[Code of Federal Regulations]
[Title 49, Volume 2]
[Revised as of October 1, 2002]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR180.205]
[Page 1048-1051]
TITLE 49--TRANSPORTATION
CHAPTER I--RESEARCH AND SPECIAL PROGRAMS ADMINISTRATION, DEPARTMENT OF
TRANSPORTATION
PART 180--CONTINUING QUALIFICATION AND MAINTENANCE OF PACKAGINGS
--Table of Contents
Subpart C--Qualification, Maintenance and Use of Cylinders
Sec. 180.205 General requirements for requalification of cylinders.
(a) General. Each cylinder used for the transportation of hazardous
materials must be an authorized packaging. To qualify as an authorized
packaging, each cylinder must conform to this subpart, the applicable
requirements specified in part 173 of this subchapter, and the
applicable requirements of subpart C of part 178 of this subchapter.
(b) Persons performing requalification functions. No person may
represent that a repair or requalification of a cylinder has been
performed in accordance with the requirements in this subchapter unless
that person holds a current approval issued under the procedural
requirements prescribed in subpart I of part 107 of this chapter. No
person may mark a cylinder with a RIN and a requalification date or
otherwise represent that a DOT specification or special permit cylinder has
been requalified unless all applicable requirements of this subpart have
been met. A person who requalifies cylinders must maintain the records
prescribed in Sec. 180.215 at each location at which it inspects, tests,
or marks cylinders.
(c) Periodic requalification of cylinders. Each cylinder bearing a
DOT specification marking must be requalified and marked as specified in
the Requalification Table in this subpart. Each cylinder bearing a DOT
special permit number must be requalified and marked in conformance with this
section and the terms of the applicable special permit. No cylinder may be
filled with a hazardous material and offered for transportation in
commerce unless that cylinder has been successfully requalified and
marked in accordance with this subpart. A cylinder may be requalified at
any time during or before the month and year that the requalification is
due. However, a cylinder filled before the requalification becomes due
may remain in service until it is emptied. A cylinder with a specified
service life may not be refilled and offered for transportation after
its authorized service life has expired.
(1) Each cylinder that is requalified in accordance with the
requirements specified in this section must be marked in accordance with
Sec. 180.213.
(2) Each cylinder that fails requalification must be:
(i) Rejected and may be requalified in accordance with Sec. 180.211;
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 DOT-3 series cylinder,at the first requalification due on
and after
[[Page 1049]]
October 1, 2002, the set pressure of a pressure relief device must be
set at test pressure with a tolerance of plus zero and minus 10%.
(d) Conditions requiring test and inspection of cylinders. Without
regard to any other periodic requalification requirements, a cylinder
must be tested and inspected in accordance with this section prior to
further use if--
(1) The cylinder shows evidence of dents, corrosion, cracked or
abraded areas, leakage, thermal damage, 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 been over-
heated; or
(4) The Associate Administrator determines that the cylinder may be
in an unsafe condition.
(e) Cylinders containing Class 8 (corrosive) liquids. A cylinder
previously containing a Class 8 (corrosive) liquid may not be used to
transport a Class 2 material in commerce unless the cylinder is--
(1) Visually inspected, internally and externally, in accordance
with paragraph (f) of this section and the inspection is recorded as
prescribed in Sec. 180.215;
(2) Requalified in accordance with this section, regardless of the
date of the previous requalification;
(3) Marked in accordance with Sec. 180.213; and
(4) Decontaminated to remove all significant residue or impregnation
of the Class 8 material.
(f) Visual inspection. Except as otherwise provided in this subpart,
each time a cylinder is pressure tested, it must be given an internal
and external visual inspection.
(1) The visual inspection must be performed in accordance with the
following CGA Pamphlets: C-6 for steel and nickel cylinders
(incorporated by reference; see Sec. 171.7 of this subchapter); C-6.1
for seamless aluminum cylinders (incorporated by reference; see
Sec. 171.7 of this subchapter); C-6.2 for fiber reinforced composite
special permit cylinders (incorporated by reference; see Sec. 171.7 of this
subchapter); C-6.3 for low pressure aluminum cylinders (incorporated by
reference; see Sec. 171.7 of this subchapter); C-8 for DOT 3HT cylinders
(incorporated by reference; see Sec. 171.7 of this subchapter); and C-13
for DOT 8 series cylinders (incorporated by reference; see Sec. 171.7 of
this subchapter).
