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MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION C-III
Compiled under the direction of the Committees responsible for the subjects shown herein.
This issue of the Specifications for Tank Cars is presented in dual form with SI units
parenthetical to conventional units. Guidelines for this conversion are given in Appendix H.
Published by
Printed in U.S.A.
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Copyright © 2014 by the Association of American Railroads (AAR)
Safety and Operations
425 Third Street SW
Suite 1000
Washington, DC 20024
All rights reserved, including the right to reproduce this book in any form. It is the AAR’s intention that this
publication be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform
interchange of rail equipment in North America. To this end, only excerpts of a rule or specification may be
reproduced by the purchaser for their own use in promoting this objective. No portion of this publication may be
displayed or otherwise made available to multiple users through any electronic distribution media including but not
limited to a local area network or the Internet. No portion may be sold or used for advertisement or gain by any entity
other than the AAR and its authorized distributor(s) without written permission from the AAR.
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
ORDERING INFORMATION
Copies of the various sections of this manual can be obtained as follows:
CIRCULAR Subscriptions to Circular Letters of the AAR Safety and Operations’ Technical Services are available in
LETTER hardcopy or electronic format (online access via AAR’s Web page at http://aarcirculars.aar.org. Circulars
SUBSCRIPTIONS are issued at least monthly and include industry letter ballots and results, arbitration decisions, notification
of rules and standards revisions, industry early warning and maintenance advisories, and other
information related to mechanical rules and standards. Subscriptions are valid for one year.
For ordering information, contact the following:
Phone: Toll-free 877-999-8824, Direct 719-584-0538
Fax: 719-584-7157
Email: pubs@aar.com
AAR Web page: http://www.aar.org
TTCI Web page: http://www.aar.com
MSRP-A1 The MSRP-A1 Table of Contents is an inclusive index of all MSRP specifications, standards, and
INDEX recommended practices. It is available online at http://www.aar.com/standards/publications.php. This
easy-to-access document is a convenient way to quickly identify in which manual a specific document
resides. The index is updated weekly, enabling the user to see in "real-time" which documents have been
updated via Circular Letter.
MSRP-AS MSRP-AS serves as a supplement to all MSRP sections and is available as a free download at
ADMINISTRATIVE http://www.aar.com/standards/publications.php. All users are governed by the administrative standards in
STANDARDS MSRP-AS in addition to the standards and specifications in each section of the Manual of Standards and
SUPPLEMENT Recommended Practices.
TECHNICAL For technical questions regarding this manual, contact the following:
QUESTIONS Executive Director, Tank Car Safety
Association of American Railroads
425 Third Street SW
Suite 1000
Washington, DC 20024
Email: kdorsey@aar.org
Phone: 202-639-2262
Fax: 202-639-2356
11/2014 C-III–i
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
C-III–ii 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
TO THE USER
Section C, Part III, Specifications for Tank Cars, Manual of Standards and Recommended Practices
of the Association of American Railroads is Specification M-1002, and it is issued under the
authority of the Risk Management Committee. It covers tanks for “dangerous” commodities (or
hazardous materials) subject to U.S. and Canadian government regulation with supplementary
AAR requirements, and tanks for commodities not classified as hazardous materials and
consequently subject only to AAR regulation. The car structure is covered by a portion of Section C,
Part II, Specification M-1001, as well as a portion of this specification. There are six chapters:
• Chapter 1: Introductions, Approvals, and Reports
• Chapter 2: AAR Special Requirements for DOT Tank Cars
• Chapter 3: Specifications for AAR Tank Car Tanks
• Chapter 4: Reserved
• Chapter 5: General Design and Test Requirements
• Chapter 6: Car Structure Design and Test Requirements
There also is a series of appendices covering tank appurtenances, tank design, materials, welding,
repairs, alteration, lining, marking, nondestructive testing, and certification of tank car shops. This
publication supplements the U.S. Department of Transportation (DOT) Hazardous Materials
Regulations for Railroad Transportation, Title 49 CFR, Parts 170-180.
Revisions and additions to text and figures are identified by a bold, black, vertical line on the
unbound margin of the page adjacent to the affected change. The date of such revisions and
additions is indicated by date at the bottom of the page.
USER’S GUIDE
Section C, Part III, consists of the following:
• Preface: A listing of the subjects covered in the individual volumes making up this
manual. This preface is part of each section.
• Table of Contents: Identification of the chapters and appendices in numerical order.
• Specification M-1002: The body of this volume is a single specification setting forth
mandatory requirements for virtually all phases of tank car design.
• Recommended Practices: Appendix J and Appendix U
RELATED SECTIONS
Section C, Part III, Specifications for Tank Cars, should be used in conjunction with Section C, Car
Construction Fundamentals, and Section C, Part II, Specifications for Design, Fabrication and
Construction of Freight Cars. Other sections containing pertinent information are the following:
• Section B—Couplers and Freight Car Draft Components
• Section D—Trucks and Truck Details
• Section E—Brakes and Brake Equipment
• Section G—Wheels and Axles
• Section H—Journal Bearings and Lubrication
RESPONSIBILITY
The coverage of Section C, Part III, Specifications for Tank Cars, is the responsibility of the AAR
Tank Car Committee.
EFFECTIVE DATE
This November 2014 issue of M-1002 includes Tank Car Committee actions through the January
2007 meeting.
11/2014 C-III–iii
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
PREFACE
The Manual of Standards and Recommended Practices of the Safety and Operations Department,
Association of American Railroads, is issued by authority of the Management Committee of the
Division and includes all regularly adopted specifications, standards, and recommended practices
of the Association of American Railroads.
The manual is composed of the following sections:
• Section AS—Administrative Standards Supplement serves as a supplement to all MSRP
sections (this is available as a free download at http://www.aar.com/standards/publications.php)
• Section A—Table of Contents, Alphabetical and Numerical Index of Sections B through S
inclusive (this is available as a free download at http://www.aar.com/standards/publications.php)
• Section B—Freight Car Draft Components (100 Series)
• Section C—Car Construction—Fundamentals and Details (200 and 2000 Series)
• Section C, Part II—Design, Fabrication, and Construction of Freight Cars, M-1001
• Section C, Part III—Specifications for Tank Cars, M-1002
• Section D—Trucks and Truck Details (300 and 3000 Series)
• Section E—Brakes and Brake Equipment (300, 400, 3000, and 4000 Series)
• Section E, Part II—Electronically Controlled Brake Systems (4200 Series)
• Section F—Sensors
• Section G—Wheels and Axles (600 Series)
• Section G, Part II—Wheel and Axle Shop Manual (600 and 700 Series)
• Section H—Journal Bearings and Lubrication (700 Series)
• Section H, Part II—Roller Bearing Shop Manual (700 Series)
• Section H, Part III—Lubrication (Shop) Manual (700 Series)
• Section I—Intermodal Equipment Manual
• Section J—Specification for Quality Assurance, M-1003
• Section K, Part I—Railway Electronics Systems Architecture and Concepts of Operation
(9000 Series)
• Section K, Part II—Locomotive Electronics and Train Consist System Architecture
(9100 Series)
• Section K, Part III—Wayside Electronics and Mobile Worker Communications
Architecture (9200 Series)
• Section K, Part IV—Office Architecture and Railroad Electronics Messaging (9300 Series)
• Section K, Part V—Electronics Environmental Requirements and System Management
(9400 Series)
• Section K, Part VI—Railway Data Management and Communications (9500 Series)
• Section L—Lettering and Marking of Cars (900 Series)
• Section M—Locomotives and Locomotive Interchange Equipment (500 and 5000 Series)
• Section N—Multi-Level Manual (800 Series)
• Section S—Casting Details
• Section S, Part II—Truck Details and Casting Codes (300 and 3000 Series)
• Section S, Part III—Coupler and Yoke Details (100 Series)
Specifications are designated with an “M” prefix (e.g., M-900). Standards are prefixed “S” (e.g.,
S-900). Recommended Practices carry the prefix “RP” (e.g., RP-900).
C-III–iv 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
TABLE OF CONTENTS
Chapter Subject Page
1 Introductions, Approvals, and Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–1
2 AAR Special Requirements for DOT Tank Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–69
3 Specifications for AAR Tank Car Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–83
4 Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–99
5 General Design and Test Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–101
6 Car Structure Design and Test Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–113
LIST OF FORMS
See back of book for AAR forms for reproduction by the proponents.
Form 4-2 Application for Approval and Certificate of Construction
Form 4-2.1 Approval AAR Tank Committee
Form 4-3 Application for Approval of Pressure Relief Device
Form 4-4 AAR Tank Service Trial Report
Form 4-5 Application for Approval of Valves, Closures, and Fittings
Form 4-6 Final Service Trial Inspection Report
Form 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures,
and Fittings
CHAPTER 1
INTRODUCTIONS, APPROVALS, AND REPORTS
CONTENTS
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves,
Closures, and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–56
1.4.9 AAR Service Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–57
Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
1.4.10 Final Service Trial and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
1.4.11 Certified Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–64
1.5 Certification of Independent Third Parties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
1.5.2 Requirements and Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
1.5.3 Procedures for Obtaining Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
1.6 Document Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–66
DOT-105J100W 8-31-81 — — i/
DOT-105J200W 8-31-81 — — i/
DOT-105J300W 8-31-81 — — i/
DOT-105J400W 8-31-81 — — i/
DOT-105J500I 3-16-09
DOT-105J500W 8-31-81 — — i/
DOT-105J600I 3-16-09
DOT-105J600W 8-31-81 — — i/
DOT105S100W 8-31-81
DOT105S200W 8-31-81
DOT-105S300W 8-31-81 — — i/
DOT-105S400W 8-31-81 — — i/
DOT-105S500W 8-31-81 — — i/
DOT-105S600W 8-31-81 — — i/
DOT-105J200ALW 8-31-81 — — i/
DOT-105J300ALW 8-31-81 — — i/
ICC-106A800XNC — — 12-19-64 —
DOT-107A 1-13-32 9-15-71 — —
ICC-108 7-1-27 — 8-31-56 —
ICC-108A 7-1-27 — 8-31-56 —
DOT-109A100ALW 6-18-57 12-31-71 — —
DOT-109A200ALW 6-25-57 12-31-71 — —
DOT-109A300ALW 9-23-57 12-31-71 — —
DOT-109A300W 6-15-51 12-31-71 — —
DOT-110A500W 8-21-51 12-19-64 — j/
DOT-110A600W 2-12-75 — — j/
DOT-110A1000W 12-19-64 — — j/
DOT-112J200W 10-16-91 — — k/
DOT-112J500I 3-16-09
DOT-112J500W 10-19-77 7-13-78 — k/
DOT-112S200W 10-16-91 — — k/
DOT-112S600I 3-16-09
DOT-112T200W 10-16-91 — — k/
DOT-120A100W 10-18-94 — — —
DOT-120A200W 10-18-94 — — —
DOT-120A300W 11-10-66 — — —
DOT-120A400W 9-20-72 — — —
DOT-120A500W 3-2-72 — — —
DOT-120A600W 3-19-74 — — —
DOT120J100W 3-19-74
DOT120J200W 3-19-74
DOT120J600W 3-19-74
DOT-121A500W 11-13-68 — 3-2-72 m/
Table 1.2 Data for tank cars in interchange service not otherwise listed in these specificationsa/
Specification AAR-201A70W 113A175Wb/ 113D120Wb/
Lading temp, °F –423 –155
Material Al Alloy ASTM A240–304, –304L, or TC133
Insulation Optional 179.400–4
Burst pressure, psi (kPa) 350 (2413) 440 (3034) 300 (2068)
Tank construction Fusion-welded Fusion-welded. Impact tests
req’d. (welds and plate)
Minimum plate thickness 1/2 in. (5/8 in. bottom) 5/16 in. 3/16 in.
Shell
Heads 5/8 in. or 1/2 in. (2:1) 5/16 in. 3/16 in.
Dome 1/2 in. — —
Dome expansion capacity 2% — —
Test pressure, psi (kPa) 70 (483) 175 (1207) 120 (827)
Pressure relief devices Valve Valve and vent Valve and vent
Valve S-T-D pressure, psi 35 (241) 115 (793) 75 (517)
(kPa)
Valve vapor-tight pressure, psi 28 (193) 95 (655) 60 (413)
(kPa)
Valve flow rating pressure, psi 45 (310) 125 (862) 85 (586)
(kPa)
Vent burst pressure, psi (kPa) — 175 (1207) 120 (827)
Bottom outlet Optional — —
a/ Obsolete ICC tank car specifications conform to corresponding DOT specifications except for
method of tank construction or fittings arrangement. Metric equivalents shown for pressures
only.
b/ See also M-1002, 1982
Attachments to nozzle of jacket flashing, outage markers, eye bolt hinge tabs, and H&B
manway hinge tabs may be added after unit PWHT.
NPT American Standard Taper Pipe Thread
On-site inspection An evaluation performed at a tank car facility to determine if the tank car activities it B
performs comply with the applicable AAR specifications and federal regulations.
Operator/user A facility that loads or unloads a tank and then offers the car for transportation. U
Outside agency A company or individual who provides NDT services and whose qualifications to T
provide these services have been reviewed and approved by the employer contracting
the company or individual.
Pad An attachment welded directly to the tank under a bracket or light structure for the R
purpose of preventing damage to the tank through fatigue, over-stressing, denting,
puncturing, or tearing.
Padding The introduction of an inert gas under pressure into the vapor space of a tank car tank 2
to create a nonflammable or moisture-free atmosphere.
Patch plate A steel plate applied as an overlay in a corroded area. R
Pit A surface defect resulting from localized corrosion where the cavity diameter at the R
metal surface is equal to or less than the cavity depth.
Pits (grouped) Adjacent pits that are separated by a distance less than two times their average R
diameter.
Pits (random) Adjacent pits that are separated by a distance greater than six times the material R
thickness.
Plug weld A weld made in a circular hole in one member of a joint, fusing that member to another W
member. A fillet-welded hole is not to be construed as conforming to this definition.
Postweld heat treatment Any heat treatment subsequent to welding. W
Practical examination An examination used to demonstrate an individual’s ability in conducting the NDT T
methods that will be performed for the employer. For practical examinations, questions
and answers need not be written, but observations and results must be documented.
Preheat The heat applied to the base metal or substrate to attain and maintain the preheat R, W
temperature.
Preheat temperature, The temperature of the base material in the volume surrounding the point of welding R, W
welding immediately before welding is started. In a multi-pass weld, it is also the temperature
immediately before the second and subsequent passes are started.
Pressure plate A bolted manway cover that is designed for the mounting of pressure relief devices, 1
valves, and other closures.
Pressure regulator at The pressure 10 psig higher than the start-to-open pressure; the regulator is adjusted A
10 scfm air and set to flow 10.0 scfm ± 1.0 scfm of air at this pressure.
Pressure regulator start- The pressure at which the flow is 0.2 scfm to 0.6 scfm of air as measured with a flow A
to-open pressure meter or by collecting a timed volume of air by the displacement of water.
Pressure regulator The pressure with a flow of less than 0.1 scfm and nearly bubble tight. The lower limit A
reclosing pressure for an acceptable reclosing pressure is 80% of the start-to-open pressure.
Pressure regulator valve A device used to maintain a constant pressure in a tank car. As the pressure in the tank A
car increases, the valve opens to relieve pressure.
Purposes include, but are not limited to the following: measure fluid pressure and
temperature; sample fluids in the tank; detect or determine liquid levels; or relieve over-
pressures for purposes of emergency relief or temperature control.
Vapor valve Any valve that is opened or closed manually or automatically to permit the passage of A
vapor into or out of the tank.
Vaporizer A device used to evaporate liquefied compressed gases, usually where the required 5
flow rate exceeds the normal flow rate achieved by natural heat transfer from the
atmosphere.
Vapor-tight pressure The pressure, measured at the valve inlet after closing, at which no further fluid flow is A
detected at the downstream side of the seat of a pressure relief valve.
Visual An inspection of valves, fittings, and closures, without disassembly, for obvious signs D
of defects.
Visual inspection A nondestructive test method utilizing vision to detect surface imperfections in W
materials (including welds).
Weld surfacing or weld The application by welding of a layer, or layers, of material to a surface to obtain desired R, W
buildup dimensions or properties, as opposed to making a joint.
Welder One who performs manual or semiautomatic welding. W
Welding operator One who operates adaptive control, automatic, mechanized, or robotic welding W
equipment.
Class DOT-104W tank cars are insulated carbon steel nonpressure cars with an expansion dome
and having a minimum expansion capacity of 2% in the dome.
Class DOT-105A, J, or S***W tank cars are insulated carbon or alloy steel pressure cars, with a
manway nozzle, designed for top loading and unloading; bottom outlet or washout prohibited.
Class 105A or J***ALW tank cars are similar except that they have aluminum alloy tanks. Class
105A***F has forge-welded tanks.
Table 1.4 Class DOT-105A, J, or S***W suffix letters
A = equipped with top-and-bottom shelf couplers
J = equipped with jacketed thermal protection, tank head puncture
resistance, and top-and-bottom shelf couplers
S = equipped with tank head puncture resistance and top-and-bottom shelf
couplers
Class DOT-106A***X tanks are uninsulated carbon steel tanks designed to be removed from the
car structure for filling or emptying and designed to a maximum stress level in the shell.
Table 1.5 Class DOT-106A***X suffix letters
X = Fusion-welded longitudinal tank seam and forge-welded head seams
XNC = Nickel clad
NCI = Nickel—chromium—iron
Class DOT-107A**** tank cars are uninsulated high-pressure service cars having several
permanently mounted seamless, forged, and drawn steel tanks designed to a maximum stress
level in the shell.
Class DOT-109A***W tank cars are insulated or uninsulated carbon steel pressure cars with a
manway nozzle, designed for top loading and unloading, bottom washout optional.
Class DOT-109A***ALW tank cars are similar except they have aluminum alloy tanks.
Class DOT-110A***W tanks are uninsulated carbon steel tanks designed to be removed from the
car structure for filling or emptying and designed to a burst pressure.
Class DOT-111A***W* tank cars are insulated or uninsulated nonpressure cars without an
expansion dome. The expansion capacity in the tank is 2%. Class DOT-111A***W* tank cars built
for specific services or requiring special fittings or materials of construction are designated by
suffix letters or numerals. Class DOT-111A***F* have forge-welded tanks converted from
Specification ICC-105A300, 400, or 500. Suffix letters are shown in Table 1.6.
Table 1.6 Class DOT-111A***W* suffix letters
Bottom Bottom
Tank Outlet Washout
ALW1 Aluminum alloy
ALW2 Aluminum alloy No
W1 Carbon steel
W2 Carbon steel No
W3a/ Carbon steel
W4a/ Carbon steel No No
W5 Carbon steel, elastomer lined No No
W6 Alloy steel
W7 Alloy steel No No
F1 Carbon steel
F2 Carbon steel No
a/ Insulation required.
Class DOT-112A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel
pressure cars, with a manway nozzle and without bottom connections, designed for top loading and
unloading.
Table 1.8 Class DOT-112A, J, S, or T***W suffix letters
A = equipped with top-and-bottom shelf couplers
J = equipped with jacketed thermal protection, tank head puncture resistance,
and top-and-bottom shelf couplers
S = equipped with head shields and top-and-bottom shelf couplers
T = equipped with nonjacketed thermal protection system, top-and-bottom shelf
couplers, and head shields
Class DOT-113****W tank cars are vacuum-insulated cars having an inner container and carbon
steel outer shell. The insulation system is designed for a holding time. Class DOT-113 cars are
designed for specific loading and shipping temperatures and have certain materials and fittings
requirements as designated by the intermediate letter.
Table 1.9 Class DOT-113****W suffix letters
A = Minus 423 °F (–253 °C) loading; high alloy steel inner container; special
fittings and insulation for refrigerated (cryogenic) liquid hydrogen
C = Minus 260 °F (–162 °C) loading; high alloy steel inner container; special
fittings for refrigerated (cryogenic) liquid natural gas, refrigerated
(cryogenic) liquid methane (DOT exemption required), or refrigerated
(cryogenic) liquid ethylene
D = Minus 155 °F (–104 °C) loading; nickel alloy steel inner container; special
fittings for refrigerated liquid ethane (DOT exemption required) or
refrigerated (cryogenic) liquid ethylene
Class DOT-114A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel
pressure cars with a manway nozzle and optional noncircular cross-section. An additional group of
valves and fittings may be provided in another location.
Table 1.10 Class DOT-114A, J, S, or T***W suffix letters
A = equipped with top-and-bottom shelf couplers
J = equipped with jacketed thermal protection, tank head puncture resistance,
and top-and-bottom shelf couplers
S = equipped with head shields and top-and-bottom shelf couplers
T = equipped with nonjacketed thermal protection system, top-and-bottom shelf
couplers, and head shields
Class DOT-115A***W* tank cars are insulated nonpressure cars having an inner container and
carbon steel outer shell with optional bottom connections. Suffix letters are shown in Table 1.11.
Table 1.11 Class DOT-115A***W* suffix letters
W1 = Steel inner container
W6 = Alloy steel inner container
ALW = Aluminum inner container
Class DOT-120A, J, or S***W tank cars are insulated pressure cars with a manway nozzle. An
additional group of valves and fittings may be provided in another location
Class DOT-120***ALW tank cars are similar except that they have aluminum alloy tanks.
Class AAR-204 tank cars are vacuum-insulated cars having an inner container and carbon steel
outer shell. They are designed for loading of liquid argon, nitrogen, or oxygen. Specification AAR-
204W tank cars are similar in concept to Class DOT-113****W cars. Suffix letters are shown in
Table 1.13.
Table 1.13 Class AAR-204 suffix letters
X = Conversion from XT boxed tank cars
W = Fusion-welded alloy steel inner container and carbon steel outer shell
Class AAR-207A**W* pressure-differential covered hopper cars are designed for 15 psig
(103 kPa) minimum internal pressure and are used for the transportation of granular commodities
that are unloaded pneumatically. Suffix letters are shown in Table 1.15.
Table 1.15 Class AAR-207A**W* suffix letters
W = Carbon steel fusion-welded tank
ALW = Aluminum alloy fusion-welded tank
W6 = Alloy steel fusion-welded tank
Specification AAR-208 tank cars are nonpressure cars having wood-staved metal hooped tanks
for the transportation of certain food-grade materials.
Class AAR-211A***W* tank cars are insulated or uninsulated nonpressure cars without an
expansion dome. The numeral after “W” designates specific outlet and bottom connection options.
These cars conform, with certain exceptions, to Class DOT-111A***W*. Suffix letter or numerals
are shown in Table 1.16.
Table 1.16 Class AAR-211A***W* suffix letters
W1 = Carbon steel tank
2% minimum expansion capacity in tank
Optional bottom outlet or washout
W2 = Carbon steel tank
No bottom outlet
Optional bottom washout
W3 = Carbon steel tank
2% minimum expansion capacity in tank
Insulation required
Optional bottom outlet or washout
W4 = Carbon steel tank
No bottom outlet washout
Elastomer lining
W5 = Carbon steel, elastomer lined
No bottom outlet
No washout
W6 = Alloy steel
Optional bottom outlet or bottom washout
W7 = Alloy steel
No bottom outlet or bottom washout
ALW = Aluminum alloy tank
1.3.6.5 In addition to valves and/or closures approval requirements, the fittings arrangement on
the tank car also requires approval. The fittings arrangement is identified on the Form AAR 4-2
and is approved as part of the tank car design. If the fittings arrangement is altered, the alteration
must be approved. The alteration of the fittings arrangement must be submitted using the Form
AAR 4-2.
1.3.7 Editions of Referenced Specifications
Unless a specific year is recorded after the specification number, wherever AAR, ASTM, AWS, or
other specifications are noted, the latest editions are approved.
1.3.8 Calibration and Capacity Tables
1.3.8.1 Calibration
The procedures for tank car calibration are set forth in API Standard 2554, “Measurement and
Calibration of Tank Cars.” For all cars constructed after May 1, 2001, gauged or strapped
capacities shall be rounded to the nearest 10-gal and 50-L increments. Rounding is to be
performed after any conversion of units. For cars constructed prior to May 1, 2001, conformance to
this standard is optional.
1.3.8.2 Capacity Tables
For all cars constructed after May 1, 2001, capacity tables shall be provided by the car builder.
Capacity tables shall conform to the following:
1.3.8.2.1 Tables shall list outage volumes (volume of air or vapor above the surface of a liquid)
corresponding to distances measured downward from the shell-full (zero-outage) level.
1.3.8.2.2 Tables shall begin at the shell-full (zero-outage) level and continue for the full depth of
the tank.
1.3.8.2.3 If English units are used, volumes shall be whole U.S. gallons and distances shall be
inches in one-quarter-inch increments. If metric units are used, volumes shall be whole liters and
distances shall be whole centimeters.
1.3.8.2.4 All tables must show an effective date.
1.3.8.2.5 For reference, the following conversion factors are to be used:
• Multiply U.S. gallons by 3.785 to convert to liters.
• Multiply imperial gallons by 1.201 to convert to U.S. gallons.
• Multiply imperial gallons by 4.545 to convert to liters.
• Multiply inches by 2.540 to convert to centimeters.
1.3.8.2.6 Tank cars may be grouped when assigning capacity tables if the measured (water
gauged or strapped) shell-full capacity of the tank is within 0.1% of the shell-full capacity used in
the gauge table.
1.3.9 Gauging
Tank car tanks can be gauged by built-in gauge marker, tell-tale valve, or electronic or magnetic
gauging device as may be in accordance with the specification. Gauging can alternatively be
accomplished by scale weighing, liquid metering, or by use of poles and outage/innage tables,
depending upon the commodity and class of car involved. Procedures for gauging tank car tanks
are detailed in API Measurement Standard 3.2, “Tank Gauging—Gauging Petroleum and
Petroleum Product in Tank Cars.”
Effective August 1, 2005, tank cars equipped with slip tube gauging devices must have them
removed no later than the next tank qualification event. Cars altered under this rule need not
meet the capping kit requirements of Appendix E, paragraph 3.1.6.
1.4.1.1 AAR Tank Car Application for Approval and Certificate of Construction
Web-Based System
Effective January 1, 2015, applicants are required to use the AAR Tank Car Application for
Approval and Certificate of Construction Web-Based System for submittal of applications for tank
car designs. This system encompasses the entire process of seeking approval of tank car designs.
Tank car design applicants, AAR, and certified ITPs are required to obtain access to this system
and will use it in processing applications through the approval process, including the certificate of
construction submittal. A system user guide is available to those who obtain access.
To obtain access to the Tank Car Application for Approval and Certificate of Construction
Web-Based System, contact Railinc’s Customer Support Center (CSC) where the application is
hosted and maintained on behalf of the AAR. Customer support can be reached at 877-724-5462 or
via email to csc@railinc.com.
1.4.1.1.1 Drawings and Supporting Documents
In addition to the Form AAR 4-2, which must be completed in its entirety by the applicant, all
applicable drawings and supporting documents must also be uploaded following the outlined
instructions within the system. These drawings/documents must all be in PDF format.
1.4.2 Approval of Precedent and Nonprecedent Tank Car Designs (Form AAR 4-2)
All applications for approval, both nonprecedent and precedent (as defined herein), must be
submitted to the Executive Director—Tank Car Safety using Form AAR 4-2, Application for
Approval and Certificate of Construction. Form AAR 4-2 is reproduced in this manual in Fig. 1.1,
and paragraph 1.4.3.1 contains instructions for its completion.
Precedent applications (i.e., applications based on prior Committee-approved applications) will
be evaluated by AAR staff as described in paragraph 1.4.2.3.
Nonprecedent applications (and listed major deviations from precedent applications) will be
reviewed and evaluated by a certified ITP, selected by AAR staff from a list of contractors approved
by the Tank Car Committee. Handling of nonprecedent applications is further described in
paragraph 1.4.2.2.
1.4.2.1 Fees
Application fees are listed in the Office Manual of the AAR Interchange Rules, Appendix E. In
addition, applicants are responsible for the cost associated with the review of applications by an
ITP. Applicants will receive invoices for fees related to the application process.
1.4.2.2 Nonprecedent Applications
Nonprecedent applications are those not based on previously approved designs. When required by
AAR Specification M-1001 or paragraph 1.4.2.5 of this specification, one copy of the application
with multiple sets of drawings must also be furnished to the AAR Technical Services Section for
approval of brake systems and car structure.
The certified ITP assigned by AAR staff will review the application for compliance with AAR and
DOT/TC requirements and will deal directly with the applicant to resolve any discrepancies. The
Director must receive copies of all correspondence related to resolution of questions on the
application. The AAR will be notified by the certified ITP through the web-based system that the
application is satisfactory. The ITP is required to respond to either the applicant or AAR, as
appropriate, within 21 days of receipt of the application. If a discrepancy leads to an application
revision, the ITP is required to respond to the applicant or AAR within 14 days of receipt of the
revised application.
In the event that an ITP and the applicant cannot resolve discrepancies in an application and the
ITP recommends against approval, the applicant may request Tank Car Committee review of the
application in accord with the process outlined in paragraph 1.4.2.12.
Line Instruction
1. Indicate by an “X” in the appropriate block whether nonprecedent or precedent approval,
based on a precedent already approved by the Committee, is requested. AAR staff will
assign nonprecedent requests to the Committee or to an ITP, as appropriate.
2. Indicate if the application concerns construction, conversion, alteration, repair, or other
(provide description for “other”).
3. Enter the application number, which will be provided by the Director on request. The
number will be prefixed to indicate the nature of the application according to the following
code. This application number will become the certificate number upon receipt of
certification.
In the event that the method of approval changes after submission, the AAR staff will
revise the prefix to correspond to the proper code.
4. Enter the date of the original application. Dates of revisions to the application must be
shown under “Revisions.”
4.1 Enter the date the order was made with the Tank Car Builder. MM/DD/YYYY
5. Enter a file number or builder lot number.
6. Enter the name of the applicant. For new construction, the applicant must be the tank car
builder. For conversion, alteration, or repair, the applicant must be the car owner or the
facility authorized to perform such work.
7. Enter the tank specification to which the tank is to be built (e.g., DOT-111A100W1).
8. If the car is to be operated under a specification other than the one shown on Line 7, the
stenciled specification must be entered here (e.g., AAR-211A100W1).
9. The reporting marks and car numbers entered here must be those that are or will be
recorded in the “Official Railway Equipment Register” covering the car or cars in question.
10. Enter the total number of cars represented by the car numbers or series shown on Line 9.
11. If the car is designed for a specific commodity, enter its proper shipping name. If the car
is not designed for a specific commodity or is limited to certain commodities, enter the
words “(Initial lading) and products authorized by DOT Part 173 for which there are no
special commodity requirements and nonregulated commodities compatible with this
class of car.” If special commodity stenciling is required, it must be shown under “Notes.”
Line Instruction
12. If the car is designed for a specific commodity, enter the weight of the commodity in
pounds per gallon or pounds per gallon and kilograms per liter. When Line 11 shows “DOT
Part 173” and an initial commodity, show the weight of the initial commodity.
13. Enter the tank capacity in U.S. gallons or U.S. gallons and liters. For nonpressure cars,
record shell-full volume. For pressure cars, record shell-full volume plus volume of
manway nozzle.
14. Enter the as-designed outage in U.S. gallons or U.S. gallons and liters.
15. Enter the material specifications for tank shell and heads and their respective
through specifications and thicknesses.
16.
17.
18.
15.1 Indicate whether or not the tank head material is normalized. (Yes= normalize; No=not
normalized)
15.2 Indicate whether or not the tank head is spliced. (Yes or No)
15.3 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the
impact test temperature.
16.1 Indicate whether or not the tank shell material is normalized. (Yes= normalize; No=not
normalized)
16.2 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the
impact test temperature.
19. Where linings are required by the specification, the lining material and thicknesses must
be shown.
20. Enter tank inside diameter, in inches, at center and at tank ends. May also be submitted
21. in both inches and millimeters.
22. This item refers to dished heads and, when such heads are used, the main radius in inches
or inches and millimeters must be entered.
23. Enter the actual test pressure for which the tank is designed, including maximum
pressure relief device setting permitted by 49 CFR 179.15. Use psi or psi and kPa.
24. Enter the type of insulation used (e.g., fiberglass, cork, polyurethane, etc.)
25. Enter the thickness of insulation in inches, or inches and millimeters, for all insulated
tanks.
26. The thermal conductivity of the insulation must be shown in the units indicated at 60 °F
(15.6 °C). (Mineral wool, ceramic fiber, or other thermal protection materials are not
considered insulation.) SI equivalent units are kJ•mm/h•m2•°C.
27. These items must indicate whether the pressure relief device is a valve, vent, or breather
28. vent. The number of such devices and the start-to-discharge pressure or bursting pressure
must be shown in psi or psi and kPa.
27.1 Enter the number of safety relief devices.
29. For pressure relief devices, the required flow capacity in cubic feet per minute, or cubic
feet per minute and cubic meters per second, must be entered.
30. When pressure relief devices are used, enter the actual flow capacity provided.
31. Enter the exterior tank surface area in square feet or square feet and square meters.
32. For tank cars with an underframe, enter “full.” For stub sill cars, enter the code for the
stub sill style (see Appendix R, Exhibit R-2, fourth page, for builder and sill codes).
Line Instruction
33. Enter the height from top of rail to the center of gravity of the tank car in inches or inches
and millimeters. If the center of gravity height exceeds 84 in. (2130 mm) on cars with four-
wheel trucks having 6 1/2 in. × 12 in. journals or larger, an asterisk must be used to refer
to a comment under “Notes,” indicating car truck centers or truck spring travel.
34. Enter the estimated light weight of the completed car in pounds or pounds and kilograms.
35. Indicate if car is constructed to AAR Clearance Diagram Plate B, C, E, or F.
36. The rail load limit must be shown and must be compatible with the truck capacity for the
number and size of axles used. If gross weight on rail exceeds 263,000 lb with
6 1/2 in. × 12 in. journals, approval of the AAR Equipment Engineering Committee is
required (see paragraph 1.4.2.6).
37. Enter the truck capacity in tons.
38. If the car is fitted with head shields, indicate whether “half ” or “full.”
38.1 Enter the thickness in inches of the head shield material.
39. Drawings. Enter the drawing number of all drawings relevant to the application in the
through first column headed “Drawing Number.” Enter information in the next two columns
53. concerning prior approvals in accord with the following instructions.
a. If a cited drawing is being submitted for ITP or Committee consideration without
reference to a previously approved drawing, leave the second and third columns blank.
Prints must be furnished and an explanation provided by letter or separate sheet.
b. If a cited drawing has been previously approved by an ITP or the Committee and
nothing has changed on that drawing, enter the application number of the prior
approval in the third column and leave the second column blank. Submission of these
precedent drawings is not required unless the application includes both precedent and
nonprecedent drawings that will require ITP review, in which case all drawings are to
be submitted, including the precedent drawings.
c. If a cited drawing is based on a previously approved drawing, but with changes
permitted under paragraph 1.4.2.4, enter the precedent drawing number in the second
column and its approved application or certificate number in the third column. Prints
of the new drawings must be furnished with the application, and deviations from the
precedent drawing must be explained by letter or on an attached sheet.
d. Applications prefixed F, G, H, J, or K may not be referenced. Only applications under
which a drawing has been reviewed and approved may be referenced.
e. If a precedent drawing is from a current application that is pending approval, indicate
“Pend” after the application number in the third column.
f. If drawings cited as prior approvals have not been approved within the past 10 years,
such drawings must be resubmitted with the application.
g. All prints of drawings and calculations submitted with Form AAR 4-2, must carry a
current approval signature or initial by the proponent, and must be marked with the
application number with which they are submitted.
54. Applications for new construction must include a drawing that indicates structural welds
to be inspected during requalification. For jacketed cars, the drawing must include
dimensions referenced to a visible area of the car.
1.4.3.1.2 Application for approval of new tanks to be mounted on existing car structures must be
accompanied by a statement under “Notes” that “Car structure complies with all requirements of
the AAR Interchange Rules and is suitable for continued service.”
1.4.3.1.3 Applications for conversion, alteration, or repair must indicate current specification,
former lading, date built new, and previous certificate number(s) under “Notes” and must show
specification and new commodity on Line 7 and Line 11, respectively. Supply a supplemental
sheet, if necessary, to associate the car numbers with their previous certificate numbers.
1.4.3.1.4 For applications covering welded repairs on tanks using procedures or materials that
have not been previously approved, fill in Lines 1 through 38, inclusive. Description of damage to
tank, date, place, and circumstances of damage, together with proposed method of making repairs,
must also be submitted under “Notes” on a continuation sheet.
1.4.3.1.5 For applications covering reconditioning of manway covers for tank cars covered by
DOT 179.100, submit data on original construction, certificate numbers, and car specification,
with drawing numbers used in original construction. Application must include drawings and a
detailed explanation of how repairs are to be made.
1.4.3.1.6 Applications submitted by facilities other than the fabricator of tank shell and heads for
assembly of new tank cars must be accompanied by a statement under “Notes” that “Tank shell
and head fabrication by... (certified facility). Completed car will comply with all applicable AAR
and DOT requirements.”
1.4.3.1.7 Certain car designs, appurtenances, valves, fittings, or attachments may be declared by
the Tank Car Committee to be subject to service trials before general acceptance for new
construction. Such service trials and their restrictions must be identified by the applicant or AAR
under “Notes.” Service trial numbers are assigned by the Director. See paragraph 1.4.9.
1.4.3.1.8 DOT exemptions, special approvals (SAs), or Canadian special permits applicable to the
car or commodity must be identified under “Notes.” A copy of the latest revision must be submitted
with the application.
1.4.3.1.9 Applications for increased truck capacity must be supported by justification (with
calculations if necessary) to verify the structural adequacy of the car for increased capacity and
braking requirements.
1.4.3.1.10 Valves are to be identified by manufacturer, size, and identification number on the
drawings or application, whether or not supplied by the proponent.
1.4.3.1.11 The method of anchoring the jacket of an insulated car must be submitted with Form
AAR 4-2.
1.4.3.2 Approval
AAR staff complete the “Approval” section of Form AAR 4-2 based on action taken on the
application.
1.4.3.3 Certification
The “Certification” section of Form AAR 4-2 is to be completed only after the approved application
has been received from AAR and the referenced construction, alteration, conversion, or repair has
been completed. Certification is accepted only from a responsible Quality Control representative
acting for the facility performing the work, from an officer of the company performing the work, or
from the car owner. When signed by all parties, the completed Form AAR 4-2 is recognized as the
Certificate of Construction for the car or cars identified thereon.
SIGNATURE
TITLE
CERTIFICATION: The cars enumerated below conform to the above approved description and to all applicable DOT and AAR requirements, including specifications,
regulations, rules of interchange, and the DOT Railroad Safety Appliance Standards. Copy of this Certificate of Construction will be furnished to the owner and others as
required by 49 CFR Part 179.5 before these cars are placed in service.
Initials and Car Numbers
Name Date
Title
Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction
Date _____________________________
1.4.5.1.6 Metallic fittings require Tank Car Committee approval unless all of the following
conditions are met:
• Parts are manufactured in accordance with a nationally recognized standard (e.g., SAE,
ASME, ANSI, MIL) or Appendix M.
• Parts are designed to meet or exceed the operating pressure rating of a tank car.
• Parts are designed to be leak tight.
• Parts must be joined in accordance with Appendix E, as specified by the tank car
manufacturer or owner, or ASME Section 8, Division 1.
• Fitting must be marked with the name of the manufacture and pressure rating and with
additional markings as agreed to by purchaser and manufacturer.
• Approval is granted for the application of the fitting to the tank car when the Form AAR
4-2 for the tank car is approved for a specific application for new construction, alteration,
conversion, or repair.
1.4.5.2 Approval of Service Equipment
Tank car service equipment must be approved by the Tank Car Committee. Approvals of service
equipment must be renewed every 10 years. Approvals will be marked with the expiration date,
which shall be the end of the month in which the approval was executed plus 10 years. Table 1.17
outlines the devices by group, committee approval, and what form is to be used. The application
process, instructions, and forms are provided within this chapter.
Note: All submitted materials must be marked with an assigned AAR number.
1.4.6.1.2 The application package for pressure relief devices shall consist of the following:
• Form AAR 4-35
• Test results required in Appendix A, paragraph 5.3
• Drawings (assembly drawing and any additional drawing necessary to describe the device
including a Bill of Material)
• Flow test facility’s report, if applicable
• Supplemental information as applicable
• Application fee per Appendix E of the Office Manual of the AAR Interchange Rules
1.4.6.2 Instructions
1.4.6.2.1 The following instructions must be followed by the applicant when completing the
application and certification portions of the form:
• The applicant must request an AAR number from the Executive Director.
• The applicant must be the valve manufacturer or its agent.
• The date must be that on which the application is completed.
• The applicant’s number blank is for the convenience of the applicant.
• The device identification number is for the convenience of the applicant (e.g., catalog
number).
1.4.6.2.1.1 The numbered items must be entered as follows:
Line Instruction
1. Identify the manufacturer of the device.
2. Record the test facility used to determine the flow capacity of pressure relief valves, as
required in Appendix A.
