c) Schedule for periodic z:nspections and tests. Each Specifi cation portable tank must be tested and inspected in ac cordance with the following schedule:

(1) Each 1M 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 in spection 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 veal's.

(3) Each Specification 56 or 57 portable tank must be given a periodic inspection and test at least once ev ery 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. For 1M and UN portable tanks the intermediate 2.5 year periodic in spection and test must include at least an internal and external examination of the portable tank and its fit tings taking into account the hazardous materials in tended to be transported; a leakage test; and a test of the satisfactory operation of all service equipment. Sheath ing, thermal insulation, etc. need only be removed to the extent required for reliable appraisal of the condition of the portable tank. For portable tanks intended for the transportation of a single hazardous material, the inter nal examination may be waived if it is leakage tested in accordance with the procedures in paragraph (h) of this section prior to each filling, or if approved by the Associ ate Administrator. Portable tanks used for dedicated transportation of refrigerated liquefied gases that are not fitted with inspection openings are excepted from the internal inspection requirement.

(e) Periodic inspection and test. The 5 year periodic inspec tion and test must include an internal and external ex amination and, unless excepted, a pressure test as specified in this section. Sheathing, thermal insulation.

etc. need only to be removed to the extent required for reliable appraisal of the condition of the portable tank.

Except for DOT Specification 56 and 57 portable tanks.

reclosing pressure relief devices must be removed from the tank and tested separately unless they can be tested while installed on the portable tank. For portable tank3 where the shell and equipment have been pressure-test ed separately, after assembly they must be subjected to gether to a leakage test and effectively tested and inspected for corrosion. Portable tanks used for the transportation of refrigerated, liquefied gases are ex cepted from the requirement for internal inspection and the hydraulic pressure test during the 5-year periodic inspection and test, if the portable tanks were pressure tested to a minimum test pressure of 1.3 times the de sign pressure using an inert gas as prescribed in § 178.338--16(a) and (b) of this subchapter before put ting the portable tank into service initially and after any exceptional inspections and tests specified in paragraph

(f) of this section.

(f) Exceptional inspection and test. The exceptional inspec tion and test is necessary when a portable tank show5 evidence of damaged or corroded areas, or leakage. or other conditions that indicate a deficiency that could af fect the integrity of the portable tank. The extent of the exceptional inspection and test must depend on the amount of damage or deterioration of the portable tank.

Pipeline and Hazardous Materials Safety Administration, DOT § 180.605L:

It must include at least the inspection and a pressure

L L.: test according to paragraph (e) of this section. Pressure relief devices need not be tested or I'eplaced unless there is reason to believe the relief devices have been affected by the damage or deterioration.

L

(g) Internal and external examination. The internal and ex ternal examinations must ensure that:

(1) The shell is inspected for pitting, corrosion, or abra sions, dents, distortions, defects in welds or any oth er conditions, including leakage, that might render the portable tank unsafe for transportation;

(2) The piping, valves, and gaskets are inspected for cor roded 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 gas kets:

(4) Missing or loose bolts or nuts on any flanged connec tion or blank flange are replaced or tightened;

(5) All emergency devices and valves are free from corro sion, distortion and any damage or defect that could prevent their normal operation. Remote closure de vices 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 condi tion.

(h) Pressure test procedures for specification 51, 56, 57, 60, 1M or UN portable tanks.

I I

(1) Each Specification 57 portable tank must be leak tested by a minimum sustained air pressure of at least 3 psig applied to the entire tank. Each Specifi cation 51 or 56 portable tank must be tested a minimum pressure (air or hydrostatic) of at 2 psig or at least one and one-half times the design pressure (maximum allowable working pressure, or re-rated pressure) ofthe tank, whichever is greater.

The leakage test for portable tanks used for refriger ated liquefied gas must be performed at 90% of lVlAWP. Leakage tests for all other pOl'table tanks must be at a pressure of at least 25% of MAWP. Dur ing each air pressure test, the entire surface of all

I joints under pressure must be coated with or im mersed in a solution of soap and water, heavy oil, or other material suitable for the purpose of detecting

I leaks. The pressure must be held for a period of time sufficiently long to assure detection of leaks, but in no case less than five minutes. During the air or hy drostatic test, relief devices may be removed, but all the closure fittings must be in place and the relief de

I vice openings plugged. Lagging need not be removed

I from a lagged tank ifit is possible to maintain the re quired test pressure at constant temperature with the tank disconnected from the source of pressure.