(2) 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.
(3) Each cylinder subject to visual inspection must be approved,
rejected, or condemned according to the criteria in the applicable CGA
pamphlet.
(4) In addition to other requirements prescribed in this paragraph
(f), a DOT specification or special permit cylinder made of aluminum alloy
6351-T6 must be inspected for evidence of sustained load cracking in the
neck and shoulder area in accordance with the cylinder manufacturer's
written recommendations, which must be approved in writing by the
Associate Administrator.
(g) Pressure test. (1) Unless otherwise provided, each cylinder
required to be retested under this subpart must be retested by means
suitable for measuring the expansion of the cylinder under pressure.
Bands and other removable attachments must be loosened or removed before
testing so that the cylinder is free to expand in all directions.
(2) The pressure indicating device of the testing apparatus must
permit reading of pressures to within 1% of the minimum prescribed test
pressure of each cylinder tested, except that for an analog device,
interpolation to \1/2\ of the marked gauge divisions is acceptable. The
expansion-indicating device of the testing apparatus must also permit
incremental reading of the cylinder expansion to 1% of the total
expansion of each cylinder tested or 0.1 cm<SUP>3</SUP>, whichever is
larger. Midpoint visual interpolation is permitted.
(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 <plus-minus>1.0% of the prescribed test pressure of
any cylinder tested that day. The pressure indicating device,
[[Page 1050]]
itself, must be certified as having an accuracy of <plus-minus>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, gives a stable reading of expansion and is accurate to
<plus-minus>1.0% of the total expansion of any cylinder tested or 0.1
cubic centimeter, whichever is larger. The expansion-indicating device
itself must have an accuracy of <plus-minus>0.5%, or better, of its full
scale.
(4) The test equipment must be verified to be accurate within
<plus-minus>1.0% of the calibrated cylinder's pressure and corresponding
expansion values. This may be accomplished by bringing the pressure to a
value shown on the calibration certificate for the calibrated cylinder
used and verifying that the resulting total expansion is within
<plus-minus>1.0% of the total expansion shown on the calibration
certificate. Alternatively, calibration may be demonstrated by bringing
the total expansion to a known value on the calibration certificate for
the calibrated cylinder used and verifying that the resulting pressure
is within <plus-minus>1.0% of the pressure shown on the calibration
certificate. The calibrated cylinder must show no permanent expansion.
The retester must demonstrate calibration in conformance with this
paragraph (g) to an authorized inspector on any day that it retests
cylinders. A retester must maintain calibrated cylinder certificates in
conformance with Sec. 180.215(b)(4).
(5) Minimum test pressure must be maintained for at least 30
seconds, and as long as necessary for complete expansion of the
cylinder. 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, the test may be repeated at a pressure increased by 10% or
100 psig, whichever is less. This paragraph (g) does not authorize
retest of a cylinder otherwise required to be condemned under paragraph
(i) of this section.
(h) Cylinder rejection. A cylinder must be rejected when, after a
visual inspection, it meets a condition for rejection under the visual
inspection requirements of paragraph (f) of this section.
(1) Except as provided in paragraphs (h)(3) and (h)(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 requalified in conformance with
requirements in Sec. 180.211, it may not be filled with a hazardous
material and offered for transportation in commerce 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 Sec. 180.211.
(i) Cylinder condemnation. (1) A cylinder must be condemned when--
(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.
[[Page 1051]]
(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 over-heated.
(2) When a cylinder must be condemned, the requalifier must stamp a
series of X's over the DOT specification number and the marked pressure
or stamp ``CONDEMNED'' on the shoulder, top head, or neck using a steel
stamp. Alternatively, at the direction of the owner, the requalifier may
render the cylinder incapable of holding pressure. In addition, the
requalifier must 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 or obliterate the ``CONDEMNED'' marking.
[Code of Federal Regulations]
[Title 49, Volume 2]
[Revised as of October 1, 2002]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR180.209]
[Page 1051-1054]
TITLE 49--TRANSPORTATION
CHAPTER I--RESEARCH AND SPECIAL PROGRAMS ADMINISTRATION, DEPARTMENT OF
TRANSPORTATION
PART 180--CONTINUING QUALIFICATION AND MAINTENANCE OF PACKAGINGS
--Table of Contents
Subpart C--Qualification, Maintenance and Use of Cylinders
Sec. 180.209 Requirements for requalification of specification cylinders.