3. Record the location of the test facility.
4. Record the date the flow rating tests were conducted.
5. Write the authorized observer’s name here.
6. Record the identity of each device tested, as required in Appendix A, paragraph 5.2.
7. Record the start-to-discharge pressure in psi (or psi and kPa) of each device tested.
8. Record the flow rating pressure in psi (or psi and kPa) of each device tested.
9. Record the vapor-tight pressure in psi (or psi and kPa) of each device tested.
10. Record the flow capacity in cfm (air) or cfm and m3/s (air).
11. Record the official flow capacity in scfm (air) or scfm and standard m3/s (air), obtained at
the required flow rating pressure in psi (or psi and kPa) by an approved method (see
Appendix A, paragraph 5.2).
12. Enter Regulated Commodity, Non-Regulated Commodity, or Specific Commodity.
13. Drawings. Under these items, all drawings relevant to the application must be listed in
through the first column headed “Drawing Number.” Information for columns two and three under
“Precedent” shall be determined by the appropriate following instructions:
14.
15.
16.
a. If a drawing has been previously approved by the Tank Car Committee, enter the
certificate number of the approval in the third column and leave the second column
blank. Prints need not be submitted.
b. If a new drawing is submitted for Committee consideration, leave the second and third
columns blank. Prints must be furnished and an explanation provided by letter or
separate sheet.
c. If a new drawing is submitted for Committee consideration and a precedent drawing
is appropriate, enter the precedent drawing and its application or certificate number
in columns two and three. If the precedent is pending before the Committee, indicate
“Pend” after the application number. Prints of the new drawing must be furnished and
deviations must be explained by letter or separate sheet.
d. If a precedent is pending before the Committee, indicate “Pend” after the application
number. Prints of the new drawings are not required to be submitted, but deviations
must be explained by letter or separate sheet.
e. Under b, c, or d above, if the same new drawing and precedent are shown on another
pending application, this information must also be indicated by letter or separate
sheet. The first approval received must be the approval of record for the drawing.
C-III [M-1002] 48 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 CHAPTER 1
Line Instruction
f. All drawings submitted with Form AAR 4-3 must carry a current approval signature
or initial by the proponent.
14 Note: When the design of a pressure relief device is such that the spring follower is guided
by the mounting nozzle, the mounting nozzle shall be considered as a required part of the
application and a drawing of the nozzle in sufficient detail to show critical dimensions
shall be included. When the pressure relief device design does not require the mounting
nozzle to act as a guide for the spring follower, the word “None” can be used in the space
for this item.
1.4.6.2.2 Certification
The applicant signs the form under “Certification” attesting to the above entries.
1.4.6.2.3 Approval by AAR Tank Car Committee
1.4.6.2.3.1 The Executive Director—Tank Car Safety completes the approval section of the form
based on action taken on the application.
1.4.6.2.3.2 The Approval of Service Trial section is designated for approving the device for a
service trial.
1.4.6.2.3.3 The Approval of Design section is designated for approving the device either after
successful completion of a service trial or in the case where a service trial is not required and the
device is approved without a service trial.
1. Manufacturer
Address
2. Test facility name 3. Test facility location
4. Test date 5. Observer
6. Device 7. Start-to-discharge 8. Flow rating 9. Vapor-tight 10. Flow capacity
Number psi kPa psi kPa psi kPa SCFM std.m3/s
11. Official flow capacity (air) scfm ( std. m3/s) at flow rating pressure psi ( kPa)
Test medium
12. Commodity: Regulated Commodity Nonregulated Commodity Specific Commodity
Precedent
The following drawings apply Drawing number Application/
Latest revision Drawing number Certificate
13. Valve Assembly……………………………………..
14. Valve Mounting Nozzle……………………………..
15. ……………………………………………………….
16. ……………………………………………………….
REVISIONS:
CERTIFICATION: The above data is correct. The capacity test complies with AAR Specifications for Tank Cars, Appendix A and
the devices tested conform with the drawings listed above.
By: Title
APPROVAL of Service Trial by AAR Tank Car Committee
AAR Service Trial Required Service Trial Number: ST-__________
Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device
1.4.7.1.2 The application package for valves, closures, and fittings shall consist of the following:
• Form AAR 4-5
• Drawings (assembly drawing and any additional drawing necessary to describe the device
including a Bill of Material)
• Flow test facility’s report, if applicable
• Supplemental information as applicable
• Application fee per Appendix E of the Office Manual of the AAR Interchange Rules
Note: All submitted materials must be marked with an assigned AAR number.
1.4.7.2 Instructions
1.4.7.2.1 The following instructions must be followed by the applicant when completing the
application and certification portions of the form.
• The applicant must request an AAR number from the Executive Director.
• Applicant must be the manufacturer of the device or its agent.
• The date must be that on which the application is completed.
• Describe the device and its function in accord with the definitions and requirements of
Appendix A.
• Spaces for the applicant’s number and the device identification number are for the
convenience of the applicant (e.g., index, catalog, or type numbers).
1.4.7.2.2 The numbered items must be entered as follows:
Line Instruction
1. Identify the manufacturer of the device.
2. Record the test facility that tested the device, if other than the manufacturer’s.
3. Record the date testing was completed for subject device.
4. Indicate the applicant’s observer’s name and title.
5. Indicate the procedure used to test the prototype device and the number of devices tested.
6. Indicate the number of cycles to which a device was subjected at high and low
temperatures and at the given pressure, as well as the specific test medium used (e.g., air,
water, etc.).
7. Indicate the commodity or commodity type.
8. Indicate the flow rate of the device in gallons per minute, or gallons per minute and liters
per minute, if applicable.
9. Indicate the drawing number showing the application of the device to the car and the basic
material. When applicable, reference a precedent drawing with AAR application number.
Line Instruction
10. Indicate the drawing number of the device assembly and basic material and, when
applicable, reference a precedent drawing with AAR application number.
11. Indicate the drawing number and material specification of individual parts.
12. Provide a basic statement that the facility has a quality control program to provide
compliance with drawings and specifications.
1.4.7.2.3 Revisions/Certification
• The “Revisions” space is provided to indicate any revisions to the original application.
• The applicant signs the form under “Certification,” attesting to the above entries.
1.4.7.2.4 Approval by AAR Tank Car Committee
The Executive Director—Tank Car Safety completes the approval section of the form based on
action taken on the application.
The Approval of Service Trial section is designated for approving the device for a service trial.
The Approval of Design section is designated for approving the device either after successful
completion of a service trial or in the cases where service trial is not required and the device is
approved without a service trial.
1. Manufacturer
2. Address City State Zip
3. Test facility if other than the manufacturer Address
4. Test date 4. Observer
Title: .
TEST PROCEDURE
5. Description of prototype testing:
6. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
7. Commodity: Regulated Commodity___ Non Regulated Commodity ___ Specific Commodity
8. Flow rate (if applicable) gpm ( L/min)
Drawing Number Precedent
Applicable drawings Material latest revision Drawing Number Application/Certificate
9. Device application . . . . . .
10. Device assembly . . . . . . . .
11. Device details . . . . . . . . . .
12. Quality Control Statement
REVISIONS:
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars, Appendix A. The devices
tested conform with drawings listed above.
By Title
APPROVAL AAR Tank Car Committee Service Trial Required
Date Approved for Service Trial
Service Trial Number
(Signature) on behalf of Tank Car Committee
APPROVAL AAR Tank Car Committee Service Completed / Not Required
Date Service Trial Completed Date AAR Received Form AAR 4-6 .
Date Approved _____________________________________
Expiration Date ____________________________________ ________________________________________________
(Signature) on behalf of Tank Car Committee
Form AAR 4-5 Revised 10/2014
Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings
1.4.8 Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings
1.4.8.1 Procedures for Renewal—Application Form AAR 4-7
1.4.8.1.1 To secure approval for renewal of approval for pressure relief devices, valves, closures,
and fittings as required by paragraph 1.3.6, the completed application package as defined in
paragraph 1.4.8.1.2 must be submitted to the following:
Executive Director—Tank Car Safety
Association of American Railroads
425 Third Street S.W., Suite 1000
Washington, D.C. 20024
1.4.8.1.2 The application package for renewals shall consist of the following:
• Form AAR 4-7
• Drawings (assembly drawing and any additional drawing necessary to describe the device
including a Bill of Material)
• Flow test facility’s report, if applicable
• Supplemental information as applicable
• Application fee per Appendix E of the Office Manual of the AAR Interchange Rules
Note: All submitted materials must be marked with an assigned AAR number.
1.4.8.2 Instructions
1.4.8.2.1 The following instructions must be followed by the applicant when completing the
application and certification portions of the form.
• The applicant must request an AAR number from the Executive Director
• Applicant must be the manufacturer of the device, or its agent.
• The date must be that on which the application is completed.
• Spaces for the applicant’s number and the device identification number are for the
convenience of the applicant (e.g., index, catalog, or type numbers).
1.4.8.2.2 The numbered items must be entered as follows:
Line Instruction
1. Enter the AAR Number assigned by the Executive Director.
2. Enter the date which the application is completed.
3. Enter the previous AAR approval number under which the device was approved by the
Tank Car Committee.
4. Enter the applicant’s name.
5. Enter the applicant’s Address, City, State, and ZIP.
6. Provide an applicable drawing number.
7. Enter the latest revision.
8. Enter the date of the latest revision.
9. Enter detail description of the device.
10. For convenience of the applicant, enter the device ID No. (e.g., index, catalog, type
numbers).
11. If the subject device is unchanged, the applicant signs the certification attesting to the
entries on the form and enters the applicant’s title.
12. Identify the previous and current drawings, and if on service trial the service trial number.
Line Instruction
13. Indicate whether or not the change supersedes the drawings.
14. Describe the changes and the reasons for making the changes.
15. Provide a statement about the operational effect of the changes.
16. Identify the drawing submitted with this application.
17. If the device has changed, then the applicant signs the certification that the data is correct
and conforms with AAR Specifications for Tank Cars and the device conforms with
drawing listed on the form
1.4.8.3 Certification
The applicant signs the “Certification,” attesting to the entries. Enter the applicant’s title. Applies
to Line 11 or 17, whichever is applicable.
1.4.8.4 Approval
The Executive Director completes the approval section of the form based on action taken on the
application.
CERTIFICATION: The subject device is unchanged from the previous approval, and conforms with the
latest revision of AAR Specifications for Tank Cars, Appendix A. The device conforms
with drawing listed above.
13. New drawing supersedes previous one
or does not obsolete it
CHANGES REASONS FOR CHANGES
14. a. a.
b. b.
c. c.
d. d.
(if needed use supplemental sheet)
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars,
Appendix A. The device conforms with drawing listed above.
Date Approved:
(Signature) on behalf of Committee
Form AAR 4-7 8/1/2014
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures, and
Fittings
C-III [M-1002] 56 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 CHAPTER 1
1.4.9.2.2.2 The maximum number of units that can be applied to tank cars may be exceeded if
authorized by the Executive Director or his designee. After receipt of approval for non-regulated
service, the maximum number of units that may be applied in regulated service is no longer
restricted.
1.4.9.2.2.3 The devices in the service trial must average 5,000 loaded miles and 10 loaded trips
per year. If at the 1-year anniversary one or both of these averages are not being met, the applicant
may apply to the Tank Car Committee for modification of these averages.
1.4.9.2.2.4 For non-regulated commodities, each car set of the device must be subjected to a trial
of 1 year minimum duration.
1.4.9.2.2.5 For regulated commodities, each car set of the device must be subjected to a trial of
2 years minimum duration.
1.4.9.2.2.6 Successful completion of 1 year, 5,000 loaded miles, and 10 load cycles in regulated
commodity service may be used to qualify the device for non-regulated service.
1.4.9.2.2.7 In cases where a proponent believes that the standard field service trial format is not
applicable when considering the intended application of the service equipment in the field, the
applicant can propose an alternate field service trail format as an attachment to the applicable
Form AAR 4-3 or 4-5. Proper justification, including applicable test data, must be submitted as
part of the attachment to Form AAR 4-3 or 4-5.
1.4.9.2.2.8 If the service trial is not completed within 3 years from the start date, the service trial
will be terminated and any approvals will be revoked unless continuation is requested from the
applicant and approved by the AAR Tank Car Committee.
1.4.9.2.2.9 Difficulties experienced during the service trial (e.g., leakage, breakage, or
performance problems) must be reported as soon as known to the Executive Director for review by
the Tank Car Committee and reported on the next submitted Form AAR 4-4. The report should
include a description of the issue along with the corrective action. If the analysis indicates an
operational issue (failure to close or otherwise secure the device) and does not affect the
functionality of the device, report as such on the next Form AAR 4-4 and no further analysis is
required as part of the service trial.
1.4.9.2.3 Teardown Inspection
The purpose of the teardown is to examine a number of devices at the conclusion of their service
trial and determine from signs of wear what should be the qualification interval for the device.
1.4.9.2.3.1 Observer of Teardown
Unless the Tank Car Committee has specified their observer of the teardown, the observer shall be
the QA manager of the applicant.
1.4.9.2.3.2 Teardown of Device
Before tearing down a device, it must be subjected to the applicant’s acceptance test of
manufacture and must be cycled one time with the device meeting the test requirements of
Appendix D.
All components of a torn-down device must be kept together for 180 days pending Tank Car
Committee request to examine the device.
1.4.9.2.3.3 Documentation
Copies of any tests and notes of conditions found shall be kept. Photographs of each step of the
teardown process and each individual component must be kept.
A copy of the test and inspection procedure and copies of each bench test and appropriate
photographs shall be included with the submission of the Form AAR 4-6.
1.4.9.2.3.4 At the conclusion of a service trial, Form AAR 4-6 “Final Service Trial Inspection
Report,” with any design changes the service trial indicates are necessary must be submitted to
the Tank Car Committee for approval with a copy of the original application. The Tank Car
Committee may request additional tests to supplement the manufacturer’s tests or service trials
prior to acceptance of the device.
1.4.9.3 Service Trial Report Form AAR 4-4
Service trial data must be submitted to the Executive Director on Form AAR 4-4, AAR Tank Car
Service Trial Report, at 6 month intervals before the April and October meetings of the Tank Car
Committee, no later than April 1 and October 1. Failure to submit the report may result in
cancellation of service trial authorization and revocation of all approvals. The Executive Director
shall be notified when the service trial starts; 90 days before the 2-year service trial ends; and
90 days before teardown is planned.
1.4.9.3.1 Instructions
1.4.9.3.1.1 The following instructions must be followed by the proponent when completing the
Service Trial Report.
• AAR number is the same number used on Forms AAR 4-2, AAR 4-3, or AAR 4-5.
• AAR docket number is the number assigned by the Director to review a specific item when
requested by the Tank Car Committee.
• AAR service trial number is the number issued by the Director at the time the application
is processed.
• Reporting company is the applicant or applicant’s representative having knowledge of the
performance and service of the device.
• The date must be the date on which the report is completed.
• Period covered is the period from the date of application or date of last report to the
required reporting date as specified above.
1.4.9.3.1.2 Enter the numbered items as follows:
Line Instruction
1. The applicant’s number blank is for the convenience of the applicant.
2. The device identification number is for the convenience of the applicant (e.g., catalog
number).
3. Record the date the device was initially installed on the car.
4. Describe the device as it was described on Form AAR 4-2, 4-3, or 4-5, giving function in
accord with the definitions and requirements of Appendix A.
5. Record the total number of cars authorized by the Tank Car Committee to have device
applied and the number of cars covered by the individual report.
6. Record the specific car numbers.
7. Indicate the commodity or commodity type.
8. Indicate the date of initial installation of the device.
9. Indicate the number of loaded trips and total miles the car moved in the period covered by
the report.
Line Instruction
10. Show the total number of loaded trips and the total distance for each car to date for this
service trial. Indicate the average trips and distance for all cars.
11. Indicate the loading temperature of commodity, if known and applicable.
12. Indicate the unloading temperature of commodity, if known and applicable.
13. Indicate the loading pressure, if applicable.
14. Indicate the unloading pressure, if applicable.
15. Indicate the operational or performance difficulties encountered. Specify by car number.
16. These items provide recommendations to the Tank Car Committee.
through
17.
18.
AVERAGES
Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report
Line Instruction
1. Enter the name and address of the applicant to whom service trial is assigned.
2. Enter the name and address of the device manufacturer, if different than that of the
applicant.
3. The description designation and/or model number of the device should be the same as
4. shown on Form AAR 4-3 (see Fig. 1.3) or Form AAR 4-5 (see Fig. 1.4).
5. Enter the total number of devices of this description or model number in the service trial
sample.
6. Enter the number of devices from the service trial sample that are included in the tests
and inspections reported.
7. Enter the total load/unload cycles, total loaded mileage, and total service time for the
service trial sample and average for the devices to be torn down. (Details for each device
or car should be available on Form AAR 4-4 submitted during the service trial.)
8. Enter actual test conditions to which each teardown sample is subjected (see Chapter 1,
paragraph 1.4.9 for teardown sample size). Comment on test results, physical condition,
corrosion, wear, etc. Compare critical dimensions to original.
9. Show drawing numbers and indicate revisions made during service trial.
10. Conclusions are those of the proponent after the tear down.
11. Recommendations are those of the designated Tank Car Committee observer.
12. The form is signed by the applicant or manufacturer (or agent) performing the tests and
inspections. The signature of the independent observer (if designated by the Committee)
also appears.
13. Upon successful completion based on the comments in Lines 10 and/or 11, the Executive
Director will approve the Final Service Trial Inspection Report and complete the approval
of the Form AAR 4-3 or 4-5, as appropriate.
1.4.10.2.3 The samples examined must have had the full range of service trial experience.
3. Description of device
4. Device designation or model no.
5. Total number of devices in service 6. Number of devices for teardown
7. Service data for service equipment under this inspection
Total load/unload cycles and average Total loaded mileage and average
Total service time and average
Test remarks……………...
Physical condition…….….
Compare critical final
dimensions to original.…..
9. Drawing numbers…….…....
(Ref. Form AAR 4-3 or AAR 4-5)
Revisions made…….….....
Revision date…….….........
10. Conclusions
12. CERTIFICATION
The above data is correct and complies with the AAR Specifications for Tank Cars, Appendix A. Devices tested
conform to the drawings listed above.
(Signature) (Signature)
Title Title
Company Company
Date approved
(Signature) on behalf of Tank Car Committee
Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report
1.6.4.1 Table 1.20 lists the documents that must be retained by each certified and registered tank
car facility:
Table 1.20 Documents retained by certified and registered tank car facility
Document Retention Period
Certification/registration of facilities 6 years
Welding procedure and procedure qualification While valid
Performance qualification of welders and operators While valid, plus 90 days
Procedure qualification While valid
NDT written practice While valid
NDT certification records While valid, plus 90 days
NDT procedure requirements While valid
Results of radiographic examinations (radiographs may be retained or discarded) 5 years
Exhibit B-1 Subcontractor’s evaluation sheet (requires an annual review) While valid
1.6.4.2 Table 1.21 lists the documents that must be retained by each registered manufacturer of a
tank car pressure relief device, and service equipment:
Table 1.21 Documents retained by registered manufacturer of tank car pressure relief device and service equipment
Document Retention Period
Final service trial inspection report 2 years
Service trial report Duration of trial
Approval of pressure relief devices 10 years
Approval of valves and fittings 10 years
1.6.4.3 Table 1.22 lists the documents that must be retained by each lining or coating owner:
CHAPTER 2
AAR SPECIAL REQUIREMENTS FOR DOT TANK CARS
CONTENTS
2.1.4.2 The steelmaking practice for new fabrication and plates for repairs to tank shell, heads,
and manway nozzles shall provide resistance to hydrogen-induced cracking and blistering. The
steel must meet the following requirements:
• Tensile strength is not to exceed 85 ksi.
• The steel shall have a specification of 0.006% maximum sulfur content and be calcium
treated to obtain the minimum number of inclusions, inclusion shape control, and
maximum resistance to hydrogen blistering.
• Steels with sulfur content above 0.003% shall be tested for hydrogen-induced cracking per
National Association of Corrosion Engineers (NACE) Standard TM-02-84, or be
ultrasonically scanned per ASTM A578, Level C (using a 1 in. circle).
2.1.4.3 Tanks must be postweld heat treated between 1125 °F and 1225 °F (607.2 °C and
662.8 °C). Postweld heat treatment at alternative lower temperatures referenced in Appendix W is
prohibited.
2.1.4.4 If welding or welded repairs are required on the tank shell, heads, or manway nozzle after
the tank is postweld heat treated, repairs must be made per Appendix R, paragraph 4.1.
2.1.4.5 The maximum hardness of the tank and welds after postweld heat treatment must not
exceed 20 HRC. If weld repairs are required, hardness measurements shall be made per
Appendix R, paragraph 4.1.
2.1.4.6 Valves, valve parts, and other appurtenances normally in contact with the lading must
comply with NACE Publication MR-01-75 or be of the following materials:
• Gold
• Platinum
• Nickel (except electrolytic and electroless)
• Monel (except free-machining)
• PTFE
• Fluoroelastomer copolymer/tripolymer
• Aluminum-silicon-bronze
2.1.4.7 Pressure relief valves must be in combination with either a breaking pin device or a
rupture disc. See DOT 179.15 (e). If the pressure relief valve is in combination with a rupture disc,
the tank must be 112A400W, stenciled -200W and equipped with a combination device set for
-200W requirements, having the disc rated at 150 psig (1034 kPa) and the valve start-to-discharge
at 142 psig (979.1 kPa). The space between the rupture disc and valve must be vented and the vent
must be closed in transportation.
The vent must be checked at each loading to ensure that the rupture disc is not leaking. If the
rupture disc is defective, it must be replaced and the pressure relief valve tested for proper
operation.
2.1.4.8 Studs and bolts used to fasten any valves or fittings to the cover plate or the cover plate to
the manway ring must meet one of the following specifications:
• ASTM A193-B7M including Supplement S3 requiring 100% hardness testing
• ASTM A193-B7—Maximum hardness Brinell 237 (Rc 22)
• ASTM A320-L7—Maximum hardness Brinell 237 (Rc 22)
• ASTM A193-B8, Class 2, Type 304 stainless steel, carbide solution treated and strain
hardened to Brinell 320 (Rc 35) maximum hardness
Rolled threads are required for all studs and bolts.
2.1.4.9 Nuts used to fasten any valves or fittings to the cover plate or the cover plate to the
manway ring must meet one of the following specifications:
• ASTM A194-2HM including Supplement S7 requiring 100% hardness testing
• ASTM A194-2—Maximum hardness Brinell 237 (Rc 22)
• ASTM A194-8F, Type 303 stainless steel, carbide solution treated, machined from cold
drawn bar, Brinell 300 (Rc 32) maximum hardness
2.1.4.10 Fasteners used in valve assemblies must conform to the National Association of
Corrosion Engineers Publication MR-01-75 and must be approved for anhydrous hydrogen fluoride
service. Ferritic stainless steels are prohibited.
2.1.4.11 Each tank car must be marked “HYDROGEN FLUORIDE” in accord with DOT 172.330.
2.1.4.12 Inspection and Repairs
See Appendix R, paragraph 4.1.
2.1.5 Vinyl Chloride
All tank cars ordered after May 1, 2001, for vinyl chloride service must be equipped with cover
plates as shown in Appendix E, Fig. E.9 (20 in. diameter) or Fig. E.11 (22 in. diameter). Refer to
Fig. E.10 (20 in. diameter cover plate) or Fig. E.12 (22 in. diameter cover plate) for details on
nozzle joints. For details on openings, see Figs. E.19 through E.19.25.
2.1.6 Aluminum Tank Car Tanks
The following commodities are not authorized in aluminum tank car tanks:
• Carbon tetrachloride
• Chloroform
• Ethylene dichloride
• Methylene chloride
• Propylene dichloride
2.1.7 Totally Contained Commodities (Shipped in Tank Cars not Equipped with
Pressure Relief Devices)
2.1.7.1 The transportation of totally contained commodities in tank cars not equipped with
pressure relief devices must be approved by the Tank Car Committee and be carried out in tank
cars stenciled as AAR Specification tank cars. A DOT exemption is required for totally contained
transportation in a DOT Specification tank car.
2.1.7.2 Proponents desiring to transport a product in a tank car without a pressure relief device
must petition the Tank Car Committee by submitting an Form AAR 4-2 (see Fig. 1.1 on page
C-III–42), requesting approval. Technical justification must be submitted with the application and
must include calculations made with the AFFTAC simulation model or approved equivalent
analysis, indicating that the car will survive at least 100 minutes in a pool fire before rupturing.
Such calculations must consider the thermal properties of the commodity, including the coefficient
of expansion, expected exothermic reactions, and other considerations specified by the Tank Car
Committee.
2.1.7.3 Tank Cars must be marked with a commodity stencil as specified in Appendix C,
paragraph 5.1.
2.2.3.3.2 By using the filling nozzle as a local protective device for the service equipment fitted on
the manway cover plate, in which case, the following apply:
• The filling nozzle and its closure are designed to meet the conditions of paragraph 2.2.3.5.
• No service equipment or part thereof extend higher than the top surface of the filling
nozzle cover structure, nor extend beyond the perimeter of the manway cover.
• Except for the following item, the service equipment is mounted to the manway cover plate
or to a nozzle welded to the manway cover plate or fill opening through a welded or flanged
connection.
• If an air connection is provided, the connection may be threaded, and pipe elements must
be at least extra-strong (XS) in wall thickness and located where ample roll-over protection
is afforded by the filling nozzle. This fitting may be mounted to the manway cover plate or
to a nozzle through a threaded connection.
2.2.3.4 The service equipment fitted on top of nonpressure tank cars built before August 1, 2002,
in sulfuric acid service must meet the requirements of paragraph 9.2.1 of Appendix E or must be
protected by one or more of the following methods by August 1, 2011:
2.2.3.4.1 By fitting a protective device as per paragraph 2.2.3.3.1.
2.2.3.4.2 In the case of service equipment fitted on the manway cover plate, by using the filling
nozzle as a local protective device, where
• the service equipment is a non-reclosing pressure relief device mounted on the manway
cover plate through a welded or flanged connection and the device or part thereof does not
extend higher than 1 in. above the top surface of the filling nozzle cover structure, nor
extend beyond the perimeter of the manway cover;
• the service equipment is an eduction pipe and its closure assembly made with minimum
NPS 2 extra strong (XS) and the assembly or part thereof does not extend higher than 4 in.
above the top surface of the filling nozzle cover structure, nor extend beyond the perimeter
of the manway cover; and
• the service equipment is mounted as per paragraph 2.2.3.3.2 bullets 3 and 4.
2.2.3.4.3 In the case of a non-reclosing pressure relief device mounted on an existing nozzle but
located outside of the manway cover plate, the device may not meet the conditions of
paragraph 2.2.3.5 nor be fitted with a protective device meeting the conditions of
paragraph 2.2.3.5 if
• the device is mounted to the nozzle through a welded or flanged connection; and
• the device or any part thereof extends no more than 8 in. above the top face of the nozzle’s
flange and no more than 20 in. above the outer longitudinal centerline of the tank shell as
shown in Fig. E.25.4.
2.2.3.5 The protective device or unprotected service equipment under consideration and tank
must withstand, at a minimum, the following loads applied to the top fittings assembly and nozzle:
1/2W vertical in the downward direction, 1W horizontal in the longitudinal direction, and 1/2W
horizontal in the lateral direction, with each load applied separately as a uniform load over the
projected plane of the element(s) under consideration. For horizontal loads, the height of the
projected plane is from the top of the tank shell at the centerline to the height of the item. 1W is
the car’s maximum gross weight on rail minus the weight of the trucks. The stress must not exceed
the following:
• The minimum specified tensile strength of the material for the tank, nozzle(s), unprotected
service equipment, and protective device (where applicable); and
• The critical buckling stresses of the assembly under consideration.
2.2.15.3.6 The pool fire analysis shall use a fire with a minimum temperature of 1,500 °F
(816 °C). The torch fire analysis shall use a fire with a minimum temperature of 2,200 °F
(1,205 °C).
2.2.15.3.7 The analysis must consider the heat flux through tank discontinuities, protective
housings, underframes, metal jackets, insulation, and thermal protection.
2.2.15.4 The thermal conductivity of the thermal protection and insulation material, as a
function of temperature, shall be based upon actual test data.
2.2.16 Re-Stenciling AAR Class Cars to DOT/TC Class
AAR-class tank cars may be re-stenciled to DOT/TC class provided the following conditions are
met:
2.2.16.1 The original construction of the cars must be in accordance with the DOT/TC
specification.
2.2.16.2 At the time of conversion, cars must be qualified to the DOT/TC specification in
accordance with the applicable federal regulation.
2.2.16.3 Identification plates have been added or replaced in accordance with the applicable
federal regulation and with Appendix C, paragraph 3.0.
2.2.16.4 The proponent must submit Exhibit R-1 to AAR.
2.3 Special Requirements (Proposed Revisions to DOT Specifications)
2.3.1 AAR Special Requirements for DOT Tank Cars
2.3.1.1 Bottom Outlets and Bottom Washouts
Reference DOT 179.100-14(a)(3), 179.103-5(b)(4), 179.200-17(a)(7), 179.200-17(b)(3),
179.220-18(a)(6), and 179.220-18(b)(3):
2.3.1.1.1 If the outlet (or washout) nozzle and its closure extends, a) more than 1 in. beyond the
shell envelope and is not provided with bottom discontinuity protection, or b) beyond the bottom
discontinuity protection, or c) below the bottom surface of a continuous center sill, a machined
breakage groove or bolted connection must be incorporated that is designed to fail without
rupturing the tank shell when a horizontal load is applied. The breakage groove or bolted
connection must be located, a) within 1 in. of the tank envelope, or b) within the envelope of a
protective device, or c) above the bottom surface of a continuous center sill. In addition, except for
special application, the breakage groove or the bolted connection must be designed to withstand a
1,000 ft·lb (1356 Nm) torque without exceeding the shearing yield strength. The bolted connection
must have threads or a necked-down cross-section located in the shear plane. A breakage groove, if
used, must be a V-groove, cut (not cast) to a depth that will leave the thickness of the nozzle at the
base of the groove not over 1/4 in. (6.35 mm).
2.3.1.1.2 The strength of the breakage groove or breakage groove equivalent must not exceed
60% of the primary valve connection to the universal flange using the minimum published tensile
strength of the nozzle material (for a V-groove) or of the nozzle bolting material, and the minimum
published yield strength of the valve-to-universal flange bolting material. If the maximum tensile
strength of the nozzle bolting is known and used, then this connection strength may be equal to
the calculated valve-to-universal flange bolting strength based on minimum yield. Connection
strength for two load applications must be analyzed—one with the load applied at the lowest point
of the nozzle assembly and one with the load applied at the nozzle breakage groove or equivalent
bolted connection or at the lowest point of the valve protective device. In both cases, the calculated
loads must be based on the combined tensile and shear stress.
Tank car heads must be normalized after forming, unless specific approval is granted for a
facility’s equipment and controls.
2.5.2.4 Class DOT/TC-111 cars with high-alloy steel tanks (111****W6 and 111****W7) must
have heads and shells at least 1/2 in. thick and be equipped with half-head shields if not jacketed.
Jacketed tanks must be at least 7/16 in. thick and be equipped with 1/2 in. thick jacket heads.
2.5.3 Class DOT/TC Pressure Cars
2.5.3.1 In addition to the requirements of paragraph 2.5.1, Class DOT/TC-105, 112, 114, and 120
tank cars having a gross weight on rail over 263,000 lb must conform to paragraph 2.5.1 and be
equipped with a metal jacket and tank head protection.
2.5.3.2 Notwithstanding paragraph 2.5.3.1, if the federal regulations authorize the use of a tank
car without a metal jacket, the AAR requirement for a metal jacket is waived, if not required by
car specification, provided that the tank heads and shell are constructed from normalized AAR
TC128 Grade B steel and the required thickness of the tank heads and shell is increased by at
least 1/16 in. over minimum specification thickness. Tank head protection is required.
2.5.4 Class DOT/TC-113 Cryogenic Cars
Class DOT/TC-113 cryogenic cars with gross weight over 263,000 lb must meet the requirements
of paragraph 2.5.1.
2.5.5 Class DOT/TC-115 Nonpressure Tank Cars (tank within a tank)
In addition to the requirements of paragraph 2.5.1, Class DOT/TC-115 cars with gross weight over
263,000 lb must meet the requirements of paragraphs 2.5.2.1 and 2.5.2.2.
2.6 Top Fittings Protection Requirements for Nonpressure Cars
For protection of top fittings against rollovers and accidental horizontal loads, all new nonpressure
Class DOT/TC tank cars ordered after July 1, 2010, used to transport Packing Group I (high
hazard) and Packing Group II (medium hazard) materials must be equipped per paragraph 9.2.1
of Appendix E.
2.7 Requirements for Cars Built for the Transportation of Packing Group I and II
Materials with the Proper Shipping Names “Petroleum Crude Oil,” “Alcohols, n.o.s.,”
and “Ethanol and Gasoline Mixture”
2.7.1 Cars ordered after October 1, 2011, for the transportation of packing Group I and II
materials with the proper shipping names “petroleum crude oil,” “alcohols, n.o.s.,” and “ethanol
and gasoline mixture” must comply with the following requirements.
2.7.2 Top Fittings Protection
2.7.2.1 Class 111 tank cars used to transport packing Group I and II materials with the proper
shipping names “petroleum crude oil,” “alcohols, n.o.s.,” and “ethanol and gasoline mixture” must
be equipped per Appendix E, paragraph 9.2.1.
2.7.3 Pressure Relief Devices
Class 111 tank cars used to transport packing Group I and II materials with the proper shipping
names “petroleum crude oil,” “alcohols, n.o.s.,” and “ethanol and gasoline mixture” must be
equipped with reclosing pressure relief devices. Upon approval of Pipeline and Hazardous Safety
Administration (PHMSA), a non-reclosing device can be used where the applicant demonstrates
that a non-reclosing device is required and affords an equivalent level of safety.
CHAPTER 3
SPECIFICATIONS FOR AAR TANK CAR TANKS
CONTENTS
Paragraph Subject Page
3.1 (AAR.100) Specifications Applicable to Class AAR-203W and AAR-211W Tank Car Tanks. . . . . . . . C-III–85
3.1.1 (AAR.100-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–85
3.1.2 (AAR.100-2) Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–85
3.1.3 (AAR.100-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–85
3.1.4 (AAR.100-10) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–85
3.1.5 (AAR.100-11) Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–85
3.1.6 (AAR.100-16) Gauging Devices, Top Loading and Unloading Devices, Venting Devices, and Air
Inlet Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–85
3.1.7 (AAR.100-17) Bottom Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–85
3.1.8 (AAR.100-18) Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–86
3.1.9 (AAR.100-24) Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–86
3.1.10 (AAR.100-25) Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–86
3.1.11 (AAR.100-26) Certificate of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–86
3.2 (AAR.200) Specifications Applicable to Class AAR-204W Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . C-III–86
3.2.1 (AAR.200-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–86
3.2.2 (AAR.200-2) Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–86
3.2.3 (AAR.200-4) Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–86
3.2.4 (AAR.200-5) Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
3.2.5 (AAR.200-6) Bursting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
3.2.6 (AAR.200-8) Thickness of Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
3.2.7 (AAR.200-11) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
3.2.8 (AAR.200-12) Postweld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
3.2.9 (AAR.200-18) Test of Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
3.2.10 (AAR.200-20) Pressure Relief Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–87
3.2.11 (AAR.200-24) Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.2.12 (AAR.200-25) Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.2.13 (AAR.200-26) Certification of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.3 (AAR.300) Specifications Applicable to Class AAR-206W Tank Car Tanks. . . . . . . . . . . . . . . . . . . . . C-III–88
3.3.1 (AAR.300-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.3.2 (AAR.300-2) Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.3.3 (AAR.300-10) Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.3.4 (AAR.300-19) Pressure Relief Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.3.5 (AAR.300-25) Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–88
3.3.6 (AAR.300-26) Stenciling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–89
3.3.7 (AAR.300-27) Certificate of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–89
3.4 (AAR.400) Specifications Applicable to Class AAR-207W Pressure Differential Covered Hopper
Cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–89
3.4.1 (AAR.400-1) General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–89
11/2014 C-III [M-1002] 83
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
CHAPTER 3 M-1002
Table 3.1 DOT specifications for Class AAR-203W and AAR-211W tanks
AAR Specification Applicable DOT Specification
AAR-203W DOT-103W
AAR-203DW DOT-103DW
AAR-211A60W1 DOT-111A60W1
AAR-211A60ALW1 DOT-111A60ALW1
AAR-211A100W1 DOT-111A100W1
AAR-211A100W6 DOT-111A100W6
AAR-211A100ALW1 DOT-111A100ALW1
3.1.2 (AAR.100-2) Approval
For the procedure for securing approval, see paragraph 1.4.
3.1.3 (AAR.100-4) Insulation
3.1.3.1 If insulation is applied, insulating material must be approved.
3.1.3.2 Insulation must be covered with a jacket made of approved material that is applied so as
to be weather tight.
3.1.3.3 The exterior surface of a carbon steel tank and the inside surface of a carbon steel jacket
must be given a protective coating.
3.1.4 (AAR.100-10) Welding
3.1.4.1 Radioscopic examination of welded joints of carbon steel or alloy steel tanks is not a
requirement of this specification.
3.1.4.2 Welded joints of aluminum tanks must be radioscoped in accord with Appendix W.
3.1.5 (AAR.100-11) Postweld Heat Treatment
The portions of carbon steel tanks to which anchorage or draft sills are attached must be postweld
heat treated in accord with Appendix W.
3.1.6 (AAR.100-16) Gauging Devices, Top Loading and Unloading Devices, Venting
Devices, and Air Inlet Devices
When gauging devices, top loading and unloading devices, and venting and air inlet devices are
installed, protective housing is not required.
3.1.7 (AAR.100-17) Bottom Outlets
Bottom outlets on AAR specification tank cars must conform to DOT-179.200-17 except that
external valves may be of any approved design.
3.2.10.4 Off-loading pressure relief valve. For the purpose of allowing transfer of lading at a
pressure higher than the transport pressure relief valve setting, a second pressure relief valve,
hereinafter called the off-loading pressure relief valve, is permitted, provided an approved safety
interlock is installed in such a way as to automatically provide an unrestricted discharge path
from the inner container to the transport pressure relief valve at all times when the tank car is in
transportation. The design must be such that the safety interlock must not affect the discharge
path of the off-loading pressure relief valve at any time. The off-loading pressure relief valve shall
be set to a start-to-discharge pressure no higher than 35 psi ±3 psi (221 to 262 kPa). The capacity
of this off-loading pressure relief valve must be sufficient to limit the pressure within the inner
container to a maximum of 45 psi (310 kPa) when the insulation space is filled with air or gaseous
lading at atmospheric pressure and the outer shell is at 130 °F (54.4 °C). When used, the
off-loading pressure relief valve need not be retested nor should a stencil be used.
3.2.11 (AAR.200-24) Stamping
To certify that the tank complies with all specification requirements, each tank must be stamped
in accord with DOT 179.400-24, except that the AAR specification number must be stamped in lieu
of the DOT specification number.
3.2.12 (AAR.200-25) Stenciling
The outer shell must be stenciled in accord with DOT 179.400-25, except that the AAR
specification number must be stenciled in lieu of the DOT specification number.
3.2.13 (AAR.200-26) Certification of Construction
See paragraph 1.4.4.
3.3 (AAR.300) Specifications Applicable to Class AAR-206W Tank Car Tanks
3.3.1 (AAR.300-1) General
Tanks built under these specifications must meet the requirements of DOT 179.220 and 179.221,
except as provided in the following paragraphs. Where AAR paragraph numbers are omitted, the
provisions of DOT 179.220 and 179.221 apply.
3.3.2 (AAR.300-2) Approval
For the procedure for securing approval, see paragraph 1.4.
3.3.3 (AAR.300-10) Welding
Radioscopic examination of welded joints of the inner container is not a requirement of this
specification.
3.3.4 (AAR.300-19) Pressure Relief Devices
Tank cars used to transport nonregulated commodities that give off flammable vapors at or below
150 °F (65.6 °C), as determined by Tagliabue’s open-cup tester per ASTM D1310, must be
equipped with pressure relief valves. Tank cars used to transport other commodities must be
equipped with pressure relief valves or rupture disc devices.
3.3.5 (AAR.300-25) Stamping
To certify that the tank complies with all specification requirements, each tank must be stamped
as follows:
3.3.5.1 If the tank is built in compliance with all requirements of DOT 179.220, the tank must be
stamped in accord with DOT 179.220-25.
3.3.5.2 If the tank is not radioscoped, it must be stamped in accord with DOT 179.220-25, except
that the AAR specification number must be stamped in lieu of the DOT specification number.
Pd
t = ---------------------- (SI units)
2000SE
where
d = inside diameter, millimeters
E = welded joint efficiency = 0.9E1 where E1 is the joint efficiency shown in Table 3.2
P = minimum required bursting pressure, kPa
S = minimum tensile strength of plate material, MPa, as prescribed in Table M.10
t = minimum design thickness of plate after forming, millimeters
3.4.6.3 If plates are clad with material having tensile strength properties at least equal to the
base plate, the cladding may be considered a part of the base plate when determining thickness. If
cladding material does not have tensile strength at least equal to the base plate, the base plate
alone must meet the thickness requirements.