L

(2) Each Specification 60 portable tank must be retested by completely filling the tank with water or other liq uid having a similar viscosity, the temperature of the liquid must not exceed 37. 7°C (lOO°F) during the test, and applying a pressure of 60 psig. The portable tank must be capable of holding the prescribed pres sure for at least 10 minutes without leakage. evi dence of impending failure, or failure. All closures shall be in place while the test is made and the pres sure shall be gauged at the top of the tank. Safety de vices and/or vents shall be plugged during this test.

L L

(3) Each Specification 1M 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 transporta tion of non-refrigerated liquefied gases must be hy drostatically tested with water, or other liquid of similar density and viscosity, to a pressure not less than 130% of its maximum allowable working pres sure. UN portable tanks used for the transportation of refrigerated liquefied gases may be tested hydro statically 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 I'eached 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 I'eached. 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 al'e intended to be trans ported in the portable tanks. For liquid, solid and non-refrigerated liquefied gases, the minimum test pressure for specific hazardous materials are speci fied in the applicable T Codes assigned to a particu lar hazardous material in the § 172.101 Table of this subchapter. While under pressure the tank shall be inspected for leakage, distortion, or any other condi tion 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. porta ble tank that fails must be rejected and may not be used again for the transportation of a hazardous ma terial unless the tank is adequately repaired, and, thereafter, a successful test is conducted in accor dance 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 suc cessful 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 sec tion.

(i) Rejection criteria. When evidence of any unsafe condition is discovered, the portable tank may not be returned to service until it has been repaired and the pressure test is repeated and passed.

(j) Repair. The repair of a portable tank is authorized, pro vided such repairs are made in accordance with the re quirements prescribed in the specification for the tank's original design and construction. In addition to any oth er provisions of the specification, no portable tank may be repaired so as to cause leakage or cracks or so as to increase the likelihood ofleakage or cracks near areas of stress concentration due to cooling metal shrinkage in welding operations, sharp fillets, reversal of stresses, or otherwise. No field welding may be done except to non pressure parts. Any cutting, burning or welding opera tions on the shell of an 1M or UN portable tank must be done with the approval of the approval agency and be done in accordance with the requirements of this sub chapter, taking into account the pressure vessel code

•I

180.appA used for the construction of the shelL A pressure test to the original test pressure must be performed after the work is completed.

(k) Inspection and test markings. (1) Each 1M or UN por table tank must be durably and legibly marked, in English. with the date (month and year) of the last pressure test, the identification markings of the ap proval agency witnessing the test, when required, and the date of the last visual inspection. The mark ing must be placed on or near the metal identifica tion plate, in letters and numerals of not less than 3 mm (0.118 inches) high when on the metal identifi cation plate, and 12 mm (0.47 inches) high when on the portable tank.

(2) Each Specification DOT 51, 56, 57 or 60 portable tank must be durably and legibly marked, in Eng lish, with the date (month and year) of the most re cent 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 let ters 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 un der a previously authorized specification may con tinue to be marked with smallel' markings if originally authorized under that specification (for example, DOT Specification 57 portable tanks).

(1) Record retention. The owner of each portable tank or his authorized agent shall retain a written record of the date and results of all required inspections and tests, in cluding an ASME manufacturer's date report, if applica ble, and the name and address of the person performing the inspection or test, in accordance with the applicable specification. The manufacturer's data report, including a certificate(s) signed by the manufacturer, and the au thorized design approval agency, as applicable, indicat ing compliance with the applicable specification of the portable tank, must be retained in the files of the owner, or his authorized agent, during the time that such por

49 CFR Ch. 1 (11-10 Edition) table tank is used for such service, except for Specifica tions 56 and 57 portable tanks.

ApPE:'iDIX A TO PART ISO-INTERNAL SELF-CLOSING STOP VALVE

EMERGENCY CLOSURE TEST FOR LIQUEFIED COMPRESSED GASES

l. In performing this test, all internal self-dosing 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 valw~.

the three-way toggle valve handle or its cable attachment must be activated to verify that the toggle handle moves the closed position.

ApPENDIX B TO PART lSf).-ACCEPTABLE I:><TERNAL SELF-CLOSI:\G STCl?

VALVE LEAKAGE TESTS FOR CARGO TANKS TRA:IISPORTING LIQlTFlL:

COMPRESSED GASES

For internal self-closing stop valve leakage testing, is defined as any leakage through the internal valve or to the atmosphere that is detectable when the "&:'-.--0 is in the closed position. On some valves this will require ::'-0 closure of the pressure by-pass port.

(a) },tleter Creep 'Test.

1. An operator of a cargo tank equipped with a calibrat,,_ meter may check the internal self-closing stop valve fe' leakage through the valve seat using the meter as a [:7.

measurement indicator. The test is initiated by .__ delivery process or returning product to the cargo tar":::

through the delivery system. This may be performed a:

•••••I

I ..

I ..

824 ~