(a) Periodic qualification of cylinders. (1) Each specification
cylinder that becomes due for periodic requalification, as specified in
the following table, must be requalified and marked in conformance with
the requirements of this subpart. Requalification records must be
maintained in accordance with Sec. 180.215. Table 1 follows:
Table 1.--Requalification of Cylinders \1\
------------------------------------------------------------------------
Specification under which Minimum test
cylinder was made pressure (psig) \2\ Test period (years)
------------------------------------------------------------------------
DOT 3....................... 3000 psig........... 5
DOT 3A, 3AA................. 5/3 times service 5, 10, or 12 (see
pressure, except Sec. 180.209(b),
noncorrosive (f), (h), and (j)
service (see Sec.
180.209(g)).
DOT 3AL..................... 5/3 times service 5 or 12 (see Sec.
pressure. 180.209(j))
DOT 3AX, 3AAX............... 5/3 times service 5
pressure.
3B, 3BN..................... 2 times service 5 or 10 (see Sec.
pressure (see Sec. 180.209(f))
180.209(g)).
3E.......................... Test not required...
3HT......................... 5/3 times service 3 (see Secs.
pressure. 180.209(i) and
180.213(c))
3T.......................... 5/3 times service 5
pressure.
4AA480...................... 2 times service 5 or 10 (see Sec.
pressure (see Sec. 180.209(e)(14)
180.209(g)).
4B, 4BA, 4BW, 4B-240ET...... 2 times service 5, 10, or 12 (see
pressure, except Sec. 180.209(e),
non-corrosive (f), and (j))
service (see Sec.
180.209(g)).
4D, 4DA, 4DS................ 2 times service..... 5
DOT 4E...................... 2 times service 5
pressure, except
non-corrosive (see
Sec. 180.209(g)).
4L.......................... Test not required...
8, 8AL...................... .................... 10 or 20 (see Sec.
180.209(i))
Special Permit cylinder.......... See current See current
special permit. special permit
Foreign cylinder (see Sec. As marked on 5 (see Secs.
173.301(j) of this cylinder, but not 180.209(KB) and
subchapter for restrictions less than 5/3 of 180.213(d)(iii))
on use). any service or
working pressure
marking.
------------------------------------------------------------------------
\1\ Any cylinder not exceeding 2 inches outside diameter and less than 2
feet in length is excepted from volumetric expansion test.
\2\ For cylinders not marked with a service pressure, see Sec.
173.301(e)(1) of this subchapter.
(b) DOT 3A or 3AA cylinders. (1) A cylinder conforming to
specification DOT 3A or 3AA with a water capacity of 56.7 kg (125 lb) or
less that is removed from
[[Page 1052]]
any cluster, bank, group, rack, or vehicle each time it is filled, may
be requalified 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; cyclopropane;
ethylene; helium; hydrogen; krypton; neon; nitrogen; nitrous oxide;
oxygen; sulfur hexafluoride; xenon; fluorinated hydrocarbons, liquefied
hydrocarbons, and mixtures thereof that are commercially free from
corroding components; permitted mixtures of these gases (see
Sec. 173.301(d) of this subchapter); and permitted mixtures of these
gases with up to 30 percent by volume of carbon dioxide, provided the
gas has a dew point at or below minus (52 deg.F) at 1 atmosphere.
(iii) Before each refill, the cylinder is removed from any cluster,
bank, group, rack or vehicle and passes the hammer test specified in CGA
Pamphlet C-6 (incorporated by reference; see Sec. 171.7 of this
subchapter).
(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) 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 Sec. 173.302a(b) (2), (3) and
(4) of this subchapter.
(3) Except as specified in paragraph (b)(2) 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. A DOT 4-series cylinder, except a 4L
cylinder, that at any time shows evidence of a leak or of internal or
external corrosion, denting, bulging or rough usage to the extent that
it is likely to be weakened appreciably, or that has lost five percent
or more of its official tare weight must be requalified before being
refilled and offered for transportation. (Refer to CGA Pamphlet C-6 or
C-6.3, as applicable, regarding cylinder weakening.) After testing, the
actual tare weight must be recorded as the new tare weight.