3.4.7 (AAR.400-7) Materials
3.4.7.1 Carbon steel plate used to fabricate car shell, hatch nozzles, and, if subjected to internal
pressure, hopper sheets, must be as specified in Appendix M, paragraph 3.1 or 3.7.
3.4.7.2 Aluminum alloy plate used to fabricate car shell, hatch nozzles and, if subject to internal
pressure, hopper sheets, must be as specified in Appendix M, paragraph 3.2.
3.4.7.3 Alloy steel used to fabricate car shell, hatch nozzles and, if subjected to internal pressure,
hopper sheets, must be as specified in Appendix M, paragraph 3.3.1.
3.4.7.4 All parts and items of construction in contact with the lading must be made of a material
compatible with plate material and not subject to rapid deterioration by the lading or be coated or
lined with suitable corrosion-resistant material.
3.4.7.5 All external projections that may be in contact with the lading and all castings, forgings,
or fabrications used for fittings or attachments to the shell that may be in contact with the lading
must be made of material to an approved specification. See Appendix M, paragraph 4.5 for
approved casting material specifications for fittings.
3.4.8 (AAR.400-8) Heads
3.4.8.1 Heads must be of approved contour and may be flanged and dished or ellipsoidal, convex
outward.
3.4.8.2 Flanged and dished heads must have a main inside radius not exceeding 10 ft (3050 mm)
and an inside knuckle radius not less than 6% of the main inside radius.
3.4.8.3 Ellipsoidal heads must be an ellipsoid of revolution in which the major axis must equal
the diameter of the shell adjacent the head and the minor axis must be one half the major axis.
3.4.9 (AAR.400-9) Welding
3.4.9.1 All joints must be fusion-welded in compliance with Appendix W. Welding procedures,
welders, and fabricators must be approved.
3.4.9.2 Radioscopic examination of welds is not required provided appropriate reduction is made
in joint efficiency as specified in Table 3.2.
3.4.9.3 Partial radioscopy must include not less than one radiograph of each intersection of all
longitudinal and circumferential butt joints, single or double welded; one radiotape of at least 6 in.
for each 50 ft (152 mm for every 15200 mm) or fraction thereof of circumferential single- or
double-welded butt joint; and one radiotape of at least 6 in. for each 50 ft (152 mm for every
15200 mm) or fraction thereof of longitudinal single- or double-welded butt joint. In addition, at
least one radiotape of at least 6 in. (152 mm) must be made from any 10 ft (3050 mm) of completed
butt weld of each procedure and thickness made by each welder or welding operator. A spot
examined may coincidentally represent one procedure, one thickness, one welder or welding
operator, any 10 ft (3050 mm) of weld, and one 50 ft (15200 mm) interval of weld.
3.4.9.3.1 For each intersection that is radiographed, one required radiotape of a longitudinal or
circumferential weld may be omitted as long as each procedure and thickness made by each welder
or welding operator is represented by at least one radiograph or radiotape.
3.4.9.3.2 Radiography of intersections must be as required in Appendix W, paragraph 18.3.4.
3.4.9.3.3 When a radiograph of a longitudinal or circumferential weld does not comply with the
acceptance standards, two additional areas adjacent to the defective welding must be
radiographed. When the welding and the adjacent areas comply with the acceptance standards,
the defective area must be repaired and radiographed. When the welding of the adjacent area does
not comply with the acceptance standards, then the entire length of all butt joints of the tank shell
must be radiographed.
3.4.9.4 Welding is not permitted on or to ductile iron or malleable iron fittings.
3.4.10 (AAR.400-10) Postweld Heat Treatment
Postweld heat treatment of welded joints is not a requirement of this specification.
3.4.11 (AAR.400-11) Car Structure
See the Manual of Standards and Recommended Practices, Section C, Part II, “Specifications for
Design, Fabrication, and Construction of Freight Cars,” Specification M-1001, Chapter 6.
3.4.12 (AAR.400-12) Hatch Nozzles, Covers, and Openings in Shell
3.4.12.1 Hatch nozzles must be of approved design of cast, forged, or fabricated metal.
3.4.12.2 At least one hatch nozzle must be at least 16 in. (406 mm) inside diameter to serve as a
manway.
3.4.12.3 All hatch covers not hinged to the shell must be attached to the outside of the shell by at
least a 3/8 in. (9.52 mm) chain or its equivalent.
3.4.12.4 All joints between manway covers and their seats must be made tight against leakage by
the use of gaskets of suitable material.
3.4.12.5 Openings in the shell for hatches and other fittings must be reinforced in accord with
Appendix E.
3.4.13 (AAR.400-13) Internal Structure
Any structure, such as baffles, hopper plates, slope sheets, troughs, conduits, air ducts, aerator
devices, conveyors, or any other structure introduced as a permanent attachment in the shell to
contain or move the lading by any means, must be designed to adequately support the lading
during loading, transit, and unloading.
3.4.14 (AAR.400-14) Outlets
3.4.14.1 Outlets must be designed to withstand car test pressure and must be equipped with
dust-type closures.
3.4.14.2 Outlets and associated fittings, piping, and other external projections on the bottom of
the shell must comply with minimum rail clearance requirements of Appendix E.
3.4.15 (AAR.400-15) Gauging Devices, Bottom Outlet Valve Operating Rods, Venting
and Air Inlet Devices, and Loading and Unloading Pipes Extending Through the Shell
Class AAR-207 cars do not require the inclusion of gauging devices, bottom outlet valve operating
rods, venting and air inlet devices, or loading and unloading pipes extending through the shell.
When installed, however, these devices must be of approved design and be tightly closed. Interior
unloading pipes must be securely anchored within the shell.
3.4.20.2 Total air discharge capacity of pressure relief device or devices in cfm (or cfm and m3/s)
at standard conditions must be stenciled on the car near the air inlet connection in letters and
figures at least 1 1/2 in. (38.1 mm) tall.
Table 3.4 Individual specification requirements applicable to Class AAR-207W pressure differential covered hopper cars)
AAR Specification 207A20W 207A28W 207A40W 207A40W6 207A48ALW 207A48W 207A60ALW 207A60W 207A80ALW 207A80W
Material [see paragraph 3.4.7 (AAR.400-7)] Steel Steel Steel Alloy Steel Al Alloy Steel Al Alloy Steel Al Alloy Steel
Insulation [see paragraph 3.4.4 Optional Optional Optional Optional Optional Optional Optional Optional Optional Optional
(AAR.400-4)]
Bursting Pressure, psi (kPa) 50 (345) 70 (483) 100 (689) 100 (689) 120 (827) 120 (827) 150 (1034) 150 (1034) 200 (1379) 200 (1379)
[see paragraph 3.4.5 (AAR.400-5)]
Test Pressure, psi (kPa) 20 (138) 28 (193) 40 (276) 40 v 48 (331) 48 (331) 60 (414) 60 (414) 80 (552) 80 (552)
[see paragraph 3.4.17 ( AAR.400-17)]
C-III [M-1002] 95
Pressure relief Valve: 15 (82.7 21 (117 30 (186 30 (186 36 (228 36 (228 45 (290 45 (290 60 (393 60 (393
Start-to-Discharge Pressure, to 124) to 165) to 228) to 228) to 269) to 269) to 331) to 331) to 434) to 434)
psi ±3 psi (kPa range)
Specifications for Tank Cars
Valve Flow Rating Pressure, 18 (124) 24 (165) 33 (228) 33 (228) 40 (276) 40 (276) 50 (345) 50 (345) 66 (455) 66 (455)
psi (kPa) (maximum)
Vapor-Tight Pressure 12 (83) 17 (117) 24 (165) 24 (165) 29 (200) 29 (200) 36 (248) 36 (248) 48 (331) 48 (331)
(minimum) psi (kPa)
AAR Manual of Standards and Recommended Practices
Vent Bursting Pressure, Maximum 15 (103) 21 (145) 30 (207) 30 (207) 36 (248) 36 (248) 45 (310) 45 (310) 60 (414) b b
psi (kPa) [see paragraph 3.4.16
(AAR.400-16)]
CHAPTER 3
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
CHAPTER 3 M-1002
CHAPTER 4
RESERVED
CHAPTER 5
GENERAL DESIGN AND TEST REQUIREMENTS
CONTENTS
5.1.4.7 All material used in the construction of a tank car must be examined before and during
fabrication for the purpose of detecting possible defects that would affect the safety of the tank.
5.1.5 Openings in Tank
Openings in tanks for manway nozzle, dome opening, or other fittings must be reinforced as
required in Appendix E.
5.1.6 Placard Holders
5.1.6.1 Each tank car must be equipped with at least four metal placard holders, permanently
attached by suitable brackets, located one at each end and each side of tank car, placed toward the
right and preferably near to and below the DOT and AAR stencils. Tank cars used exclusively for
the transportation of commodities for which DOT regulations do not require placards do not
require placard holders. Tank cars that are in dedicated product service for the transportation of
commodities for which DOT regulations require placards may display permanent placards (decal
or stencil) and do not require placard holders.
5.1.6.2 Holders must be designed to provide for secure attachment for each application, removal,
or reversal of the placards prescribed by the DOT regulations and must be of sufficient size to
permit placards to be applied with opposite points of the diamond in vertical or horizontal
positions, respectively. For design of an approved placard holder, see Appendix E. Holder brackets
must be designed to minimize transmission of vibration to placard holders.
5.1.7 Safety Appliances
Safety appliances must be in accord with Appendix S.
5.1.8 Stenciling
Stenciling must comply with individual specification requirements and Appendix C.
5.1.9 Lifting Provision Test
This test refers to the lifting provision requirements shown in the Manual of Standards and
Recommended Practices, Section C, Standard S-234. Each design of a tank car lifting provision is
subject to a test by loading at least one of the lifting provisions as follows:
5.1.9.1 The vertical component of the load applied to each lifting provision tested must be a
minimum of 25% of the gross weight (mass) on rail.
5.1.9.2 The direction of the applied load must be at 45° from the vertical and as near as possible
to a vertical plane parallel to the longitudinal centerline of the car and extending through the
center of the lifting provision.
5.1.9.3 After application and release of the required load, visual inspection must reveal no
evidence of permanent deformation in the tank car tank, bolster, or lifting provision, except that
local deformation is permitted in the hook bearing area.
5.2 Tank Anchors
5.2.1 Anchors, General
5.2.1.1 Anchor design must comply with Appendix E, paragraph 11.0. Anchors must be attached
to tank shells by fusion welding. They must be attached to center sills or to members attached to
center sills by means of rivets, two-piece rivets, or bolts. Rivets and two-piece rivets must comply
with Appendix M, paragraph 4.4. Bolts must comply with the current issue of ASTM A325 or
ASTM A490. Nuts must meet specifications compatible with threaded parts. Washers, if used,
must be hardened steel. After installation, all bolts must be mechanically deformed to prevent
loosening of the nuts.
5.2.1.2 Anchors for aluminum tanks must be aluminum.
R – W 5 560
S u = ------------------------------------------ , kN (SI units)
R
where
R = Rail load limit, kg
W = Mass of trucks plus underframe, kg
5.2.1.6.2 When a multiple-piece anchor is used, the minimum requirement must be 120% of the
requirement for a single-piece anchor.
5.2.1.6.3 The bearing strength of the connections with respect to the webs of the anchor and sill
must be greater than the shear strength of the fasteners. For aluminum anchors, the allowable
bearing stress of the web plates must be twice the tensile strength (unwelded condition) for
purposes of computing the bearing strength of the joint. For steel anchors, the allowable bearing
stress must be 2.25 times the tensile strength. The interfastener buckling stress must be
computed by the following formula. Critical buckling stress (cr) must be equal to or greater than
the maximum compressive stress in the member (anchor or sill) due to Su. The thickness of the
connected elements of the anchor and sill must be not less than 7/16 in. (11.1 mm).
0.076 u 2 b 2
cr = u – ----------------------------
- ---
E t
where
cr = critical buckling stress, psi (MPa)
u = compressive strength of anchor or sill material, psi (MPa)
E = modulus of elasticity, psi (MPa)
b = fastener spacing, in. (mm)
t = thickness of anchor or sill material, in. (mm)
5.2.1.6.4 When the anchor welded to the tank is attached by means of driven rivets, two-piece
rivets, or bolts to another member that is attached to the underframe by means of driven rivets,
two-piece rivets, or bolts, both connections must comply with the minimum shearing and bearing
requirements. Only one connection (the weaker connection, either the anchor-to-intermediate
member or intermediate member-to-underframe) need be used as a reference when calculating the
required shear strength of the welded connection between the tank and the anchor in accord with
paragraph 5.2.1.6.5.
5.2.1.6.5 The shear strength of the welded connection (using the weld efficiencies defined in
Appendix E, paragraph 5.1) between the tank and the anchor must be at least 1.4 times the shear
strength of the fasteners securing the anchor to the underframe and not less than the values listed
in Table 5.1.
5.2.1.6.6 For computing ASTM A502 Gr. 1 rivet shear and bearing areas, the diameter of the
reamed hole is used. The diameter of the reamed hole must not exceed the nominal diameter of the
rivet by more than 1/16 in. (1.59 mm).
For computing two-piece rivet shear and bearing areas, the nominal diameter of the rivet is used.
Locking grooves are not allowed in the shear plane. The diameter of the reamed hole must not
exceed the nominal diameter of the two-piece rivet by more than 1/16 in. (1.59 mm).
For computing bolt shear and bearing areas, the nominal diameter of the bolt is used. Threads are
not allowed in the shear plane. Bolt holes must be finish drilled or reamed to size. The diameter of
the finished hole must not exceed the nominal diameter of the bolt by more than 1/16 in.
(1.59 mm).
5.2.1.6.7 For calculating connection values, the design ultimate shear strength of the fastener in
the installed (driven) condition must be used as listed in Table 5.2.
5.2.2.2 The section area of the tank band must be at no place less than 1 in.2 (645 mm2). A
threaded end 1 1/8 in. or more in diameter, with body consisting of a flat band 2 in. by 1/2 in.
(50.8 mm by 12.7 mm), or round iron 1 1/8 in. (28.6 mm) in diameter, will be accepted as meeting
this requirement.
5.2.2.3 Cars having tanks fusion-welded to body bolsters and multiunit tank car tanks do not
require tank bands.
5.3 Head Shields
5.3.1 Design and Test Requirements for Head Shield Attachments
When head shields are required in accord with the provisions of DOT 173.31(b)(3), the attachment,
design calculations, and test results must meet the following requirements and be approved by the
Tank Car Committee.
5.3.1.1 Design Conditions
The attachments must be designed so that under the most severe conditions imposed by the
following combinations of forces, the calculated stresses will not exceed the minimum yield
strength of the material.
combined with
1,250,000W 5 560 000W
Longitudinal F longitudinal = ----------------------------------s- F longitudinal = ----------------------------------s-
W W
In-Train Environment:
Vertical F vertical = 3W s F vertical = 29.42W s
combined with
Lateral F lateral = 1.25W s F lateral = 12.26W s
where
F = Uniformly distributed load acting on head shield, lb (N)
Ws = Weight (mass) of head shield including attachments thereto, lb (kg)
W = Light-weight (tare) of car, lb (kg)
h = Vertical distance between centerline of coupler and center of gravity of empty car, ft (mm)
Wc = Light-weight of car (W) less weight of trucks, lb (kg)
L = Length over tank heads, ft (mm)
5.4.2.2.4 Supply containers must be secured by attachments that will withstand, without
permanent deformation, uncombined accelerations of 20 times force of gravity longitudinal, 10
times force of gravity vertical, and 5 times force of gravity transverse, based on the weight of
container and attachments plus contents.
5.4.2.2.5 Welding to the shell, head, or any part of the container is prohibited except when
performed by a container manufacturer.
5.4.2.2.6 Metal boxes or shields protecting containers must be painted white and must be
stenciled “FLAMMABLE GAS” in letters not less than 1 1/2 in. (38.1 mm) tall. When the contents
are nonflammable, the stenciling must be “NONFLAMMABLE GAS” in letters not less than
1 1/2 in. (38.1 mm) tall.
5.4.3 Valves
5.4.3.1 Valves on cars must be in the following sequence from supply container to outlet where
gas is to be used: supply container shut-off valve, excess flow valve (for flammable compressed
gases), back-flow check valve (where more than one container is used), manual shut-off valve, and
a pressure regulating system.
5.4.3.2 An excess flow valve must be installed in a flammable gas supply container outlet
connection to prevent flow of gas in case of breakage of the manual shut-off valve or piping. Other
excess flow valves must be installed as required by the design of the piping system so that a break
at any point in the system between the supply container and point of use will cause the excess flow
valve to function.
5.4.3.3 The manual shut-off valve must be located so as to be accessible in case of emergency and
must be stenciled or marked “GAS SHUT-OFF VALVE.”
5.4.3.4 Where more than one supply container is installed, a back-flow check valve also must be
installed.
5.4.3.5 The pressure regulating system must consist of one of the following arrangements:
5.4.3.5.1 A high-pressure or first-stage regulator and a low-pressure or second-stage regulator to
control flow of gas to engine, heater, or other use.
5.4.3.5.2 A single-stage regulator to control flow of gas from supply container to engine, heater, or
other use.
5.4.3.5.3 A single-unit two-stage regulator to control flow of gas from supply container to engine,
heater, or other use.
5.4.4 Piping
5.4.4.1 Piping from supply container to first-stage regulator must be not less than Schedule 80
steel, brass, or copper pipe; or seamless copper, brass, or steel tubing. Steel pipe or tubing shall be
adequately protected against exterior corrosion. Copper tubing must be Type “K” or equivalent,
having a minimum wall thickness of 0.049 in. (1.24 mm).
5.4.4.2 Aluminum pipe or tubing are prohibited.
5.4.4.3 Welded pipe joints must be used wherever possible.
5.4.4.4 Brazed copper tubing joints must be of brazing material joined at not less than 1,000 °F
(538 °C) and must be of such properties so as not to decrease in strength when threaded joints are
used.
5.4.4.5 Cast iron or aluminum fittings are prohibited.
5.4.4.6 Suitable provision must be made to compensate for thermal expansion and contraction.
5.4.4.7 For nonflammable compressed gases, stainless braided PTFE hose may be used.
5.4.5 System
5.4.5.1 All parts of the system must be adequately protected from loose objects propelled from the
roadbed.
5.4.5.2 Container and piping system must be arranged for a single car function. Extension of the
piping system to an adjacent car is not authorized.
5.4.5.3 All piping and connections on each side of an excess flow valve must have a greater flow
capacity than the rated flow capacity of the excess flow valve.
5.4.5.4 All hose subject to container pressure must be designed for a minimum bursting pressure
of 1,250 psi (8618 kPa). Hoses used on the low-pressure side of a regulator must be designed for a
bursting pressure of five times the pressure setting of the regulator. Hoses must be resistant to
action of the gas in its liquid and vapor phases.
5.4.5.5 After installation, the piping, valves, fittings, and accessories must be tested and proved
tight at a pressure equal to one and one-half times the normal pressure at 60 °F (15.6 °C) at which
the system will operate.
5.4.5.6 Pipes, fittings, and accessories must be clamped and fastened to protect them from
vibration, strain, or wear from the usual freight car motions and impacts.
5.4.5.7 A pressure relief valve must be installed between any two shut-off valves or any condition
in the piping where liquid may be trapped.
5.4.5.8 Vents or discharge lines for pressure relief valves must be sized so as not to restrict the
flow of gas from the pressure relief valve when the relief valve is fully opened. When flexibility is
necessary, flexible hose may be used. Vents or discharge lines from relief valves must be located as
far as practical from sources of ignition. A rain cap or other protector must be used to keep water
and dirt from entering the pipe or valve.
5.4.5.9 Regulating equipment and controls must be protected by metal cabinets or shields to
prevent damage or tampering and to give protection from the weather. Car framework may be
used where practical to form part of this shielding.
5.4.5.10 All valves and accessories between the tank and first-stage regulator must have a
minimum design pressure of 250 psi (1724 kPa).
5.4.6 Engine and Heater Fittings
5.4.6.1 Exhaust pipes must be insulated or shielded and positioned to prevent injury to
personnel.
5.4.6.2 An automatic shut-off device must be provided to shut off the fuel to the gas-air mixer
when the engine is stopped.
5.4.6.3 An automatic shut-off valve must be provided to shut off the flow of fuel in the event the
pilot light is extinguished or the combustion air (for systems with other than gravity air supply) is
insufficient for proper combustion.
5.4.7 Vaporizers for Liquefied Gases
5.4.7.1 For liquid withdrawal utilizing a vaporizer, there must be a regulator in accord with
paragraph 5.4.3.5 to control the flow of gas from the fuel container to the engine or heater.
5.4.7.2 Vaporizers must have a minimum design pressure of 250 psi (1724 kPa).
5.4.7.3 Combustion exhaust gases must not be used as a direct means of heat supply for the
vaporization of fuel.
C-III [M-1002] 110 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 CHAPTER 5
CHAPTER 6
CAR STRUCTURE DESIGN AND TEST REQUIREMENTS
The tank car structure design and test requirements are located in the Manual of Standards and
Recommended Practices, Section C, Part II, “Specifications for Design, Fabrication, and
Construction of Freight Cars,” Specification M-1001, Chapter 6.
APPENDIX A
TANK CAR VALVES AND FITTINGS
CONTENTS
APPENDIX A
TANK CAR VALVES AND FITTINGS
1.0 INTRODUCTION
Appendix A describes AAR requirements for the design, testing, materials, and marking of tank
car valves and fittings:
• Pressure relief devices, including the determination of relieving capacity requirements
• Liquid and vapor valves, including bottom loading and unloading valves
• Vacuum relief valves
• Liquid level control and gauging devices
• Temperature sensing equipment and thermowells
• Bottom washouts
• Accessories and special appurtenances related to handling the lading
2.0 SPECIFICATIONS FOR MATERIALS
2.1 Metals
All devices covered by this appendix must be fabricated from materials that are resistant to
corrosive or solvent action of the lading in the liquid or gas phase and are suitable for the service
temperature.
2.2 Nonmetallic Materials
Cars Built to
All Other 49 CFR
Non-Regulated Flammable Specified Regulated Subpart C
Commodities Liquids Corrosives Commodities (Pressure Cars)
Primary Prohibited Prohibited Allowed Prohibited Prohibited
Closures See
paragraphs 2.2.1
and 2.2.4
Secondary Allowed Prohibited Allowed Allowed Prohibited
Closures See See See
paragraphs 2.2.2, paragraphs 2.2.2 paragraphs 2.2.2,
2.2.3, 2.2.4, and 2.2.5 and 2.2.4 2.2.3, 2.2.4, and 2.2.5
Gaskets, See See See See See
O-Rings, paragraph 2.2.4 paragraph 2.2.4 paragraph 2.2.4 paragraph 2.2.4 paragraph 2.2.4
and Seals
2.2.1 Except for components that are used in aluminum sulfate, ammonium chloride, ferric
chloride, hydrochloric acid, hydrofluosilicic acid, sulfuric acid, or phosphoric acid service,
nonmetallic material must not be used for any primary pressure-containing parts of any device
covered by this appendix. Gaskets, O-rings, valve seat seals, or rupture discs are exempted,
provided the requirements of paragraph 2.2.4 are met. Nonmetallic rupture disc devices may be
used as primary closures, provided they meet the requirements of paragraphs 2.2.4 and 2.2.5.
2.2.2 Nonmetallic material may be used for any secondary pressure-containing parts of any
device covered by this appendix, provided the requirements of paragraphs 2.2.4 and 2.2.5 are met.
Nonmetallic material, except for gaskets and seals, may not be used for any secondary pressure-
containing parts for cars used to transport flammable liquids. Nonmetallic plugs and caps may not
be used on any car built to the requirements of 49 CFR Part 179 Subpart C (pressure cars). A
nonmetallic component may not be combined with a metallic component when the interface of the
components is an NPT thread. Examples would be a cap/plug, siphon pipe/cap, or a blind
flange/plug but would not include any threaded connections designed to Figs. E.18 through E.18.3
(bottom outlet caps) Nonmetallic material may be used for secondary pressure-containing parts of
any device that is used in aluminum sulfate, ammonium chloride, ferric chloride, hydrochloric acid,
hydrofluosilicic acid, sulfuric acid, or phosphoric acid service without meeting the requirements of
paragraph 2.2.5. The material used to construct these components must be compatible with the
product, and the component must be designed and tested to the appropriate pressure.
2.2.3 For newly designed metallic pressure retaining components or devices, the use of
nonmetallic protective coverings for metal parts is permissible, provided such coatings do not
interfere with proper operation of the device. Protection against ignition arising out of static
current buildup must be addressed in all newly designed nonmetallic pressure retaining
components or devices.
2.2.4 It is the shipper’s responsibility to ensure that all nonmetallic materials are compatible
with the lading and the service temperature.
2.2.5 When required in paragraphs 2.2.1 and 2.2.2, components manufactured of nonmetallic
materials (including design changes to existing devices) must be tested in a manner that is
representative of the operating environment in which they are intended to be used without
showing signs of leakage or distress. Testing shall as a minimum include, but not be limited to, the
following:
• Pressure Identification Test—Each device design shall be tested at a pressure one and one
quarter the maximum operating pressure (33% of the burst pressure of the car class on
which it is intended to be used) for a minimum period of 10 minutes. Pressure test must be
performed at ambient, 150 °F (65.5 °C) or a higher temperature as determined by the
manufacturer, and –30 °F (–34.4 °C).
• Torque Testing—When applicable (e.g., cap, plugs, etc.), each device shall be torque tested
in an appropriate manner that represents the application and removal of said device to the
car. Torque test must be performed at ambient, 150 °F (65.5 °C) or a higher temperature
as determined by the manufacturer, and –30 °F (–34.4 °C).
• Product Compatibility Test—Representative samples of the material(s) of construction of
the device shall be tested for resistance to corrosion and/or solvent action of the lading in
the liquid and gas phase at temperatures to which the device will be exposed in service.
Testing should be performed per ASTM D543 or an equivalent nationally recognized
standard.
• Life expectancy—The life expectancy of the component shall be determined by the
component manufacturer. Consideration should be given to but not be limited to the
results of UV exposure test under maximum expected atmospheric conditions, expansion
and contraction, creep, and all of paragraph 2.2 at both the minimum and maximum
operating conditions too which the component will be exposed.
Note: Test results must be submitted with the application for approval to the Tank Car Committee.
The manufacturer must have procedures in its quality program to ensure that nonmetallic
production parts are physically identical, within established tolerances, to the parts that were
qualification tested.
2.2.6 The manufacturer of nonmetallic components used in a device or the manufacturer of
nonmetallic devices is subject to the facility certification and quality assurance requirements of
Appendix B.
3.3.6 All primary and secondary fittings and closures, except pressure relief devices, must be
designed to be leak-tight.
3.3.6.1 All liquid and vapor valves must have pipe plugs, pipe caps, quick disconnect closures, or
blind flanges on the outlets to prevent escape of product in case of leakage. All liquid and vapor
valving that utilizes tongue-and-groove flange facing shall conform to Figs. E.19 through E.19.9,
except that 3 in. full-port ball valves used on nonpressure cars may, as an option, use ANSI B16.5
large tongue design as shown in Fig. E.19.24.
3.3.6.2 The control valve on top of a gauging device must have, on the discharge side of the valve,
a solid (not cored) pipe plug, with or without an orifice, or an orifice in the valve body to restrict
flow. Orifice size in the plug or valve body must be no larger than No. 54 drill size [0.055 in.
(1.397 mm)].
For alterations to remove bottom fittings after August 1, 2005, that will utilize a welded primary
closure (other than alterations that apply a tank shell insert), Appendix R, paragraph 14.6 must
be followed.
3.3.6.3 For new construction after July 1, 1976, all liquid and vapor closures used in normal
loading and unloading operations, except gauging device plugs or sampling valve plugs, must be
fastened by an approved means to prevent misplacement under conditions incident to
transportation or use.
3.3.6.4 For new construction or modification after August 1, 2005, except for tank shells with no
bottom opening, bottom flanges for future application of bottom fittings must include primary and
secondary closures.
3.3.6.5 For new construction after July 1, 1976, all liquid and vapor closures used in normal
loading and unloading operations, except gauging device plugs or sampling valve plugs, must be
fastened by an approved means to prevent misplacement under conditions incident to
transportation or use.
3.3.7 When a pressure relief device is mounted on a hinged manway cover, the design must be
approved and must incorporate sufficient clearance to preclude damage to the device as the
manway cover is swung to the full open position.
3.3.8 Effective January 1, 1989, for new construction and effective January 1, 1991, for all rebuilt
cars, cars receiving 150 man-hours or more of repairs or for new fittings added to cars during
alteration or conversion, the following applies:
3.3.8.1 Means must be provided for use of 1/8 in. diameter cable-type railroad seal to prevent
access to tank interiors resulting from casual vandalism. (Removal of valves, caps, quick-
disconnect caps, plugs, flanges, and other closures, or any operation requiring the use of tools, is
not casual vandalism. Destruction of the 1/8 in. diameter cable-type railroad seal or an equivalent
means of securement is visual evidence of tampering.) Care must be exercised in the design not to
inhibit emergency response team action.
3.3.8.2 Primary closures (access to tank) must have seal provision. Vacuum relief valves are
exempt from this sealing requirement.
3.3.8.3 Operating valves and fittings must have provision for sealing the operating mechanism or
be enclosed in a protective housing with seal provision.
3.3.8.4 Protection of rupture disc devices may be provided by weather covers with seal provision.
3.3.8.5 Effective July 1, 2013, new valves and fittings must be traceable to the location at
which the valve or fitting was applied. This can be accomplished either by physical means of a
“station stencil tag” or “lead seal” attached by use if rivets, cable, wire, or other suitable means
or by an alternative electronic means tied to the serial number on the fitting.
3.3.9 On cars ordered built new after July 1, 2013, the use of tapered pipe threads such as
American National Standard taper pipe threads (NPT) (ANSI B1.20.1) to attach a primary fitting
having a connection 1 in. or greater in size is prohibited. When non-taper pipe threads are used as
means of attachment and the primary fitting has a secondary closure, a mechanical stop must be
employed to prevent rotation of a fitting. When a hole 1 in. or greater in size is reduced to less than
1 in. by means of a bushing or threaded insert, the bushing or threaded insert must be seal-
welded.
3.3.10 On cars ordered built new after July 1, 2013, the use of tapered pipe threads such as
American National Standard taper pipe threads (NPT) (ANSI B1.20.1) to attach a primary closure
having a connection 1 in. or greater in size is prohibited.
3.4 Valve Configuration
The configuration of a valve and its components must minimize the possibility of trapping and
collecting dirt or residue, which adversely affect the operation of the valve.
3.5 Aspiration of Liquid
When a pressure relief valve extends 6 in. (152 mm) or more below the inside top of the tank shell,
the total cross-section of all areas through which liquid could aspirate must not exceed 3.5% of the
vapor inlet area.
3.6 Resetting
If the operating conditions of a pressure relief valve are changed so as to require a higher or lower
set pressure, the valve may not be reset more than 10% above nor 10% below the marked set
pressure. If the operating conditions of a valve are changed so as to require a new spring for a
different pressure, the valve must be adjusted and remarked by the manufacturer (or by the car
owner with the valve manufacturer’s permission).
3.7 Rupture Disc Device
3.7.1 A rupture disc device must be so designed that the means for holding the rupture disc in
place will prevent distortion or damage to the disc when properly applied. Rupture disc device
closures must be chained or otherwise fastened to prevent misplacement.
3.7.2 Tank cars built or converted after January 1, 1978, must not be equipped with rupture disc
devices having a rupture disc retained by a threaded component that directly contacts the rupture
disc unless the rupture disc device was manufactured after May 1, 1994. Such devices on tank cars
built prior to January 1, 1978, may remain in service, but, if defective, must not be replaced in
kind.
3.7.3 When a rupture disc device is used, means for inspection of the top portion of the disc
without releasing clamping pressure on the disc must be provided.
3.7.4 Tank cars ordered built, converted, or rebuilt after May 1, 1994, that are equipped with
rupture disc devices and are placed in regulated commodity service must be equipped with a surge
pressure reduction device.
3.7.5 All non-pressure tank cars that are equipped with rupture disc devices, excluding
combination devices, and that are placed in regulated commodity service, except for molten sulfur,
acrylamide, and Class 9 elevated temperature materials, must be equipped with a surge pressure
reduction device at their next qualification after July 1, 2013.
3.8 Combination Devices
If a pressure relief valve is used in combination with a rupture disc, provision must be made to
detect any accumulation of pressure between the disc and the valve. The detection device must be
a needle valve, trycock, tell-tale indicator, or other approved device. The detection device must be
closed during transportation.
3.9 Application
Except where multiple pressure relief devices are equipped with an approved three-way selector
valve, there must be no intervening valve between the pressure relief device and the vapor space of
the tank.
3.10 Vacuum Relief Valve
3.10.1 Gravity-actuated vacuum relief valves must not be applied or replaced in kind.
3.10.2 Vacuum relief valves installed prior to July 1, 2013, must be designed to seal bubble-tight
down to the start-to-open pressure and up to 100 psi (689 kPa) positive pressure. The integrity of
the seal must not be affected after opening the valve against 100 psi (689 kPa) positive pressure.
The minimum start-to-open pressure must be designed for negative 0.75 psig (5.17 kPag).
3.10.3 Effective July 1, 2013, for new tank car construction or at the time of the next qualification
of existing tank cars, vacuum relief valves must meet the following conditions:
• Must be designed to seal bubble-tight down to the start-to-open pressure and up to
165 psig (1138 kPag).
• The minimum start-to-open pressure must be designed for negative 0.75 psig (5.17 kPag).
• Must be designed so that they cannot be manually actuated from the outside.
• Must be within the permissible tolerance for start-to-open pressure as follows:
3.10.4 Effective July 1, 2013, manually actuated vacuum relief valves must not be replaced in
kind.
3.11 Maintenance
3.11.1 Repair work on pressure relief devices involving machining, grinding, welding, or other
alterations or modifications can be performed only by the valve manufacturer, or by the car owner
or user with the valve manufacturer’s permission, except as listed below.
3.11.2 If a trained specialist is available, the seating surfaces of metal-to-metal seat valves may
be lapped. The flat gasket face on the valve body mounting surface, or the gasket tongue, may be
machined to remove nicks and burns. The tolerances on the gasket tongue must not be exceeded.
3.12 Sampling Line Device
A sampling line valve, when used, must be constructed of austenitic or ferritic stainless steel. A
needle valve may have integral male threads that attach directly to the cover plate, provided the
threaded portion has a minimum Schedule 80 thickness. If a needle valve is attached using a pipe
nipple, the nipple must be made of Schedule 80 austenitic stainless steel pipe. Valves not so
equipped must be retrofitted not later than the next pressure relief valve or tank qualification
date, or at the time of any fitting repair or modification, whichever occurs first.
5.2.5.3 When installing surge suppression devices, the flow capacity derived from
paragraph 5.2.5.2 must be multiplied by an appropriate discharge flow coefficient, determined by
the surge suppression device manufacturer, to provide for an allowance for restricted flow. See
paragraph 4.7. This is the rated flow capacity of the pressure relief system.
5.2.5.4 If there is a change in the rupture disc device or any installed surge suppression device
that affects the flow capacity, the tank car owner must recalculate the flow capacity of the pressure
relief system as stated above.
5.2.6 For the purpose of the test, each device must have a mounting that approximates a typical
approach channel and has, at the outlet, a passage that approximates a typical discharge channel.
5.3 Test Reports
5.3.1 The flow capacity must be reported in cubic feet per minute (or cubic feet per minute and
cubic meters per second) of air at standard conditions.
5.3.2 The official flow capacity of a device established under paragraph 5.2.4 above must be taken
as the average of tests of three devices of the same design, size, and pressure setting.
5.3.3 The official flow capacity of a rupture disc device is the smallest capacity of the devices
tested, as determined in paragraph 5.2.5 above.
5.3.4 Flow rating, materials of construction, general arrangement, and assembly data in
sufficient detail to determine compliance with the requirements of Appendix A must be submitted
with Form AAR 4-3 to the Director and the Tank Car Committee.
5.3.5 Pressure regulator valves shall be tested in accordance with Table A.1 and documented
with Form AAR 4-3, “Application for Approval of Pressure Relief Device” (see Fig. 1.3 in
Chapter 1).
6.0 MARKING
6.1 Pressure Relief Valves
6.1.1 Each pressure relief valve must be plainly and permanently marked by the valve
manufacturer or reconditioner with the required data.
6.1.2 The marking on each pressure relief valve may be placed on the valve or on a plate or plates
securely fastened to the valve. The marking must include the following and must be maintained
for the life of the valve:
• The name or identifying mark of the manufacturer
• Manufacturer’s design or type number
• Serial number (effective for valves built after December 31, 2003)
• Set pressure, psi (or psi and kPa)
• Official flow capacity, cubic feet per minute (or cubic feet per minute and cubic meters per
second) of air at standard conditions
• Flow rating pressure, psi (or psi and kPa)
6.3.1 Each device with a net free-flow area of more than 1/2 in.2 (323 mm2) must be marked to
indicate the following:
• The name or identifying mark of the manufacturer
• Manufacturer’s design or type number
• Serial number (effective for valves built after July 1, 2013)
• Type of trim
• Pressure-temperature limitations
6.3.2 All pressure-retaining valve body castings shall be marked in accordance with the
appropriate ASTM specification, including material identification with the grade symbols (e.g.,
WCB, WC9, CF8M, etc.), heat numbers, or a lot number traceable to either a heat number or
month poured.
6.3.3 For valve bodies constructed with more than one pressure-retaining casting, each casting
must comply with the applicable ASTM marking requirement. This does not apply to bonnets,
yokes, or body inserts.
6.3.4 Marking requirements of paragraphs 6.3.2 and 6.3.3 above become effective for castings
manufactured after December 1, 2001.
6.4 Liquid Level Control and Gauging Devices
6.4.1 Each device must be marked to indicate the following:
• The name or identifying mark of the manufacturer
• Manufacturer’s design or type number
• Serial number (effective for valves built after July 1, 2013)
• Pressure rating
6.4.2 For all gauging devices, when removed from a car, each separable component that affects
gauging accuracy must be identified to ensure proper reinstallation.
6.4.3 For all gauging devices manufactured after December 31, 2003, the manufacturer must
ensure that each device indicates, when applicable, the specific gravity for which it is intended.
0.82
Qa = Gu A (for F=1, see Table A.5) Equation 7.1.1b
0.82
Q a = 2G i UA (for F<1, see Table A.5) Equation 7.1.1 c
where
A = the total outside surface area of the tank or inner container (ft2)
C = the gas constant that is a function of the ratio of specific heats at standard conditions. For liquids, if this
variable is unknown, 315 is a safe value (see Table A.4)
F = the environmental factor, equal to 1.0 for noninsulated tank cars, or calculated as follows for insulated
tank cars or thermally protected tank cars, provided the overall system will remain effective at
temperatures up to 1200 °F:
1,200 – t -
F = 8U
---------------------------------
34,500 Equation 7.1.1 d
Gi = the gas factor for insulated containers (see Table A.5)
Gu = the gas factor for noninsulated containers (see Table A.5)
L = the latent heat of vaporization in Btu per pound at flowing conditions
M = the molecular weight of the product
Qa = the minimum rate of discharge in cubic feet per minute of free air at standard conditions
T = the temperature of product at flowing conditions, °R (Rankine)
t = the temperature of gas at flowing conditions, °F
U = the overall thermal conductance of the insulating material at 100 °F, Btu/h-ft2-F
Z = the compressibility factor at flowing conditions. For liquids, if this variable in unknown, 1 is a safe value.
7.1.1.1 Minimum Flow Capacity
When the physical properties of a liquid product are not known, the minimum flow capacity of a
pressure relief device may be calculated as follows:
P – 85
Q min = Q a 1 + 1/4 -------------------- Equation 7.1.1.1a
85
where P is the flow rating pressure (psig) per 49 CFR 179.15(b)(4), and Qa is calculated
using the following physical properties:
C = 325 L = 130 Btu/lb
t = 190 °F M = 63
T = 650 °R Z = 0.864
This paragraph is applicable only for pressure relief devices with a start-to-discharge pressure less
than or equal to 165 psig.
7.1.2 SI Units
0.82
6,500FA ZT-
Q a = ------------------------------ ------ Equation 7.1.2a
LC M
0.82
Qa = Gu A (for F=1, see Table A.5) Equation 7.1.2b
0.82
Q a = 2G i UA (for F<1, see Table A.5) Equation 7.1.2 c
where
A = the total outside surface area of the tank or inner container (m2)
C = the gas constant that is a function of the ratio of specific heats at standard conditions. For liquids, if this
variable is unknown, 315 is a safe value (see Table A.4)
F = the environmental factor, equal to 1.0 for noninsulated tank cars, or calculated as follows for insulated
tank cars or thermally protected tank cars, provided the overall system will remain effective at
temperatures up to 648.88 °C:
649 – t -
F = 8U
----------------------------
391,800
where P is the flow rating pressure (psig) per 49 CFR 179.15(b)(4), and Qa is calculated
using the following physical properties:
C = 325 L = 302 kJ/kg
t = 87.8 °C M = 63
T = 361 °K Z = 0.864
This paragraph is applicable only for pressure relief devices with a start-to-discharge pressure less
than or equal to 1138 kPa.
