180.509—Requirements for inspection and test of specification tank cars.
(a) General.
(1)
Each tank car facility shall evaluate a tank car according to the requirements specified in § 180.511.
(2)
Each tank car that successfully passes a periodic inspection and test must be marked as prescribed in § 180.515.
(3)
A written report as specified in § 180.517(b) must be prepared for each tank car that is inspected and tested under this section.
(b) Conditions requiring inspection and test of tank cars.
Without regard to any other periodic inspection and test requirements, a tank car must have an appropriate inspection and test according to the type of defect and the type of maintenance or repair performed if:
(1)
The tank car shows evidence of abrasion, corrosion, cracks, dents, distortions, defects in welds, or any other condition that makes the tank car unsafe for transportation. An example is if maintenance is performed to replace a fitting, then only a leakage pressure test needs to be performed.
(2)
The tank car was in an accident and damaged to an extent that may adversely affect its capability to retain its contents.
(4)
The Associate Administrator for Safety, FRA, requires it based on the existence of probable cause that a tank car or a class or design of tank cars may be in an unsafe operating condition.
(c) Frequency of inspection and tests.
Each tank car shall have an inspection and test according to the requirements of this paragraph.
(1)
For Class 107 tank cars and tank cars of riveted construction, the tank car must have a hydrostatic pressure test and visual inspection conforming to the requirements in effect prior to July 1, 1996, for the tank specification.
(3)
For fusion welded tank cars, each tank car must have an inspection and test in accordance with paragraphs (d) through (k) of this section.
(i)
For cars transporting materials not corrosive to the tank, every 10 years for the tank and service equipment (i.e., filling and discharge, venting, safety, heating, and measuring devices).
(ii)
For non-lined or non-coated tank cars transporting materials corrosive to the tank, an interval based on the following formula, but in no case shall the interval exceed 10 years for the tank and 5 years for service equipment:
Where:
i is the inspection and test interval.
t1 is the actual thickness.
t2 is the allowable minimum thickness under paragraph (g) of this section.
r is the corrosion rate per year.
(iii)
For lined or coated tank cars transporting a material corrosive to the tank, every 10 years for the tank, 5 years for the service equipment.
(A)
When a lining or coating is applied to protect the tank shell from the lading, the owner of the lining or coating shall determine the periodic inspection interval, test technique, and acceptance criteria for the lining or coating. The owner must maintain at its principal place of business all supporting documentation used to make such a determination, such as the lining or coating manufacturer's recommended inspection interval, test technique, and acceptance criteria. The supporting documentation must be made available to FRA upon request.
(B)
The owner of the lining or coating shall provide the periodic inspection interval, test technique, and acceptance criteria for the lining or coating to the person responsible for qualifying the lining and coating.
(d) Visual inspection.
At a minimum, each tank car facility must visually inspect the tank externally and internally as follows:
(1)
An internal inspection of the tank shell and heads for abrasion, corrosion, cracks, dents, distortions, defects in welds, or any other condition that makes the tank car unsafe for transportation, and except in the areas where insulation or a thermal protection system precludes it, an external inspection of the tank shell and heads for abrasion, corrosion, cracks, dents, distortions, defects in welds, or any other condition that makes the tank car unsafe for transportation;
(2)
An inspection of the piping, valves, fittings, and gaskets for indications of corrosion and other conditions that make the tank car unsafe for transportation;
(3)
An inspection for missing or loose bolts, nuts, or elements that make the tank car unsafe for transportation;
(4)
An inspection of all closures on the tank car for proper securement in a tool tight condition and an inspection of the protective housings for proper securement;
(e) Structural integrity inspections and tests.
At a minimum, each tank car facility shall inspect the tank car for structural integrity as specified in this section. The structural integrity inspection and test shall include all transverse fillet welds greater than 0.64 cm (0.25 inch) within 121.92 cm (4 feet) of the bottom longitudinal center line; the termination of longitudinal fillet welds greater than 0.64 cm (0.25 inch) within 121.92 cm (4 feet) of the bottom longitudinal center line; and all tank shell butt welds within 60.96 cm (2 feet) of the bottom longitudinal center line by one or more of the following inspection and test methods to determine that the welds are in proper condition:
(5)
Optically-aided visual inspection (e.g., magnifiers, fiberscopes, borescopes, and machine vision technology).
(f) Thickness tests.
(1)
Each tank car facility shall measure the thickness of the tank car shell, heads, sumps, domes, and nozzles on each tank car by using a device capable of accurately measuring the thickness to within ±0.05 mm (±0.002 inch).
(2)
After repairs, alterations, conversions or modifications of a tank car that result in a reduction to the tank car shell thickness, the tank car facility shall measure the thickness of the tank car shell in the area of reduced shell thickness to ensure that the shell thickness conforms to paragraph (g) of this section.
(g) Service life shell thickness allowance.