(d) Cylinders 5.44 kg (12 lb) or less with service pressures of 300
psig or less. A cylinder of 5.44 (12 lb) or less water capacity
authorized for service pressure of 300 psig or less must be given a
complete external visual inspection at the time periodic requalification
becomes due. External visual inspection must be in accordance with CGA
Pamphlet C-6 or C-6.1 (incorporated by reference; see Sec. 171.7 of this
subchapter). The cylinder may be proof pressure tested. The test is
successful if the cylinder, when examined under test pressure, does not
display a defect described in Sec. 180.205(i)(1) (ii) or (iii). Upon
successful completion of the test and inspection, the cylinder must be
marked in accordance with Sec. 180.213.
(e) Proof pressure test. A cylinder made in conformance with
specifications DOT 4B, 4BA, 4BW, or 4E used exclusively for: liquefied
petroleum gas that meets the requirements in Table I of ASTM D 1835,
Standard Specification for Liquefied Petroleum (LP) Gases (incorporated
by reference; see Sec. 171.7 of this subchapter); anhydrous
dimethylamine; anhydrous methylamine; anhydrous trimethylamine; methyl
chloride; methylacetylene-propadiene stabilized; or
dichlorodifluoromethane, difluoroethane, difluorochloroethane,
chlorodifluoromethane, chlorotetrafluoroethane, trifluorochloroethylene,
or mixture thereof, or mixtures of one or more with
trichlorofluoromethane; and commercially free from corroding components
and protected externally by a suitable corrosion-resistant coating
[[Page 1053]]
(such as galvanizing or painting) may be requalified by volumetric
expansion testing every 12 years instead of every five years. As an
alternative, the cylinder may be subjected to a proof pressure test at
least two times the marked service pressure, but this latter type of
test must be repeated every seven years after expiration of the first
12-year period. When subjected to a proof pressure test, the cylinder
must be carefully examined under test pressure and removed from service
if a leak or defect is found.
(f) Poisonous materials. A cylinder conforming to specification DOT
3A, 3AA, 3B, 4BA, or 4BW having a service pressure of 300 psig or less
and used exclusively for methyl bromide, liquid; mixtures of methyl
bromide and ethylene dibromide, liquid; mixtures of methyl bromide and
chlorpicrin, liquid; mixtures of methyl bromide and petroleum solvents,
liquid; or methyl bromide and nonflammable, nonliquefied compressed gas
mixtures, liquid; commercially free of corroding components, and
protected externally by a suitable corrosion resistant coating (such as
galvanizing or painting) and internally by a suitable corrosion
resistant lining (such as galvanizing) may be tested every 10 years
instead of every five years, provided a visual internal and external
examination of the cylinder is conducted every five years in accordance
with CGA Pamphlet C-6 (incorporated by reference; see Sec. 171.7 of this
subchapter). The cylinder must be examined at each filling, and rejected
if a dent, corroded area, leak or other condition indicates possible
weakness.
(g) Visual inspections. A cylinder conforming to a specification
listed in the table in this paragraph and used exclusively in the
service indicated may, instead of a periodic hydrostatic test, be given
a complete external visual inspection at the time periodic
requalification becomes due. External visual inspection must be in
accordance with CGA Pamphlet C-6 or C-6.3, as applicable (incorporated
by reference; see Sec. 171.7 of this subchapter). When this inspection
is used instead of hydrostatic pressure testing, subsequent inspections
are required at five-year intervals after the first inspection. After
September 30, 2003, inspections must be made only by persons holding a
current RIN and the results recorded and maintained in accordance with
Sec. 180.215. Records must include: date of inspection (month and year);
DOT specification number; cylinder identification (registered symbol and
serial number, date of manufacture, and owner); type of cylinder
protective coating (including statement as to need of refinishing or
recoating); conditions checked (e.g., leakage, corrosion, gouges, dents
or digs in shell or heads, broken or damaged footring or protective ring
or fire damage); disposition of cylinder (returned to service, returned
to cylinder manufacturer for repairs or condemned). A cylinder passing
requalification by the external visual inspection must be marked in
accordance with Sec. 180.213. Specification cylinders must be in
exclusive service as shown in the following table:
------------------------------------------------------------------------
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, Butadiene, inhibited, that is
DOT 4B, DOT 4BA, DOT 4BW. commercially free from
corroding components.
DOT 3A, DOT 3A480X, DOT 3AA, DOT 3B, Cyclopropane that is
DOT 4AA480, DOT 4B, DOT 4BA, DOT 4BW. commercially free from
corroding components.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 4B, Fluorinated hydrocarbons and
DOT 4BA, DOT 4BW, DOT 4E. mixtures thereof that are
commercially free from
corroding components.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, Liquefied hydrocarbon gas that
DOT 4B, DOT 4BA, DOT 4BW, DOT 4E. is commercially free from
corroding components.