7.1.3 Alternate Flow Capacity
As an option to the requirements of paragraph 7.1 above, any tank car transporting a non-
regulated material, Class 8 material, or other material for which the regulations permit the use of
a non-reclosing pressure relief device [ref. DOT 173.31(b)(2)] requires a pressure relief device with
a flow capacity not less than 1,100 scfm, providing that the start-to-discharge pressure does not
exceed 165 psi. This paragraph applies whether the car is equipped with a rupture disc device or a
pressure relief valve. This paragraph does not apply to any material requiring a flow capacity, as
calculated per paragraph 7.1, that exceeds 19A0.82 (conventional units) or 0.06A0.82 (SI units),
where A is the same value used in the paragraph 7.1 calculation.
7.2.2 In addition to the requirement of paragraph 7.2.1 above, the pressure relief valve capacity
must be sufficient to limit the pressure within the inner container to the flow rating pressure
specified in the tank specification when the insulation space is filled with air or gaseous lading
(whichever requires the greater capacity) at atmospheric pressure and the outer shell...
...is at 130 °F:
130 – t 2
Q a = ------------------------------- G i U c A (conventional units) Equation 7.2.2a
4 1,200 – t 2
Notes:
1. In paragraphs 7.2.1 and 7.2.2 above, Uc is the overall thermal conductance of the insulating
material filled with air or gaseous lading, at atmospheric pressure, whichever provides the
greater thermal conductance.
2. In paragraph 7.2.2 above, the value of Uc at the average temperature of the insulation may be
used. For liquid hydrogen, the value of Uc must be chosen on the basis that the insulation space
is filled with gaseous hydrogen at one atmosphere.
3. The net free flow area through any part of the pressure relief valve must be not less than
3/16 in.2 (1.21 cm2).
4. The Gi values for ethylene and hydrogen in Table A.5 are given for both rupture disc device and
pressure relief valve settings of Class DOT-113 cars used for these commodities.
W = CKAp M
----- Equation 8.0a
T
where
W = the mass flow rate of gas or vapor, lb/h
C = the constant for gas or vapor, a function of the ratio of specific heats, k=Cp/Cv (with dimension)
K = the coefficient of discharge, dimensionless
A = the actual area of discharge orifice or nozzle area, in.2
p = the upstream pressure (the set pressure multiplied by 1.10) plus atmospheric (flow rating pressure)
M = the molecular weight of the gas or vapor
T = the temperature of the gas at flowing conditions, °R
For real gases, an empirical correction can be made to Equation 8.0a by using the equation of
state:
pv = ZRT Equation 8.0b
where
v = the gas specific volume in ft3/lb
R = the gas constant
Z = the compressibility factor
For a tank engulfed in fire under “quasi-steady state” conditions, the heat absorbed by the liquid is
used to vaporize it, and the vapor generated is expelled through the pressure relief valve. The
vapor flow through the pressure relief valve is given by the following equation:
W = Q L lb h Equation 8.0d
where
Q = the amount of heat absorbed by the liquid cargo, Btu/h
L = the latent heat of vaporization at flowing conditions, Btu/lb
Assume that a given relief valve is tested with dry air at 60 °F (520 °R), the pressure differential is
sufficient for critical flow. For this case, Equation 8.0c can be written as follows:
Ma
W a = C a KAp ------------
- Equation 8.0 e
Za Ta
where
Ca = 356 (for air K=1.4)
Ma = 28.97
Ta = 520 °R
Za = 1.0
where
C
k = ------p- Equation 8.0 h
Cv
where
Wa = the air rated equivalent capacity in lb/h at 60 °F inlet temperature
where
vo = 13.1 ft3/lb, specific volume of air at 60 °F, 14.7 psia
60 = the conversion factor from hours to minutes
When the specific heat ratio k from which C is calculated is not known, a value of C=315 is
considered a conservative value.
The fundamental equation used in calculating the amount of heat absorbed by a liquid cargo
container exposed to fire can be expressed as follows:
Q = qFEA w Equation 8.0 m
where
Q = the rate of heat absorption by the liquid, Btu/h
q = the heat flux from the fire (per unit wetted area completely exposed to fire), Btu/h-ft2
F = the dimensionless fire exposure factor
Aw = the total wetted surface area of the container, ft2
E = the fraction of surface of vessel exposed to fire
Experimental data indicate that the heat flux q from a free-burning hydrocarbon fire can reach
values up to 34,500 Btu/h ft2 to bare container surfaces. Substituting this value for q in Equation
8.0n gives the following:
633,000FEA w
Q a = ----------------------------------- ZT
------- Equation 8.0 o
LC M
It should be noted that Equation 8.0o breaks down near the critical point of the mixture, where L
approaches zero. For this reason, this equation should not be used where values of L are less than
50 Btu/lb.
Factor E is defined as the fraction of the wetted surface of the vessel exposed to fire. Fire test data
(Cummings) indicate that as the size of a vessel increases, the fraction of the wetted surface
exposed decreases in accordance with the following expression:
1 -
E = ----------- Equation 8.0p
0.18
A
where
A = the total area of container in ft2
To include a factor of safety, if the total wetted surface area of the container Aw in Equation 8.0o is
to equal A, then the product
0.82
Ea w = EA = A Equation 8.0q
where
F = the environmental factor that can vary between 0 and 1
U = the overall thermal conductance BTU/h-ft2 at 100 °F
t1 = the assumed external surface temperature under the fire conditions = 1200 °F
t2 = the temperature of the gas (liquid) at flowing conditions
q = the heat flux from the fire/unit wetted area exposed to fire = 34,500 BTU/h-ft2
The product of the three factors of U is equal to eight, and Equation 8.0t becomes the following:
8U 1,200 – t 2
F = -----------------------------------
- Reference Equation 7.1.1d
34,500
For a noninsulated container (bare tank), F = 1. For all other cases (insulation, thermal protection,
and linings), the value of F should be calculated and used in Equation 8.0r.
To simplify use of the formula for commonly encountered gases and pressures, set
73.4 1,200 – t 2 ZT
G i = --------------------------------------- ------- Equation 8.1 c
LC M
Substituting,
0.82
Qa = Gi Uc A Reference Equation 7.2.1a
The derivation of Equation 7.2.2a is based on an outer shell temperature of 130 °F. The weight of
lading vaporized is given by the following:
U c A 130 – t 2
w = ----------------------------------- , lb/h Equation 8.1d
L
From Compressed Gas Association’s (CGA’s) Basic Consideration for Pressure Relief Device
standards,
13.1wC a ZTM a
Q a = ---------------------- -----------------
- Equation 8.1 e
60C Za Ta M
ZT Gi
------- = --------------------------------------------------
- Equation 8.1 h
M 73.4 1,200 – t 2 LC
Substituting,
130 – t 2
Q a = ------------------------------- G i U c A Reference Equation 7.2.2a
4 1,200 – t 2
+ 1-
k-----------
Cp 2 k–1
k = ------- ; C = 520 k ------------ When C is not shown, 315 is a safe value.
Cv k+1
Start-to- Flow
Discharge Rating Gua⁄ Gia⁄
Pressure Pressure
Conv. SI Conv. SI
Commodity psi kPa psia⁄ kPa units units units units
Acetic acid 75 517 85 586 42.9 0.1421 4.10 0.0007
Acetone 75 517 85 586 35.70 0.1183 3.91 0.0006
Acrylonitrile 75 517 85 586 33.12 0.1097 3.42 0.0005
Acrylonitrile 165 1138 181.5 1252 35.44 0.1170 3.40 0.0005
Ammonia, anhydrous 225 1551 247.5 1706 21.34 0.0707 2.678 0.0004
Ammonia, anhydrous 247.5 1706 270 1862 21.63 0.0716 2.693 0.0004
Ammonia, anhydrous 255 1758 280.5 1934 21.80 0.0722 2.716 0.0004
Ammonia, anhydrous 280.5 1934 306 2110 21.93 0.0726 2.726 0.0004
Ammonia, anhydrous 300 2068 330 2275 22.22 0.0736 2.749 0.0004
Ammonia, anhydrous 330 2275 360 2482 22.26 0.0737 2.754 0.0004
Ammonia, anhydrous 375 2586 412.5 2844 23.27 0.0771 2.836 0.0005
Argon, refrigerated liquidb⁄ 60 414 60 414 55.7 0.1845 9.5 0.0015
Benzene 75 517 85 586 40.80 0.1351 4.18 0.0007
Benzoic acid 75 517 85 586 38.01 0.1254 2.48 0.0004
Butadiene 75 517 85 586 39.73 0.1316 4.905 0.0008
Butadiene 225 1551 247.5 1706 49.89 0.1652 5.689 0.0009
Butadiene 247.5 1706 270 1862 51.33 0.1700 5.806 0.0009
Butadiene 255 1758 280.5 1934 52.02 0.1723 5.862 0.0009
Butadiene 280.5 1934 306 2110 53.72 0.1779 6.001 0.0010
Butadiene 300 2068 330 2275 55.37 0.1834 6.136 0.0010
Carbon dioxide 375 2586 412.5 2844 48.56 0.1608 6.621 0.0011
Carbon dioxide 450 3103 495 3413 52.53 0.1737 7.07 0.0011
Carbon disulfide 225 1551 247.5 1706 47.85 0.1579 4.74 0.0008
Chlorine 225 1551 247.5 1706 49.8 0.1649 6.12 0.0010
Chlorine 375 2586 412.5 2844 55.7 0.1845 6.56 0.0011
Chlorodifluoromethane (R22) 247.5 1706 270 1862 65.89 0.2183 8.22 0.0013
Chloroform 165 1138 181.5 1252 54.82 0.1809 5.53 0.0009
Cyclohexane 75 517 85 586 43.26 0.1433 4.41 0.0007
Decene (Decylene) 75 517 85 586 50.81 0.1683 4.03 0.0006
Dichlorodifluoromethane 225 1551 247.5 1706 77.10 0.2554 9.34 0.0015
Dichlorodifluoromethane 255 1758 280.5 1934 80.56 0.2668 9.66 0.0016
Dichlorodifluoromethane 300 2068 330 2275 85.75 0.2840 10.14 0.0016
Difluoroethane 225 1551 247.5 1706 53.16 0.1761 6.441 0.0010
Difluoroethane 300 2068 330 2275 60.66 0.2009 7.18 0.0012
Difluoromonochloroethane 75 517 85 586 53.66 0.1777 6.707 0.0011
Difluoromonochloroethane 225 1551 247.5 1706 66.19 0.2192 7.696 0.0012
Difluoromonochloroethane 300 2068 330 2275 73.41 0.2431 8.324 0.0013
Dimethylamine, anhydrous 225 1551 247.5 1706 42.77 0.1417 4.86 0.0008
Dimethylamine, anhydrous 247.5 1706 270 1862 44.08 0.1460 4.97 0.0008
Start-to- Flow
Discharge Rating Gua⁄ Gia⁄
Pressure Pressure
Conv. SI Conv. SI
Commodity psi kPa psia⁄ kPa units units units units
Dimethylamine, anhydrous 255 1758 280.5 1934 44.60 0.1477 5.01 0.0008
Dimethylamine, anhydrous 280.5 1934 306 2110 46.08 0.1526 5.14 0.0008
Dimethylamine, anhydrous 300 2068 330 2275 47.71 0.1580 5.28 0.0009
Dimethylamine, anhydrous 330 2275 360 2482 49.78 0.1649 5.46 0.0009
Dimethylamine, anhydrous 375 2586 412.5 2844 53.63 0.1776 5.81 0.0009
Dimethyl ether 225 1551 247.5 1706 42.68 0.1414 5.161 0.0008
1-Dodecene 75 517 85 586 40.07 0.1322 2.80 0.0004
Dowtherm “A” 165 1138 181.5 1252 54.02 0.1789 2.60 0.0004
Ethyl acrylate 75 517 85 586 46.21 0.1531 4.56 0.0007
Ethyl alcohol 75 517 85 586 23.71 0.0785 2.54 0.0004
Ethylene oxide 75 517 85 586 31.54 0.1045 3.80 0.0006
Ethylene, refrigerated liquid 75 517 85 586 35.9 0.1189 5.30 0.0009
Ethylene, refrigerated liquid 90 621 100 689 36.7 0.1216 5.40 0.0009
Ethylene, refrigerated liquidb⁄ 120 827 120 827 37.7 0.1249 5.53 0.0009
Fertilizer ammoniating solution 75 517 85 586 9.54 0.0316 1.21 0.0002
Fertilizer ammoniating solution 225 1551 247.5 1706 10.79 0.0357 1.37 0.0002
Fertilizer ammoniating solution 375 2586 412.5 2844 11.88 0.0393 1.51 0.0002
Hydrogen, refrigerated liquid 30 207 40 276 44.4 0.1471 8.3 0.0013
Hydrogen, refrigerated liquidb⁄ 60 414 60 414 47.5 0.1573 9.0 0.0015
Hydrogen chloride 450 3103 495 3413 51.68 0.1712 6.87 0.0011
Liquefied petroleum gasc⁄ 75 517 85 586 40.85 0.1353 5.085 0.0008
Liquefied petroleum gasc⁄ 225 1551 247.5 1706 50.29 0.1666 6.260 0.0010
Liquefied petroleum gasc⁄ 247.5 1706 270 1862 51.42 0.1703 6.355 0.0010
Liquefied petroleum gasc⁄ 255 1758 280.5 1934 52.94 0.1753 6.526 0.0011
Liquefied petroleum gasc⁄ 280.5 1934 306 2110 54.98 0.1821 6.733 0.0011
Liquefied petroleum gasc⁄ 300 2068 330 2275 56.89 0.1884 6.924 0.0011
Liquefied petroleum gasc⁄ 330 2275 360 2482 59.97 0.1986 7.247 0.0012
Liquefied petroleum gasc⁄ 375 2586 412.5 2844 66.07 0.2188 7.890 0.0013
Liquefied petroleum gasc⁄ 450 3103 495 3413 83.18 0.2755 9.769 0.0016
Methyl alcohol 75 517 85 586 20.84 0.0690 2.29 0.0004
Methyl chloride 225 1551 247.5 1706 42.78 0.1417 5.149 0.0008
Methyl mercaptan 225 1551 247.5 1706 37.99 0.1258 4.264 0.0007
Methyl methacrylate 75 517 85 586 48.52 0.1607 4.74 0.0008
Monochlorodifluoromethane 225 1551 247.5 1706 60.5 0.2004 7.6 0.0012
Monochlorodifluoromethane 300 2068 330 2275 66.3 0.2196 8.1 0.0013
Monoethanolamine 165 1138 181.5 1252 26.00 0.0858 2.03 0.0003
Monoethylamine (ethylamine) 247.5 1706 270 1862 39.65 0.1313 4.35 0.0007
Monoisopropanolamine 165 1138 181.5 1252 31.33 0.1034 2.54 0.0004
Monoisopropylamine 225 1551 247.5 1706 41.48 0.1369 4.39 0.0007
Start-to- Flow
Discharge Rating Gua⁄ Gia⁄
Pressure Pressure
Conv. SI Conv. SI
Commodity psi kPa psia⁄ kPa units units units units
Monoisopropylamine 280.5 1934 306 2110 47.60 0.1571 4.90 0.0008
Monomethylamine, anhydrous 225 1551 247.5 1706 31.47 0.1042 3.71 0.0006
Monomethylamine, anhydrous 247.5 1706 270 1862 32.25 0.1068 3.78 0.0006
Monomethylamine, anhydrous 255 1758 280.5 1934 32.56 0.1078 3.81 0.0006
Monomethylamine, anhydrous 280.5 1934 306 2110 33.30 0.1103 3.87 0.0006
Monomethylamine, anhydrous 300 2068 330 2275 34.12 0.1130 3.94 0.0006
Monomethylamine, anhydrous 330 2275 360 2482 35.11 0.1163 4.03 0.0007
Monomethylamine, anhydrous 375 2586 412.5 2844 37.93 0.1256 4.27 0.0007
Nitrogen fertilizer solution 75 517 85 586 9.54 0.0316 1.21 0.0002
Nitrogen fertilizer solution 225 1551 247.5 1706 10.79 0.0357 1.37 0.0002
Nitrogen fertilizer solution 375 2586 412.5 2844 11.88 0.0393 1.51 0.0002
Nitrogen, refrigerated liquidb⁄ 60 414 60 414 54.7 0.1812 9.4 0.0015
Nitrosyl chloride 225 1551 247.5 1706 56.99 0.1888 6.707 0.0011
Oxygen, refrigerated liquidb⁄ 60 414 60 414 50.6 0.1676 8.6 0.0014
Phenol solution 75 517 85 586 36.50 0.1209 2.95 0.0005
Phenol solution 165 1138 214.5 1479 43.02 0.1425 3.05 0.0005
Phosphorus trichloride 225 1551 247.5 1706 64.40 0.2133 6.10 0.0010
Styrene monomer 75 517 85 586 43.97 0.1456 3.78 0.0006
Sulfur dioxide 150 1034 165 1138 37.28 0.1235 4.54 0.0007
Sulfur dioxide 225 1551 247.5 1706 39.58 0.1311 4.69 0.0008
Sulfur dioxide 375 2586 412.5 2844 43.66 0.1446 4.97 0.0008
Tertiary butyl mercaptan 225 1551 247.5 1706 57.72 0.1912 5.42 0.0009
1,1,1,2-Tetrafluoroethane 300 2068 330 2275 77.69 0.2573 9.30 0.0015
Toluene Diisocyanate 375 2586 412.5 2844 45.79 0.1511 1.78 0.0003
Trichlorosilane 375 2586 412.5 2844 98.84 0.3274 9.67 0.0015
Trifluorochloroethylene 225 1551 247.5 1706 63.4 0.2100 8.2 0.0013
Trifluorochloroethylene 300 2068 330 2275 84.59 0.2802 10.00 0.0016
Trimethylamine, anhydrous 225 1551 247.5 1706 59.26 0.1963 6.66 0.0011
Trimethylamine, anhydrous 247.5 1706 270 1862 61.36 0.2032 6.84 0.0011
Trimethylamine, anhydrous 255 1758 280.5 1934 62.20 0.2060 6.92 0.0011
Trimethylamine, anhydrous 280.5 1934 306 2110 65.34 0.2164 7.20 0.0012
Trimethylamine, anhydrous 300 2068 330 2275 68.63 0.2273 7.50 0.0012
Trimethylamine, anhydrous 330 2275 360 2482 73.43 0.2432 7.94 0.0013
Trimethylamine, anhydrous 375 2586 412.5 2844 83.10 0.2752 8.84 0.0014
Vinyl chloride 150 1034 165 1138 42.45 0.1406 5.116 0.0008
Vinyl chloride 225 1551 247.5 1706 46.36 0.1535 5.404 0.0009
Vinyl chloride 247.5 1706 270 1862 47.43 0.1571 5.485 0.0009
Vinyl chloride 255 1758 280.5 1934 47.94 0.1588 5.524 0.0009
Vinyl chloride 280.5 1934 306 2110 49.18 0.1629 5.620 0.0009
Start-to- Flow
Discharge Rating Gua⁄ Gia⁄
Pressure Pressure
Conv. SI Conv. SI
Commodity psi kPa psia⁄ kPa units units units units
Vinyl chloride 300 2068 330 2275 50.37 0.1668 5.712 0.0009
Vinyl fluoride 450 3103 495 3413 64.94 0.2151 8.336 0.0014
Vinyl methyl ether 75 517 85 586 38.64 0.1280 4.709 0.0008
Vinyl methyl ether 225 1551 247.5 1706 46.94 0.1555 5.301 0.0009
Notes to Table A.5:
a• When lower flow rating pressures than those shown are used, the values of Gu and Gi are on
the safe side and may be used as shown or may be calculated using the prescribed formulas.
For higher flow rating pressures than shown, the values must be calculated. Wherever specific
Gi and Gu values are listed, they must be used to calculate flow rate requirements.
b• Values are for sizing the rupture disc device flow capacity. For argon, nitrogen, and oxygen,
these values may also be used to calculate (conservatively) the flow capacities of pressure
relief valves.
c• The same value must be used for liquid hydrocarbon gas.
APPENDIX B
CERTIFICATION OF TANK CAR FACILITIES
CONTENTS
APPENDIX B
CERTIFICATION OF TANK CAR FACILITIES
1.0 ADMINISTRATIVE PROVISIONS
1.1 Introduction
This specification has been formulated by the Tank Car Committee of the Association of American
Railroads. Each tank car facility that performs tank car activities requiring certification to this
specification should note that there are other sections of the AAR Manual of Standards and
Recommended Practices (MSRP), the Field Manual of the AAR Interchange Rules, and the Office
Manual of the AAR Interchange Rules that contain additional requirements. S-2034 certification is
required for tank car facilities certified to manufacture and/or assemble tank cars. The MSRP
sections are outlined in the “To The User” and “Preface” section of this specification (Section C,
Part III, Specifications for Tank Cars, Manual of Standards and Recommended Practices (MSRP)
of the AAR, Specification M-1002).
1.2 Scope
Appendix B describes the process and procedures that tank car facilities must follow to obtain and
maintain certification from AAR. Appendix B outlines those activities performed by tank car
facilities that require tank car facility certification. Tank car activities performed by tank car
facilities must comply with all applicable AAR specifications and federal regulations. Appendices
referenced in this specification refer to those in M-1002 unless otherwise specified. Depending
upon the facility’s total scope of work, the facility may be subject to other AAR technical
certifications and/or QA commodity code requirements.
1.3 Objective
AAR M-1002 certification requires an evaluation of a tank car facility’s ability to meet the
requirements outlined in this appendix. The evaluation is followed by certification. Annual
evaluations are conducted to maintain the certification.
2.1.2 Regarding Activity Code C6, the following activities do not require certification; replacing
in-kind rupture disks, bottom outlet valve caps, nonpressure hinged manway gaskets and/or fill-
hole cover gaskets, bottom outlet valve cap gaskets, magnetic gauging device rods, O-rings in
gauging device caps, O-rings in thermometer well housing tubes, secondary closures, chains, and
flanges external to valves.
2.1.3 Regarding Activity Codes C7, C8, C9, C10, and C11, certification is required only when the
facility installs, inspects, qualifies, removes, and/or repairs interior linings and coatings in tank
cars that transport materials that are corrosive to the tank as defined in Appendix L,
paragraph 7.0, or that are reactive to the tank as defined in 49 CFR §180.503.
2.1.4 If a facility is certified to activity code C8 and/or C10, the facility would require activity
code C9.
2.3.8 Demonstration of repair level RL1 capability requires, at a minimum, a welder qualified by
the facility in accord with Appendix W using the facility’s qualified welding procedure
specifications (WPS) per Appendix W. This capability can be demonstrated by performing a
welded repair to a tank car tank or by a test plate. This welded repair must be witnessed during
the on-site inspection. If the demonstration is performed on a tank car tank, the qualified welder
must perform a welded repair in accord with Appendix R. If the demonstration is performed on a
test plate, it must be performed in accord with paragraph 2.3.10. The facility is required to
perform and document both nondestructive testing using NDT methods MT or PT and postweld
heat treatment as prescribed in Appendix R. During the on-site inspection, the inspector must
witness the NDT examination and verify the documentation; and at a minimum, witness only the
setup of postweld heat treatment.
2.3.9 Demonstration of repair level RL2 capability requires, at a minimum, a welder qualified by
the facility in accord with Appendix W using the facility’s qualified welding procedure
specifications (WPS) per Appendix W. This capability can be demonstrated by performing a defect
repair (insert or through shell/head crack) to a tank car tank or using a test plate. If the
demonstration is performed on a tank car tank, the qualified welder must perform the repair in
accord with Appendix R. If the demonstration is performed on a test plate, it must be performed in
accord with paragraph 2.3.11. During the on-site inspection, the inspector must witness the NDT
examination and verify the documentation; and at a minimum, witness only the setup of postweld
heat treatment.
2.3.10 In lieu of a tank car facility demonstrating repair level RL1 capability on a tank car, a
facility is permitted to use a test plate provided that the test plate material is from the listed
materials in the material group(s) identified in the application for certification. The test plate
must be the contour of a tank car tank and be a minimum size of 4 ft (1.2 m) in width and 4 ft
(1.2 m) in height. The qualified welder must perform a fillet weld that simulates a weld
attachment using a material from a material group for which the facility seeks certification. The
fillet weld size must be a minimum 5/16 in. (8 mm), and the length must be a minimum of 12 in.
(305 mm).
2.3.11 In lieu of a tank car facility demonstrating repair level RL2 capability on a tank car, a
facility is permitted to use a test plate provided that the test plate material is from the listed
materials in the material group(s) identified in the application for certification. The test plate
must be the contour of a tank car tank and be a minimum size of 4 ft (1.2 m) in width and 4 ft
(1.2 m) in height. The qualified welder must perform a double-weld butt joint on a tank shell insert
with 1 in. (25.4 mm) minimum corner radius. The insert must restore original contour. The
minimum size of the insert must be at least 1 ft2 (.092 m2) in size. The qualified welder must
demonstrate, at a minimum, horizontal position 2G and vertical position 3G butt welds.
Table B.3 Repair levels for activity codes B24 and/or B83
Repair Level Description
RL1 Demonstrate proficiency in performing welding to tank car tank material, NDT method MT or PT, and post-weld
heat treatment. This level excludes repairing a through-the-tank-car tank defect (insert or through-the-shell/
head crack). This demonstration must be performed on a tank car tank or test plate and must be performed
on a material from a material group for which the facility seeks certification.
RL2 Demonstrate proficiency in performing welding to tank car tank material, NDT, and post-weld heat treatment.
This level includes repairing a through-the-tank-car tank defect (insert or through-the-shell/head crack). This
demonstration must be performed on a tank car tank or test plate and must be performed on a material from
a material group for which the facility seeks certification.
2.3.12 Tank car facility certification is not required for facilities that manufacture and/or repair
pressure-retaining tank component(s) on behalf of the certified tank car facilities as long as the
certified facility adheres to paragraph 2.3.15.
2.3.13 Tank car facility certification is required for facilities that manufacture and/or repair
pressure-retaining tank component(s) to their own controlled designs and specifications.
2.3.14 Tank car facility certification is required for facilities that manufacture and/or repair
pressure-retaining tank component(s) to controlled designs and specifications of a non-certified
tank car facility.
2.3.15 Each certified tank car facility that authorizes work using services and/or equipment as
described in paragraph 2.7.1 requires an Exhibit B-1 and must verify that the work is in
compliance with all applicable specifications and regulations.
2.3.16 The facility must possess the latest published issues of MSRP M-1002 “Specifications for
Tank Cars,” Field Manual of the AAR Interchange Rules, and Office Manual of the AAR
Interchange Rules, and any other current applicable AAR publications covering tank car work it
certifies as meeting AAR requirements, including a current file of Safety and Operations
publications (Circular Letters). The facility must also have the applicable federal regulations. A
listing of current AAR publications is shown on the preface page of this manual. Information on
where to obtain AAR publications can be found in the “Ordering Information” section of M-1002 or
online at http://www.aarpublications.com.
2.4 Quality Assurance Program Certification
Each facility wishing to obtain certification by the AAR Tank Car Committee in accord with this
specification must also obtain certification in accord with the AAR Manual of Standards and
Recommended Practices, Section J, “Specification for Quality Assurance” (M-1003).
2.5 Car Builder Certification
Each facility wishing to obtain certification by the AAR Tank Car Committee in accord with this
specification for activity code A19 (manufacture of tank cars) and/or B78 (assemble tank cars)
must also obtain certification in accord with MSRP Section C, Standard S-2034, “Car Builder
Certification.”
2.6 Minimum Personnel Qualifications
2.6.1 Welders and Welding Operators
2.6.1.1 All personnel engaged in welding on tank car tanks must be performance-qualified in
accord with Appendix W. Welders certified per Appendix W shall be considered to meet the
requirements of AAR Manual of Standards and Recommended Practices, Section C Part II (M-
1001), paragraph 5.1.8.2.
2.6.1.2 All other welders at a certified facility must be qualified per AAR Manual of Standards
and Recommended Practices, Section C Part II (M-1001), paragraph 5.1.8.2.
2.6.2 Inspection Personnel—Welding, Nondestructive Testing, and Coating/Lining
Inspection
2.6.2.1 All certified facilities performing nondestructive testing or coating/lining inspection must
have available at least one person qualified and certified in the inspection method in accordance
with the company’s written practice, as applicable per Appendix L or Appendix T.
2.6.2.2 Those facilities that do not employ personnel with the above qualifications must submit a
list of those companies they intend to use for those services by utilizing an Exhibit B-1. The
certified facility must verify in writing that these companies utilize personnel with the above
qualifications and that inspections will be made in accord with applicable requirements.
3.1.5 Once the application package has been reviewed and it is deemed to consist of all required
information, the Executive Director or agent will appoint an individual or team representing the
Tank Car Committee to inspect the facility requesting certification. The on-site inspection for
initial certification as outlined in paragraph 3.2 of this appendix.
3.2 On-Site Inspection for Certification
3.2.1 An inspector (individual or team) assigned by the Executive Director representing the Tank
Car Committee will inspect the facility requesting certification.
3.2.2 The inspector will contact the facility and determine if the facility deems itself capable of
demonstrating the applicable proficiencies of those tank car activities outlined in the application.
If the facility is ready, an on-site inspection will be scheduled. If the facility is not ready, it must
advise the inspector when it is ready, at which time the on-site inspection will be scheduled.
3.2.3 The on-site inspection for certification will be performed during the same scheduled
timeframe as the required QA audit outlined in AAR Manual of Standards and Recommended
Practices, Section J, “Quality Assurance Program Specification” (M-1003).
3.2.4 The Exhibit B-2 will be used to document the on-site inspection and will indicate the results
of the on-site inspection.
3.2.5 Upon completion of the on-site inspection, the inspector will provide the completed Exhibit
B–2 to the Executive Director.
3.3 Certification
3.3.1 Approval under this specification applies only to one facility. If a company desires that more
than one facility be approved, each facility must be approved independently.
3.3.2 Approval of a facility to any activity code(s) is based upon the Exhibit B–2.
3.3.3 Upon receipt of the completed Exhibit B-2, the inspector will review, and if no deficiencies
were noted, the report will be provided to the Executive Director for final review prior to providing
the Exhibit B-2 to the Tank Car Committee for action.
3.3.4 Any deficiencies noted during the on-site inspection will be provided to the facility by the
inspector. The facility must provide a written response to the inspector within 10 business days
from the date of correspondence, with the corrective actions addressing the deficiencies. The
written response may be sent via email as an attachment.
3.3.5 In the event that the facility fails to respond within 10 business days from the date of
correspondence on the deficiencies to the inspector, the inspector will notify the Executive Director
or agent.
3.3.6 Upon acceptance of corrective actions by the inspector, the Exhibit B-2 will be forwarded to
the Executive Director or agent for final review prior to providing the Exhibit B-2 to the Tank Car
Committee for action.
3.3.7 Upon approval by the Tank Car Committee, the Executive Director will provide the facility
with the certification letter and the Exhibit B-2.
3.3.8 Certification to this specification is in effect for a period of 6 years, subject to an annual
evaluation.
Table B.4 Alignment of M-1002 and M-1003 certification for all tank car activity codes
Year M-1002 Certification M-1003 Certification
1 Initial Certification Initial Certification
2 Annual Evaluation Compliance Audit
3 Annual Evaluation Compliance Audit
4 Annual Evaluation Recertification
5 Annual Evaluation Compliance Audit
6 Annual Evaluation Compliance Audit
7 Recertification Recertification
3.7 Recertification
3.7.1 Recertification follows the same process as initial certification. Refer to paragraph 3.0 of
this appendix.
3.7.2 Each M-1002-certified facility must be recertified at intervals of 6 years from the original
certification date.
3.7.3 It is the responsibility of the facility to initiate the recertification proceedings 6 months
prior to the expiration date of the current certification.
3.7.4 Recertification is not automatic and can be denied if the tank car facility no longer complies
with AAR Manual of Standards and Recommended Practices, Section C Part III, “Specification of
Tank Cars” (M-1002) and federal regulations.
3.8 Denial of Certification
In the event the Tank Car Committee finds that the applicant’s facility is not suitable for
certification, the applicant may request that an additional on-site inspection be performed at the
facility. The applicant must bear all expenses of this additional on-site inspection. If the results of
the additional on-site inspection are not suitable for certification, the matter may be appealed to
the Association of American Railroads’ Assistant Vice President, Environment and Hazardous
Materials.
3.9 Revocation of Certification
3.9.1 Facility certification will be revoked if the facility fails to maintain AAR M-1003 Quality
Assurance certification.
3.9.2 A facility may have certification revoked by formal action of the Tank Car Committee for
documented evidence of failure to meet the requirements of M-1002. In such cases, the facility
management must prove that sufficient corrective remedies and quality assurance measures have
been implemented before any written reapplication is eligible for approval. This must be verified
by an on-site inspection by an inspector (individual or team assigned by the Tank Car Committee).
Reapplication must be in accord with specified procedures for an original application.
3.15.2 In lieu of physically mailing and/or faxing written notification to the Executive Director,
the written notification can be in electronic format (i.e., MS Word or PDF file) and sent via email to
the Executive Director.
3.15.3 Exhibits
• Exhibit B–1 Subcontractor Evaluation Sheet
• Exhibit B–2 AAR Tank Car Facility Inspection and Evaluation Form
• Exhibit B–3 Application for Tank Car Facility Technical Certification and Change
Notification Form
• Exhibit B–3A Certification Additional Information Form
EXHIBIT B–1
2 Address 3 City
7 Name 8 Title
12 Email Address
Part 3: Subcontractor Activity
13 Select the applicable activities provided to the Certified Facility :
For each activity identified above, explain how the company representative responsible for that activity verifies that the
subcontractor understands and conforms to the requirements of the Association of American Railroads Manual of
Standards and Recommended Practices, Section C Part III, Specification for Tank Cars (M-1002).
14 Personnel
15 Processes
16 Equipment
17 Service
18 Product
20 Name 21 Title
25 Address 26 City
30 Signature (Attesting)
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EXHIBIT B–3
APPLICATION FOR TANK CAR FACILITY TECHNICAL CERTIFICATION
AND CHANGE NOTIFICATION FORM
This form is both the application for AAR Technical Certification for a single tank car facility and used as change
notification as required by paragraph 3.10. This application must be accompanied by an initial payment as required by
paragraph 3.13. This form is part of the application package (see paragraph 3.1.2), which must be submitted to
5 If you are an existing AAR Registered Tank Car Facility, provide the following:
What is your Station Stencil?
Do you prefer to keep the same Station Stencil? Yes No
Part 2: Tank Car Facility Information
6 Station Stencil (Assigned by AAR; however Station Stencil request can be made in field 36 Comments)
7 Company Name
8 Address 9 City
20 Company Name
21 Name 22 Title
23 Address 24 City
25 State/Province 26 ZIP/Postal Code 27 Country
28 Office Phone 29 Cell Phone 30 Fax
31 Email Address
Part 5: Recipient of Certification from AAR
32 Select the Recipient (NOTE: This facility must have the ability to produce the certification letter upon request.)
Applicant (Part 4) Primary Contact (Part 3)
EXHIBIT B–3
APPLICATION FOR TANK CAR FACILITY TECHNICAL CERTIFICATION
AND CHANGE NOTIFICATION FORM
Part 6: Facility Certification Information
NOTE: Certified facility must be capable of performing, or arrange to have performed, all associated tank car activities for
which the facility is certified.
33 Select activity codes that apply:
A19 Manufacturer of tank cars
B82 Manufacture of tank car tanks, including support structure, that are moved to and from the facility without trucks
(running gear)
B83 Repair tank car tanks that are moved to and from the facility without trucks (running gear)
B84 Qualification of tank car tanks that are moved to and from the facility without trucks (running gear)
B85 Manufacturer of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
B86 Repair of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
C6 Removal and replacement of tank car service equipment (including changing of gaskets)
RL2—Demonstrate proficiency in performing welding to tank car tank material, NDT, and postweld heat treatment. This level
includes repairing a through-the-tank-car tank defect (insert or through-the-shell/head crack). This demonstration must be
performed on a tank car tank or test plate and must be performed on a material from a material group for which the facility
seeks certification.
EXHIBIT B–3
APPLICATION FOR TANK CAR FACILITY TECHNICAL CERTIFICATION
AND CHANGE NOTIFICATION FORM
37 Comments
This is to attest that the information provided in this application meets all requirements of M-1002, Appendix B, and that
all information required by M-1002, Appendix B, Form B-3A, has been included.
38 Applicant’s Name 39 Applicant’s Signature
42 Title
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APPENDIX C
MARKING OF TANK CARS
CONTENTS
APPENDIX C
MARKING OF TANK CARS
1.0 INTRODUCTION
1.1 Scope
This appendix describes AAR requirements for marking of tank cars, including stenciling and
stamping. It supplements the general requirements of the Manual of Standards and
Recommended Practices, Section L, Standard S-910.
2.0 STENCILING OF TANK CARS
2.1 New Tank Cars
New tanks and new car structures, or new tanks for existing cars, must be stenciled as required by
the applicable specification and the following notes. All required markings for tank cars must be in
English (required information also may be displayed in a second language). The stenciling is
shown in Fig. C.2 and Fig. C.3. When stenciling is prescribed on tank and tank is insulated, the
stencils must be applied on the jacket.
2.2 Repainted Tank Cars
When existing cars are repainted and restenciled, all required markings for tank cars must be in
English (required information also may be displayed in a second language) and stenciling must
comply with the following notes:
2.3 Notes
See Fig. C.2 and Fig. C.3.
2.3.1 Tanks
2.3.1.1 Initials and number of DOT, TC, or AAR specifications applicable to the tank car’s
operating specification must be stenciled on both sides of the tank in letters and numerals at least
1 1/2 in. (38.1 mm) high.
2.3.1.2 Water capacity in U.S. gallons and liters must be stenciled on tank cars as follows:
• Pressure and nonpressure tank cars: shell-full volume on both heads of the tank or the
jacket.
• Compartment tank cars: shell-full volume of each compartment, on both sides of the
tank or jacket, near manway. The capacity of each compartment may also be stenciled on
the heads of the tank or the jacket. Compartments must be identified numerically,
beginning with the B-end compartment as No. 1 and numbering consecutively toward the
A-end. The compartment identification stencil must be located immediately below the
capacity stencil for each compartment, be of the same size, and consist of the number only.
2.3.1.3 When tanks are designed and are authorized for transportation of a particular commodity
only, “(NAME OF COMMODITY),” or such other wording as may be required to indicate the limits
of usage of the car, must be marked in letters at least 1 in. (25.4 mm) high on each side of the tank.
For those commodities listed in DOT 172.330, the name of the commodity must be marked on each
side of the tank in letters at least 3.9 in. (100 mm) high and at least 0.24 in. (6.0 mm) wide.
2.3.1.4 When tanks are converted from one class to another or when a conversion results in a
change in tank qualification interval, the date of conversion must be stenciled below the tank built
date.
2.3.1.5 When exterior thermal coatings are applied, see Field Manual of the AAR Interchange
Rules, Rule 80.E.1 for marking requirements.
2.3.1.6 A qualification stencil is to be applied at the time that the tank is qualified.
2.3.1.7 Tanks made of clad plates must have stenciled on the tank “(MATERIAL) CLAD TANK.”
These marks must be in letters at least 1 1/2 in. (38.1 mm) high and placed immediately below the
car specification stencil.
2.3.1.8 DOT-112S and 114S cars in anhydrous ammonia service must be painted or cleaned every
5 years to functionally restore the original white appearance. Year painted or cleaned must be
stenciled on the car.
2.3.1.9 When cars are equipped with exterior heater coils with inlet or outlet pipe caps removed,
they must be stenciled “EXTERIOR HEATER PIPES-NO INLET OR OUTLET PIPE CAPS
REQUIRED” in letters at least 1 in. (25.4 mm) high.
2.3.1.10 Stub sill, nonpressure, nonexterior-coiled tank cars built prior to July 1, 1974, that
qualify for defect card protection under Field Manual of the AAR Interchange Rules, Rule 95 must
be stenciled “AAR CERTIFIED SS NUMBER XX” in 1 1/2 in. (38.1 mm) letters below the light
weight stencil on each side of the tank. Certified status number is as assigned by the Equipment
Engineering Committee.
2.3.1.11 If the load limit is restricted or reduced for any reason, a 3 in. (76.2 mm) star symbol
must be added immediately to the left of the load limit stencil. See Field Manual of the AAR
Interchange Rules, Rule 70.
2.3.1.12 Stencil carbon dioxide (CO2) tank cars with the stencils specified in Chapter 2,
paragraph 2.1.1.
