Guidelines for the Operation, Assembly, Repair, Testing ...

1 Guidelines for the Operation, assembly , Repair, Testing and Inspection of Hazardous Material Cargo Tanks FINAL REPORT Submitted to: Department of Transportation Federal Motor Carrier Safety Administration June 2009 FOREWORD The purpose of this report is to assist the Federal Motor Carrier Safety Administration (FMCSA) in identifying factors that affect the service life of a cargo tank and to assist in the development of industry-informed Guidelines to provide methods, programs, processes, and procedures that will minimize the effects of factors that reduce the service life of a cargo tank. The basis for these Guidelines includes industry comments, regulatory documents, and professional organizations guidance. NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Government assumes no liability for its contents or the use thereof. The contents of this Report reflect the views of the contractor, who is responsible for the accuracy of the data presented herein.

2 The contents do not necessarily reflect the official policy of the Department of Transportation. This Report does not constitute a standard, specification, or regulation. The United States Government does not endorse products or manufacturers named herein. Trade or manufacturers names appear herein only because they are considered essential to the objective of this document. 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. 4. Title and Subtitle Guidelines for the Operation, assembly , Repair, Testing and Inspection of Hazardous Material Cargo Tanks 5. Report Date June 30, 2009 6. Performing Organization Code 7. Author(s) Darrell Bowman, Andrew Marinik, Tammy Trimble, Stephanie Baker, and Allen Selz (Pressure Sciences, Inc.) 8. Performing Organization Report No. 9. Performing Organization Name and Address Virginia Tech Transportation Institute 3500 Transportation Research Plaza Blacksburg, Virginia 24061 10. Work Unit No. (TRAIS) 11.

3 Contract or Grant No. VTRC # 08-0669-10 FMCSA # TMC75-07-H-00008 Task Order # 2 12. Sponsoring Agency Name and Address Department of Transportation Federal Motor Carrier Safety Administration Hazardous Materials Division West Wing, MC-ECH 1200 New Jersey Ave. SE Washington, DC 20590 13. Type of Report and Period Covered Draft Report. 14. Sponsoring Agency Code FMCSA 15. Supplementary Notes This program was administered through the Federal Motor Carrier Safety Administration (FMCSA) and the Virginia Transportation Research Council (VTRC). The FMCSA Authorized Organizational Technical Representative (AOTR) is James Simmons and the VTRC Principal Investigator (PI) is Mike Perfater. 16. Abstract This document consists of Guidelines and recommendations related to operations , assembly , repair, Testing and inspection of cargo tanks hauling hazardous materials. This document is the result of research findings from the project titled: Research to Identify the Factors that Affect the Service Life of Cargo Tanks [VTRC # 08-0669-10, FMCSA # TMC75-07-H-00008 Task Order # 2].

4 17. Key Words Hazardous Materials, Specification Cargo Tanks, Maintenance, Repair, assembly , Testing , Inspection, operations 18. Distribution Statement 19. Security Classif. (of this report) Unclassified 20. Security Classif. (of this page) Unclassified 21. No. of Pages 105 22. Price N/A Form DOT F (8-72) Reproduction of completed page authorized. SI* (MODERN METRIC) CONVERSION FACTORS APPROXIMATE CONVERSIONS TO SI UNITSS ymbol When You Know Multiply By To Find Symbol in ftydmiin2ft2 yd2 acmi2fl oz galft3 yd3 ozlbT oFfcfllbf lbf/in2 LENGTH inches millimeters feet meters meters miles kilometers AREA square inches square millimeters square feet square meters square yard square meters miles square kilometersVOLUME fluid ounces milliliters gallons liters cubic feet cubic meters cubic yards cubic meters NOTE.

5 Volumes greater than 1000 L shall be shown in m3 MASS tons (2000 lb) megagrams (or "metric ton") TEMPERATURE (exact degrees) Fahrenheit 5 (F-32)/9 Celsius or (F-32) ILLUMINATION and PRESSURE or STRESS poundforce newtons poundforce per square inch kilopascals mm m m km 2mm2m2mha km2mL L 3 m3 mgkgMg (or oC lx cd/m2N kPa "t") APPROXIMATE CONVERSIONS FROM SI UNITS Symbol When You KnowMultiply ByTo Find Symbol mmm mkm2mm2m 2m hakm2 mL L3 m3 mgkgMg (or oClx 2cd/mN kPa "t") LENGTH millimeters inches meters feet meters yards miles AREA square millimeters square inches square meters square feet square yards square miles VOLUME milliliters fluid ounces liters gallons cubic meters cubic feet cubic meters cubic yards MASS (or "metric ton") short tons (2000 lb) TEMPERATURE (exact degrees)

6 Celsius +32 Fahrenheit ILLUMINATION lux foot-candles foot-LambertsFORCE and PRESSURE or STRESS newtons poundforce kilopascals poundforce per square inch in ft yd mi 2 inft2 yd2 ac mi2 fl oz gal ft3 yd3 ozlbT oF fc fllbf 2lbf/in*SI is the symbol for th e International System of Units. Appropriate rounding should be made to comply with Section 4 of ASTM E380. (Revised March 2003) TABLE OF CONTENTS 1..1 THE CARGO TANK INDUSTRY ..1 CARGO TANK REGULATIONS, STANDARDS, AND CODES ..1 METHODS ..2 Participants .. 2 Data Collection .. 3 Data Analysis .. 3 RESULTS AND DISCUSSION ..4 STRUCTURE OF THE Guidelines DOCUMENT.