DOT 3A, DOT 3AA, DOT 3A480X, DOT 3B, Liquefied petroleum gas that
DOT 4B, DOT 4BA, DOT 4BW, DOT 4E. meets the requirements in
Table I of ASTM D 1835,
Standard Specification for
Liquefied Petroleum (LP) Gases
(incorporated by reference;
see Sec. 171.7 of this
subchapter).
DOT 3A, DOT 3AA, DOT 3B, DOT 4B, DOT Methylacetylene-propadiene,
4BA, DOT 4BW, DOT 4E. stabilized, that is
commercially free from
corroding components.
DOT 3A, DOT 3AA, DOT 3B, DOT 4B, DOT Anhydrous mono,
4BA, DOT 4BW. di,trimethylamines that are
commercially free from
corroding components.
DOT 4B240, DOT 4BW240.................. Ethyleneimine, inhibited.
------------------------------------------------------------------------
[[Page 1054]]
(h) Cylinders containing anhydrous ammonia. A cylinder conforming to
specification DOT 3A, 3A480X, or 4AA480 used exclusively for anhydrous
ammonia, commercially free from corroding components, and protected
externally by a suitable corrosion-resistant coating (such as paint) may
be requalified every 10 years instead of every five years.
(i) Requalification of DOT-8 series cylinders. (1) Each owner of a
DOT-8 series cylinder used to transport acetylene must have the cylinder
shell and the porous filler requalified in accordance with CGA Pamphlet
C-13 (incorporated by reference; see Sec. 171.7 of this subchapter).
Requalification must be performed in accordance with the following
schedule:
----------------------------------------------------------------------------------------------------------------
Shell (visual inspection) Porous filler requalification
requalification ---------------------------------------
Date of cylinder manufacture ----------------------------------------
Initial Subsequent Initial Subsequent
----------------------------------------------------------------------------------------------------------------
Before January 1, 1991.......... Before January 1, 10 years.......... Before January 1, Not required.
2001. 2011.
On or after January 1, 1991..... 10 years \1\...... 10 years.......... 3 to 20 years \2\. Not required.
----------------------------------------------------------------------------------------------------------------
\1\ Years from date of cylinder manufacture.
\2\ For a cylinder manufactured on or after January 1, 1991, requalification of the porous filler must be
performed no sooner than 3 years, and no later than 20 years, from the date of manufacture.
(2) Unless requalified and marked in accordance with CGA Pamphlet C-
13 (incorporated by reference; see Sec. 171.7 of this subchapter) 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 Sec. 180.215.
(5) The person performing a visual inspection or requalification
must mark the cylinder as specified in Sec. 180.213.
(j) Cylinder used as a fire extinguisher. Only a DOT specification
cylinder used as a fire extinguisher and meeting Special Provision 18 in
Sec. 172.102(c)(1) of this subchapter may be requalified in accordance
with this paragraph (j).
(1) A DOT 4B, 4BA, 4B240ET or 4BW cylinder may be tested as follows:
(i) For a cylinder with a water capacity of 5.44 kg (12 lb) or less,
by volumetric expansion test using the water jacket method or by proof
pressure test. A requalification must be performed by the end of 12
years after the original test date and at 12-year intervals thereafter.
(ii) For a cylinder having a water capacity over 5.44 kg (12 lb)--
(A) By proof pressure test. A requalification must be performed by
the end of 12 years after the original test date and at 7-year
intervals; or
(B) By volumetric expansion test using the water jacket method. A
requalification must be performed 12 years after the original test date
and at 12-year intervals thereafter.
(2) A DOT 3A, 3AA, or 3AL cylinder must be requalified by volumetric
expansion test using the water jacket method. A requalification must be
performed 12 years after the original test date and at 12-year intervals
thereafter.
(KB) Requalification of foreign cylinders filled for export. A
cylinder manufactured outside the United States, other than as provided
in Sec. 171.12a of this subchapter, that has not been manufactured,
inspected, tested and marked in accordance with part 178 of this
subchapter may be filled with compressed gas in the United States, and
shipped solely for export if it meets the following requirements, in
addition to other requirements of this subchapter:
(1) It has been inspected, tested and marked (with only the month
and year of test) 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 Sec. 173.301(l) of this subchapter.