2.3.1.13 If the commodity is designated a poison-inhalation hazard, the sides of the tank car tank
or jacket must be stenciled “INHALATION HAZARD” in 3.9 in. (100 mm) minimum letters near
the commodity stencil location.
2.3.1.14 Tank cars with interior lining or coating are to be marked per paragraph 2.3.3.3 below.
2.3.2 Running Gear
2.3.2.1 On cars equipped with center sills, reporting marks must be stenciled on the underframe,
center sills or side sills, and both truck bolsters. On stub sill cars, reporting marks must be
stenciled on both truck bolsters.
2.3.2.2 The consolidated stencil for lubrication and air brakes is to be applied in accord with Field
Manual of the AAR Interchange Rules, Rule 80.
2.3.2.3 When the owner desires cars to be marked to provide information with respect to
couplers, brake beams, wheels, raised wheel seat axles, heater systems, or volume of the tank,
such marks must be stenciled on the heads of the tank in letters at least 1 1/2 in. (38.1 mm) high.
For long travel springs, see Field Manual of the AAR Interchange Rules, Rule 50. For
abbreviations, see paragraph 2.3.4.7 below.
2.3.2.4 The brake lever diagram metal badge plate must be located as shown in Figs. C.2 and C.3.
See Field Manual of the AAR Interchange Rules, Rule 88.
2.3.2.5 When tank cars have been inspected in accord with Field Manual of the AAR Interchange
Rules, Rule 88B.2, they must be stenciled in accord with paragraph 2.3.3.4 below.
2.3.2.6 Tank cars equipped with high-friction brake shoes must be stenciled “00 INCH HF COMP
SHOES” in letters at least 1 1/2 in. (38.1 mm) high on the side sill at each corner of the car.
2.3.3.2.5 When service equipment qualification occurs at more than one facility, the station
stencil block shall show the station stencil for the facility that finalizes the qualification. For
example, if the excess flow valves and eduction pipes are qualified at one facility, and then the
liquid and vapor valves are qualified later at another facility, then the station stencil of the latter
facility shall appear in the station stencil block.
2.3.3.2.6 Valves and fittings may be replaced in kind on tank cars without changing the
qualification dates marked on the tank when performed by a certified facility. The facility
replacing the valve or fitting shall maintain records of the valve or fitting replacement throughout
the qualification interval.
2.3.3.2.7 When installing a valve or fitting on a tank car, including new cars, existing cars, and at
the time of qualification, the facility installing the valve or fitting must follow the requirements of
Appendix A, paragraph 3.3.8.5.
2.3.3.3 Coating/Lining Qualification
2.3.3.3.1 Lining applicator, type of lining, and year applied shall be marked on the tank (or
jacket) in the general area of the consolidated stencil in letters and numerals at least 1 in.
(25.4 mm) high. For linings used for product purity only, enter “PP” and “NONE” for the
qualification and due dates on the qualification stencil. A station stencil is required.
2.3.3.3.2 The year in which the coating or lining is inspected and the inspection due date must be
applied and/or maintained in the location specified on the qualification stencil (Fig. C.5 or Fig. C.9)
in letters and numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.3.4 88.B.2 Inspection
The year in which a Rule 88.B.2 inspection is performed and the inspection due date must be
applied and/or maintained in the location specified on the qualification stencil (Fig. C.5 or Fig. C.9)
in numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.3.5 Stub Sill Inspection
The year in which a stub sill inspection is performed and the inspection due date must be applied
and/or maintained in the location specified on the qualification stencil (Fig. C.5 or Fig. C.9) in
numerals at least 1 in. (25.4 mm) high. A station stencil is required.
2.3.4 General
2.3.4.1 The location, sizes, and spacing of letters and numerals must be as shown in Figs. C.2 and C.3.
2.3.4.2 The reporting mark assigned by the AAR must be stenciled as shown on car sides and
ends. The reporting mark and number may be stenciled on top of the car on or near the
longitudinal center line at the B-end, reading from B-end to A-end. If so stenciled, the size and
spacing must be the same as on the side of the tank or jacket.
2.3.4.3 Arrangement of the reporting mark, load limit, and light weight must be as shown, except
that the entire arrangement may be moved, if necessary, to suit the construction of the car. For
example, the light weight stencil may be applied on the same line as the load limit stencil.
2.3.4.4 When a tank car has a consolidated stencil applied, the date built new (month and year) is
not required to be stenciled on the right side of the tank as shown in Fig. C.2 and Fig. C.3. See
Field Manual of the AAR Interchange Rules, Rule 80. The date converted or rebuilt (month and
year), if applicable, must be stenciled as shown. For separate built dates for car structure and
tank, see Field Manual of the AAR Interchange Rules, Rule 88B.1.d.
2.3.4.5 The sum of the load limit and the car light weight must not exceed the rail load limit,
based on axle capacity.
2.3.4.6 All cars having dimensions exceeding Plate B in MSRP Section C, Standard S-2026, must
have the appropriate stencil shown in the AAR Manual of Standards and Recommended Practices,
Section L, Standard S-913, applied directly to the right of the reporting marks.
2.3.4.7 The following optional abbreviations may be used for tank car stenciling. Abbreviations
should not be used when the meaning would be made unclear or awkward. They should be used
when stenciling information referenced in paragraph 2.3.2.3 above; for example, “No. 18 BR BM”
for Number 18 brake beam.
Table C.1 Optional abbreviations for tank car stenciling
Abbreviation Definition Abbreviation Definition Abbreviation Definition
BM Beam FRA AIP FRA Alternative PP Product purity
BOT Bottom Inspection and Test PRD Pressure relief device
BR Brake Procedure PSI Pounds per square
BLT Built GAL Gallons inch
CAPY Capacity GR Gear PVC Polyvinyl Chloride
COMB PRD Combination pressure HF High friction RSD Raised
relief device HTR Heater RPKD Repacked
COMP Composition IDT In Date Test REQ Required
CONT Controls INT Interior SPGR Sparger
CONV Converted KG Kilograms SPRG Spring
CPL Coupler L Liters SP Special Permit
CTC Canadian Transport LB Pounds SR Safety Permit—Rail
Commission LNG RMVL Lining removal ST Service Trial
CUFT Cubic Feet LT Light STL Steel
DOT Department of LMT Limit STNLS Stainless
Transportation LD Load TC Transport Canada
DFT Draft LUB Lubricated THERMO Thermometer
E Exemption MAG Magnetic W Wear, Wrought
ELEC Electric MO Month WT Weight
EXS Extended service NO Number WHLS Wheels
EXT Exterior OPR Operated
2.3.4.8 Unless otherwise specified in a special permit, competent authority, approval, or AAR
service trial, the special permit, competent authority, approval, or AAR service trial number must
be marked as shown in Fig. C.2 or Fig. C.3. When a Federal Railroad Administration-approved
alternative inspection program authorizes an extended interval, the letters “FRA AIP” must
appear as shown in Fig. C.2 or Fig. C.3. The marking must have a width of at least 0.24 in.
(6.0 mm) and a height of at least 3.9 in. (100 mm).
2.3.4.9 If operation of the tank car is restricted for any reason under 49 CFR 215.203(a), the
symbol “-R”, of the same size as the reporting mark, must be stenciled immediately thereafter,
followed by a term or terms identifying the restriction in letters at least 1 in. (25.4 mm) high. See
also 49 CFR 215.303.
2.3.4.10 If desired by car owner or lessee, a stencil indicating “LEASED TO—COMPANY” may be
placed on both sides of the tank or jacket, near the ladder or near the bottom outlet, in letters at
least 1 in. (25.4 mm) high.
2.3.4.11 Special instructions related to tank cleaning, special fittings, or other items affecting the
use and service of the tank car (e.g., emergency numbers, trust agreements, restrictions on air
pressure used) may be marked, at the owner’s option, on both sides near the center of the tank,
near the bottom outlet, or on or near the manway. Additional information may be added to the
qualification stencil at the owner’s or shipper’s option.
2.3.4.12 For dual (conventional and metric) stenciling, required on new and repainted tank cars
after January 1, 1982, see the AAR Manual of Standards and Recommended Practices, Section L,
Standard S-914.
2.3.4.13 Whenever a year is required to be marked on a tank, it must be marked using four
characters (e.g., 2003). Whenever the month and year are required to be marked on a tank, they
must be marked using six characters (e.g., 01 2003).
2.3.4.14 When a tank car is approved for extended service status, the tank car must be marked
“EXS” after the reporting mark and number (e.g., ABCX 0000 EXS) on both sides.
3.0 TANK IDENTIFICATION PLATES
3.1 General
3.1.1 After July 25, 2012, to certify compliance with federal requirements, the tank manufacturer
must install two identical permanent identification plates in accord with 49 CFR 179.24.
3.1.2 Plates are to be unpainted and of a size suitable to contain the following items of text.
Letters must be a minimum of 3/16 in. high and be clearly stamped, etched, or embossed on the
plates.
3.1.3 See Fig. C.1 for an example of the marking on an identification plate.
CARBUILDERS NAME: KEN DORSEY TANK CAR COMPANY
BUILDERS SERIAL NUMBER: 0000-00-001
CERTIFICATE OF CONSTRUCTION/EXEMPTION: A049006/E-13195
TANK SPECIFICATION: DOT-111A100W1
TANK SHELL MATERIAL/HEAD MATERIAL; TC128B/A516
INSULATION MATERIALS; CERAMIC FIBER/FIBERGLASS
INSULATION THICKNESS: 0.5 IN./3.5 IN.
UNDERFRAME/STUB SILL TYPE: PGK 001
DATE BUILT: OCT 2003
The Xs indicate the manufacturer’s identification and the numbers indicate the style number
assigned by the manufacturer.
7.3 New cars ordered after July 1, 1996, must be equipped with manway style decals/stencils per
Fig. C.4. Manways designed to accommodate the AAR standard gasket, as defined in Appendix E,
paragraph 3.3.5.3, are to be designated “MANWAY STYLE: AAR-1.”
7.4 Manway cover gasket dimensions may also be shown on the manway style decal/stencil. If
shown, the gasket dimensions must be in 1/4 in. (6.35 mm) minimum height letters and numbers
and must be the same gasket dimensions as shown in the applicable Manway Style Chart or as
determined to be appropriate by the car owner or shipper.
Minimum Area of
Retroreflective Sheeting Equivalent Number of
Car Length over End Sills per Side 4 in. × 18 in. Reflectors
Up to 50 ft 3.5 ft2 7
Over 50 ft to 60 ft 4.0 ft2 8
Over 60 ft to 70 ft 4.5 ft2 9
Over 70 ft to 80 ft 5.0 ft2 10
Over 80 ft to 90 ft 5.5 ft2 11
Over 90 ft to 100 ft* 6.0 ft2 12
* Cars over 100 ft long must be equipped with an additional 0.5 ft2
of retroreflective sheeting on each side for every additional 10 ft
of length.
8.4 Location
8.4.1 Reflectors are to be oriented vertically. Reflectors are not to be applied over existing or
required car stencils and markings.
8.4.2 Individual reflectors are to be spaced along the length of the car, with one reflector applied
at least every 12 ft, as practicable. If existing stencils, appurtenances, or discontinuous surfaces
make it impracticable to apply reflectors at least every 12 ft, they shall be applied at the smallest
interval greater than 12 ft that is practicable.
8.4.3 Two 4 in. × 18 in. reflectors, one above the other, or one 4 in. × 36 in. reflector is to be
applied as close to each car end as is practicable. Reflectors are not to be applied in the portion of
the car side occupied by safety appliances.
8.4.4 The reflectors are to be centered vertically on the horizontal centerline of the tank, or as
near as practicable. If it is not practicable to safely apply the reflectors centered vertically about
the horizontal centerline of the tank, the reflectors may be applied with their top edges no lower
than the horizontal centerline of the tank.
8.4.5 Reflectors are not to be applied in the splash zone beneath the manway. The splash zone is
a vertical band 2 ft minimum, 4 ft preferred, on each side of the manway centerline.
8.4.6 Reflectors, decals, and stenciling are not to be overlapped.
N
HORIZONTAL
CENTERLINE
OF TANK O
9" DOT XXXXX
T
U
ABCX 00000
CAPY 00000 GAL Typical placement of retroreflective sheeting per paragraph 8.0 in this specification.
CAPY 00 000 L
______________
______________
CL HEAD W Notes:
1. See paragraph 8.4.4 for placement of reflectors.
2. Reflectors are not to be applied in the splash zone beneath the manway of any tank
E car. The splash zone is a vertical band 2 ft minimum, 4 ft preferred, on each side of
AAR Manual of Standards and Recommended Practices
X
STENCIL B-END OF CAR AS SHOWN
STENCIL A-END OF CAR IN SAME MANNER
Fig. C.2 DOT and AAR stencil requirements for qualified tank cars
11/2014
M-1002
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX C
L 2.3.2.4—Brake lever badge plate (BL only) X 2.3.2.1—1 1/2 in. minimum
N
HORIZONTAL DOT XXXXX O
CENTERLINE (MATERIAL) CLAD TANK
OF TANK DISC 000 PSI
SAFETY VALVE 000 PSI P
TESTED 20XX DUE 20XX
9" TANK 000 PSI
TESTED 20XX DUE 20XX
ABCX 00000R (RESTRICTION) COMMODITY HEATER PIPES 000 PSI
LD LMT 00000 LB 00 000 KG C INHALATION HAZARD TESTED 20XX DUE 20XX
1" AAR STXXXX (MATERIAL) LINED TANK R
3" LT WT 00000 LB 00 000KG APPLIED MO/YR
DOTE OR SRXXXX
AAR CERTIFIED S S (NUMBER) PRESSURE TEST NOT REQ'D U
3" LETTERS 7'0" MAX
3" SPACES BLT XX-XXXXX
CONV XX-XXXXX
E
TOP OF RAIL
T
ELEVATION
I Q K S L
Typical placement of retroreflective sheeting per paragraph 8.0 in this specification.
V
W Placement window for typical application of retroreflective sheeting
ABCX 00000
CAPY 00000 GALS
CAPY 00 000 L
______________
______________ implementation date, and to cars that are painted and marked in kind.
CL HEAD Y
Notes:
1. See paragraph 8.4.4 for placement of reflectors.
2. Reflectors are not to be applied in the splash zone beneath the manway of any tank
E
car. The splash zone is a vertical band 2 ft minimum, 4 ft preferred, on each side of
AAR Manual of Standards and Recommended Practices
Z
STENCIL B-END OF CAR AS SHOWN
STENCIL A-END OF CAR IN SAME MANNER
Fig. C.3 DOT and AAR stencil requirements for other tank cars*
11/2014
M-1002
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX C
I 2.3.4.4—See remark f.—1 1/2 in. minimum W 2.3.1.2—1 1/2 in. minimum
Blank Decal
Example
41 11
------
16
41 -----3- 1
16 --- Typ.
4
16 15
------
24"
16
1
8 1--- 1
--- Typ. 8 8 8 --- Typ.
2 4 4
1 1--- LINING 2
2
88.B.2 INSPECTION 2 6 1---
2
LINING
88.B.2 INSPECTION
STUB SILL INSPECTION
Fig. C.6 Qualification stencil—shown with added lines for additional information
(reference paragraph 2.3.4.11 above)
Fig. C.7 Qualification stencil—shown with paragraph references for required items
41 11
------
16
41 -----3- 1
16 --- Typ.
4
16 15
------
24"
16
1
8 1--- 1
--- Typ. 8 8 8 --- Typ.
2 4 4
1 1--- LINING 2
2
88.B.2 INSPECTION 2 6 1---
2
APPENDIX D
RETEST AND QUALIFICATION REQUIREMENTS
CONTENTS
APPENDIX D
RETEST AND QUALIFICATION REQUIREMENTS
1.0 INTRODUCTION
Appendix D describes AAR and DOT requirements for retest and qualification of tank car tanks.
2.0 QUALIFICATION AND MAINTENANCE REQUIREMENTS FOR DOT TANK CAR
TANKS
Qualification and maintenance requirements for tanks built under DOT specifications are set
forth in 49 CFR Part 180, Subpart F.
2.1 AAR Tank Car Tanks
2.1.1 Applicability
This program establishes the minimum acceptable framework for an owner’s qualification
program for AAR Class tank cars and components not subject to federal regulations. AAR Class
tank cars subject to the hazardous material regulations must comply with the regulations in
49 CFR 180.500.
2.1.1.1 Owners shall follow this program in developing their written procedures (work
instructions), as required by 49 CFR 179.7(d), for use by tank car facility employees. The owner’s
qualification program for each tank car, or a fleet of tank cars, must identify where to inspect, how
to inspect, and the acceptance criteria. Tank car facilities must incorporate the owner’s
qualification program into their quality assurance program, as required by 49 CFR 179.7(a)(2),
(b)(3), and (b)(5).
2.1.1.2 This section applies to any person who manufactures, fabricates, marks, maintains,
repairs, inspects, or services tank cars to ensure continuing qualification.
2.1.1.3 Any person who performs a function prescribed in this program shall perform that
function in accordance with this program.
2.1.2 Quality Assurance Program
The quality assurance program requirements of the AAR Manual of Standards and Recommended
Practices, Section J, Specification M-1003, apply.
2.1.3 Requirements for Qualification
Each tank car owner shall ensure that a tank car facility does the following:
• Inspects and tests (examines) each item
• Evaluates each item according to the acceptable results of inspection and test
• Marks each tank car as specified
• Prepares the documentation as required
2.1.4 Conditions Requiring Qualification of Tank Cars
Without regard to the qualification compliance date requirements, an owner shall ensure that a
qualification of the tank is performed if
• the tank bears evidence of damage caused by fire; or
• the Tank Car Committee 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.
ADDITIONAL THICKNESS
10-YEAR INSPECTION INTERVAL
F
5-YEAR INSPECTION INTERVAL
A B C D E
3.1.2 All of the inspections mentioned herein shall be conducted in accord with the requirements
of 49 CFR Part 180 and AAR Specification M-1002, Appendix T.
3.1.2.1 Acceptable methods for use during tank qualification are as shown in Appendix T, Table
T.1. The applicability of any particular method for a given inspection area shall be determined by
the NDT Level III. Additional inspection methods may be employed if any uncertainty arises.
3.1.2.2 Thickness tests shall be performed as follows:
• Thickness readings shall be taken at the bottom, one side (90°), and the top of the tank
shell within 6 in. of each circumferential weld seam on each side of the circumferential
weld seam. One thickness reading shall be taken at the center of each tank head. Two
thickness readings shall be taken on each tank nozzle and one at the sump, when so
equipped.
• When corrosion or other damage that reduces shell thickness is found either by thickness
readings or other inspection, additional readings shall be taken to map the thinned area.
• Shell thickness measurements on rubber-lined and coated tanks must be taken at the time
of lining/coating application.
Table D.3 Required tank car qualifications/inspections
Where Required Description Maximum Interval
49 CFR Part 180, Visual inspection 10 years
Transport Canada (TC) TP14877
49 CFR Part 180, Structural integrity inspection 10 years
Transport Canada (TC) TP14877
49 CFR Part 180, Thickness test 180.509 (f)
Transport Canada (TC) TP14877
49 CFR Part 180, Safety systems 10 years
Transport Canada (TC) TP14877
49 CFR Part 180, Lining or coating (for materials corrosive to the tank) 180.509 (i)
Transport Canada (TC) TP14877
49 CFR Part 180, Leakage pressure test After assembly
Transport Canada (TC) TP14877
49 CFR Part 180, Service equipment (including pressure relief devices) 180.509 (c)
Transport Canada (TC) TP14877
Field Manual Rule 88.B.2 Thorough inspection of load-carrying members, end 10 years, or as required by
sills, side sills, draft systems, trucks, tank car jackets, Note 1
and hand brakes
AAR Circular Stub draft sills, sill pads, sill attachments welds At tank qualification or mileage
CPC-1094 (outboard of bolsters) limit
AAR M-1002, Appendix D, Stub draft sills, sill pads, sill attachments welds With structural integrity
paragraph 3.1.1.4 (inboard of bolsters) inspection
Note 1. Tank cars released into service after rebuilding or after heavy repair must receive an inspection in accordance with
the Field Manual of the AAR Interchange Rules, Rule 88.B.2.b. The term "heavy repair" means that the total labor hours on a
tank car exceed 85 hours because of accidental damage. Accidental damage means a physical defect in the tank parent metal
or tank jacket caused by fire, natural disaster, or contact with another object during the operation of the tank, and is not limited
to abrasion, buckling, corrosion, cracks, cuts, dents, distortions, defects in welds, gouging, and any painting, coating, and lining
associated thereto. Tank and component qualifications required by 49 CFR Part 180 and Transport Canada (TC) TP14877,
including any purging, cleaning, and water testing associated with qualification, are not included in the 85 hours, nor are interior
coating repairs included in the 85 hours when the tank interior is coated for the sole purpose of product purity.
3.2.1.4 Valves and fittings may be replaced in kind on tank cars without changing the
qualification dates marked on the tank when performed by a facility that is certified to activity
code C6. The facility replacing the valve or fitting shall maintain records of the valve or fitting
replacement throughout the qualification interval.
In te g ra l to ta n k
S ta r t
New
R e s ea l
F a il
P a ss
R e b uild Le a k T e st P a ss / F a il S to p
C o m p o n e n t M a in te n an c e C o m p o ne n t Q ua lific a tio n
3.6.1.3 A single cap gasket of 1/4 in. (6.35 mm) maximum thickness must be used. Multiple gaskets
must not be used.
3.6.2 Thread surfaces and gasket seating surfaces must be visually inspected for corrosion and/or
mechanical damage. Parts that are unsuitable must be removed from service.
3.7 Securement of Manway Covers, Protective Housings, Valves, and Fittings for
Pressure and Nonpressure Cars
3.7.1 To ensure that every car is inspected once, this section will remain in effect until April 1,
2006.
3.7.2 At the time of the first tank test or qualification for existing equipment after April 1, 1996,
each tank car shall have the bolts, studs, and nuts securing pressure-retaining parts inspected for
proper engagement.
3.7.3 As a minimum, two fasteners from each bolt circle shall be inspected. Where all
engagements are the same in a bolt circle, any two fasteners may be inspected. Where all
engagements are not the same, the largest and smallest engagements shall be inspected (i.e., the
tallest and shortest stud projections, or the longest and shortest projections of bolts or studs
through nuts).
3.7.4 If inspection of the initial lot demonstrates that those fasteners meet the requirements of
paragraphs 3.7.4.4 and 3.7.4.5 below, then the remaining fasteners do not have to be inspected. If
the initial lot does not meet the requirements of paragraphs 3.7.4.4 and 3.7.4.5, the remaining
fasteners must be inspected and any noncompliant fasteners must be adjusted or replaced to bring
them into compliance.
3.7.4.1 If fittings are disassembled at the time of the tank test, this inspection must be conducted
during or after reassembly.
3.7.4.2 Engagement depth of studs may be determined by physical or ultrasonic measurement. If
ultrasonic testing is used, ASTM E797-87 or ASME 797 procedures may be used for reference.
3.7.4.3 The engagement depth must be calculated using the following formulae:
3.7.4.3.1 For studs securing manway cover plates on pressure cars (or similar type arrangements on
nonpressure cars):
3- (in.)
l e = l s – l a + t p + -----
16
3.7.4.5 As a minimum, nuts must be fully engaged; that is, no nut threads may be showing.
3.7.4.6 Bolts, studs, and nuts applied after April 1, 1996, shall conform to Appendix M,
paragraphs 1.2.3 and 4.2 (for pressure cars), or Appendix M, paragraph 4.2.3 (for nonpressure
cars).
4.2.2 Steps Common to Both General Purpose Tanks and Pressure Car Tanks
Step Action
1. Determine the tank’s last contents.
2. Observe safety procedures and protective clothing requirements in effect for the test
location and environment. Determine suitability for safe testing.
(CAUTION: Valves, fittings, and tanks may retain harmful product residues.)
3. Remove pressure relief devices and blank off the openings.
4. Remove or open all heater system, thermowell, and sealed gauging device closures during
the test period.
5. Install a certified test gauge (see paragraph 4.5 below for gauge standards).
6. Fill the tank completely with test liquid to the top of the manway nozzle. Vent gases while
filling.
7. Apply tank specification hydrostatic test pressure.
8. Disconnect the pressure source from the tank.
9. Test gauge must be open to tank during the holding period, as follows:
10. During the holding period, inspect the tank shell, or jacket, and all closures for leakage.
11. If test liquid is to be removed, removal should be continuous. Provide positive venting
while draining.
12. If internal inspection is not to be performed, skip to step 16.
13. Prior to vessel entry, safety procedures shall be observed. Tank interior is to be dried by
suitable means. Remove loose dirt, scale, rust, and sludge.
(CAUTION: Tank atmospheres and residues can be hazardous.)
14. Results of visual internal inspection shall be reported to car owner in writing.
15. When tank shell thickness readings are indicated, they shall be determined by an
appropriate nondestructive test method.
16. Observe recommended practice per paragraph 3.2 above for valves and fittings.
17. After retest, the reassembled tank must be subjected to at least 15 psi (103.421 kPa)
internal pressure and connections tested for leakage. Closures and handles are to be in
serviceable condition and properly attached.
18. Stencil car as required in accord with Appendix C, paragraph 2.3.3.
19. Prepare a Certificate of Test Form (see paragraph 5.0 below) or documentation as required
by DOT per 180.517(b) and send to car owner.
4.2.3 Steps Unique to Pressure Tanks (When Manway Covers Are Removed)
Step Action
1. Carefully clean manway nozzle gasket mating surfaces and inspect for cuts, corrosion,
cracks, warping, and other damage. Contact car owner for corrective action if defects exist.
2. Remove valves, fittings, and gaskets from the manway cover.
3. Inspect excess flow valves. Check for seat tightness if required.
4. Clean the manway cover assembly and thoroughly inspect it for corrosion, bent or broken
piping, weld defects, warping, etc. Contact car owner for corrective action if defects exist.
5. Carefully inspect thermowell and gauging device attachment welds for undercuts, cracks,
and other weld-related defects. If it is necessary to repair them, contact the car owner to
ensure use of proper securement design and approved welding procedures. After repair,
test to ensure their ability to retain tank test pressure.
6. Inspect studs for corrosion, improper insertion, or other defects. Insert studs to full depth,
with specification stamping exposed. Studs must comply with Appendix M, paragraphs
1.2.3 and 4.2.
7. Apply a new manway cover gasket and install the assembly. Care must be taken to avoid
gasket displacement and damage to gaskets, grooves, eduction pipes, or stud threads.
8. Tighten nuts per paragraph 3.2.1 above and Fig. D.3.
9. Install valves and fittings to manway cover and tighten per paragraph 3.2.1 above.
10. Inspect valves and fittings for compliance with provisions of 49 CFR 179.100-17(a), and
Appendix A, paragraph 3.15.
11. Perform the steps listed in paragraph 4.2.2 above, steps 17 through 19, to complete the
process.
Step Action
1. Inspect the manway nozzle, cover, and old gasket for indication of warping or out-of-round
conditions.
2. Remove the manway cover gasket, carefully clean the gasket mating surface, and inspect
it for cuts, corrosion, cracks, warping, or other damage. Contact the car owner if defects
exist.
3. Apply a new manway cover gasket and, when applicable, apply in accord with
paragraph 6.0 below. Care must be taken to avoid gasket displacement or damage to the
gasket, seat, or groove.
4. Inspect all eyebolt lug attachment welds for evidence of corrosion or condition that would
affect serviceability. Repair as necessary.
5. Inspect the manway eyebolt assemblies for serviceability and compliance with pressure
release provisions of 49 CFR 179.201-6.
6. Tighten the manway cover per paragraph 3.2.1 above and Fig. D.3, limiting tightening
force to avoid cutting the gasket and/or distorting the cover. Use of a wrench with a 12 in.
handle is recommended.
7. Inspect valves and fittings after reapplication for compliance with the provisions of
49 CFR 179.200-16(b) and Appendix A, paragraph 3.15.
8. Perform the steps listed in paragraph 4.2.2 above, steps 17 through 19, to complete the
process.
Step Action
1. Remove the pressure relief valve from the car.
2. Cover the nozzle opening to avoid introducing contaminants to the car.
3. Carefully clean the gasket mating surfaces and inspect them for cuts, cracks, corrosion,
warping, or other damage. Contact the car owner or lessee for corrective action if defects
exist.
4. Inspect the valve for product damage and for missing, bent, or broken parts.
5. Inspect the valve per manufacturer’s guidelines and replace unusable parts. Repair work
shall be limited per Appendix A, paragraph 3.11.
6. Elastomeric materials used for gaskets or gasket seals must be replaced. Observe
dimensional and compatibility provisions of paragraph 3.2 above.
7. Reassemble per manufacturer’s guidelines. Avoid introducing foreign matter to the valve
interior.
8. Install the valve to the test rack using a suitable gasket.
9. Using a certified test gauge per paragraph 4.5 below, apply the specified test pressure with
suitable gas.
10. Note the pressure at which the valve starts to discharge (STD).
11. Reduce the pressure slowly and note the pressure when the valve is bubble-tight [vapor-
tight pressure (VTP)].
12. If the valve does not function within prescribed pressure ranges as defined in Table D.4,
the cause shall be determined and corrected and the valve retested.
13. Stencil cars as required in accord with Appendix C, paragraph 2.3.3.
14. Prepare documentation as required by DOT and send to car owner.
Step Action
1. Fill completely with test liquid. Vent while filling.
2. Install certified test gauge (see paragraph 4.5 below for gauge standards).
3. Apply 200 psig hydrostatic test pressure.
4. Disconnect the pressure source from the heater system.
5. Inspect for leakage while under test pressure. Determine that no leakage occurs. Maintain
test for 10 minutes.
6. Remove test liquid completely.
7. Stencil car as required in accord with Appendix C, paragraph 2.3.3.
8. Complete documentation as required by DOT and send to the car owner.
Fig. D.3 Recommended sequence and tightening procedures for resecuring tank car tank manway covers, valves,
fittings, and flanges
Line Instruction
1. The reporting marks and car numbers must be those that are or will be recorded in the
Official Railway Equipment Register covering the cars being tested. Fig. D.4, Certificate of
Test Form, allows one car to the form.
2. Show the tank specification to which the tank is presently certified. (This item must be
known to make sure that the tank is tested to the required pressure, in lieu of any lower
pressure indicated by the stenciled specification.)
3. When the car is being operated under another specification, the stenciled specification
must be entered here.
4. Show the capacity in U.S. gallons (liters). For nonpressure cars, record shell-full volume.
For pressure cars, record shell-full volume plus the volume of the manway nozzle.
5. Show the pressure to which the tank was tested.
6. Show the pressure to which the interior heater system was tested. [Minimum to be not less
than 200 psi (1379 kPa)].
7. This item is divided into two identical sections to record the following data for one or more
pressure relief valves as required by car design. Pressure relief valves are numbered from
the B-end or the BL-side.
a. Show the name and location of the company testing the pressure relief valve.
b. Show the name and location of the company applying the pressure relief valve.
c. Show the pressure relief valve manufacturer and the model number.
d. Show the serial number of the specific valve tested.
e. This item must show the start-to-discharge pressure of the valve being tested and must
be within the tolerance for the given valve setting in DOT 179.15(b)(5). Note: For a
pressure relief valve used in combination with a breaking pin or rupture disc, the
requirements of DOT 179.15(e)(3) apply, and the pressure relief valve tests at the
reduced test pressure must be shown.
f. This item must show the vapor-tight condition of the valve being tested and must not
be less than the minimum for the given valve setting in the applicable retest table.
Note: For a pressure relief relief valve used in combination with a breaking pin or rup-
ture disc, the requirements of DOT 179.15(e)(3) apply, and at least the minimum
reduced vapor-tight pressure must be shown.
g. This item indicates whether or not the elastomeric valve seals have been replaced.
Enter a yes or no.
h. If the answer to item g. is yes, indicate the material of construction of the new
elastomeric seals.
Line Instruction
8. This item is divided into two parts for the information required when the pressure relief
valve is equipped with a combination device (breaking pin or rupture disc).
a. Show the pressure rating of the rupture disc.
b. Show the pressure to which the complete breaking pin device was tested with the lower
diaphragm in place.
Note: See Appendix C, paragraph 2.3.3.2, for stenciling requirements for tank cars
equipped with combination pressure relief devices.
9. This item is divided into two parts to describe the rupture disc devices on the car.
a. Indicate the number of rupture disc devices on the car.
b. Indicate the pressure rating of the rupture disc applied to the tank car after test.
10. Certify that the excess flow valves have been checked for tightness.
11. This item must record the components being tested and the corresponding dates they were
last tested.
Note: A pressure relief valve applied from stock that was tested within six months of
installation and protected from deterioration may be considered as having been tested on
the date of installation and may be so stenciled.
12. This item records the built/conversion date of the car, as well as the date of the last test, if
different.
13. This item is divided into three parts to indicate the year stenciled on the car that the tank,
pressure relief valve, and/or interior heater system will be due for next test.
a. Tank (date stenciled on car)
b. Pressure relief valve (date stenciled on car)
c. Interior heater system (date stenciled on car)
14. Record the name and location of the facility that performed the tank and/or heater system
test.
The individual responsible for “certification” attests to the accuracy of the tests indicated
above by signing and dating at the bottom of the form.
Elastomeric ——— A
ACF-1
18"/8
(3152118)
Hard 19 1/4" × 17" × 1/8"
Elastomeric ——— A
ACF-2
20"/8
(3156812)
Hard 21 1/4" × 18 7/8" × 1/8"
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
A
Elastomeric 21 1/2" × 18 3/4" × 1/4"
ACF-7
20"/8
(3-A-5299C)
Hard 21 5/8" × 18 7/8" × 1/8"
Elastomeric —— A
ACF-8
18"/8
(3-N-3680)
Hard 19 1/2" × 16 7/8" × 1/8"
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
Elastomeric —— A
ACF-9
20"/8
(3-F-6077)
Hard 21 1/4" × 18 7/8" × 1/8"
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
Table D.6 Manway Style Chart for General American Transportation Companya/
(page 1 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD × ID × THK) Diagramc/
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
Table D.6 Manway Style Chart for General American Transportation Companya/
(page 2 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD × ID × THK) Diagramc/
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
Table D.6 Manway Style Chart for General American Transportation Companya/
(page 3 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD × ID × THK) Diagramc/
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
Table D.7 Manway Style Chart for General Electric Railcar Servicesa/
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD × ID × THK) Diagramc/
A
GE-1 18"/8 Elastomeric 19 3/8" × 17" × 1/8"
A
GE-2 20"/8 Elastomeric 21 3/8" × 19" × 1/8"
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
C-III [M-1002] 222 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX D
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
Table D.9 Manway Style Chart for Union Tank Car Companya/
(page 1 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD × ID × THK) Diagramc/
a/ Alternative manway gasket styles shown in Table D.11 may be substituted for those shown in
this Manway Style Chart.
b/ Recommend manway bolts be lightly lubricated.
c/ Minimum 1/8 in. clearance required at “A” for gasket compression before tightening bolts.
d/ RTC denotes cars originally built by Richmond Tank Car Company.
Table D.9 Manway Style Chart for Union Tank Car Companya/
(page 2 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD × ID × THK) Diagramc/
HARD
A
Elastomeric 20 1/8" × 17" × 1/4"
SOFT
UTC-8 18"/6
Hard 19 13/16" × 17 9/16" × 1/8" A
HARD
A
Elastomeric 23" × 20 5/16" × 1/8"
UTC-9 21"/8
Hard 23" × 20 1/2" × 1/8"
Table D.9 Manway Style Chart for Union Tank Car Companya/
(page 3 of 3)
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsb/ Gasket Type (OD × ID × THK) Diagramc/
Table D.11 Manway Style Chart for Alternate Manway Gasket Styles
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsa/ Gasket Type (OD × ID × THK) Diagramb/
20"/6
GASKET
GATX #3,6 with 5/8"wall Elastomeric Nozzle rim style
nozzle
20" I.D.
NOZZLE
20"/6-8-10
Elastomeric GASKET
Various with 5/8" wall Nozzle rim style
or hard
nozzle
20" I.D.
NOZZLE
18"/6-8-10
Elastomeric GASKET
Various with 5/8" wall Nozzle rim style
or hard
nozzle 18" I.D.
NOZZLE
Table D.12
Nominal Dia./ Gasket Dimensions
Manway Style Number of Boltsa/ Gasket Type (OD × ID × THK) Diagramb/
21 5/8" × 19 1/2" × 1/8"
Elastomeric 21 5/8" × 19 1/2" × 3/16"
21 5/8" × 19 1/2" × 1/4"
Klincher 20"/1
Hard 21 11/16" × 19 5/8" × 1/8"
APPENDIX E
DESIGN DETAILS
CONTENTS
APPENDIX E
DESIGN DETAILS
1.0 INTRODUCTION
1.1 Scope
Appendix E describes AAR requirements for certain design details on tank cars and tank car
tanks.
1.2 Dimensions and Tolerances
1.2.1 The illustrations in this appendix are intended to indicate the degree of standardization
and interchangeability required and are not construction drawings. Methods of dimensioning and
geometric characteristics such as concentricity, roundness, and symmetry should conform to ANSI
Y14.5, “Dimensioning and Tolerancing.”
1.2.2 The following notes apply to illustrations in Figs. E.5 through E.13 and E.19 through
E.19.25:
1.2.2.1 Unless otherwise specified, standard tolerances for decimal dimensions are ±0.005 in. and
standard tolerances for fractional dimensions are ±1/64 in.
1.2.2.2 Unless otherwise specified, the fit of screw threads is Class 2A and 2B (ANSI B1.1).
1.2.2.3 Standard tolerance on taper pipe threads is ±1 thread.
1.2.2.4 Engagement of taper pipe threads conforms to American Standard Taper Pipe Threads
(NPT) (ANSI B2.1).
3.1.4 If the thickness calculated by the following formula exceeds that listed in DOT
179.101-1(a), the calculated thickness is the required minimum.
t = d 0.3p
----------- + 1.78Whg
----------------------- t = d 0.0003p
-------------------- + 1.78Whg
-----------------------
S Sd
3 S Sd
3
where where
t = thickness of manway cover required at center, in. t = thickness of manway cover required at center, mm
d = mean diameter of gasket groove, in. d = mean diameter of gasket groove, mm
hg = 1/2 [manway bolt circle diameter minus d], in. hg = 1/2 [manway bolt circle diameter minus d], mm
p = pressure relief valve flow rating pressure shown in p = pressure relief valve flow rating pressure shown in
Appendix A, Table A.2 or A.3, psi Appendix A, Table A.2 or A.3, kPa
S = 1/3 minimum tensile strength value for cover S = 1/3 minimum tensile strength value for cover
material, as shown in Appendix M, psi material,as shown in Appendix M, MPa
W = 2 W = 2
0.3927d p + 0.7854dmp + 152,500 lb 0.3297d p- + 0.7854dmp
------------------------- ----------------------------- + 678 000 , N
m = 2.00 for 1/8 in. thick unfilled PTFE gasket, in. 1000 1000
or m = 50.8 for 3.18 mm thick unfilled PTFE gasket, mm
3.00 for spiral-wound stainless steel gasket,a/ in. or
76.2 for spiral-wound stainless steel gasket,a/ mm
a/ For other gasket materials, see ASME Code for Unfired Pressure Vessels, Section VIII,
Division 1.
3.1.5 For cars built after April 1, 1996, studs for pressure-retaining parts and protective housing
covers must engage for a minimum depth equal to the diameter plus 1/8 in. As a minimum, nuts
must be fully engaged; that is, no nut threads may be showing.
3.1.6 Cars built or altered after December 1, 2003, for transportation of Class 2 or PIH materials,
with the exception of those listed below, must have manway covers that are designed to
accommodate capping kits. Sufficient clearance for capping kits must exist above and around all
fittings. Accommodations must be made for closures and safety chains. Port openings must be of a
suitable size for capping kit brackets and must be oriented to facilitate capping. See Figs. E.29 and
E.30 for typical capping kit dimensions and clearance requirements. The following cars are
excepted from this requirement:
• Cars transporting carbon dioxide
• Class DOT-113 and AAR-204W cars
• Cars altered to remove slip tube gauging devices under Chapter 1, paragraph 1.3.9.
3.2 Openings in Pressure Car Manway Covers
3.2.1 Manway covers may be equipped with openings as illustrated in Figs. E.19 through E.19.23,
inclusive, or other approved openings.
3.2.2 Openings less than 2 3/8 in. (60.3 mm) diameter need not be reinforced.
3.2.3 When two or more openings are spaced center-to-center closer than two times their average
diameter, reinforcement must be provided. To provide this reinforcement, the manway cover
thickness must be calculated by either of the following methods:
3.2.3.1 Assume a single opening, concentric with the cover gasket surface, of a diameter that will
circumscribe all through openings in the group, and calculate as provided in paragraph 3.2.4
below.
3.2.3.2 Calculate as provided in paragraph 3.1.4 above, except that the quantity under the
square root sign in the equation must be doubled.
3.2.4 Manway covers having an opening greater than one half of dimension d must be designed
as a loose flange in accord with ASME Code for Unfired Pressure Vessels, Section VIII, Division 1.
