(a) Before a tank car is placed in service, the party assembling the completed car shall furnish to car owner, Bureau of Explosives, and the Secretary, Mechanical Division, Association of American Railroads, a report in proper form certifying that tanks and their equipment comply with all the requirements of this specification and including information as to serial numbers, dates of tests, and ownership marks on tanks mounted on car structure.
(b) Purchaser of tanks shall provide for inspection by a competent inspector as follows:
(1) Inspector shall carefully inspect all material and reject that not complying with Sec. 179.500-5.
(2) Inspector shall stamp his official mark on each forging or seamless tube accepted by him for use in making tanks, and shall verify proper application of heat number to such material by occasional inspections at steel manufacturer's plant.
(3) Inspector shall obtain certified chemical analysis of each heat of material.
(4) Inspector shall make inspection of inside surface of tanks before necking-down, to insure that no seams, cracks, laminations, or other defects exist.
(5) Inspector shall fully verify compliance with specification, verify heat treatment of tank as proper; obtain samples for all tests and check chemical analyses; witness all tests; and report minimum thickness of tank wall, maximum inside diameter, and calculated value of D, for each end of each tank as prescribed in Sec. 179.500-4(c).
(6) Inspector shall stamp his official mark on each accepted tank immediately below serial number, and make certified report (see paragraph (c) of this section) to builder, to company or person for whose use tanks are being made, to builder of car structure on which tanks are to be mounted, to the Bureau of Explosives, and to the Secretary, Mechanical Division, Association of American Railroads.
(c) Inspector's report required herein shall be in the following form:
(Place)________________________________________________________________
(Date)_________________________________________________________________
Steel Tanks
It is hereby certified that drawings were submitted for these tanks under AAR Application for Approval ------------ and approved by the AAR Committee on Tank Cars under date of ------------.Built for ------------------------ CompanyLocation at_____________________________________________________________Built by ------------------------ CompanyLocation at_____________________________________________________________Consigned to ------------------ CompanyLocation at_____________________________________________________________Quantity________________________________________________________________Length (inches)_________________________________________________________Outside diameter (inches)_______________________________________________Marks stamped into tank as required in Sec. 179.500-17 are:
DOT-107A* * * *
Note 1: The marked test pressure substituted for the * * * * on each tank is shown on Record of General Data on Tanks attached hereto. Serial numbers ---- to ---- inclusiveInspector's mark________________________________________________________Owner's mark____________________________________________________________Test date_______________________________________________________________Water capacity (see Record of Hydrostatic Tests).Tare weights (yes or no) (see Record of Hydrostatic Tests).These tanks were made by process of_____________________________________
Steel used was identified as indicated by the attached list showing the serial number of each tank, followed by the heat number.
Steel used was verified as to chemical analysis and record thereof is attached hereto. Heat numbers were stamped into metal. All material was inspected and each tank was inspected both before and after closing in ends; all material accepted was found free from seams, cracks, laminations, and other defects which might prove injurious to strength of tank. Processes of manufacture and heat-treatment of tanks were witnessed and found to be efficient and satisfactory.
Before necking-down ends, each tank was measured at each location prescribed in Sec. 179.500-4(c) and minimum wall thickness in inches at each location was recorded; maximum inside diameter in inches at each location was recorded; value of D in inches at each location was calculated and recorded; maximum fiber stress in wall at location showing larger value for (D\2\ + d\2\)/(D\2\-d\2\) was calculated for \7/10\ the marked test pressure and recorded. Calculations were made by the formula: S=[0.7P(D\2\-d\2\)/(D\2\ + d\2\)]
Hydrostatic tests, tensile test of material, and other tests as prescribed in this specification, were made in the presence of the inspector, and all material and tanks accepted were found to be in compliance with the requirements of this specification. Records thereof are attached hereto.
I hereby certify that all of these tanks proved satisfactory in every way and comply with the requirements of Department of Transportation Specification No. 107A* * * *.