(1)
A tank car found with a shell thickness below the required minimum thickness after forming for its specification, as stated in part 179 of this subchapter, may continue in service if:
(i)
Construction of the tank car shell and heads is from carbon steel, stainless steel, aluminum, nickel, or manganese-molybdenum steel; and
(ii)
Any reduction in the required minimum thickness of the tank shell or head is not more than that provided in the following table:
| Damage type | Class DOT 103, 104, 111, and 115 tank cars | Class DOT 105, 109, 112, and 114 tank cars | ||
|---|---|---|---|---|
| Top shell and tank head | Bottom shell | Top shell and tank head | Bottom shell | |
| Corrosion | 3.17 mm (0.125 inch) | 1.58 mm (0.063 inch) | 0.79 mm (0.031 inch) | 0.79 mm (0.031 inch). |
| Corrosion and mechanical | 3.17 mm (0.125 inch) | 1.58 mm (0.063 inch) | 0.79 mm (0.031 inch) | 0.79 mm (0.031 inch). |
| Corrosion, local | 4.76 mm (0.188 inch) | 3.17 mm (0.125 inch) | 1.58 mm (0.063 inch) | 1.58 mm (0.063 inch). |
| Mechanical, local | 3.17 mm (0.125 inch) | 1.58 mm (0.063 inch) | 1.58 mm (0.063 inch) | 1.58 mm (0.063 inch). |
| Corrosion and mechanical, local | 4.76 mm (0.188 inch) | 3.17 mm (0.125 inch) | 1.58 mm (0.063 inch) | 1.58 mm (0.063 inch). |
| Notes: 1. The perimeter for a local reduction may not exceed a 60.96 cm (24 inch) perimeter. Local reductions in the top shell must be separated from other reductions in the top shell by at least 40.64 cm (16 inches). The cumulative perimeter for local reductions in the bottom shell may not exceed 182.88 cm (72 inches). | ||||
| 2. Any reduction in the tank car shell may not affect the structural strength of the tank car so that the tank car shell no longer conforms to Section 6.2 of the AAR Specifications for Tank Cars (IBR, see § 171.7 of this subchapter). | ||||
| 3. Any reduction applies only to the outer shell for Class DOT 115 tank cars. | ||||
| 4. For Class DOT 103 and 104 tank cars, the inside diameter may not exceed 243.84 cm (96 inches). | ||||
(1)
Tank car thermal protection systems, tank head puncture resistance systems, coupler vertical restraint systems, and systems used to protect discontinuities (i.e., skid protection and protective housings) to ensure their integrity.
(ii)
Testing the reclosing pressure relief device with air or another gas to ensure that it conforms to the start-to-discharge pressure for the specification or hazardous material in this subchapter.
(i) Lining and coating inspection and test.
When this subchapter requires a lining or coating, at a minimum, each tank car facility must inspect the lining or coating installed on the tank car according to the inspection interval test technique, and acceptance criteria established by the owner of the lining or coating in accordance with paragraph (c)(3)(iii) of this section.
(j) Leakage pressure test.
(1)
After reassembly of a tank car or service equipment, a tank car facility must perform a leak test on the tank or service equipment to detect leakage, if any, between manway covers, cover plates, and service equipment. The test may be conducted with the hazardous material in the tank. When the test pressure exceeds the start-to-discharge or burst pressure of a pressure relief device, the device must be rendered inoperative. The written procedures and test method for leak testing must ensure for the sensitivity and reliability of the test method and for the serviceability of components to prevent premature failure.
(2)
Interior heater systems must be tested hydrostatically at 13.87 Bar (200 psig) and must show no signs of leakage.
(k) Alternative inspection and test procedures.
In lieu of the other requirements of this section, a person may use an alternative inspection and test procedure or interval based on a damage-tolerance fatigue evaluation (that includes a determination of the probable locations and modes of damage due to fatigue, corrosion, or accidental damage), when the evaluation is examined by the Association of American Railroads Tank Car Committee and approved by the Associate Administrator for Safety, FRA.
(l) Inspection and test compliance date for tank cars.
(1)
After July 1, 2000, each tank car with a metal jacket or with a thermal protection system shall have an inspection and test conforming to this section no later than the date the tank car requires a periodic hydrostatic pressure test (i.e., the marked due date on the tank car for the hydrostatic test).
(2)
After July 1, 1998, each tank car without a metal jacket shall have an inspection and test conforming to this section no later than the date the tank car requires a periodic hydrostatic pressure test (i.e., the marked due date on the tank car for the hydrostatic test).
(3)
For tank cars on a 20-year periodic hydrostatic pressure test interval (i.e., Class DOT 103W, 104W, 111A60W1, 111A100W1, and 111A100W3 tank cars), the next inspection and test date is the midpoint between the compliance date in paragraph (l)(1) or (2) of this section and the remaining years until the tank would have had a hydrostatic pressure test.
[Amdt. 180-8, 60 FR 49079, Sept. 21, 1995, as amended by Amdt. 179-50, 61 FR 33256, June 26, 1996; 62 FR 51561, Oct. 1, 1997; 63 FR 52851, Oct. 1, 1998; 66 FR 45391, Aug. 28, 2001; 68 FR 75765, Dec. 31, 2003; 71 FR 54398, Sept. 14, 2006]