3.3 Design—Covers for Nonpressure Cars
3.3.1 Flat manway covers for nonpressure cars must be designed in accord with ASME Code for
Unfired Pressure Vessels, Section VIII, Division 1, Part UG-34, except as provided in
paragraph 3.3.3 below. Openings in cover must be reinforced in accord with ASME Code Part
UG-39.
3.3.2 Dished manway covers for nonpressure cars must be designed in accord with ASME Code
for Unfired Pressure Vessels, Section VIII, Division 1, Appendix 1-6, except as provided in
paragraph 3.3.3 below. Openings in cover must be reinforced in accord with ASME Code Part UG-
37.
3.3.3 The following additions or exceptions to ASME Code must be used when calculating covers
in accord with paragraphs 3.3.1 and 3.3.2 above:
• S = 1/3 minimum tensile strength value for cover material, as shown in the appropriate
ASTM or AAR specification
• P = tank test pressure
• When the bolt spacing exceeds 2a + t, the maximum flange moment must be multiplied by
the factor
bolt spacing-
----------------------------
2a + t
where
a = nominal bolt size
t = flange thickness
3.3.4 As an alternate to the requirements of paragraph 3.3.1 or 3.3.2 above, the cover may be
proven by testing as follows:
3.3.4.1 The closure must hold 1.25 times the prescribed tank test pressure for a minimum of
10 minutes without leakage or evidence of stress.
3.3.4.2 The test must be conducted with the closure secured to its typical mating components,
without special sealing techniques, using gaskets and bolting materials as intended for service.
3.3.4.3 Stresses in the closure must not exceed the material’s specified minimum yield strength,
as shown in the appropriate ASTM or AAR specification.
3.3.5 Hinged manway covers applied to new tank cars after July 1, 1996, are to be designed to
retain, under normal operating conditions, the manway gaskets listed in paragraph 3.3.5.3 below
and designated as standard manway style AAR-1 (see appropriate manway style chart in
Appendix D, Tables D.5 through D.10 and D.12). Typical machined grooves are illustrated in
Fig. E.26. Other groove configurations or retention methods are acceptable provided that the
following criteria are met:
3.3.5.1 Elastomeric flat gaskets retained by the manway cover are to be retained by overlapping
the manway cover gasket groove on both the inside and outside edges. This overlap is to be 1/16 in.
on the inside and 1/32 in. on the outside, nominal dimensions. See Fig. E.26, item C.
3.3.5.2 Hard flat gaskets retained by the manway cover are to be retained by overlapping the
manway cover gasket groove on the inside or outside edges. This overlap is to be 1/16 in. nominal.
See Fig. E.26, items A and B.
3.3.5.3 Any gasket configuration that produces an effective seal and provides adequate retention
may be applied at the manway.
3.3.5.4 The hinged manway cover must also be able to properly retain and effectively seal when
equipped with the standard gaskets listed below:
• Elastomerica/ gasket: 21 11/16 in. O.D. × 19 1/2 in. I.D. × 1/4 in. thick
• Hard gasket: 21 5/8 in. O.D. × 19 1/2 in. I.D. × 1/8 in. thick
a/ Elastomeric refers to a solid “rubber” type material, such as EPDM, Viton®,
Buna-N, or Neoprene, without any reinforcement or fibers.
3.3.5.5 Modified designs that are not in accord with the above criteria must be submitted for
approval.
3.3.6 Hinged manway covers are to be designed to allow machining so that the recommended
sealing surface finish for the service gasket may be achieved. The specifications presented below
are guidelines that will produce sealing surfaces compatible with the majority of gasket materials.
Other surface specifications may be submitted for approval.
3.3.6.1 Gasket sealing surfaces are to be machined to obtain a surface finish in the range of
63 microinches to 500 microinches, RMS.
3.3.6.2 Gasket sealing surface may be machined with concentric or spiral grooves. Grooving tool
should have a radius cutting surface.
3.3.7 For a new manway design or for a design not shown in the manway style charts in
Appendix D, Tables D.5 through D.10, design information and appropriate drawings are to be
submitted to AAR for inclusion in M-1002.
3.3.8 For cars built after April 1, 1996, studs for pressure-retaining parts and protective housing
covers must engage for a minimum depth equal to the diameter plus 1/8 in. As a minimum, nuts
must be fully engaged; that is, no nut threads may be showing.
3.4 Openings in Protective Housing Cover
When a weather cover designed for vertical discharge is required to cover an opening in a
protective housing cover, the weather cover must be of the self-closing type. See Fig. E.15 for
typical design.
3.5 Pressure Car Manway Seals
When required for U.S. Customs seal, two adjacent studs on a pressure car manway flange must be
1 1/4 in. longer than standard length and be provided with 3/8 in. seal holes 7/8 in. from the outer
end. The seal holes must be aligned to accept a 1/4 in. diameter by 6 in. long cable seal, Brooks
Cable Seal Lock Model B No. 8903106, or U.S. Customs-approved equivalent. See Figure Fig. E.17.
Sealing compounds may be used to retain stud orientation.
4.0 PRESSURE RELIEF DEVICE CONNECTIONS FOR NONPRESSURE CARS
4.1 Standard Connections
Standard pressure relief device connections are shown in Fig. E.21. Modified designs may be
submitted for approval.
D = diameter of the bottom of the hole in which the plug is made, in. (mm)
L = shear value for plug weld, lb (kN)
S = minimum tensile strength of the plate material, psi (MPa)
5.2.3 Plug weld holes must have a diameter not less than T + 1/2 in. (T + 12.7 mm) and not more
than 2 in. (50.8 mm), where T = thickness of plate or attached part in which hole is made.
5.2.4 See paragraph 6.1 below for plug welds on interior compartment heads.
90
= -------
d for nonpressure tanks
---
t
= 175
---------
d for pressure tanks
---
t
where
d = inside diameter of tank at transition joint, in. (mm)
t = design thickness of tank plate at transition joint, in. (mm)
= slope change across transition joint in degrees
7.2 y must not be less than 12 in. (305 mm) for outlets and washouts.
7.4 Under any conditions of wear, the minimum clearance above top of rail of body-mounted
valves, caps, and other fixtures shall be 9 in. (229 mm) on an empty car and 7 in. (178 mm) on a
loaded car, excluding exterior heater coil caps, which must be left off in transit, and cap retaining
chains.
8.2.8 Bottom outlet valve handles, unless stowed separately, must be designed to either bend or
break free on impact, or the handle in the closed position must be located above the bottom surface
of the skid.
8.2.9 Bottom profile of the protective device must provide a sliding surface without
discontinuities.
9.0 PROTECTION OF BOTTOM AND TOP DISCONTINUITIES ON NONPRESSURE
TANK CAR TANKS
9.1 Bottom Protection
9.1.1 On new nonpressure stub sill tank cars and on nonpressure stub sill tank cars converted or
altered to add bottom fittings, an approved method of protection against impact shall be provided
for bottom discontinuities that project beyond the shell envelope, such as bottom outlets,
washouts, blind flanges, or sumps, but excluding those discontinuities that have the following
characteristics:
• Extend 1 in. (25.4 mm) or less beyond the shell envelope, measured on the longitudinal
bottom centerline.
• Support safety or brake appliances or other appurtenances.
• Incorporate a continuous longitudinal slope at a 1:3 ratio or shallower in the portion
extending beyond 1 in. (25.4 mm) from the shell envelope, measured on the longitudinal
bottom centerline.
• Are capable of resisting the design conditions specified in paragraphs 9.1.2.1, 9.1.2.2, and
9.1.2.3 below, without rupturing the tank.
9.1.2 For bottom discontinuities not excluded above, a protective device must be designed as
follows:
9.1.2.1 A load, normal to the slope of the protective device, whose vertical component equals the
rail load minus the weight (mass) of the trucks, must be applied.
9.1.2.2 The above load must be considered as concentrated on any transverse line on the
protective device.
9.1.2.3 The stresses in the tank shell, protective device, and their connections must not exceed
the minimum tensile strength of the material. The stresses in the webs of the protective device
must not exceed the critical buckling stress.
9.1.2.4 The longitudinal slope of the protective device must not exceed a ratio of 1:3.
9.1.2.5 Any vertical extension of the discontinuity below the protective device must be designed
to break off without rupturing the tank or releasing lading. The protective device must extend
down to, or below, the level of the discontinuity or its designed breaking point.
• For bottom outlets, the skid should extend down to the breakage groove or to the extremity
of parts comprising the equivalent of a breakage groove.
• For washouts and blind flange closures, the skid should extend down to the bottom of the
studs attaching the bottom closure.
• For sumps or other discontinuities not exempted in paragraph 9.1.1 above, the skid should
extend down to the extremity of the sump or discontinuity.
9.1.2.6 The skid, when used, must be of fabricated, cast, or forged design and be of material
compatible with that to which it is attached.
9.1.2.7 The design of the protective device must take into account any abrupt change in stiffness
from the long, rigid, protective device to the flexible tank shell.
9.1.3 Sumps of approved design do not require protection when, on insulated cars, they are
totally contained within the jacket profile, do not exceed the nominal thickness of the insulation,
and do not extend more than 2 1/2 in. (63.5 mm) below the tank shell. Sump reference here is to
weld cap type or pressed steel sumps (pressed into tank shell or a separate pressing welded into or
onto the tank shell). This exclusion does not include sumps formed of straight nozzles with
essentially flat cover plates.
9.1.4 Class 207W pressure differential covered hopper cars are excluded from the requirements
of this section.
9.1.5 Levels of protection, as specified per 49 CFR 173.31(b)(5), are defined as follows:
9.1.5.1 Level A requires meeting the requirements of paragraphs 9.1.1, 9.1.2, and 9.1.3 above.
9.1.5.2 Level B requires that fittings exceeding the dimensions listed below be protected with a
protective device constructed to the requirements of paragraph 9.1.2 above.
• For all bottom outlets extending more than 1 in. (25.4 mm) below the tank shell exterior
• For all blind flanges and washouts (not having internal closure) that extend more than
2 5/8 in. (66.7 mm) below the tank shell exterior (inclusive of bolting)
• For all internally closed washouts that extend more than 5 in. (127 mm) to the breakage
groove or shear plane measured from the bottom tank shell exterior
• For sumps greater than 5 in. (127 mm) that are not contoured and contoured sumps made
of pipe caps or pressed steel that have a straight wall projection exceeding 1 3/4 in.
(44.5 mm) below the tank shell exterior.
9.1.5.3 Level C requires that fittings exceeding the dimensions listed below be protected with a
protective device constructed to the requirements of paragraph 9.1.2 above:
• For all bottom discontinuities extending more than 5 in. (127 mm) below the tank shell
exterior (measurement to the shear plane, if any, and inclusive of bolting) with the
following exception: contoured sumps made of pipe caps of pressed steel, having a straight
wall projection below the tank shell exterior not in excess of 1 3/4 in. (44.5 mm).
9.2 Top Protection
9.2.1 When top fittings discontinuity protection is specified for nonpressure cars, the following
requirements must be met:
9.2.1.1 The protective structure must be as tall as the tallest fitting involved, must provide
protection for those fittings, without overstressing the tank shell and nozzles, when subjected to
forces of 1/2W in the vertical downward direction, 1W horizontal in the longitudinal direction, and
1/2W horizontal in the lateral direction.
• W is defined as the designed gross rail load of the car, less trucks.
• The forces are applied separately and uniformly over the projected plane of the protective
structure perpendicular to the direction of the force.
• For horizontal loads, the projected plane extends from the top of the tank to the top of the
protective structure.
• In the case of multiple nozzles, the forces are applied uniformly over their combined
projected area if the reinforcement zones of the nozzle, as defined in paragraph 2.3.1 of this
appendix, have a positive overlap. If there is no overlap of the reinforcement zones, each
nozzle must be protected so that it can withstand the applied loads independent of the
other nozzles.
• Calculations should use the minimum specified tensile strength of the material for the
tank, nozzle(s), unprotected service equipment, and protective device (where applicable).
• Stresses must not exceed the critical buckling stresses of the assembly under
consideration.
9.2.1.2 The design stresses must not exceed the minimum specified tensile stress for the tank,
nozzle, and protective housing, provided that the critical buckling stresses are not exceeded.
9.2.1.3 The protective structure must not reduce the pressure relief device flow capacity below
the minimum required.
9.2.1.4 The protective structure must provide a means of drainage with a minimum flow area
equivalent to six 1 in. diameter holes (4.71 in.2).
9.2.1.5 The strength of the attachment of the protective structure to its base structure should not
exceed 70% of the attachment strength of the base structure to its base structure. For example, if
the protective structure is attached to the nozzle, the strength of the attachment of the protective
structure to the nozzle may not exceed 70% of the strength of the attachment of the nozzle to the
tank.
9.2.1.6 Individual fittings may be unprotected if there is no loss of lading when subjected to the
design loads in paragraph 9.2.1.1. If unprotected fittings are used in conjunction with a protective
structure, the design loads are shared in proportion to the projected areas of the protective
structure and the fittings.
9.2.1.7 Discontinuity protection is not required for manway covers that have internal or external
shear rings designed to resist the horizontal loads as defined in paragraph 9.2.1.1.
9.2.1.8 No discontinuity protection is required for internal safety relief valves, cover plates, blind
flanges, or plugs.
10.0 NONCIRCULAR NOZZLES
When noncircular nozzles are applied to a nonpressure tank car tank, the following conditions
must be met:
10.1 If the long dimension exceeds twice the short dimension, the resistance necessary to provide
against excessive distortion due to twisting moment must be verified, as provided in
paragraph 10.5 below.
10.2 If the long dimension is not parallel to the circumference of the shell, the design adequacy
must be verified, as provided in paragraph 10.5 below.
10.3 The nozzle must be designed to sustain bending stresses as determined by the following
steps:
10.3.1 Consider the flat portion of an unrestrained noncircular nozzle as a flat plate, fixed at the
vertical tangent points and simply supported at the top and bottom, and calculate the bending
stress f in the center of the flat portion. See Table E.5 and the following formula:
10.3.2 Calculate the bending stress c in the center of the curved portion by multiplying the
bending stress in the flat portion by the factor determined from Table E.6.
c = q f
where
10.3.3 The computed stress must not exceed one third of the minimum tensile strength of the
nozzle material.
10.4 Only the nozzle thickness in excess of that required for the bending load can be considered
as available as reinforcement.
10.5 As an alternative, or when the provisions of paragraphs 10.1 and 10.2 cannot be met, the
adequacy of a noncircular nozzle and its reinforcement may be verified using five 3-gauge rosettes,
applied as shown in Fig. E.22. When the tank is pressurized to its hydrostatic test pressure, the
measured stresses must not exceed the following:
Rosette
#1 #4 u
u
------ ------ where
3 3
= maximum principal stress, psi (MPa)
#2 u #5 u
------ ------ u = minimum tensile strength of the material, psi (MPa)
3 3 = maximum shear stress, psi (MPa)
#3 u
------
4
S b = Mc
6
-------- 10 Mc-
I S b = ----------------
I
where
W = design load (rail load limit less weight [mass] of trucks and underframe), uniformly distributed over the length
of the tank between heads, lb (kg)
Sb = nominal stress due to design load, psi (MPa)
M = moment at the extreme ends of the anchor, in. · lbf (N · m)
c = outside radius of tank shell, in. (mm)
I = moment of inertia of cross-section of tank shell at extreme ends of the anchor, in.4 (mm4)
11.2 The nominal stress in the tank shell at the extreme ends of the anchor, calculated for design
load with amplification factor and 1,250,000 lb (5560 kN) impact force, must not exceed the
minimum tensile strength of the tank shell material as given in Appendix M, calculated by the
following formula:
11.3 Anchor designs must be verified by calculations or test to ensure that the tank will not
experience permanent deformation at the ends of the anchor under the imposition of impact loads
as specified in the Manual of Standards and Recommended Practices, Section C, Part II,
“Specifications for Design, Fabrication, and Construction of Freight Cars,” Specification M-1001,
Chapter 6.
11.4 In lieu of designing to paragraphs 11.1 and 11.2 above, anchors on steel, stainless steel, and
aluminum cars may be constructed using reinforcing plates, placed between the anchor and the
tank, that conform to the following:
11.4.1 The thickness of the reinforcing plate must be not less than 0.5 in. (12.7 mm).
11.4.2 The reinforcing plate must extend transversely, beyond each leg of the anchor, for a
minimum distance of the outside radius of the tank divided by 10.
11.4.3 The length of the reinforcing plate, extending beyond the extreme ends of the anchor, must
be not less than
2 2
4 R t -
----------------------
L = --- 4 2
3 31 –
where
L = length of reinforcing plate beyond the extreme ends of the anchor, in. (mm)
R = outside radius of tank shell, in. (mm)
t = reinforcing plate thickness, in. (mm)
= Poisson’s ratio
11.4.4 The reinforcing plates must have corner radii not less than 2 1/2 in. (63.5 mm).
11.4.5 For aluminum tanks, the anchor reinforcement may be combined with the tank shell into
one plate, provided the thickness is at least 1/2 in. (12.7 mm) more than the minimum thickness
required for the shell in DOT 179.100-6 or 179.200-6, with the abutting edges tapered in accord with
this appendix.
11.4.6 Plate elements of an anchor section that conform to paragraphs 11.4.1 and 11.4.2 above,
and whose length, L, beyond the extreme ends of the anchor leg, conforms to paragraph 11.4.3
above, may be considered to be reinforcement plates.
12.0 HEAD-TO-SILL ATTACHMENTS
New stub sill tank cars that are equipped with head braces must be designed such that the
outboard edge distance of the tank head reinforcing pad, measured in the longitudinal direction
from the toe of the head brace-to-pad weld to the toe of the pad-to-tank weld is not less than l,
where l is determined by the following formula:
2 2
S up t p + S ut t t
l = 1.5 ---------------------------------- conventional or SI units
S yt t t
where
3
"
16 1
8 "
3
" OPENING
16
1
8 "
3
" OPENING
16
SECTION AA
¾" R
¼ ½"
IN
12
"M
10 12
½
10
"
¾
"
¼"
¼"
A
½" MAX 3
8 "R
A
2 16" MAX
1 ½" R
2 16" MIN
13
5
¾" R
2 8 " MAX
2 16" MIN
7
8 "R
2¼
"
2¼
"
5
"
1¾
¼"
¼
"M
¾" R
"
¾
IN
10
METHOD OF ATTACHMENT
OPTIONAL
PLACARD OUTLINE
4.76 3.18
4.76 OPENING
3.18
4.76 OPENING
SECTION AA
19.0 R
8
31
IN
31
0M
8
27
26
3
6.35
6.35
A
12.7 MAX 9.52 R
A
38.1 R
71.4 MAX
58.7 MIN
19.0 R
66.7 MAX
55.6 MIN
22.2 R
57
.2
.2
57
.4
44
6.35
IN
19.0 R
27
METHOD OF ATTACHMENT
OPTIONAL
PLACARD OUTLINE
Note: All dimensions in mm. Appendix H must be followed when using SI units.
HEAD SHAPE
L
L TAPER MAY
BE INSIDE L
WELD OR OUTSIDE
SEE NOTE
PREFERRED
(CENTER LINES COINCIDE) PERMISSIBLE PREFERRED
NOTE:
LENGTH OF THE REQUIRED
TAPER L MAY INCLUDE
THE WIDTH OF THE WELD.
IN ALL CASES L SHALL BE
NOT LESS THAN THREE TIMES
THE OFFSET BETWEEN THE
ABUTTING PLATES.
Fig. E.2 Butt welding of plates of unequal thickness
PLANE IN SHEAR
END WELD
IN SHEAR
PLANE
SIDE WELD
SINGLE
Fig. E.3 Fillet welds
FULL FILLET
INTERIOR TANK HEAD
D T1
TANGENT POINT
T T
FULL FILLET TANGENT POINT
WELD
3T MIN OR 2T MIN OR
1 ½" MIN 1'' MIN
JOINT A JOINT B
FULL FILLET
T1 T1
16" MIN
WELD
½" MIN
1
8 " MIN
3
T T
JOINT C JOINT D
Fig. E.4 Acceptable joints for interior heads of compartment tank cars
FULL FILLET
INTERIOR TANK HEAD
WELD
D
TANGENT POINT T1
T T
FULL FILLET
WELD TANGENT POINT
3T MIN OR 2T MIN OR
38.1 MIN 25.4 MIN
JOINT A JOINT B
FULL FILLET
4.76 MIN
T1
T1
WELD
T T
TANGENT
TANGENT POINT POINT
SINGLE WELDED
BUTT WITH BACKUP SINGLE WELDED
BUTT WITH BACKUP
15° to 20° 15° to 20°
JOINT C JOINTD
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.4.1 Acceptable joints for interior heads of compartment tank cars—SI units
54 ° 54 °
VENTING VALVE
SAMPLING VALVE (OPTIONAL)
1/4' PIPE TAP, TOP AND BOTTOM
3/4'' PIPE TAP, BOTTOM (OPTIONAL)
DRAIN
DRAIN
.
AD
67
'R
/2'
/8'
71
'R
AD
LOADING AND DISCHARGING VALVE
.
LONGITUDINAL
CL OF TANK
23'' D
D.
IA. IA.
31'' D
RA
'R
EQUALLY SPACED
AD
LOADING AND
.
DISCHARGING
DRAIN
13 1
VALVE
/2'' R
AD.
DRAIN HOLES 1'' DIA. (OPTIONAL SIZE AND LOCATION) GAUGING DEVICE (VENTING VALVE OPTIONAL)
DRAIN HOLES 13/16'' DIA.
Fig. E.5 Standard manway cover for 18 in. manway (see details in Fig. E.19 series)
54 ° 54 °
VENTING VALVE
SAMPLING VALVE (OPTIONAL)
1/4' PIPE TAP, TOP AND BOTTOM
3/4'' PIPE TAP, BOTTOM (OPTIONAL)
DRAIN
DRAIN
DRILL AND TAP FOR 3/4'' STUDS
DRILL 1 5/16'' HOLES
FOR 1 1/8'' STUDS
.
AD
17
0R
5R
19
AD
.
LOADING AND DISCHARGING VALVE
LONGITUDINAL
CL OF TANK
D.
584
IA. DIA.
A
73817'' D
1R
19
7R
GASES OTHER THAN CHLORINE)
18
EQUALLY SPACED
AD
.
LOADING AND
DISCHARGING
VALVE DRAIN
343
RAD
.
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.5.1 Standard manway cover for 18 in. manway (see details in Fig. E.19 series)—SI units
33'' DIA.
31'' DIA.
25 ½" DIA.
1
8 "
2¼" MIN.
1 ¾"
3
8 " ¼"R ¼"
17¼" DIA. DRILL AND TAP THROUGH
3/4'' 10 UNC 2B
19.238'' ± .010'' DIA.
19 ½" DIA.
1
" DIA. GROOVES
16
20'' DIA.
19¾" DIA. 1
16 " DIA. GROOVE
3
"
16
NOTE:
838 DIA.
787 DIA.
648 DIA.
DRILL 1 5
" DIA. HOLES FOR 1
16
1
8 " DIA. STUDS
3.18
57.2 MIN.
44.4
6.35 R
6.35
NOTE:
WITH WELDING:
515.70 TO 516.20 AS MACHINED.
515.07 TO 516.83 AS CAR COMPLETED.
DRAIN
54° 54 °
DRAIN
DRAIN
EQUALLY SPACED
ON 25'' DIA. B.C.
35'' DIA.
IA. 25'' D
33'' D IA.
IA.
'' D
1/2
27
DRAIN
DRAIN
61'' DIA. DRAIN HOLES ON 29'' DIA. B.C. 6 13 16" DIA. DRAIN HOLES
Fig. E.7 Standard manway cover for 20 in. manway (see details of openings in Fig. E.19 series)
DRAIN
54° 54 °
DRAIN
DRAIN
EQUALLY SPACED
ON 635 DIA. B.C.
889 DIA.
DIA. 635
838 DIA.
IA.
'D
698
DRAIN
DRAIN
61'' DIA. DRAIN HOLES ON 737 DIA. B.C. 6 13 16" DIA. DRAIN HOLES
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.7.1 Standard manway cover for 20 in. manway (see details of openings in Fig. E.19 series)—SI units
35'' DIA.
33'' DIA.
27 ½" DIA.
DRILL 1
5
" DIA. HOLES FOR 1
16
1
8 " DIA. STUDS
1
8 "
2 ¼" MIN.
1 ¾"
3
8 " ¼" R ¼"
19 ¼" DIA. DRILL AND TAP THROUGH
3/4'' 10 UNC 2B
21.238'' ± .010'' DIA.
21 ½" DIA.
1
" DIA. GROOVES
16
22'' DIA.
22.263'' ± .010'' DIA.
21 ¾" DIA. 1
" DIA. GROOVE
16
3
16 "
NOTE:
1 NEW CONSTRUCTION OR REPAIR
INCLUDING FULL FILL OF GROOVE
WITH WELDING:
± .010'' AS MACHINED
± .035'' AS CAR COMPLETED
2
TOLERANCES ARE NOT APPLICABLE
20'' DIA. FOR FIELD INSPECTION OF EXISTING
CARS OR MINOR GROOVE REPAIRS.
Fig. E.8 Detail of cover and nozzle joint for 20 in. manway
889 DIA.
838 DIA.
698 DIA.
DRILL 1
5
" DIA. HOLES FOR 1
16
1
8 " DIA. STUDS
3.18
57.2 MIN.
44.4
6.35 R
6.35
546 DIA.
1.59 DIA. GROOVES
559 DIA.
565.23 TO 565.73 DIA.
552 DIA.
1.59 DIA. GROOVE
537.93 to 538.42 DIA. 2 3
DRILL AND TAP THROUGH
1 8 " 7 UNC 2B
1
NOTE:
29
" DIA. THROUGH
32
29
" DIA. THROUGH
32
27" DIA.
25" DIA. ANGLE VALVE INTERFACE
DRAIN HOLES 1" DIA. THROUGH SEE Fig. E.19.8 FOR DETAILS
ON 29" DIA. BOLT CIRCLE (3 PLACES)
LOCATED AS SHOWN
(6 PLACES)
F
E
E
F
36°
36°
R8
45°
½
¼
R7
45° 45°
LONGITUDINAL AXIS
½ OF TANK CAR
¾
R6
36°
36°
45°
33" DIA.
GAUGING DEVICE INTERFACE 31" DIA. BC
SEE Fig. E.19.25 FOR DETAILS
TWENTY 1 5 16" DIA. HOLES
EQUALLY SPACED
COVER TO NOZZLE JOINT ON 25" DIA. BC
SEE Fig. E.10 FOR DETAILS
SAFETY VALVE INTERFACE
SEE Fig. E.19.20 FOR DETAILS
TWENTY HOLES DRILLED AND
TAPPED FOR ¾"10 STUDS
EQUALLY SPACED ON 31" DIA. BC
Fig. E.9 Standard manway cover for 20 in. manway—VCM (see details of openings in Fig. E.19 series)
33" DIA.
31" DIA. BC
1
8 " 27" DIA.
25" DIA. BC
EQUALLY SPACED
(20 PLACES)
1
" DIA. GROOVES
16
1
" DEEP
32
16" GASKET IN
1
THIS GROOVE
Fig. E.10 Detail for cover and nozzle joint for 20 in. manway—VCM
29
" DIA. THROUGH
32
29
" DIA. THROUGH
32
29" DIA.
DRAIN HOLES 1" DIA. THROUGH 27" DIA. ANGLE VALVE INTERFACE
SEE Fig. E.19.8 FOR DETAILS
ON 31" DIA. BOLT CIRCLE
LOCATED AS SHOWN (3 PLACES)
(6 PLACES)
45° S
)P LACE
. (2
T YP
F
E
F
E
36°
36°
45°
R8
½
45° 45°
LONGITUDINAL AXIS
OF TANK CAR
5 8 "
R7
36°
36°
45°
35" DIA.
GAUGING DEVICE INTERFACE
SEE Fig. E.19.25 FOR DETAILS 33" DIA. BC
EQUALLY SPACED
COVER TO NOZZLE JOINT ON 27" DIA. BC
SEE Fig. E.12 FOR DETAILS
SAFETY VALVE INTERFACE
SEE Fig. E.19.20 FOR DETAILS
TWENTY HOLES DRILLED AND
TAPPED FOR ¾"10 STUDS EQUALLY
SPACED ON 33" DIA. BC
Fig. E.11 Standard manway cover for 22 in. manway—VCM (see details of openings in Fig. E.19 series)
35" DIA.
33" DIA. BC
1
8 " 29" DIA.
27" DIA. BC
EQUALLY SPACED
(20 PLACES)
1
" DIA. GROOVES
16
1
" DEEP
32
THIS GROOVE
Fig. E.12 Detail for cover and nozzle joint for 22 in. manway—VCM
0.75"
34.00" +.00
-.25 FOR 20" MANWAY
+.00
36.00" -.25 FOR 22" MANWAY
13.50" ±.75
4.00" ± .25
Ø5.00" ± .25
0.88" DIA. THROUGH FOUR HOLES
TWENTY HOLES EQUALLY SPACED
EQUALLY SPACED 27.50" DIA. MIN. FOR 20" MANWAY
STRADDLE 4" HOLES
29.50" DIA. MIN. FOR 22" MANWAY
Fig. E.13 Protective housing for 20 in. and 22 in. VCM tank car cover plates
SLOPING-TOP TANK
MINIMUM OPENING
DISCHARGE CHANNEL
Fig. E.15 Detail for opening in protective housing cover for transporting liquefied flammable gases
C PAD DIA.
D
A F
G
A DIA.
D
B
J
B MEAN DIA.
T M H
E TN
C
3
8 " DIA. HOLE
TYPICAL
2 8"
5
HVY
HEX
COVER PLATE
7
8 "
3
8 " DIA. HOLE
1 ¼"
TOP OF STANDARD
LENGTH STUD
6'' REFERENCE
5.250''MIN. MAJOR DIAMETER
(MAX. NOT SPECIFIED)
PITCH DIA. 5.088"5.103" CHAMFER 45° TO
5 8 " DIAMETER
3
E18 STAMPED MINOR DIA. 4.979'' 5.017"
OR CAST (SEE NOTE 6)
2 ¼" REF
" 5 ½"
5 1
" OPTIONAL 125
4 8 " REF
8 16
¼"
1'' REF 3.00'' CORE REF 5
" REF
1
8
¼" 60°
2.00'' CORE
1 8 " REF
3
45° 1 ¼" REF
125 45° REF
¼" SEE NOTE 1
MINOR DIA. 4.920''MAXIMUM
3 8 " REF
7
1 ¾" (MIN. NOT SPEC.)
PITCH DIA. 5.052'' 5.064'' 4'' REF
MAJOR DIA. 5.203'' 5.226'' 6 ¼" REF
NOZZLE E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE ½" HOLE
OF COMPLETED PART FOR CAR SEAL
(OPTIONAL)
OUTLET CAP
Notes:
1. Drill and tap 2 in. or 2 1/2 in. NPT as required.
2. Outlet cap and nozzle dimensions or configuration are to be manufacturer’s option, except for thread dimensions.
3. The 5 1/4 in.–4 special 2A nozzle thread diameters are 0.020 in. less than the 5 1/4 in.–4 UN 2A of ANSI B1.1 standard.
4. The 5 1/4 in.–4 UN 2B outlet cap threads conform with ANSI B1.1 standard.
5. Typical gasket size is 5 1/4 in. O.D. × 3 1/4 in. I.D. × 1/8 in. thick.
6. Maximum minor diameter for hose couplings is 4.984 in. instead of 5.017 in.
7. If the cap or hose coupling thread minor diameter is worn to greater than 5.032 in. on any diameter at a depth greater than
1/2 in. (or accepts the No-Go gauge of Fig. E.18.7 to the 1/2 in. depth), the cap or hose coupling must be removed from
service.
8. If the nozzle thread major diameter is worn to less than 5.141 in. on any diameter for a length greater than 1 5/8 in. (or
accepts the No-Go gauge of Fig. E.18.6 to the 1 5/8 in. depth), the nozzle must be removed from service.
Fig. E.18 4 in. bottom outlet cap and nozzle thread standard
11/2014 C-III [M-1002] 275
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX E M-1002
152 REFERENCE
5.250'' MIN. MAJOR DIAMETER
(MAX. NOT SPECIFIED)
CHAMFER 45° TO
PITCH DIA. 5.088" 5.103" 137 DIAMETER
E18 STAMPED MINOR DIA. 4.979'' 5.017"
OR CAST ( SEE NOTE 8)
57.2 REF
6.35 15.9 1.59 OPTIONAL138
105 REF
25.4 REF 76.2 CORE REF
15.9 REF
6.35 60°
34.9 REF 50.8 CORE
45° 31.8 REF
45° REF
6.35 SEE NOTE 1
MINOR DIA. 4.929'' MAXIMUM
(MIN. NOT SPEC.) 98.4 REF
44.4
PITCH DIA. 5.052'' 5.064'' 102 REF
MAJOR DIA. 5.203'' 5.226'' 159 REF
NOZZLE E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE 12.7 HOLE
OF COMPLETED PART FOR CAR SEAL
(OPTIONAL)
OUTLET CAP
Notes:
1. Drill and tap 2 in. or 2 1/2 in. NPT as required.
2. Outlet cap and nozzle dimensions or configuration are to be manufacturer’s option, except for thread dimensions.
3. The 5 1/4 in.–4 special 2A nozzle thread diameters are 0.020 in. less than the 5 1/4 in.–4 UN 2A of ANSI B1.1 standard.
4. The 5 1/4 in.–4 UN 2B outlet cap threads conform with ANSI B1.1 standard.
5. Typical gasket size is 133 O.D. × 82.6 I.D. × 3.18 thick.
6. All thread dimensions are shown in conventional units.
7. Appendix H must be followed when using SI units.
8. Maximum minor diameter for hose couplings is 4.984 in. instead of 5.017 in.
9. If the cap or hose coupling thread minor diameter is worn to greater than 5.032 in. on any diameter at a depth greater
than 1/2 in. (12.7 mm) (or accepts the No-Go gauge of Fig. E.18.7 to the 1/2 in. depth), the cap or hose coupling must
be removed from service.
10. If the nozzle thread major diameter is worn to less than 5.141 in. on any diameter for a length greater than 1 5/8 in.
(41.3 mm) (or accepts the No-Go gauge of Fig. E.18.6 to the 1 5/8 in. depth), the nozzle must be removed from service.
Fig. E.18.1 4 in. bottom outlet cap and nozzle thread standard—SI units
C-III [M-1002] 276 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX E
9 ½" REF
8 ½" REF
MAJOR DIA. (MAX. NOT SPEC.)
45° CHAMFER TO 8.000'' MIN.
8 8 " DIAMETER
1
PITCH DIAMETER 7.837'' 7.858''
E18 STEEL MINOR DIAMETER 7.729'' 7.767"
STAMP (SEE NOTE 6)
OPTIONAL: 8 " HOLE (3) FOR
3
2 8 " REF
1 8 " REF
1
4 ¾" REF
½" REF 8'' 125 1''
7
8 " REF
5 1
" OPTIONAL
16
NOZZLE
E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE
OF COMPLETED PART
Fig. E.18.2 6 in. bottom outlet cap and nozzle thread standard
11/2014 C-III [M-1002] 277
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX E M-1002
241 REF
216 REF
MAJOR DIA. (MAX. NOT SPEC.)
45° CHAMFER TO 8.000'' MIN.
206 DIAMETER PITCH DIAMETER 7.837'' 7.858''
E18 STEEL MINOR DIAMETER 7.729'' 7.767"
STAMP (SEE NOTE 8)
OPTIONAL: 9.52 HOLE (3) FOR
178 REF 12.7 15.8 LOCKING SET SCREWS
15.9
73.0 REF
28.6 REF
121 REF
12.7 REF 203
15.9 REF 1.59 OPTIONAL
15.9 REF 92.1 CORE 25.5
REF OPTIONAL
12.7 31.8 REF
12.7 HOLE FOR
CAR SEAL
60° 50.8 CORE (OPTIONAL)
19.0
NOZZLE
E18 TO BE CAST OR
STEEL STAMPED TO BE
READILY IDENTIFIED
ON EITHER SURFACE
OF COMPLETED PART
Notes:
1. Drill and tap for 2 in., 2 1/2 in., or 3 in. NPT as required. OUTLET CAP
2. Outlet cap and nozzle dimensions or configuration are to be manufacturer’s option, except for thread dimensions.
3. The 8 in.–4 special 2A nozzle thread diameters are 0.020 in. less than the 8 in.–4 UN 2A of ANSI B1.1 standard.
4. The 8 in.–4 UN 2B outlet cap threads conform with ANSI B1.1 standard.
5. Typical gasket size is 203 O.D. × 152 I.D. × 3.18 thick.
6. All thread dimensions are shown in conventional units.
7. Appendix H must be followed when using SI units.
8. Maximum minor diameter for hose couplings is 7.734 in. instead of 7.767 in.
9. If the cap or hose coupling thread minor diameter is worn to greater than 7.782 in. on any diameter at a depth greater than 7/16 in.
(or accepts the No-Go gauge of Fig. E.18.9 to the 7/16 in. depth), the cap or hose coupling must be removed from service.
10. If the nozzle thread major diameter is worn to less than 7.890 in. on any diameter for a length greater than 1 1/2 in.
(38.1 mm) (or accepts the No-Go gauge of Fig. E.18.8 to the 1 1/2 in. depth), the nozzle must be removed from service.
Fig. E.18.3 6 in. bottom outlet cap and nozzle thread standard—SI units
C-III [M-1002] 278 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX E
NOTES:
1. THESE 5 ¼" 4 SPECIAL 2A NOZZLE THREAD DIAMETERS ARE
0.020" LESS THAN THE 5 ¼" 4 UN 2A OF ANSI B1.1 STANDARD.
NOTES:
1. THESE 8"4 SPECIAL 2B CAP THREAD DIAMETERS ARE 2.000"
GREATER THAN THE 6"4 UN 2B OF ANSI B1.1 STANDARD.
7 8"
1
5.141"
(2) 1 8 " × 45°
1.750"
Ø 7 16" (OPTIONAL)
2 ¾"
¾"
NO-GO GAUGE FOR
AAR 5 ¼"4 THREAD NOZZLE
NOTES:
1. ALL DIMENSIONS ARE IN INCHES.
2. ANY DIMENSIONALLY STABLE MATERIAL MAY BE USED.
Y 3. MANUFACTURING TOLERANCE: DECIMAL ±0.005 IN.
(ref. Appendix D, 4. RECERTIFICATION TOLERANCE: DECIMAL ±0.015 IN.
paragraph 3.6) 5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO SUIT
THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF THE GAUGE IS
NOT IMPAIRED.
6. MAY BE COMBINED WITH FIG. E.18.7 IN A SINGLE GAUGE CONFIGURATION.
Fig. E.18.6 Gauge for worn threads—4 in. bottom outlet nozzle
6"
(4) 32" × 45°
1
½"
1 8"
3 NO-GO GAUGE FOR
AAR 5 ¼"4 THREAD CAP OR COUPLING
0.625"
3
8 " ± 1 32"
5.032"
(2)1 8 " × 45°
NOTES:
1. ALL DIMENSIONS ARE IN INCHES.
2. ANY DIMENSIONALLY STABLE MATERIAL MAY BE USED.
3. MANUFACTURING TOLERANCE: DECIMAL ±0.005 IN.
4. RECERTIFICATION TOLERANCE: DECIMAL ±0.015 IN.
5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO SUIT
THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF THE GAUGE IS
NOT IMPAIRED.
6. MAY BE COMBINED WITH FIG. E.18.6 IN A SINGLE GAUGE CONFIGURATION.
Fig. E.18.7 Gauge for worn threads—4 in. bottom outlet cap or coupling
11/2014 C-III [M-1002] 281
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX E M-1002
10 ¼"
7.890"
(2) 8 " × 45°
1
Ø 16" (OPTIONAL)
7
1.625"
2 ¾"
NOTES:
1. ALL DIMENSIONS ARE IN INCHES.
2. ANY DIMENSIONALLY STABLE MATERIAL MAY BE USED.
Y 3. MANUFACTURING TOLERANCE: DECIMAL ±0.005 IN.
(ref. Appendix D, 4. RECERTIFICATION TOLERANCE: DECIMAL ±0.015 IN.
paragraph 3.6) 5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO SUIT
THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF THE GAUGE IS
NOT IMPAIRED.
6. MAY BE COMBINED WITH FIG. E.18.9 IN A SINGLE GAUGE CONFIGURATION.
Fig. E.18.8 Gauge for worn threads—6 in. bottom outlet nozzle
8 8"
3
13
"
16 Ø 16" (OPTIONAL)
7 (4)1 32" × 45°
11
"
1 8"
3
16
NO-GO GAUGE FOR
AAR 8"4 THREAD CAP OR COUPLING
0.563"
3
8 " ± 1 32"
7.782"
(2) 8 " ×45°
1
X = 1 ½" MINIMUM
NOTES:
1. ALL DIMENSIONS ARE IN INCHES.
2. ANY DIMENSIONALLY STABLE MATERIAL MAY BE USED.
3. MANUFACTURING TOLERANCE: DECIMAL ±0.005 IN.
4. RECERTIFICATION TOLERANCE: DECIMAL ±0.015 IN.
5. FRACTIONAL DIMENSIONS ARE FOR REFERENCE ONLY AND MAY VARY TO
SUIT THE GAUGE MANUFACTURER, PROVIDED THAT THE FUNCTION OF
THE GAUGE IS NOT IMPAIRED.