[Code of Federal Regulations]
[Title 49, Volume 2]
[Revised as of October 1, 2002]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR180.211]
[Page 1055-1056]
TITLE 49--TRANSPORTATION
CHAPTER I--RESEARCH AND SPECIAL PROGRAMS ADMINISTRATION, DEPARTMENT OF
TRANSPORTATION
PART 180--CONTINUING QUALIFICATION AND MAINTENANCE OF PACKAGINGS
--Table of Contents
Subpart C--Qualification, Maintenance and Use of Cylinders
Sec. 180.211 Repair, rebuilding and reheat treatment of DOT-4
series specification cylinders.
(a) General requirements for repair and rebuilding. Any repair or
rebuilding of a DOT 4-series cylinder must be performed by a person
holding an approval as specified in Sec. 107.805 of this chapter. A
person performing a rebuild function is considered a manufacturer
subject to the requirements of Sec. 178.2(a)(2) and subpart C of part
178 of this subchapter. The person performing a repair, rebuild, or
reheat treatment must record the test results as specified in
Sec. 180.215. Each cylinder that is successfully repaired or rebuilt
must be marked in accordance with Sec. 180.213.
(b) General repair requirements. Each repair of a DOT 4-series
cylinder must be made in accordance with the following conditions:
(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 Sec. 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 Sec. 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. (1) Repairs to
a DOT 4L cylinder must be performed in accordance with paragraphs (a)
and (b) of this section and are limited to the following:
(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
(incorporated by reference; see Sec. 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. (1) The rebuilding of a DOT 4-
series cylinder must be made in accordance with the following
requirements:
(i) The person rebuilding the cylinder must use the procedures and
equipment as authorized by the approval issued under Sec. 107.805 of
this chapter.
[[Page 1056]]
(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 (incorporated by
reference; see Sec. 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
Sec. 180.215(d)(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 Sec. 180.215(d).
(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. (1) The
rebuilding of a DOT 4L cylinder must be performed in accordance with
paragraph (d) of this section. Rebuilding of a DOT 4L cylinder is:
(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. (1) Prior to reheat treatment, each cylinder
must be given a visual inspection, internally and externally, in
accordance with Sec. 180.205(f).
(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 Sec. 180.215.
[Code of Federal Regulations]
[Title 49, Volume 2]
[Revised as of October 1, 2002]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR180.213]
[Page 1056-1058]
TITLE 49--TRANSPORTATION
CHAPTER I--RESEARCH AND SPECIAL PROGRAMS ADMINISTRATION, DEPARTMENT OF
TRANSPORTATION
PART 180--CONTINUING QUALIFICATION AND MAINTENANCE OF PACKAGINGS
--Table of Contents
Subpart C--Qualification, Maintenance and Use of Cylinders
Sec. 180.213 Requalification markings.
(a) General. Each cylinder requalified in accordance with this
subpart with
[[Page 1057]]
acceptable results must be marked as specified in this section. Required
specification markings may not be altered or removed.
(b) Placement of markings. Each cylinder must be plainly and
permanently marked on the metal of the cylinder as permitted by the
applicable specification. Unless authorized by the cylinder
specification, marking on the cylinder sidewall is prohibited.
(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. The depth of requalification
markings may not be greater than specified in the applicable
specification. The markings must be made by stamping, engraving,
scribing or other method that produces a legible, durable mark.
(1) A cylinder used as a fire extinguisher (Sec. 180.209(j)) may be
marked by using a pressure sensitive label.
(2) For a DOT 3HT cylinder, 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.
(d) Requalification markings. Each cylinder that has successfully
passed requalification must be marked with the RIN set in a square
pattern, between the month and year of the requalification date. The
first character of the RIN must appear in the upper left corner of the
square pattern; the second in the upper right; the third in the lower
right, and the fourth in the lower left. Example: A cylinder requalified
in September 1998, and approved by a person who has been issued RIN
``A123'', would be marked plainly and permanently into the metal of the
cylinder in accordance with location requirements of the cylinder
specification or on a metal plate permanently secured to the cylinder in
accordance with paragraph (b) of this section. An example of the
markings prescribed in this paragraph (d) is as follows:
[GRAPHIC] [TIFF OMITTED] TR08AU02.018
Where:
``9'' is the month of requalification,
``A123'' is the RIN,
``98'' is the year of requalification, and
``X'' represents the symbols described in paragraphs (f)(2) through
(f)(7) of this section.