7 4 2..5 CARGO TANK FLEET/FACILITY INTRODUCTION ..5 FLEET MANAGEMENT ..5 Lading Management .. 5 Record Keeping/Tracking Key Measures .. 6 Safety Policies/Procedures .. 7 Fleet/Facility Investment .. 8 DRIVER MANAGEMENT ..9 Driver Training .. 10 Driver Inspection .. 12 MAINTENANCE ..14 Preventative Maintenance .. 14 Maintenance: Protective Coating .. 17 Cleaning .. 18 Maintenance Training .. 19 3..21 CARGO TANK INTRODUCTION ..21 MOUNTING OF CARGO TANKS ON Mounting .. 21 Attachments .. 22 INSTALLATION OF EQUIPMENT AND COMPONENTS (DOT 406/DOT 407/ DOT 412) ..23 Manhole Assemblies .. 24 Accident Damage Protection .. 24 vi Pressure Relief .. 25 Tank Outlets .. 28 28 INSTALLATION OF EQUIPMENT AND COMPONENTS (MC 330/MC 331) ..29 Closure for Manhole .. 29 Openings, Inlets, and Outlets .. 29 Pressure Relief Devices, Piping, Valves, Hoses, and Fittings .. 31 Accident Damage Protection .. 32 EMERGENCY DISCHARGE CONTROL.

8 33 Emergency Discharge Control Equipment .. 33 Engine Fuel Lines .. 34 GAUGING DEVICES ..34 Liquid Level Gauging Devices .. 34 PUMPS AND COMPRESSORS ..35 INSTALLATION OF LININGS AND COATINGS ..35 4..37 CARGO TANK INTRODUCTION ..37 ADMINISTRATION REQUIREMENTS ..38 PERSONNEL REQUIREMENTS ..39 CONDITIONS REQUIRING REPAIR ..39 39 Weld Defects .. 42 Cargo Tank Distortion .. 43 Cracking .. 44 Bulkhead and Baffles Defects .. 45 Omitted or Undersized Welding Pads .. 46 REFERENCES ..47 5..48 TEST AND INSPECTION INTRODUCTION ..48 TEST AND INSPECTION SCHEDULES ..49 QUALITY CONTROL PROCEDURES ..51 SAFETY PRECAUTIONS ..54 Tank Cleaning .. 54 Confined Space Safety Precautions .. 54 Pneumatic Pressure Testing Safety Precautions .. 55 vii REGISTRATION ..55 MINIMUM QUALIFICATIONS FOR INSPECTORS AND TESTERS ..56 ACCEPTABLE RESULTS OF tests AND INSPECTIONS ..57 REPORTING AND RECORD RETENTION REQUIREMENTS ..58 REQUIREMENTS FOR TEST AND INSPECTION OF SPECIFICATION CARGO TANKS.

9 61 External Visual Inspection .. 62 Internal Visual Inspection .. 65 Lining Inspection .. 66 Pressure Test .. 67 Wet Fluorescent Magnetic Particle Test (WFMPT) .. 70 Leakage Test .. 71 Environmental Protection Agency s Method 27 Determination of vapor Tightness of Gasoline Delivery Tank Using Pressure Vacuum Test .. 73 Thickness Testing .. 76 DISCHARGE SYSTEM INSPECTION AND MAINTENANCE PROGRAM FOR CARGO TANKS TRANSPORTING LIQUEFIED COMPRESSED GASES ..81 Hose Identification .. 81 Monthly Inspections and tests .. 81 Annual Inspections and tests .. 82 INTERNAL SELF-CLOSING STOP VALVE EMERGENCY CLOSURE TEST FOR LIQUEFIED COMPRESSED GASES ..83 APPENDIX B TO PART 180 ACCEPTABLE INTERNAL SELF-CLOSING STOP VALVE LEAKAGE tests FOR CARGO TANKS TRANSPORTING LIQUEFIED COMPRESSED GASES ..83 Meter Creep Test .. 83 Internal Self-Closing Stop Valve Test .. 83 6..85 ADDITIONAL REFERENCE 49 CFR (N) EMERGENCY DISCHARGE CONTROL FOR CARGO TANK MOTOR VEHICLES IN LIQUEFIED COMPRESSED GAS SERVICE.

10 85 DEFINITIONS ..87 viii LIST OF TABLES Table 1. Maximum ambient temperature gasoline.. 26 Table 2. Required emergency discharge control capability.. 33 Table 3. Acceptable gauging devices.. 34 Table 4. Inspector requirements for various CT classes.. 38 Table 5. Compliance dates inspection and test under (c).. 50 Table 6. Partial listing of sources providing additional publications and materials.. 52 Table 7. 49 CFR (g)(1)(iv) internal test pressures for CT pressure tests .. 68 Table 8. Table 2 - allowable CT test pressure or vacuum change.. 75 Table 9. 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 CTs constructed of steel and steel alloys.. 78 Table 10. 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 CTs constructed of aluminum and aluminum alloys.. 78 Table 11. Specified minimum thickness of heads (or bulkheads and baffles when used as tank reinforcement) using mild steel (MS), high-strength low-alloy steel (HSLA), austenitic stainless steel (SS) or aluminum (AL) expressed in decimals of an inch after forming for material volume capacity in gallons per inch of length.