6. MAY BE COMBINED WITH FIG. E.18.8 IN A SINGLE GAUGE CONFIGURATION.
Fig. E.18.9 Gauge for worn threads—6 in. bottom outlet cap or coupling
1 1 88"
1
8"
3
10
5
8" DIA B.C. DRILL AND TAP FOR
3
8 - 4 - 10 UNC 28
STUDS
8"
5
IN VALVE FLANGE
¼"
2'' DIA. 1
" DIA. GROOVES
16
1
" DIA. GROOVE
16 1
7
8 " DIA.
1
1
8 " DIA.
1
8 " GASKET
3
"
16
"8
"
7
8
1
1
1''
6.35
44.4 DIA.
4.76
22.2
28.6
25.4
¼"
3 ½" DIA.
3 ¾" DIA.
1
"
16 DIA. GROOVES
3.995'' ± .003'' DIA.
2'' DIA.
1
8 " GASKET
3
"
16
1 ¼"
"
7
8
Fig. E.19.2 Detail of mounting conditions for 2 in. angle valve for tank with 2 in. eduction pipes
6.35
82.61 TO 82.75 DIA.
88.9 DIA.
50.8 DIA.
3.18 GASKET
4.76
22.2
31.8
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.3 Detail of mounting conditions for 2 in. angle valve for tank with 2 in. eduction pipes—SI units
¼"
3 ½" DIA.
1
" DIA. GROOVES
16
3 ¾" DIA.
3
"
1 ¼"
8
16
7
1 18 "
2.906'' DIA.
Fig. E.19.4 Detail of mounting conditions for 2 in. angle valve for tanks with 2 in. eduction pipes
6.35
88.9 DIA.
4.76
31.8
28.6
73.81 DIA.
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.5 Detail of mounting conditions for 2 in. angle valve for tanks with 2 in. eduction pipes—SI units
¼"
3 ¾" DIA. 1
"
16 DIA. GROOVES
2
15
16 " DIA. 1
8 " GASKET
3
"
"
16
8
1 ¼"
7
7
" MIN.
16
6.35
82.61 TO 82.75 DIA.
88.9 DIA.
95.3 DIA. 1.59 DIA. GROOVES
101.40 TO 101.54 DIA.
4.76
31.8
22.2
11.1 MIN.
Fig. E.19.7 Detail of mounting conditions for 2 in. or 3 in. angle valve for tanks with 3 in. eduction pipes—SI units
¼"
3 ½" DIA.
3 ¾" DIA. 1
" DIA. GROOVES
16
3
5
8 " DIA. 1
" DIA. GROOVE
16
2
15
16 " DIA.
1
8 " GASKET
3
"
"
16
8
1 ¼"
¾"
6.35
82.61 TO 82.75 DIA.
88.9 DIA.
95.3 DIA. 1.59 DIA. GROOVES
4.76
31.8
19.0
¼"
1 ¾" DIA.
2'' DIA. 1
" DIA. GROOVES
16
3
"
16
1 ¼" DIA.
"
8
1 ¼"
6.35
38.16 TO 38.30 DIA.
44.4 DIA.
4.76
31.8 DIA.
2.22
31.8
¼"
2'' DIA. 1
16 " DIA. GROOVES
3
"
16
1 ¼" DIA.
1 ¼"
"
7
8
¾"
1.531'' DIA.
Fig. E.19.12 Detail of mounting conditions for gauging device
6.35
44.4 DIA.
4.76
22.2
31.8 DIA.
31.8
19.0
38.89 DIA.
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.13 Detail of mounting conditions for gauging device—SI units
¼"
2'' DIA. 1
" DIA. GROOVES
16
1
7
8 " DIA. 1
16 " DIA. GROOVE
3
8 "
"
1 ¼"
8
7
3
8 "R
1 ¾" DIA.
6.35
44.4 DIA.
28.6 DIA.
3.18 GASKET
4.76
9.52
22.2
31.8
9.52 R
44.4 DIA.
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.15 Detail of mounting conditions for pressure relief valve—SI units
¼"
4 ¼" DIA.
4 ½" DIA. 1
" DIA. GROOVES
16
2 8 " DIA.
7
1
8 " GASKET
3
"
16
½"
"
1 ¼"
3
"
8
8
7
3 8 " DIA.
3
6.35
108 DIA.
9.52
85.7 DIA.
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.17 Detail of mounting conditions for pressure relief valve—SI units
IN VALVE FLANGE
¼"
4 ½" DIA.
4 ¾" DIA. 1
" DIA. GROOVES
16
4
5
8 " DIA. 1
" DIA. GROOVE
16
3 16" DIA.
1
3
"
16
1
8 " GASKET
½"
"
1 ¼"
"
8
3
7
3 ¾"
Fig. E.19.18 Detail of mounting conditions for pressure relief valve
6.35
77.8 DIA.
4.76 3.18 GASKET
12.7
22.2
31.8
9.52
95.2
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.19 Detail of mounting conditions for pressure relief valve—SI units
IN VALVE FLANGE
¼"
6 ½" DIA. 1
" DIA. GROOVES
16
6
3
8 " DIA. 1
" DIA. GROOVE
16
5
5
8 " DIA.
1
8 " GASKET
3
"
1 8"
1"
16
3
IN VALVE FLANGE
6.35
159 DIA.
165 DIA. 1.59 DIA. GROOVES
143 DIA.
3.18 GASKET
25.4
4.76
34.9
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.21 Detail of mounting conditions for pressure relief valve—SI units
¼"
7 ½" DIA.
7 ¾" DIA. 1
16 " DIA. GROOVES
7
5
8 " DIA. 1
" DIA. GROOVE
16
6
5
8 " DIA.
1
8 " GASKET
"
3
"
8
16
1 ¼"
6.35
190 DIA.
183.95 TO 184.09
168 DIA.
3.18 GASKET
4.76
22.2
31.8
Note: All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.19.23 Detail of mounting conditions for pressure relief valve—SI units
¼"
4.25" ± .02"
5.00" ± .02"
5.06" ± .02"
4.19" ± .02" 1
8 " GASKET
0.19"
¾"
1"
AS REQUIRED
Fig. E.19.24 Detail of mounting condition for 3 in. full ported flanged ball valves for nonpressure tank cars using
ANSI B16.5 large tongue design
3 ¼" DIA. BC
TAP
5
8 " 11 UNC2B ¾" DEEP
EQUALLY SPACED 1.495 ± .003" DIA.
1
" DIA. GROOVE
16
(4 PLCS) 1
32" DEEP
3
"
16
1 ¼" DIA.
¾"
1.531" DIA.
SMALLER OF
a c .7N OR .7M
2½N 2½M
M
D
2½M
b
d SMALLER OF
.7N OR .7M
D D
D N
a c SMALLER OF
2½N K .7N OR .7M
2½M
M
2½M
b ½N
d
D D
Fig. E.20.1 Reinforced openings in tank shell—built-up nozzle with pad
D N
c
a
R 2½N 2½M
M
2½M
b
d
D D
D N
SMALLER OF
¼" (6.35) OR .7N
a c
2½N K 2½M
M
2½M
b
d SMALLER OF
D D ½ M OR ½ K
D N
a c
2½M
K M
SMALLER OF
a c .7N OR .7M
R 2½N
2½M
D 2½M
SMALLER OF
b .7N OR .7M
d
D D
D N
a c
2½N 2½M
K M
2½M
b
d .7 K
D D
Fig. E.20.6 Reinforced openings in tank shell—flued opening abutting tank shell
D N
SMALLER OF
c ¼" (6.35) OR .7N
a
2½M
OR
2½N M
2½M
b
d
D D
SMALLER OF
¼" (6.35) OR .7N
D N
a c
K 2½N
2½M
M
SMALLER OF
2½M
½ M OR ½ K
b
d SMALLER OF
.7M OR .7N = TW
D D
SMALLER OF
.7N OR .7K = TW
Fig. E.20.8 Reinforced openings in tank shell—built-up nozzle with reinforcement
SMALLER OF
.7 N OR .7 L
IDD N SMALLER OF
¼" (6.35) OR .7N SMALLER OF
½ M OR ½ K
L
c
a 4" (102) ON
K 2½N 2½M
LONG CL
SMALLER OF
2½M M .7 N OR .7 L
b d
ITD IDD
IDD
IDD
2N ( 1 + 2ITD
)
WHERE N = SPECIFIED
DOME SHELL THICKNESS
(MAY BE ONE PIECE).
Fig. E.20.9 Reinforcement with internal ring for dome opening greater than 30 in. (762 mm)
SMALLER OF
N .7 N OR .7 L
SMALLER OF
IDD L ½ M OR ½ K
SMALLER OF
c ¼" (6.35) OR .7L
a 4" (102) ON
K 2½N 2½M
LONG CL
SMALLER OF
2½M M .7 N OR .7 L
b d
ITD 2N ( 1 + 2ITD
IDD
)
IDD
IDD WHERE N = SPECIFIED
DOME SHELL THICKNESS
(MAY BE ONE PIECE).
Fig. E.20.10 Reinforcement with external ring for dome opening greater than 30 in. (762 mm)
.7 N
N
L
.7 M
.7 N
K c
M a
2½M
2½N M
D 2½M
b
.7 M d
D D
Fig. E.20.11 Flued reinforcement for dome opening 30 in. or less
C-III [M-1002] 312 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX E
N
D
c
FULL a
PENETRATION 2 ½ M 2½N
WELD M
2½M 2½N
d
SMALLER OF b
¼" (6.35) OR .7N D D
12'' DIA.
7 ½" DIA. MIN.
7.1875'' ± .005'' DIA.
2 8 " DIA. MIN.
7
LINED OR UNLINED
¼"
1 ½" MIN.
305 DIA.
190 DIA. MIN
182.44 TO 182.68
73.0 DIA. MIN.
164.31 TO 165.89 LINED OR UNLINED
LINED OR UNLINED
6.35
38.1 MIN.
A A
5
EDGE OF
DISCONTINUITY 1 NOTE:
1) All strain gauges located on external tank surfaces
2) Rosettes 1 and 2 located on tank shell as shown
2'' (50.8) 2
3) Rosette 3 located in center of reinforcement
4) Rosette 4 located in center of flat portion of nozzle
5) Rosette 5 located in center of curved portion of nozzle
SECTION A-A
Fig. E.22 Strain gauge rosette location
16" TO 8 "
1 1
CHAMFER OR
3.25'' ± 0.03'' DIA. RADIUS
Note: The outside diameter of a rupture disc for use in the nominal 2 in. rupture disc device should be in the range of 3.07 to
3.20 in.
Fig. E.23 Detail of nominal 2 in.-diameter rupture disc device
1.59 TO 3.18
CHAMFER OR
81.7 TO 83.3 DIA. RADIUS
Notes:
The outside diameter of a rupture disc for use in the nominal 2 in. rupture disc device should be in the range of 3.07 to 3.20 in.
All dimensions in mm. Appendix H must be followed when using SI units.
Fig. E.23.1 Detail of nominal 2 in.-diameter rupture disc device—SI units
Fig. E.24 <This caption must become white text; there is no Fig. E24, but there must be a holder for it.>
2 3
4
6
4
Fig. E.24.1 Bolted flange closure
7
4
6
Fig. E.24.2 Threaded cap closure
4
1
Fig. E.24.5 Quick-coupling device with internal
threaded cap closure
1
5
5
7
6
8
Fig. E.24.3 Quick-coupling device with threaded plug
closure
4
1 1
4*
4
8
5
4*
* Either Location Acceptable
Fig. E.24.9 Two-piece quick-coupling device with
auxiliary valve
OUTLET CONNECTION PARTS LEGEND
1 Outlet Nozzle
2 Outlet Flange-bolted
3 Cap-Threaded
10
4 Plug – 1" NPT Minimum
4 Quick Coupling Adapter
5
6 Gasket
Fig. E.24.8 Two-piece quick-coupling device with
integral auxiliary valve 7 Plug with Dust Protector– Threaded
8 Auxiliary Valve
15 ½"
OUTSIDE DIAMETER
TANK SHELL
DIMENSION
A
OUTSIDE DIAMETER
TANK SHELL
Dimension
A
OUTSIDE DIAMETER
TANK SHELL
20"
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.4 Top fittings profile nonpressure cars—6 in. pressure relief valve
22 ¼"
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.5 Top fittings profile nonpressure cars—3 in. top style pressure relief valve
15 ¼"
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.6 Top fittings profile nonpressure cars—3 in. pressure relief valve
11/2014 C-III [M-1002] 323
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX E M-1002
15 ¾"
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.7 Top fittings profile nonpressure cars—2 in. rupture disc device
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.8 Top fittings profile nonpressure cars—rupture disc device or vacuum relief valve applied on hinged
manway cover
27 ½"
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.9 Top fittings profile nonpressure cars—pressure relief valve applied on hinged manway cover
C-III [M-1002] 324 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX E
25 ½"
OUTSIDE DIAMETER
TANK SHELL
NOTE:
NONINSULATED RUBBER-LINED CARS
Fig. E.25.10 Top fittings profile nonpressure cars—manway with nozzle—hydrochloric acid car
34"
OUTSIDE DIAMETER
TANK SHELL
NOTE:
NONINSULATED RUBBER-LINED CARS
Fig. E.25.11 Top fittings profile nonpressure cars—manway with nozzles and valve—hydrochloric acid car
26 ¾"
OUTSIDE DIAMETER
TANK SHELL
Fig. E.25.12 Top fittings profile nonpressure cars—manway with nozzles—sulfuric acid car
NOMINAL NOMINAL
1
" OVERLAP
16
OVERLAP 1
"
16
(A) SHOWN WITH HARD GASKET RETAINED ON I.D. (B) SHOWN WITH HARD GASKET RETAINED ON O.D.
NOMINAL
1
"
32
1
" OVERLAP
16
Note: Other gasket groove configurations or combinations of the grooves shown are allowed as long as the conditions of
paragraph 3.3.1 in this appendix are met. The gaskets shown in this figure are to illustrate retention methods and overlaps
required. Any of the gaskets could be used in any of the grooves.
Fig. E.26 Gasket grooves for AAR-1 manway style
C-III [M-1002] 326 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX E
Ø*
QTY (*)
ON * B.C.
Ø* Ø* Ø* Ø* ØB
*
Blind Flange for
DIM
Blind Flange for Blind Flange for
Gauging Device A
1-in. Angle Valve Gauging Device for VCM Tank Cars
A .75 in. (19 mm) 1 in. (25 mm) .75 in. (19 mm)
B 5 in. (127 mm) 5.75 in. (146 mm) 4.5 in. (114 mm)
* Remaining dimensions to be per applicable Fig. E.19 through Fig. E.19.25.
Fig. E.27 Detail of pressure car blind flange for 1 in. angle valve or gauging device
6.00" (152 mm) * Dimensions to be per applicable Fig. E.19 through Fig. E.19.25.
Ø*
QTY (*)
ON * B.C.
Ø* Ø* Ø* Ø*
6.00" (152 mm)
*
R.81" (R21 mm) TYP
1" (25 mm)
Fig. E.28 Detail of pressure car blind flange for 2 in. or 3 in. angle valve
11/2014 C-III [M-1002] 327
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX E M-1002
8 ¼"
R1 16"
9
TRANSVERSE
CENTERLINE A A 11
"
D 8 16
SAMPLING VALVE ½"
6° TYP
THERMOMETER WELL
C
GAUGING DEVICE
B
PROTECTIVE LONGITUDINAL 9 ¼"
½"
HOUSING CENTERLINE
MOUNTING 6° TYP
(SEE NOTE)
A A
C
Ø6
DRAIN HOLES 8"
R1 8 "
3
3
8 "
LARGE SAFETY VALVE B
8" D
½"
Ø3
11
"
16
NOTE:
6° TYP
PROTECTIVE HOUSING MUST HAVE FOUR 3 1/2 IN. MINIMUM DIAMETER
5
"
16
Fig. E.29 Clearance requirements for capping kits (except chlorine cars)
6 8 " SQUARE
5
7" OD
5 32" ID
23
1 2
6BMV 24BMV
MOLDED VITON GASKET MOLDED VITON GASKET
2
PRESSURE RELIEF DEVICE
Fig. E.30 Capping clearances for standard chlorine cars with 18 in. manways
C-III [M-1002] 328 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX H
APPENDIX H
BASIC PHILOSOPHY AND PRINCIPLES FOR THE METRICATION OF THE
AAR SPECIFICATIONS FOR TANK CARS
CONTENTS
APPENDIX H
BASIC PHILOSOPHY AND PRINCIPLES FOR THE METRICATION OF THE
AAR SPECIFICATIONS FOR TANK CARS
1.0 INTRODUCTION
1.1 Scope
1.1.1 Appendix H outlines the basic philosophy and principles for the metrication of the AAR
Specifications for Tank Cars. These are the guidelines for converting the specifications from
conventional units to SI units. For conversions not specifically covered herein, see IEEE/ASTM
SI10.
1.1.2 Changes to the basic philosophy contained herein are to be made by approval of the Tank
Car Committee.
2.0 SEQUENCE
The conversion of the tank car specifications from conventional units to SI units will be
accomplished in three stages. At some later date it may be decided to omit stage 2. If stage 2 is
utilized at the time the decision is made to implement it, a decision will also be made whether or
not the SI-dimensioned tank cars and components are to be interchangeable with existing
equipment. If not, the SI-dimensioned tank cars will be the beginning of a new and independent
set of specifications.
2.1 Stages
2.1.1 Conversion of the Specifications for Tank Cars will be addressed in three stages:
For conversions not involving set percentages, the following guidelines will be used:
• For pressures below 14.696 psi—use two significant SI figures in kilopascals (kPa)
• For pressures from 14.696 to 145 psi—use three significant SI figures in kilopascals (kPa)
• For pressures or stresses from 145 psi to 1459 psi—use four significant SI figures in
kilopascals (kPa)
• When kilopascals (kPa) exceed five figures—use megapascals (MPa) to three significant
figures
• Pressures in kilopascals (kPa) are gauge pressures, unless otherwise noted. Stresses are to
be expressed in kilopascals (kPa) or megapascals (MPa), not bars.
4.3.3 Volume
Cubic feet (ft3) should be converted to cubic meters (m3) with three significant figures.
ft3 × 2.831 685 E – 02 = m3
• Cubic inches (in.3) should be converted to cubic centimeters (cm3) up to five figures
• Over five figures of cubic centimeters (cm3)—use cubic meters (m3)to three significant
figures
in. × 25.4 E + 00 = mm
• Up to 36 in.—convert to three significant SI figures of millimeters (mm)
• For 36 in. and above—round to the appropriate number of SI figures of millimeters (mm)
to arrive at the desired accuracy for the stage of conversion covered in paragraph 2.1 of
this appendix
4.3.6 Temperature
Convert Fahrenheit temperatures to three significant figures of degrees Celsius.
(°F – 32)/1.8 = °C
4.3.7 Work
Foot pounds-force (ft · lbf) should be converted to joules (J).
4.3.13 Torque
Convert torque or moment in foot pounds force (lbf · ft) to three significant SI figures of newton
meters (Nm).
6.3 Rounding
Rounding will be done to arrive at specified significant figures after the conversion.
• XXX51 will always round upward.
• XXX49 will always round down.
• XXX50 will always round to an even number, e.g., XX450 to XX4; XX350 to XX4.
When tolerance affects fits and rounding is used, the rounding will only be inward to the spread so
that the rounding will result in a tighter tolerance rather than a more permissive one.
6.4 Formulas
6.4.1 Formulas in the appendices (such as found in Appendix E paragraphs 3.1, 5.2, 7.0, and
11.0) will be revised per guidelines and a separate metric formula provided. A derivation and
example must be kept on file.
6.4.2 The derivation of the formulas in Appendix A will have a separate listing of metric
dimensions for clarity.
6.5 Stamping
Stamping specified in Chapter 3, paragraph 3.5.14, will show water capacity as 0000 GAL, or
0000 GAL and 00 000 L. Stamping specified in Chapter 3, paragraph 3.4.19, will show volumetric
capacity as 0000 CU FT, or 0000 CU FT and 000 CU M.
6.6 Plate Sizes
For showing SI equivalents, minimum required design thicknesses must be maintained (except
7/16 in., which will be equivalent to 11.0 mm).
6.7 Miscellaneous
6.7.1 Do not mix symbols and words (e.g., do not use “square m”). Use “m2” or “square meters.”
6.7.2 As industrial standards are converted to metric, their effect on the Tank Car Specifications
will be evaluated.
6.7.3 Instead of converting references to letter-size sheets 8 1/2 × 11 in. to metric, “approximately
8 1/2 × 11 in.” will be specified.
6.7.4 Only the tables in the DOT regulations, as published in the AAR Specifications for Tank
Cars, will be converted. This is for the convenience of those using the AAR specifications and is a
prelude to the proposed metrication of the DOT regulations.
6.7.5 The conventional terms (dimensions) will be retained on the drawings and titles found in
Appendix E, such as Figs. E.6, E.7, E.8, E.19, and E.19.2. They incorporate conventional
dimensions such as “Detail of Cover and Nozzle Joint for 20 in. Manway.” In such cases, there will
be only conventional units in the titles, without dualizing.
6.7.6 Conversion factors are presented for ready adaptation to computer readout and electronic
data transmission. The factors are written as a number, greater than one and less than ten, with
six or fewer decimal places. The number is followed by the letter E (for exponent), a plus or minus
sign, and two digits that indicate the power of 10 by which the number must be multiplied to
obtain the correct value. For example:
6.7.7 The number of significant figures specified are minimum. More significant figures will be
used when greater accuracy is required.
APPENDIX J
THREADED AND BOLTED FLANGE JOINT ASSEMBLY
CONTENTS
APPENDIX J
THREADED AND BOLTED FLANGE JOINT ASSEMBLY
1.0 GENERAL
1.1 Introduction
Appendix J describes the recommended practice for the correct assembly of threaded and bolted
connections of service equipment to tank cars.
1.2 Scope
This document presents general guidelines for the assembly of threaded and bolted connections
and recommended procedures. It is not a complete and comprehensive set of methods, instructions,
or procedures applicable for all situations. Each user company is encouraged to develop specific
procedures using this document as a general guide where it applies. The guidelines outlined in
this document cover the assembly elements essential for a high level of joint integrity of otherwise
correctly designed and constructed threaded and bolted flanged connections.
1.3 Before performing any work, follow plant safety procedures to relieve the pressure safely
from the tank.
• Observe current conditions.
• Utilize checklists to ensure thorough documentation of “as received” conditions.
• In particular, look for apparent leaks, loose fasteners, and gasket condition.
• Assembly personnel should report visible leaks through their proper channels/appropriate
supervisor.
1.4 Recognizing the array of areas that could lead to equipment connection failures, this
appendix uses a “best practices” approach to evaluate and work with equipment connections. In
simplified terms, this is an “inspect-to-pass” process where the equipment connection is evaluated,
and if the connection fails, additional examination and possibly rework will be required. Tank car
leaks not only endanger employees, but also result in expensive fines and remediation along with
poor visibility in the public domain.
1.5 Each tank car facility performing work in accordance with this appendix must obtain an
Association of American Railroads, Manual of Standards and Recommended Practices, Section C,
Part III, Specifications for Tank Cars, Appendix B, certification or registration, as appropriate.
2.0 THREADED CONNECTIONS
2.1 Disassembly and Inspection
2.1.1 Disassemble with an appropriate wrench to avoid damaging valve, fitting body, or flats.
2.1.2 With a wire brush, clean threads of foreign material, such as PTFE tape, joint compound,
paint, and commodity.
2.1.3 Using a clean cloth or paper towel, wipe the thread surface to remove any residual material
or solution.
2.1.4 Inspect the threads to confirm that there are no cuts, gouges, or other defect that may affect
sealing integrity.
2.1.5 Inspect the threads with an appropriate ring or plug gauge.
2.1.6 Repair damaged or out-of-tolerance threads when practical or replace in-kind.
2.2 Assembly
2.2.1 Ensure that the threads (male and female) are clean prior to assembly.
2.2.2 Apply a PTFE tape or paste to the male threads. If using tape, wrap the tape in the
direction of the thread spiral, beginning with first thread. Do not wrap outside of the threads, or
exceed three wraps of tape. Thread sealants are acceptable when used to secure the joint but not to
mask defects in the joint makeup.
2.2.3 Thread the joint slowly to avoid producing excess friction. Heat produced by friction can
cause the metal to expand before properly making the joint.
2.3 Table J.1 identifies the typical length of total thread engagement, including the first three
hand-tight lead threads, required to make a tight joint.
3.7.10 Inspect hinged and bolted manway cover, fill port cover, and eye bolts in accordance with
Appendix D.
3.7.11 If components are defective, replace in kind or according to owner instructions.
3.8 Assembly
3.8.1 Installation of Gasket
3.8.1.1 Ensure that the gasket meets the following criteria:
• Chemically compatible with the lading
• Thermally compatible with the highest and lowest temperature range (e.g.,
loading/unloading hot products)
• Mechanically suitable for the respective flange
• Dimensionally suitable
3.8.1.2 When installing the gasket, the gasket should not bind or interfere with the fasteners.
3.8.1.3 When installing the gasket, the gasket should not interfere with product flow or the
function of the pressure relief device, and the gasket should be concentric within the flange.
3.8.1.4 The size of the gasket must be sufficient to ensure gasket compression for sealing.
3.8.1.5 The gasket must have no damage after installation.
3.8.1.6 Other than in tongue and groove joints, the gasket, in general, should not be less than
1/2 in. wide.
3.9 Alignment of Mating Surfaces
3.9.1 When so marked, component must be installed in the same orientation as when removed
from the tank car using the reference mark drawn during disassembly.
3.9.2 During installation, and as the component flanges come together, the flanges should remain
parallel to prevent pinching the gasket.
3.9.3 The weight of some components can create handling challenges; and therefore, consider
supporting the weight of the component during installation with the use of a lifting device.
3.10 Installation of Fasteners
3.10.1 New Fasteners
3.10.1.1 Fasteners securing a pressure-retaining fitting must be approved in accordance with
Appendix M, or meet the design specification as annotated on the tank car drawing.
3.10.1.2 In accordance with Appendix M, paragraph 1.2.3, fasteners must have grade and
manufacturer’s identification (manway eye bolts and socket-head cap screws are excluded unless
required by the car owner).
3.10.1.3 Fastener grade markings must be oriented to allow for visible inspection.
3.10.1.4 Fasteners must be of the same grade and specification, unless specified otherwise by the
car owner.
3.10.2 If required by design, apply specified lubrication (e.g., anti-seize) to the working surfaces
of the fastener and nut (i.e., fastener threads, nut bearing surface, and if applicable, underside of
bolt head).
3.10.2.1 Some commodities may require a specialized thread lubricant (e.g., chlorine) or no
thread lubricant.
APPENDIX L
INTERIOR CLEANING, LINING, AND COATING
CONTENTS
APPENDIX L
INTERIOR CLEANING, LINING, AND COATING
1.0 INTRODUCTION
1.1 Scope
Appendix L describes the AAR requirements for interior cleaning for, and the application and
stripping of, interior linings and coatings for tank car tanks, valves, and fittings.
2.0 APPLICATION AND CLEANING OR STRIPPING OF LININGS AND COATINGS
2.1 Lining/Coating Materials
Table L.1 Lining/coating materials
Clad metal Bonding of dissimilar metal sheets or plates to form a composite
metal. The more corrosion-resistant metal acts as the interior
protective covering after the tank is fabricated.
Dispersion coating A coating where relatively large resin particles are distributed in
a solvent system as opposed to being dissolved.
Electroless plating Deposition of a metal on a base metal by chemically reducing
metal ions to metal.
Electroplating Deposition of a metal on a base metal by the passing of an electric
current through an electrolyte.
Glass Transparent or translucent inorganic material fused on base
metal.
Laminated-type A plastic substance with basic rubber-like elastic characteristics,
material applied in two or more spray-coat operations (e.g., polyvinyl
chloride and polyurethane). See DOT 179.201-3.
Lead lining Deposition of a homogeneous layer of lead to the interior of the
tank.
Metallizing Formation of a fused metallic coating by atomized spray of a
(metal spray) molten metal such as tin, aluminum, zinc, nickel, or stainless steel
on base metal.
Rubber A natural polymer (latex) coagulated into an elastic solid, applied
in sheet form.
Rubber compound A synthetic polymer with rubber-like elastic characteristics,
applied in sheet form.
2.2 Procedure
Application of interior linings and coatings must be performed using methods and materials that
will not change the designed physical or mechanical properties or function of the tank or the
function of the valves, fittings, seals, gaskets, insulation, cradle blocks, or other critical parts of the
tank car.
2.2.1 For lined tank car tanks, see additional requirements of DOT 179.201-3.
2.2.2 When stripping or applying an interior lining or protective coating, all valves and fittings
must be removed unless the contracting authority approves, in writing, other handling. If left in
place, all valves and fittings must be effectively protected.
2.3 Methods
2.3.1 Chemical Methods
2.3.1.1 When chemicals are used for the cleaning, application, or stripping of linings or coatings,
it is the responsibility of the contracting authority to determine whether the chemicals to be used
can have a damaging effect upon the tank interior, valves, fittings, seals, or gaskets.
2.3.1.2 If subject to damage, all valves and fittings must be removed; however, if the bottom
outlet valve is too difficult to remove, it must be effectively protected, and the contracting
authority must be notified.
2.3.1.3 Seals or gaskets may be retained for containment of cleaning or stripping solutions during
a chemical procedure. If the chemical procedure has a damaging effect, the seals or gaskets
exposed to the chemical procedure must be replaced. Gaskets must be replaced in kind, unless
otherwise specified by the contracting authority.
2.3.2 Thermal Methods
2.3.2.1 When thermal methods are used for cleaning, application, or stripping of linings or
coatings, it is responsibility of the contracting authority to determine whether the temperatures to
be used can have a damaging effect upon the tank car tank, valves, fittings, seals, gaskets,
insulation, exterior coatings, or cradle blocks.
2.3.2.2 Valves, fittings, seals, or gaskets can be damaged when the temperature exceeds 150 °F
(65.6 °C). If subject to such damage, all valves and fittings must be removed; however, if the
bottom outlet valve is too difficult to remove, it must be effectively protected, and the contracting
authority must be notified.
2.3.2.3 Consideration must be given to all other car components if any procedure is to be used
that exposes such components to elevated temperatures.
2.3.2.4 Certain types of insulation can be damaged by temperatures above 250 °F (121 °C). Wood
and composition cradle blocking materials can be damaged above 425 °F (218 °C). Tank car tank
material can be damaged if the temperature exceeds 350 °F (177 °C) for aluminum or 800 °F
(427 °C) for steel tanks. If subject to damage, such areas must be effectively protected, and the
contracting authority must be notified.
2.3.3 Mechanical Methods
2.3.3.1 Cleaning, application, and stripping techniques that entail the use of scrapers or other
mechanical tools, sand, shot, grit, or other abrasive blasting can cause damage to the tank car
tank, valves, fittings, seals, and gaskets.
When mechanical tools are used, the valves, fittings, seals, and gaskets must be effectively
protected from damage. When sand, shot, grit, or other abrasive blasting is used, all valves,
fittings, seals, and gaskets must be removed; however, if the bottom outlet valve is too difficult to
remove, it must be effectively protected, and the contracting authority must be notified.
2.3.3.2 Tank shell thickness is critical. If a weld bead is blended by grinding, air hammer
scraping, or contouring, care must be taken not to cause sharp notches or gouges and to avoid
reduction in tank shell plate thickness.
5.0 COMPLIANCE
5.1 All interior cleaning, lining, or coating applications or stripping must be performed in accord
with the provisions of this specification.
5.2 Facilities that apply, inspect, strip, or repair interior protective coatings and/or linings for
protection of tank car tanks against corrosion must maintain applicable standards, guidelines, and
procedures covering application, testing, and removal of interior protective coatings and/or linings.
5.3 Facilities that apply, inspect, qualify, or repair interior protective coatings and/or linings for
the purpose of tank protection shall develop and implement a quality assurance program in
compliance with all requirements of 49 CFR 179.7, this appendix, AAR specifications or rules, and
DOT/TC regulations.
5.4 The interior surface, prime coat, or adhesive layer and all subsequent coats of interior
protective coatings and linings shall meet conditions of acceptance as agreed upon by the
contracting authority and the applicator, with consideration of the material manufacturer’s
recommendations.
5.5 The contracting authority shall prepare an inspection and test plan per 49 CFR 180.509.
6.0 APPLICATION/REMOVAL REPORTING AND RECORD RETENTION
6.1 Reporting
6.1.1 A report, including copies of final inspection report forms, must be furnished by the
applicator to the contracting authority and car owner stating, at a minimum, the following:
• That the application/removal of the coating or lining has been accomplished in accord with
the provisions of Appendix L (reporting for application of a rubber lining is covered in DOT
179.201-3.);
• The date (month and year) that the interior coating or lining was applied or stripped;
• The type of interior coating or lining applied or stripped; and
• The car stenciling, including capacity and lightweight changes, if applicable
6.1.2 No report is required for cleaning of tank cars.
6.2 Record Retention
6.2.1 The applicator shall retain inspection reports for each car for not less than 5 years.
6.2.2 The contracting authority shall retain inspection records for each lining/coating for not less
than 10 years, until the next application or when ownership of the lining/coating is relinquished.
6.3 See paragraph 7.0 below for record retention requirements for car in-service/inspection repair
records.
APPENDIX M
SPECIFICATIONS FOR MATERIALS
CONTENTS
6.0 Specification for High-Strength Nine Percent Nickel Alloy Steel Plates, Double Normalized and
Tempered—AAR TC133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–363
6.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–363
6.2 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–363
6.3 Impact Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–363
6.4 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–364
7.0 Specification for High-Strength Nine Percent Nickel Alloy Steel Plates, Water Quenched and
Tempered—AAR TC134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–364
7.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–364
7.2 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–364
7.3 Impact Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–365
7.4 Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–366
8.0 Supplementary Specification for ASTM A516, Grade 70 Pressure Vessel Plates for Tank Car
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
8.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
8.2 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–368
APPENDIX M
SPECIFICATIONS FOR MATERIALS
1.0 INTRODUCTION
1.1 Scope
Appendix M describes the procedures to be followed to obtain approval of proposed material
specifications for tank car tank fabrication, and it lists the material specifications that are
approved.
1.2 Approved Materials
1.2.1 Approved plate materials complying with ASTM specifications are listed in Table M.10.
Other approved plate materials are listed in Tables M.10.1 through M.10.6 and appear complete in
the following sections. Approved castings for fittings are listed in paragraph 4.0 below. Unless a
specific year is recorded after the specification number wherever AAR, ACI, ASTM, AWS, or other
specifications are noted, the latest editions are approved.
1.2.2 ASME materials, when identical to the approved ASTM materials listed in this appendix,
may be used.
1.2.3 Threaded fasteners, excluding eyebolts, securing pressure-retaining parts and tank anchors
installed after January, 2012, shall be of a specification that requires grade identification marks
and manufacturer’s identification marks, unless excluded by specification or standard due to size
or configuration. Grade marks are to be stamped on the nut end of studs.
1.3 Welded Condition
For the purpose of this specification, “welded condition” must be considered as-welded and after
postweld heat treatment, when required.
2.0 PROCEDURE FOR SECURING APPROVAL
2.1 Application for Approval
A proposed material specification must be submitted to the AAR Executive Director—Tank Car
Safety with 20 copies for consideration by the appropriate committee.
3.0 APPROVED PLATE MATERIALS FOR TANK FABRICATION
3.1 Carbon Steel Plate (Material Group 1)
Carbon steel plate must comply with one of the specifications shown in Table M.10.1 and with its
indicated minimum tensile strength in the welded condition. The plates may be clad with other
approved materials.
3.2 Aluminum Alloy Plate (Material Group 2)
Aluminum alloy plate must be suitable for fusion welding and comply with one of the
specifications shown in Table M.10.2 and with its indicated minimum tensile strength and
elongation in the welded condition.
4.2.2.2 Nuts
ASTM A194; ASTM F594
4.2.3 Washers
When used, washers shall be ASTM F436.
4.3 Threaded Fasteners for Pressure-Retaining Parts on Nonpressure Tank Car Tanks
4.3.1 Any threaded fastener used, except eyebolts, must be an ASME, ASTM, or SAE
specification or standard with markings per paragraph 1.2.3 of this appendix.
4.3.2 All threads are to be Unified Coarse as specified in ANSI B1.1.
4.3.3 Externally Threaded Fasteners
4.3.4 Eyebolts
Eyebolts manufactured after January 2012 must be marked with the material and grade. Eyebolts
shall be
• forged, machined from bar stock or plate;
• fabricated by welding from means other than using castings.; any welding must be
performed in accordance with a procedure qualified by testing for proof loads for each
material combination.
4.3.5 Washers
It is recommended that a washer compatible with the fastener material be applied under the
turned element (i.e., head of bolt or nut).
4.4 Rivets
4.4.1 Rivets must comply with the current issue of ASTM A31 or ASTM A502, Grade 1.
4.4.2 Two-piece rivets for anchor attachments must be of a medium carbon steel, processed to
either a 50,000 psi to 60,000 psi (345 MPa to 414 MPa) shear strength level or to a 126,000 psi to
157,000 psi (869 MPa to 1082 MPa) ultimate shear strength. See Chapter 5, paragraph 5.2.1.6.7.
Alloy steel ASTM A351, Grades CF8M, CN7M, CF8, CD4MCu, CF3, CF3M
ASTM A743, Grades CA-15, CF-8, CF-3, CF-3M, CF-8M, CN-7M, CF10SMnN
ASTM A744, Grades CF-8, CF-3, CF-8M, CF-3M
ASTM A747, Alloy CB7Cu-1, CB7Cu-2
Alloy steel castings, when required by DOT 179.201-4 for corrosive service,
must be tested in accord with ASTM A262 Practice A. If the specimen does
not pass Practice A, Practice B or C must be used, and the corrosion rate must
not exceed the following:
Corrosion rate
Test Procedurea/ Material in/mo mm/mo
Practice B CF-3, CF-8, CF-3M 0.004 0.102
and CF-8M
Practice C CF-3 and CF-8 0.002 0.051
a/ The test specimen may be finished on all surfaces by machining or
grinding prior to testing.
4.5.3 Gray cast iron is not authorized for fittings in contact with the lading on all classes of
tank cars. When specified for AAR 207W pressure-differential covered hopper cars, gray iron must
comply with the following:
4.7.2 The following are approved materials for interior heater coils:
4.7.3 The following are approved thicknessesa/ for interior heater coils:
Carbon steel Thickness must be 0.175 in. for 2 in. nominal pipe size and Schedule 40
for nominal pipe size over 2 in.
Stainless steel Thickness must be Schedule 40.
Aluminum Thickness must be Schedule 80.
Nickel Thickness must be Schedule 40S.
a/ For all materials, the minimum thickness must be increased 25% or to the next higher
schedule, whichever is less, when threaded joints are used.
6.4 Reports
Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of
Construction.
7.0 SPECIFICATION FOR HIGH-STRENGTH NINE PERCENT NICKEL ALLOY STEEL
PLATES, WATER QUENCHED AND TEMPERED—AAR TC134
7.1 Scope
7.1.1 This specification covers high-strength 9% nickel alloy steel plates, water quenched and
tempered, for use in fusion-welded tank car tanks.
7.1.2 Material furnished under this specification must conform to the requirements of ASTM
A553, Type I, with modifications to chemical composition and impact requirements as follows:
7.2 Chemical Composition
The steel must conform to the additional chemical composition requirements prescribed in Table
M.7.
7.4 Reports
Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of
Construction.
Notes:
a/ These plates may be clad with other approved metals.
b/ The assigned P-numbers are the same as those used in ASME Boiler and Pressure Vessel Code.
c/ Maximum stresses to be used in calculations.
d/ This material group is for Appendix B certification purposes and not welding procedure
qualification purposes.
e/ For the purpose of this specification, TC128 Grade B is to be considered a P10C, Group1 material.
f/ Weld filler metal 5556 must not be used.
g/ For fabrication, the parent plate material may be O, H112, or H32 temper, but design
calculations must be based on minimum tensile strength shown.
h/ O temper only.
i/ This material group is for Appendix B certification purposes and not welding procedure
qualification purposes.
j/ Mill test reports must be submitted to the AAR Tank Car Committee with the Certificate of
Construction.
k/ See paragraph 6.0 or paragraph 7.0 of this appendix, as applicable.
APPENDIX R
REPAIR, ALTERATION, AND CONVERSION TO TANK CAR TANKS
CONTENTS
APPENDIX R
REPAIR, ALTERATION, AND CONVERSION TO TANK CAR TANKS
1.0 INTRODUCTION
1.1 Scope
1.1.1 Appendix R describes repairs, alterations, or conversions that affect tank heads, shells,
sumps, and welds attaching connections thereto and defines required documentation for reporting.