(Signed)_______________________________________________________________
(Inspector)
(Place)________________________________________________________________
(Date)_________________________________________________________________
Record of Chemical Analysis of Steel for Tanks Numbered -------- to -------- inclusiveSize -- inches outside diameter by -- inches longBuilt by ------------------------ CompanyFor ------------------------------ Company ------------------------------------------------------------------------
Tanks Chemical analysis
Heat represented ------------------------------------------------
No. (serial Nos.) C Mn P S Si Ni Cr Mo------------------------------------------------------------------------
------------------------------------------------------------------------ These analyses were made by
(Signed)_______________________________________________________________
(Place)________________________________________________________________
(Date)_________________________________________________________________
Record of Chemical Analysis of Steel in Tanks Numbered -------- to -------- inclusiveSize ---- inches outside by ---- inches longBuilt by ------------------------ CompanyFor ------------------------------ Company ------------------------------------------------------------------------
Tanks
Heat represented Elastic Tensile Elongation Reduction
No. by test limit strength (percent in of area
(serial Nos.) (psi) (psi) 2 inches) (percent)------------------------------------------------------------------------
------------------------------------------------------------------------
(Signed)_______________________________________________________________
(Place)________________________________________________________________
(Date)_________________________________________________________________
Record of Hydrostatic Tests on TanksNumbered................................. to........................... inclusiveSize..................................... inches outside by............ ......... inches longBuilt by........................................................................... CompanyFor................................................................................ Company
----------------------------------------------------------------------------------------------------------------
Percent ratio
Total Permanent of permanent Capacity in
Serial Nos. of Actual test expansion expansion expansion to Tare weight pounds of
tanks pressure (psig) (cubic cm) (cubic cm) total (pounds) \2\ water at 60 F
expansion \1\----------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------\1\ If tests are made by method involving measurement of amount of liquid forced into tank by test pressure,
then the basic data on which calculations are made, such as pump factors, temperature of liquid, coefficient
of compressibility of liquid, etc., must also be given.\2\ Do not include protective housing, but state whether with or without valves.
(Signed)_______________________________________________________________
(Place)________________________________________________________________
(Date)_________________________________________________________________
Record of General Data on TanksNumbered................................. to........................... inclusiveBuilt by........................................................................... CompanyFor................................................................................ Company
----------------------------------------------------------------------------------------------------------------
Data obtained as prescribed in Sec. 179.500-4(c)------------------------------------------------------------------------- Larger (S)
Marked end of tank Other end of tank value Calculated Marked Minimum------------------------------------------------------------------------- of the fiber test tensile
(D) (d) (D) factor stress in pressure strength
(t) Min. (d) Max. Calculated (t) Maximum calculated D\2\ + psi at \7/ in psig ofSerial thickness inside value of D Minimum inside value of D d\2\/ 10\ marked stamped materialNo. of of wall diameter in thickness diameter in D\2\- test in tank in psi
tank in inches in inches=d + of wall in inches=d + d\2\ pressure recorded
inches 2t in inches inches 2t----------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------
(Signed)_______________________________________________________________ [Amdt. 179-32, 48 FR 27708, June 16, 1983, as amended by 66 FR 45391, Aug. 28, 2001]
Sec. Appendix A to Part 179--Procedures for Tank-Head Puncture-
Resistance Test
1. This test procedure is designed to verify the integrity of new or untried tank-head puncture-resistance systems and to test for system survivability after coupler-to-tank-head impacts at relative speeds of 29 km/hour (18 mph). Tank-head puncture-resistance is a function of one or more of the following: Head thickness, jacket thickness, insulation thickness, and material of construction.
2. Tank-head puncture-resistance test. A tank-head puncture-resistance system must be tested under the following conditions:
a. The ram car used must weigh at least 119,295 kg (263,000 pounds), be equipped with a coupler, and duplicate the condition of a conventional draft sill including the draft yoke and draft gear. The coupler must protrude from the end of the ram car so that it is the leading location of perpendicular contact with the impacted test car.
b. The impacted test car must be loaded with water at six percent outage with internal pressure of at least 6.9 Bar (100 psig) and coupled to one or more ``backup'' cars which have a total weight of 217,724 kg (480,000 pounds) with hand brakes applied on the last ``backup'' car.
c. At least two separate tests must be conducted with the coupler on the vertical centerline of the ram car. One test must be conducted with the coupler at a height of 53.3 cm (21 inches), plus-or-minus 2.5 cm (1 inch), above the top of the sill; the other test must be conducted with the coupler height at 79 cm (31 inches), plus-or-minus 2.5 cm (1 inch), above the top of the sill. If the combined thickness of the tank head and any additional shielding material is less than the combined thickness on the vertical centerline of the car, a third test must be conducted with the coupler positioned so as to strike the thinnest point of the tank head.
3. One of the following test conditions must be applied: ------------------------------------------------------------------------
Minimum velocity
Minimum weight of attached ram of impact in km/ Restrictions
cars in kg (pounds) hour (mph)------------------------------------------------------------------------119,295 (263,000)............... 29 (18).......... One ram car only.155,582 (343,000)............... 25.5 (16)........ One ram car or one
car plus one
rigidly attached
car.311,164 (686,000)............... 22.5 (14)........ One ram car plus
one or more
rigidly attached
cars.------------------------------------------------------------------------
4. A test is successful if there is no visible leak from the standing tank car for at least one hour after impact. [Amdt. 179-50, 60 FR 49078, Sept. 21, 1995, as amended by Amdt. 179-50, 61 FR 33256, June 26, 1996; 66 FR 45390-45391, Aug. 28, 2001]
Sec. Appendix B to Part 179--Procedures for Simulated Pool and Torch-
Fire Testing
1. This test procedure is designed to measure the thermal effects of new or untried thermal protection systems and to test for system survivability when exposed to a 100-minute pool fire and a 30-minute torch fire.