(1) Upon a written request, variation from the marking requirement
may be approved by the Associate Administrator.
(2) Exception. A cylinder subject to the requirements of
Sec. 173.301(l) of this subchapter may not be marked with a RIN.
(e) Size of markings. The size of the markings must be at least 6.35
mm (\1/4\ in.) high, except RIN characters must be at least 3.18 mm (\1/
8\ in.) high.
(f) Marking illustrations. Examples of required requalification
markings for DOT specification and special permit cylinders are illustrated
as follows:
(1) For designation of the 5-year volumetric expansion test, 10-year
volumetric expansion test for cylinders conforming to Sec. 180.209(f)
and (h), or 12-year volumetric expansion test for fire
[[Page 1058]]
extinguishers conforming to Sec. 173.309(b) of this subchapter and
cylinders conforming to Sec. 180.209(e) and Sec. 180.209(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 Sec. 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 Sec. 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 Sec. 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 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''.
[Code of Federal Regulations]
[Title 49, Volume 2]
[Revised as of October 1, 2002]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR180.215]
[Page 1058-1059]
TITLE 49--TRANSPORTATION
CHAPTER I--RESEARCH AND SPECIAL PROGRAMS ADMINISTRATION, DEPARTMENT OF
TRANSPORTATION
PART 180--CONTINUING QUALIFICATION AND MAINTENANCE OF PACKAGINGS
--Table of Contents
Subpart C--Qualification, Maintenance and Use of Cylinders
Sec. 180.215 Reporting and record retention requirements.
(a) Facility records. A person who requalifies, repairs or rebuilds
cylinders must maintain the following records where the requalification
is performed:
(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 Sec. 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 special permit 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 Sec. 171.7 of this subchapter
applicable to the requalifier's activities. This information must be the
same as contained in the edition incorporated by reference in Sec. 171.7
of this subchapter.
(b) Requalification records. Daily records of visual inspection,
pressure test, and ultrasonic examination if permitted under a special permit, as applicable, must be maintained by the person who performs
the requalification until either the expiration of the requalification
period or until the cylinder is again requalified, whichever occurs
first. A single date may be used for each test sheet, provided each test
on the sheet was conducted on that date. Ditto marks or a solid vertical
line may be used to indicate repetition of the preceding entry for the
following entries only: date; actual dimensions; manufacturer's name or
symbol, if present; owner's name or symbol, if present; and test
operator. Blank spaces may not be used to indicate repetition of a prior
entry. The records must include the following information:
(1) Pressure test records. For each test to demonstrate calibration,
the date; serial number of the calibrated cylinder; calibration test
pressure; total, elastic and permanent expansions; and legible
identification of test operator. The test operator must be able to
demonstrate that the results of the daily calibration verification
correspond to the hydrostatic tests performed on that day. The daily
verification of calibration(s) may be recorded on the same sheets as,
and with, test records for that date.
(2) Pressure test and visual inspection records. The date of
requalification; serial number; DOT specification or special permit number;
marked pressure; actual dimensions; manufacturer's name or symbol;
owner's name or symbol, if present; result of visual inspection; actual
test pressure; total, elastic and
[[Page 1059]]
permanent expansions; percent permanent expansion; disposition, with
reason for any repeated test, rejection or condemnation; and legible
identification of test operator. For each cylinder marked pursuant to
Sec. 173.302a(b)(5) of this subchapter, the test sheet must indicate the
method by which any average or maximum wall stress was computed. Records
must be kept for all completed, as well as unsuccessful tests. The entry
for a second test after a failure to hold test pressure must indicate
the date of the earlier test.
(3) Wall stress. Calculations of average and maximum wall stress
pursuant to Sec. 173.302a(b)(3) of this subchapter, if performed.
(4) Calibration certificates. The most recent certificate of
calibration must be maintained for each calibrated cylinder.
(c) Repair, rebuilding or reheat treatment records. (1) Records
covering welding or brazing repairs, rebuilding or reheat treating shall
be retained for a minimum of fifteen years by the approved facility.
(2) A record of rebuilding, in accordance with Sec. 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, checKB), 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 proof pressure test on cylinder, including test
method, test pressure, total expansion, permanent expansion, elastic
expansion, percent permanent expansion (permanent expansion may not
exceed ten percent (10%) of total expansion), and volumetric capacity
(volumetric capacity of a rebuilt cylinder must be within <plus-minus>
3% 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.
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