2. Simulated pool fire test.
a. A pool-fire environment must be simulated in the following manner:
(1) The source of the simulated pool fire must be hydrocarbon fuel with a flame temperature of 871 C plus or minus 55.6 C (1600 F plus-or-minus 100 F) throughout the duration of the test.
(2) A square bare plate with thermal properties equivalent to the material of construction of the tank car must be used. The plate dimensions must be not less than one foot by one foot by nominal 1.6 cm (0.625 inch) thick. The bare plate must be instrumented with not less than nine thermocouples to record the thermal response of the bare plate. The thermocouples must be attached to the surface not exposed to the simulated pool fire and must be divided into nine equal squares with a thermocouple placed in the center of each square.
(3) The pool-fire simulator must be constructed in a manner that results in total flame engulfment of the front surface of the bare plate. The apex of the flame must be directed at the center of the plate.
(4) The bare plate holder must be constructed in such a manner that the only heat transfer to the back side of the bare plate is by heat conduction through the plate and not by other heat paths.
(5) Before the bare plate is exposed to the simulated pool fire, none of the temperature recording devices may indicate a plate temperature in excess of 37.8 C (100 F) nor less than 0 C (32 F).
(6) A minimum of two thermocouple devices must indicate 427 C (800 F) after 13 minutes, plus-or-minus one minute, of simulated pool-fire exposure.
b. A thermal protection system must be tested in the simulated pool-fire environment described in paragraph 2a of this appendix in the following manner:
(1) The thermal protection system must cover one side of a bare plate as described in paragraph 2a(2) of this appendix.
(2) The non-protected side of the bare plate must be instrumented with not less than nine thermocouples placed as described in paragraph 2a(2) of this appendix to record the thermal response of the plate.
(3) Before exposure to the pool-fire simulation, none of the thermocouples on the thermal protection system configuration may indicate a plate temperature in excess of 37.8 C (100 F) nor less than 0 C (32 F).
(4) The entire surface of the thermal protection system must be exposed to the simulated pool fire.
(5) A pool-fire simulation test must run for a minimum of 100 minutes. The thermal protection system must retard the heat flow to the plate so that none of the thermocouples on the non-protected side of the plate indicate a plate temperature in excess of 427 C (800 F).
(6) A minimum of three consecutive successful simulation fire tests must be performed for each thermal protection system.
3. Simulated torch fire test.
a. A torch-fire environment must be simulated in the following manner:
(1) The source of the simulated torch must be a hydrocarbon fuel with a flame temperature of 1,204 C plus-or-minus 55.6 C (2,200 F plus or minus 100 F), throughout the duration of the test. Furthermore, torch velocities must be 64.4 km/h [16 km/h (40 mph [10 mph) throughout the duration of the test.
(2) A square bare plate with thermal properties equivalent to the material of construction of the tank car must be used. The plate dimensions must be at least four feet by four feet by nominal 1.6 cm (0.625 inch) thick. The bare plate must be instrumented with not less than nine thermocouples to record the thermal response of the plate. The thermocouples must be attached to the surface not exposed to the simulated torch and must be divided into nine equal squares with a thermocouple placed in the center of each square.
(3) The bare plate holder must be constructed in such a manner that the only heat transfer to the back side of the plate is by heat conduction through the plate and not by other heat paths. The apex of the flame must be directed at the center of the plate.
(4) Before exposure to the simulated torch, none of the temperature recording devices may indicate a plate temperature in excess of 37.8 C (100 F) or less than 0 C (32 F).
(5) A minimum of two thermocouples must indicate 427 C (800 F) in four minutes, plus-or-minus 30 seconds, of torch simulation exposure.
b. A thermal protection system must be tested in the simulated torch-fire environment described in paragraph 3a of this appendix in the following manner:
(1) The thermal protection system must cover one side of the bare plate identical to that used to simulate a torch fire under paragraph 3a(2) of this appendix.
(2) The back of the bare plate must be instrumented with not less than nine thermocouples placed as described in paragraph 3a(2) of this appendix to record the thermal response of the material.
(3) Before exposure to the simulated torch, none of the thermocouples on the back side of the thermal protection system configuration may indicate a plate temperature in excess of 37.8 C (100 F) nor less than 0 C (32 F).
(4) The entire outside surface of the thermal protection system must be exposed to the simulated torch-fire environment.
(5) A torch-simulation test must be run for a minimum of 30 minutes. The thermal protection system must retard the heat flow to the plate so that none of the thermocouples on the backside of the bare plate indicate a plate temperature in excess of 427 C (800 F).
(6) A minimum of two consecutive successful torch-simulation tests must be performed for each thermal protection system. [Amdt. 179-50, 60 FR 49078, Sept. 21, 1995, as amended at 75 FR 53597, Sept. 1, 2010; 77 FR 60945, Oct. 5, 2012]