Repairs to connections shall be in accord with the American Welding Society (AWS) Railroad
Welding Specification D15.1, except for welds attaching connections to the tank shell or heads.
1.1.2 Forms (Exhibit R-1, Exhibit R-2, and Form SS-3), at the owners discretion, may be
transmitted electronically for any car that has received an inbound inspection and estimate prior
to January 1, 2015, at which time electronic submittal via the Web-based Tank Car Inspection
Database (TCID) becomes mandatory. To obtain access to the TCID system, use the following URL:
http://www.rsiaarproject.com.
1.2 Certified Facilities
Repairs, alterations, or conversions to tank car tanks requiring welding, riveting, or removal of
deformations must be performed only by facilities certified by the AAR for fabrication, alterations,
conversions, or repairs. See Appendix B.
1.3 General
1.3.1 When special materials, procedures, or dimensional requirements must be maintained, the
car owner must provide such data and drawings to the facility performing repair, alteration, or
conversion.
1.3.2 Unacceptable imperfections shall be removed and reexamination made to ensure complete
removal. Whenever an imperfection is removed by chipping or grinding and subsequent repair by
welding is not required, the excavated area shall be blended into the surrounding surface so as to
avoid sharp notches, crevices, or corners. Where welding is required after removal of an
imperfection, the area shall be cleaned and welding performed in accord with Appendix W for tank
heads, shell, sumps, and welds attaching connections thereto. Repairs to connections shall be in
accord with the American Welding Society (AWS) Railroad Welding Specification D15.1, except for
welds attaching connections to the tank shell or heads.
1.3.3 After an imperfection has been removed, and prior to making weld repairs, the area shall be
examined by suitable methods to ensure that the imperfection has been eliminated.
1.3.4 After repairs have been made, the repaired area shall be blended into the surrounding
surface so as to avoid sharp notches, crevices, or corners, and reexamined using the same NDT
method that failed the initial repair, and by all other methods of examination that were originally
required for the affected area.
1.4 Personnel
Repairs, alterations, and conversions shall be examined by NDT examiners, qualified per
Appendix T for methods employed.
1/ The term representative does not automatically mean the shop performing the work. It is
intended to mean an entity legally contracted to represent the owner, which may or may not
be the shop performing the work.
C-III [M-1002] 374 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX R
3.3.4 The following instructions corresponding to the line numbers and field name in the
database must be followed in filling out the report:
Instructions for Completing Exhibit R-1
Line Instruction
1. The report is the responsibility of the certified or registered facility performing the work.
2. Car reporting mark(s) and number(s).a/
3. The name of the management representative of the facility performing the work.
4. Date that the work was performed (MM/DD/YYYY).
5. Name and location of the company or station symbol of where the work was performed.
6. Enter X in boxes as applicable for all types of work performed on the car.
7. Enter original date built of the tank car (MM/YYYY). If there is a different date built
between the tank and the underframe, indicate the underframe date.
8. Enter the name of the car manufacturer.
9. Enter the original AAR certificate number under which the tank car was built.
10. Identify the commodity to be transported after the work is completed. If unknown, indicate
last contents. When listing a regulated commodity, use the DOT/TC proper shipping name.
11. Enter the as-built car specification.b/ If the car was converted by Form AAR 4-2, or if
Exhibit R-1 (for a conversion) was issued prior to the work, enter the conversion
specification.b/
12. Indicate the car specification following the work.b/
13. Indicate the stenciled car specification following the workb/
14. For repairs:
a. Describe the damage using Appendix R terminology (crack, fracture, dent, gouge, etc.)
and indicate the affected area (reference Fig. R.2, Tank location chart) and dimensions
(e.g., 10 in. crack at ABS). When repairs are required due to an accident, list the
railroad involved, the date of the accident, and the location of the accident, if the
information is available.
b. Describe the repair performed. List appropriate Appendix R references or previously ap-
proved procedures. List material specification (e.g., A516 gr. 70 plate, E7018 rod, etc.).
15. For alteration, conversion, pressure relief device change, or other work, describe the work
performed. List appropriate Appendix R references or previously approved procedures.
List material specification (e.g., A516 gr. 70 plate, E7018 rod, CS valve body, SS valve trim,
Neoprene gasket, etc.). If material is shown on the drawings listed on line 16, indicate
“Materials: See 16.”a/
16. List Tank Car Committee-approved drawings only. Drawings must relate to the work
performed. For instance, a drawing representing a crack repair for a DOT-103AW tank
cannot be used for a DOT-103CW or DOT-103DW tank that uses different steel. Indicate
the approved AAR certificate number (current within 10 years) for each drawing listed. If
reference drawings are not in the name of the applicant, the applying facility must state
at line 17 “Permission has been granted for use of drawings, by the certificate holder, for
this specific car.”
17. If it is necessary to revise a report, a new completed copy must be submitted. Indicate the
revision level, the previous date approved by car owner, and the items that were changed.
18. Print the company name and location of the facility performing the work.
19. Print the name and title of the facility’s management representative.
20. Management representative’s signature and date signed.
a/ When changing the reporting mark and/or number, show the new reporting mark and
number at line 2. Record the previous mark and number at line 15.
b/ Enter a specification without dashes or spaces (e.g. DOT111A100W1).
Exhibit R-1
15. For alterations, conversions, pressure relief devices, or other, list procedure and materials:
The cars listed above conform to all approvals mentioned and to all applicable DOT and AAR requirements, including
specifications, regulations, rules of interchange, and the DOT safety appliance standards.
FACILITY
Company name: __________________________________ Location (City/State): _______________________________
Management Representative (Name): __________________________________________ Title: __________________
Management Representative Signature: ________________________________________ Date: __________________
Rev. 04/2010
Fig. R.1 Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion
ATH BTH
ABH BBH
A-END B-END
Legend
ATS = A-end top shell BTS = B-end top shell
CTS = Center top shell CBS = Center bottom shell
ABS = A-end bottom shell BBS = B-end bottom shell
ARS = A-end right shell BRS = B-end right shell
ALS = A-end left shell BLS = B-end left shell
CRS = Center right shell CLS = Center left shell
ATH = A-end top head BTH = B-end top head
ABH = A-end bottom head BBH = B-end bottom head
Note: By convention, “Right” and “Left” sides are relative to a vantage point facing
the B-end of the car.
3.4 Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
3.4.1 Exhibit R-2 (shown in Fig. R.3) is a means for collecting information pertaining to the
following:
• tank buckle repairs
• tank corrosion repairs
• tank crack repairs
• center sill repairs
• repairs to stub sill, bolster, and cradle pad connections to tank
3.4.2 Information supplied will be entered into a database and analyzed in an effort to establish
failure trends. The AAR will maintain the database and provide periodic reports.
3.4.2.1 The owner, or owner’s designee, is responsible for providing all requested information per
paragraph 1.1.1 of this appendix. The AAR is not to receive a hard copy of Exhibit R-2.
3.4.2.2 A separate Exhibit R-2 must be prepared for each car each time nonaccident buckles,
cracks, or corrosion repairs are made to it. Up to six repairs per car may be reported on one
Exhibit R-2 by inserting information for each in the proper blank, a., b., c., d., e. or f., for each item
of information. The Exhibit R-2 software allows entry of up to 26 different repairs per car.
3.4.2.3 The information from completed Exhibit R-2 must be retained, for back-up documentation
of the work performed, by the car owner or the car owner’s representative in such a way that a
printable electronic copy or paper copy can be obtained and that changes can be detected. The
Exhibit R-2 at the back of this publication may be used as the hard copy, but is not mandatory. The
software is capable of generating a printed record of repairs, which may also serve as the hard
copy. The form used by the repair facility to provide repair information to the owner should be as
agreed upon by the two parties, and need not be the Exhibit R-2 provided in this manual.
3.4.2.4 Exhibit R-2 data in the software is entered by line number. These line numbers
correspond to the entries on the Exhibit R-2 provided in this manual. Each item of the form is to be
filled in as described below. Consult the R-2 Program User’s Guide before attempting to complete
Exhibit R-2.
Instructions for Completing Exhibit R-2
Line Instruction
1. Enter the name of the car owner.
2. Enter the car reporting mark and number.
3. Enter the name of the company having performed work on the car.
4. Enter the location of the repair shop or company at which work was performed.
5. Enter the month, day, and year of repair.
6. Enter the month and year car was built.
7. Enter the builder’s code as listed in Table R.1.
8. Enter the original AAR Certificate of Construction number under which the tank car was
approved.
9. Enter the commodity to be transported after the work is completed.
10. Enter the tank specification, as built.
11. Enter the tank specification after work is completed.
12. Enter the specification to be stenciled on the tank car after work is completed.
13. Enter the manufacturer’s stub sill design style designation and corresponding builder code
as shown in Table R.1.
14. Indicate whether or not the car is jacketed.
Line Instruction
15. Indicate whether or not the car is equipped with head braces.
16. Enter the code for the component on which failure occurred. For cracks in stub sill-related
welds, refer to Fig. R3.1 through Fig. R3.6 on page C-III–381. If “(O)-Other” is indicated,
explain in line 24—Comments.
17. Enter the code for the type of failure repaired. If “(H)-Other” is indicated, explain in
line 24—Comments.
18. Enter the code for the suspected cause of failure. Avoid indicating “(D)-Unknown” if at all
possible.
19. Select the code for the method of repair, as listed below. The following repair procedures
are listed in the corresponding paragraphs of Appendix R or in the Field Manual of the
AAR Interchange Rules:
Exhibit R-2
Fig. R.3 Exhibit R–2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs (continued)
11/2014 C-III [M-1002] 381
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX R M-1002
A1
A2
D2 A1 A2
A1 A2
C2 D1 B1
A1 C1
A2
D1 C2
C1 B1
B2 B2 B2
CL LONG CL LONG
Fig. R3.1
Fig. R3.1 Fig. R3.2 Fig. R3.2
Fig. R3.3
Fig. R3.4
NON-STRUCTURAL
A2 Fig. R3.5 A2 SEAL WELD.
NOT REPORTABLE
Fig. R3.6
A1
A2
A2
A2
B2 B2 B2
CL LONG C
A1 L LONG
SEAL WELD
A2
A1 A1
B1
A1
B1
B2
A2 CL LONG
CL LONG
Fig. R.3 Exhibit R–2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs (concluded)
C-III [M-1002] 382 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX R
14.5.4 When nonpressure tank cars are altered or repaired, or when pressure tank cars are
converted to nonpressure status, insert-type nozzle applications may be made, utilizing partial
penetration welds per Fig. R.10, subject to the following limitations:
• Applications apply to top fittings only
• Joint gap must not exceed 3/32 in. (2.38 mm) with joint ground smooth or reamed
• Nozzle size must not exceed 10 in. (254 mm) inside diameter
• The welding joint must be preheated to 250 °F (121 °C)
14.5.5 When nonpressure cars are altered or repaired, or when pressure cars are converted to
nonpressure status, lap joint nozzle applications may be made, in accord with Fig. R.11.
14.6 Permanent Closure of Bottom Outlet or Washout Flange
A bottom outlet or bottom washout flange may be internally sealed by a plate of tank car tank
material of the minimum thickness for the car specification that is welded by continuous double
full fillet or a combination of full fillet and groove welds. Radiography or ultrasonic testing and
postweld heat treatment are not required for welding to the flange.
14.7 Closures for Tongue-and-Groove Fittings Interfaces
When fittings equipped with tongue-and-groove interfaces are removed from a pressure car
manway cover plate, they must be replaced using tongued blind flanges that are in accord with
Figs. E.27 or E.28. When 3 in. full-ported flanged ball valves equipped with ANSI B16.5 large
tongue design are removed from a nonpressure car top fittings cover plate, they must be replaced
using 3-in. ANSI Class 300 blind flanges equipped with ANSI B16.5 large tongue design.
15.0 ATTACHMENTS ADDED OR RELOCATED
15.1 Welded Attachments
15.1.1 Exterior or interior brackets, supports, and reinforcement bar pads may be fillet-welded to
a tank shell per the requirements of paragraph 24.0.
15.1.2 When adding or relocating reinforcing pads or appurtenances, such as skids, washouts,
and sumps, to the bottoms of stub sill tank cars, the requirements of Appendix E, paragraph 15.0,
must be met. The fillet welds must meet Appendix W, paragraph 14.10, and the circumferential
portions of the fillet welds must be examined by magnetic particle or liquid penetrant, including
the corner and at least 3 in. of the weld extending longitudinally beyond the corner.
15.2 Anchor Rivet Caps
One-piece anchor rivet caps may be attached to a tank shell per the requirements of
paragraph 24.0. A tapped hole must be provided through the tank shell under each cap to permit
making an air test. Each test hole must be tightly closed with an approved plug after completion of
the test. Caps must be tested by applying air pressure of 100 psi (689 kPa) and must be tight
against leakage.
15.3 Welded Bolster Supports
Welded steel tanks mounted on underframes may be modified by attaching welded bolster
supports to tank bottom reinforcement plates or directly to the tank, securely fastened to
underframe, with necessary provision for expansion and contraction. Welding must be done in
accordance with the requirements of paragraph 24.0.
15.4 Welding Stud Attachments
Stud welding on carbon steel tank car tanks shall be done in accord with Table R.2. Stud welding
on tank car tanks made from P-8 (types 304L, 316L), P-22, or P-25 materials shall be done in
accord with Table R.3. Welding Purpose Code F applies for both tables.
19.3.2.2.7 To prevent harmful temperature gradient in the tank shell or adjacent appurtenances,
heater control units are to be monitored frequently by the LPWHT technician during the entire
heat-treating cycle. A temperature gradient greater than 250 °F throughout the portion of the
tank being heated is considered harmful.
19.3.2.2.8 LPWHT cycle temperatures and time are to be in accordance with Appendix W,
paragraphs 16.3 and 16.4.
19.3.2.3 Equipment Calibration
Temperature recorders are to be calibrated and heater controllers aligned annually, per written
procedure. Units are to be marked to indicate the date of calibration or alignment status (date of
calibration or alignment and due date for the next calibration or alignment), and a certificate is to
be available upon request.
19.3.2.4 Documentation
19.3.2.4.1 A written local postweld heat treatment procedure is required.
19.3.2.4.2 Temperature time record is to be recorded on a strip chart or record showing
thermocouple location, car number, and technician signature.
19.3.2.5 Heat Treating Technicians
19.3.2.5.1 LPWHT technicians shall be qualified through a written training program conducted
either in-house or by a recognized subcontractor.
19.3.2.5.2 The training program shall, as a minimum, cover the following areas: safe use of
equipment, equipment calibration, thermocouple/insulation placement, and AAR temperature
limits.
19.3.2.5.3 Technicians shall demonstrate competence in completing tasks outlined in the
company’s written LPWHT procedure.
XS
ONE PAD—ONE CIRCUIT
XS
XS OS XS OS
XS
TWO PADS—TWO CIRCUITS TWO PADS—ONE CIRCUIT FOUR PADS—ONE CIRCUIT
S
XS O
XS X
X = CONTROLLING THERMOCOUPLE
S O = MONITORING THERMOCOUPLE
XS O S = SPARE THERMOCOUPLE
NOTES:
1. TYPICAL HEATING ELEMENT AND THERMOCOUPLE PLACEMENT ARE SHOWN ON THE DIAGRAMS ABOVE. VARIATIONS TO THESE PLACEMENTS MAY BE
NECESSARY FOR SPECIAL HEATING ZONE REQUIREMENTS ON THE TANK.
2. TO AVOID PROBLEMS DURING THE HEATING CYCLE, THE PREFERRED APPLICATION IS TO USE ONE CONTROL THERMOCOUPLE PROPERLY PLACED DIRECTLY
UNDER EACH HEATING ELEMENT (PAD).
3. AT THE HEAT-TREATING TECHNICIAN’S DISCRETION, SPARE THERMOCOUPLES SHOULD BE USED IN THE HEATING ZONE IN CASE OF CONTROL
THERMOCOUPLE MALFUNCTION.
4. IF MORE THAN TWO PADS ARE USED WITH ONE CIRCUIT, AT LEAST TWO MONITOR THERMOCOUPLES ARE TO BE APPLIED FOR PROPER CONTROL.
5. THERMOCOUPLE LOCATION IS IMPORTANT. WHEN THE THERMOCOUPLE IS PLACED TOO FAR FROM THE HEATING ELEMENT OR NEXT TO A LARGE HEAT SINK,
THE HEATING ELEMENT CAN OVER-HEAT THE TANK WHILE THE THERMOCOUPLE RECORDS A SMALL TEMPERATURE INCREASE. ANY LARGE MASS OF STEEL
IN DIRECT CONTACT WITH THE TANK IN THE HEATING AREA WILL ABSORB LARGE AMOUNTS OF HEAT AWAY FROM THE THERMOCOUPLE. EXAMPLES OF HEAT
SINKS ARE REINFORCEMENT PADS, MOUNTING FLANGES, NOZZLES, BOLSTER AND DRAFT SILL WEBS, AND EXTERIOR COILS. HEAVILY INSULATING THESE
AREAS IS CRITICAL.
6. IT IS CRITICALLY IMPORTANT THAT THE HEATING ELEMENT BE PLACED DIRECTLY AGAINST THE TANK SHELL AND THE THERMOCOUPLE ATTACHMENT BE
21.1.2.3 If it is necessary to rework the fastener hole, the final diameter must be reamed. In any
case, the diameter of the resulting hole must not be greater than 1/16 in. (1.59 mm) larger than
the nominal diameter of the fastener.
21.1.2.4 If the resulting connection has unused fastener holes, they must be closed by welding or
with cover plates. When choosing holes to eliminate, do not eliminate consecutive holes or end
holes.
22.0 REPAIRS TO FIRE-DAMAGED TANK CAR TANKS
22.1 Requirements
22.1.1 Parts or portions of a tank car tank that have been exposed to fire or heat sufficient to
render their performance unsafe must be replaced.
22.1.2 Unsafe parts or portions must be identified by physical testing of removed material or by
evaluation of the physical condition of materials on the tank car tank, such as paint film,
insulation, gasket materials, surface oxidation film, etc.
22.1.3 Detailed evidence of the safe condition of any part or portion of the tank car tank that is to
be retained in service must be submitted for approval using Form AAR 4-2.
22.1.4 All valves and fittings must be removed, overhauled, and tested according to the valve
manufacturers’ instructions for suspected overheating.
Table R.2 Processing additional welding to carbon steel tank car tanks
Welding PT or MT after removal
Purpose of imperfection and PT or MT RT or UT
Car Category Code prior to welding after welding a/,b/ PWHT
Pressure cars A Yesc/ Yesc/ Yes Yes
B Yesc/ Yesc/ No Yes
C No No No No
D No No No Yes
E No No No Yes
F No No No Yes
H No No Yesd/ Yes
I No No Yes Yes
J Yes No No Yes
24.1.1 Welding to Aluminum and Stainless Steel Tank Car Tanks after Hydrostatic
Testing
When additional welding is found necessary following hydrostatic testing, the following applies for
tank car tanks fabricated from materials listed in Tables M.10.2 and M.10.3.
Table R.3 Processing additional welding to aluminum and stainless steel tank car tanks
Welding PT after removal of
Purpose imperfection and prior PT RT or UT
Car Category Code to welding after welding a/
Code Description
A Repair defective areas (after preparation for welding) greater than 3/16 in. (5 mm) deep,
of any width and length.
B Repair defective areas (after preparation for welding) equal to or less than 3/16 in.
(5 mm) deep, of any width and length.
C Weld to nozzles and flanges (when welding to the tank shell or head is involved, see
Welding Purpose Code F and/or H).
D Repair exterior coil fillet weld with weld length 6 in. (152 mm) or less.
E Repair exterior coil fillet weld with weld length over 6 in. (152 mm).
F Add or replace attachments to tank head or tank shell by fillet welding or stud welding
(including temporary welds).
H Add or replace attachments to tank head or tank shell by groove welding.
I Groove-welded inserts.
J Repair of attachment fillet welds.
24.1.3 Local Postweld Heat Treatment
Local postweld heat treatment may be used, provided that the heated area includes at least six
times the tank or head plate thickness on each side of the weld. The temperature distribution
must be controlled as follows:
24.1.3.1 Above 800 °F (427 °C), the rate of heating shall be no more than 400 °F per hour divided
by the tank thickness in inches (5644 °C divided by tank thickness in millimeters), but in no case
more than 400 °F (222 °C) per hour.
24.1.3.2 During the heating and cooling periods, there shall be no greater variation in
temperature than 250 °F (139 °C) throughout the heated area of the tank, nor shall any portion
exceed 1250 °F (677 °C).
24.1.3.3 During the holding period, there shall be no greater difference than ±50 °F (±28 °C)
throughout the heated area of the tank. During the holding period, the minimum temperature
throughout the heated area shall be not less than 1100 °F (593 °C) or greater than 1250 °F
(677 °C).
24.1.3.4 Above 800 °F (427 °C), cooling shall be done at a rate not greater than 500 °F per hour
divided by the tank thickness in inches, but in no case more than 500 °F (260 °C) per hour. Below
800 °F (427 °C), the tank may be cooled in still air.
60°
45°
INSIDE OF TANK
60°
JOINT SEPARATION
60°
JOINT SEPARATION
BACK-UP STRIP
Fig. R.8 Welding fracture that extends into riveted joint (with back-up strip)
C-III [M-1002] 402 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX R
t ACTUAL
3
" (2.38) MAX GAP
32
Fig. R.11 Lap joint nozzle application (reference paragraph 14.5.5, this appendix)
FORM SS-1
REPORT OF TANK CAR STUB SILL INSPECTION
Line Instruction
1. Enter the company name of the car owner.
2. Enter the car’s reporting mark and number.
3. List the company reporting the work that was performed.
4. List the facility and location that performed the work.
5. The date must be that on which the report was completed.
6. List manufacturer of tank car.
7. Enter the original built date of the tank car.
8. Show the most recent AAR certificate number under which the tank car is currently approved.
9. Identify the commodity to be transported in this tank car.
10. Show the tank specification, as built.
11. Show the stenciled tank specification for the tank car, as operated.
12. Enter Y (yes) or N (no) to indicate if car is jacketed.
13. Enter Y (yes) or N (no) to indicate if car is equipped with top and bottom shelf couplers.
14. Enter Y (yes) or N (no) to indicate whether car is equipped with head shields.
15. Indicate priority I for inspections required per paragraph 5.0, this appendix.
16. Enter Y (yes) or N (no) to indicate if car is equipped with head braces.
17. Enter Y (yes) or N (no) to indicate evidence of striker damage (two places).
18. Enter Y (yes) or N (no) to indicate if sill is bent or warped (four places).
19. Enter Y (yes) or N (no) to indicate evidence of sill damage due to passed couplers (four places).
20. Enter Y (yes) or N (no) to indicate evidence of damage to front lugs (four places).
21. Enter Y (yes) or N (no) to indicate evidence of damage to rear draft lugs (four places).
22. Describe prior sill repairs, if present.
23. Indicate the inspection method that was utilized to examine each weld. Refer to the
illustration. Enter Y (yes) or N (no) to indicate evidence of defects in or adjacent to the
welds A1, B1, C1, D1 (two places) or A2, B2, C2, D2 (four places). If the design incorporates
other welds, describe them and indicate the inspection method and results, as above.
A1
D2
C2 D2 D1
A1 C2
A2 A2
D1
C1
CL DRAFT B2 CL C1
B1
B2 B1
CL BOLSTER
24. Describe location and nature of defects found, reference lines 17 through 23.
25. Indicate disposition of car following the inspection (e.g., returned to service, repaired,
scrapped, etc.).
Inspector must sign the report.
APPENDIX S
LOADING APPURTENANCES FOR TANK CAR
CONTENTS
APPENDIX S
LOADING APPURTENANCES FOR TANK CAR
1.0 INTRODUCTION
1.1 Scope
Appendix S describes AAR requirements for ladders, platforms, railings, and handholds for use by
personnel loading or unloading tank cars. Safety appliance matters, as such, are covered by DOT
under 49 CFR 231.
Effective January 1, 2015 all cars built after this date must comply with the Manual of Standards
and Recommended Practices, Section C, Standard S-2044, “AAR Safety Appliance Requirements
for Freight Cars,” adopted 2014.
1.2 General
All tank cars must be equipped with a suitable platform or other arrangement for loading and
unloading. There are four basic arrangements that may be applied on tank cars, as follows:
1.2.1 Any tank car may be equipped with a side operating platform located on the hand brake
side of the car as well as one dome handhold, one operating platform handhold, and one ladder.
1.2.2 Any tank car may be equipped with an operating platform surrounding the manway and
fittings used for loading and unloading, as well as one platform safety railing and two ladders, one
on each side of the car.
1.2.3 Tank cars having tanks or jackets of such diameter that the use of side ladders will exceed
the provisions of Plates B-1 and C-1 in MSRP Section C, S-2027 and S-2029, respectively, may be
equipped with a top operating platform having access by means of top running boards and two
ladders, one at each end.
1.2.4 Tank cars having two side running boards running the full length of the tank, one on each
side, above tank center line, require no operating platform.
2.0 OPERATING PLATFORMS
2.1 Side Operating Platform
Number One
Dimensions Minimum width, 7 in. (178 mm). Minimum thickness 1 3/4 in.
(44.4 mm). Length sufficient to provide access to all operating
fittings used for loading or unloading. Supporting brackets must be
steel bars, not less than 3/8 in. × 2 in. (9.52 mm × 50.8 mm), or
equivalent.
Location On hand brake side of car.
Application Supported to prevent sagging by brackets securely fastened to tank
or to suitable bands.
2.2 Top Operating Platform
Number One for each manway or one platform surrounding all manways.
Dimensions Not specified. Supporting brackets must be steel bars, not less than
3/8 in. × 2 in. (9.52 mm × 50.8 mm) or equivalent.
Location Surrounding the manway and fittings used in loading or unloading.
Access to platform may be by side ladders or by top running boards.
Application Supported to prevent sagging by brackets securely fastened to tank,
to suitable bands, or to jacket.
APPENDIX T
NONDESTRUCTIVE EXAMINATION
CONTENTS
APPENDIX T
NONDESTRUCTIVE EXAMINATION
1.0 GENERAL REQUIREMENTS
1.1 Purpose
The purpose of this appendix is to outline the requirements of the nondestructive testing program
and the responsibilities for its administration.
1.2 Scope
This appendix contains requirements and methods for nondestructive testing and personnel
requirements when and to the extent they are specifically referenced and required by this
specification, in a tank specification, or by other referencing documents. The most commonly used
nondestructive testing methods are listed in Table T.1. Additional or alternative techniques or
methods shall be approved by the Tank Car Committee. For the purpose of this document, the
terms NDT (testing), NDE (examination or evaluation), or NDI (inspection) shall be considered
equivalent terms. When not directly covered by this specification, the ASTM Standards, Volume
03.03, Nondestructive Testing and/or ASME Section V may be used to develop nondestructive test
procedures.
1.3 Effectivity of Revisions
1.3.1 Procedures
All changes to the requirements for procedures shall be effective 6 months after publication.
1.3.2 Personnel Qualifications
All changes for the certification of personnel shall be complied with at the next certification or
6 months, whichever is later. This includes all current requirements.
1.4 Levels of Qualification
Levels of qualification are defined in terms of skills and knowledge required in a given method or
methods to perform specified NDT activities.
1.4.1 Level III: A Level III shall have the skills and knowledge to establish techniques; interpret
codes, standards, and specifications; designate the particular technique to be used; and verify the
adequacy of procedures. The Level III shall ensure that the procedures cover the particular type of
work to be performed to meet the end product requirements. The individual also shall have
general familiarity with the NDT methods. The Level III shall be capable of conducting or
directing the training and examining of NDT personnel in the methods for which the Level III is
qualified. An NDT Level III shall be responsible for the administration of the NDT program as
described in this paragraph. An AWS CWI, SCWI, or CSA 178.2 can function as a Level III for
visual weld inspection. An AWS CWI, SCWI, or CSA 178.2 can function as a Level III for remote
visual inspection if they have received documented training in the set-up, operation, and use of
remote visual equipment. The level of training shall be defined in the company’s written practice.
The individual shall ensure that the visual procedures cover the particular type of work to be
performed to meet the end product requirements.
1.4.2 Level II: A Level II shall have the skills and knowledge to set up and calibrate equipment;
conduct tests; and interpret, evaluate, and document results in accordance with procedures
approved by an NDT Level III. The Level II shall be thoroughly familiar with the scope and
limitations of the method to which certified. The Level II shall be capable of directing the work of
trainees and Level I personnel and shall be able to organize and report nondestructive testing
results.
1.4.3 Level I: A Level I shall have the skills and knowledge to properly perform specific
calibrations and tests, and with a prior written approval of the NDT Level III, to perform specific
interpretations and evaluations for acceptance or rejection and document the results in accordance
with specific approved procedures. The Level I shall be able to follow approved nondestructive
testing procedures and shall receive the necessary guidance or supervision from a certified NDT
Level II or NDT Level III individual.
1.4.4 Trainee: A person who is not yet certified to any level shall be considered a trainee.
Trainees shall work with a certified person under the direction of an NDT Level II or NDT Level
III and shall not independently conduct any tests or complete a report of test results.
1.4.5 Qualification for visual weld inspection shall be in accord with the requirements set forth in
Appendix T, paragraph 9.0.
1.5 Written Practice for Qualifying and Certifying NDT Personnel
All nondestructive testing shall be performed by personnel qualified and certified in accord with a
written practice. The written practice shall describe the program for the control and
administration of NDT personnel training, examination, and certification modeled on this
appendix and on ASNT SNT-TC-1A. The written practice shall be reviewed and approved by the
NDT Level III and shall include, as a minimum, the following:
• Levels of qualification
• Duties and responsibilities of each level of certification for determining the acceptability of
materials or components in accord with applicable codes, standards, specifications, and
procedures
• Initial and refresher training requirements
• Personnel experience requirements
• Education requirements
• Personnel examination requirements
• Record and documentation requirements, including control, responsibility, and retention
(training and initial experience will be documented)
• Recertification requirements
• Visual acuity requirements
1.6 Education, Training, and Experience Requirements for Initial Certification
1.6.1 Candidates for initial certification in NDT should have sufficient education, training, and
experience to ensure qualification in those NDT methods in which they are being considered for
certification. Documentation of prior certification may be used by an employer as evidence of
qualification for comparable levels of certification.
1.6.2 The minimum education, training, and experience requirements for NDT Level I and
Level II personnel shall be stated in the company’s written practice.
1.6.3 To be considered for certification, the NDT Level III candidate must satisfy one of the
following criteria:
1.6.3.1 A graduate from a minimum 4-year college or university curriculum with a degree in
engineering or science, plus one additional year of experience beyond the Level II requirements in
the applicable NDT method(s); or
1.6.3.2 Have completed with passing grades at least 2 years of engineering or science study at a
university, college, or technical school, plus two additional years of experience beyond the Level II
requirements in the applicable method(s); or
1.6.3.3 Have 4 years of experience beyond the Level II requirements in the applicable NDT
method(s).
1.8.1.3.2 Level II Practical Exam: The candidate shall demonstrate proficiency by performing
the applicable nondestructive test method in examining at least one sample per technique and a
minimum of two samples per method and by interpreting, evaluating, and documenting the results
of the examination. At least 10 different checkpoints requiring an understanding of the test
variables and the employer’s procedural requirements should be included in this practical
examination.
1.9 Certification
1.9.1 Certification of all levels of NDT personnel is the responsibility of the employer.
1.9.2 Certification of NDT personnel shall be based on demonstration of satisfactory qualification
in accordance with paragraphs 1.6 and 1.7 and stated written practice. Certifications that are
recognized by the employer’s written practice, including ASNT, ACCP, or CGSB certification, must
be qualified by examination as administered by the governing organizations.
1.9.3 A subcontract Level III (for the method) may be engaged by the employer to administer the
Level III examination requirements of paragraph 1.8.4. The employer shall certify the Level III
candidate for each applicable method based upon a valid endorsement by the subcontract Level III
in the method. The employer’s subcontractor who administers the Level III exam shall possess a
current ASNT, ACCP, or CGSB Level III certificate in the method for which the examination is
administered and shall be knowledgeable and familiar with the standards, specifications, and
products used or made by the employer.
1.9.4 Certification Records
Personnel certification records shall be documented by the employer for the duration specified in
the employer’s written practice and should include the following:
• Name of certified individual
• Level of certification and NDT method and any limitation or restriction
• Educational background and experience of certified individuals
• Statement indicating satisfactory completion of training in accordance with the employer’s
written practice
• Results of vision examinations prescribed in paragraph 1.8.3
• Current examination copy(ies) or evidence of successful completion of examinations
• Other suitable evidence of satisfactory qualifications when such qualifications are used in
lieu of the specific examination as prescribed in the employer’s written practice
• Composite grade(s) or suitable evidence of grades
• Approval of the Level III that verified qualifications of candidate for certification
• Date of certification and/or recertification
• Certification expiration date
• Approval of employer’s certifying authority
1.10 Technical Performance Evaluation
1.10.1 NDT personnel may be reexamined any time at the discretion of the employer and have
their certificates extended or revoked.
1.10.2 Periodically, as defined in the employer’s written practice, the technical performance of
Level I and II personnel shall be evaluated and documented by an NDT Level III or their designee.
The evaluation and documentation shall follow the format and guidelines described in the written
procedure.
1.11 Expiration
An individual’s certifications shall expire
• when employment with employer is terminated;
• at the end of 3 years for NDT Level I and Level II individuals;
• at the end of 5 years for NDT Level III individuals.
1.19.4.4 Results of the procedure demonstration shall be documented using an NDT Procedure
Qualification Record having spaces to record the procedure identification, signatures, and date. In
addition, the applicable NDT report form referenced in the procedure being qualified shall be
completed and shall describe the demonstration specimen and results.
1.19.4.5 The NDT procedure is considered qualified when the results of the demonstration
indicate the ability to detect discontinuities to the satisfaction of the NDT Level III. An NDT Level
III witness and the individual(s) who performed the demonstration examination shall sign the
Procedure Qualification Record form.
1.19.4.6 All records of the demonstration shall be documented.
1.19.4.7 If a documented probability of detection study (POD) has been performed for the NDT
method, the results will satisfy the procedure demonstration requirements of paragraph 1.19. A
procedure qualification record (PQR) must still be completed (see Fig. T.1 on page C-III–449).
1.19.5 Essential Variables
1.19.5.1 A change in those NDT parameters considered essential requires a new qualification
and demonstration of the NDT procedure.
1.19.5.2 A change of a requirement identified as a nonessential variable does not require
requalification of the NDT procedure.
1.19.5.3 All changes of essential or nonessential variables from the parameters specified by the
NDT procedure shall require revision of, or addendum to, the procedure.
1.20 NDT Reports
1.20.1 All nondestructive testing performed as required by the referencing specification shall be
documented. In addition to the requirements of the method section, the report shall contain the
following information:
• Procedure used
• Examiner identification
• Date examination was performed
• Facility responsible for test
• NDT method
• NDT equipment identification number traceable to a calibration record, where applicable.
• Test specimen identification
• Examination results
1.20.2 The following shall be either contained on the report or specifically identified in the
procedure:
• Technique
• Specific equipment and materials used
• Equipment test settings, where applicable
• Surface preparation, if required
• Post-examination cleaning, if required
1.20.3 NDT reports shown in the figures in the back of this appendix, or other forms that meet
the requirement of paragraph 1.20, shall be used for the purpose of documenting NDT
examinations.
3.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel).
3.3 Calibration
Equipment calibration shall be in accord with paragraph 1.22 above (Equipment Calibration).
3.4 Examination
3.4.1 Bubble Leak Testing (BT) (Liquid Film Solution Technique)
3.4.1.1 The bubble-forming solution shall produce a film that does not break away from the area
to be tested, and the bubbles formed shall not break rapidly as a result of to air drying or low
surface tension. Household soap or detergents are not permitted as substitutes for bubble-testing
solutions.
3.4.1.2 The leak-test solution must be suitable for the ambient temperature of the test. Local
heating or cooling is permitted, provided that the examination area and the solution remain in the
correct temperature range throughout the examination.
3.4.1.3 Application of bubble-forming solution can be any suitable method; however, bubbles
produced by the application of the solution should be minimized.
3.4.1.4 A sufficient hold/soak and dwell time shall pass prior to evaluation.
3.4.1.5 Continuous bubble growth on the surface of the object being tested indicates leakage in
the region of examination.
3.4.2 Bubble Leak Testing (BT) (Immersion Technique)
3.4.2.1 Immersion bath fluid may be water or any other suitable solution.
3.4.2.2 Immersion of the inspection area should be performed so as to minimize formation of
bubbles on the surface.
4.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel).
4.3 Calibration
4.3.1 Equipment calibration shall be in accord with paragraph 1.22 above (Equipment
Calibration).
4.3.2 Ultraviolet light intensity shall be measured with a calibrated ultraviolet light meter. A
minimum of 800 W/cm2 shall be required on the surface of the part being examined. The
intensity of the ultraviolet light shall be measured prior to the start of the inspection and at least
once every 8 hours during the inspection.
4.4 Examinations
4.4.1 Surface preparation may be necessary where contamination or irregularities could mask
indications. Any suitable mechanical process may be used to prepare the surface. The mechanical
integrity of the object of examination shall not be reduced by this process, and all requirements of
the referencing specification must be satisfied after the process is complete.
4.4.2 The surface to be examined and all adjacent areas within 1 in. of the area to be examined
shall be dry and free of dirt, grease, lint, scale, welding flux, spatter, oil, or other matter that could
cause interference with the examination. Cleaning methods shall not impair the chemical or
mechanical integrity of the object of examination.
4.4.3 After cleaning, drying of the surfaces to be examined shall be accomplished by normal
evaporation or with forced hot or cold air. Procedures shall establish a minimum period of time in
order to ensure that the cleaning solution has evaporated prior to application of the penetrant.
4.4.4 Special care is warranted when penetrant-testing nickel base alloys, austenitic stainless
steels, and titanium. When these materials are to be tested, the provisions of ASME Section V,
Article 6 shall be strictly observed for the control of contaminants.
4.4.5 Either a color contrast (visible) penetrant or a fluorescent penetrant shall be used with one
of the following penetrant processes:
• Water washable
• Post-emulsifying
• Solvent removable
5.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel).
5.3 Calibration
5.3.1 Equipment calibration shall be in accord with paragraph 1.22 above (Equipment
Calibration).
5.3.2 Each alternating current electromagnetic yoke shall have a lifting power of 10 lb minimum
at the maximum pole spacing allowed by the written procedure(s) to be used.
5.3.3 Each direct current or permanent magnetic yoke shall have a lifting power of 40 lb
minimum at the maximum pole spacing allowed by the written procedure(s) to be used.
5.3.4 Ultraviolet light intensity shall be measured with a calibrated ultraviolet light meter. A
minimum of 800 W/cm2 shall be required on the surface of the part being examined. The
intensity of the ultraviolet light shall be measured prior to the start of the inspection and at least
once every 8 hours during the inspection.
5.3.5 When required by the referencing specification, the adequacy or direction of the
magnetizing field shall be verified using a magnetic field indicator as described and shown in
ASME Section V, Article 7.
5.4 Examination
5.4.1 Examination shall be performed with the magnetizing current on during application of
examination medium and removal of excess medium.
5.4.2 The ferromagnetic particles used may be either wet or dry and may be either fluorescent or
non-fluorescent.
5.4.3 The surface to be examined and all adjacent areas within 1 in. of the area to be examined
shall be dry and free of dirt, grease, lint, scale, welding flux, spatter, oil, or other matter that could
cause interference with the examination. Cleaning methods shall not impair the chemical or
mechanical integrity of the object of examination.
5.4.4 If coatings are to be undisturbed on the part in the area of examination, it must be
demonstrated that indications can be detected through the maximum coating thickness. If
indications cannot be detected through the maximum coating thickness, either the coating shall be
removed or the requirements of ASME Section V, Article 7, Mandatory Appendix I shall be met.
5.4.5 When temporary coatings are applied in order to enhance particle contrast, it must be
demonstrated that indications can be detected through the enhancement coating.
5.4.6 The color of dry particles shall provide sufficient contrast against the surface being
examined. Dry particles shall not be used if the surface temperature of the object of examination
exceeds 600 °F.
5.4.7 The color of wet particles shall provide sufficient contrast against the surface being
examined. The particles shall be suspended in a suitable medium in the concentration
recommended by the manufacturer of the medium. Wet particle suspensions and the surface of the
part shall not exceed 135 °F.
5.4.8 Fluorescent particle examinations shall be performed using an ultraviolet light.
Fluorescent particle examination shall be performed in a darkened area. Personnel performing the
fluorescent particle examination shall enter the darkened area at least 5 minutes prior to
proceeding with the examination in order to enable eyes to adjust to dark viewing. Photosensitive
glasses shall not be worn during the test by examiners using this medium (Note: direct viewing of
ultraviolet light should not take place).
5.4.9 Rectified current may be used when direct current is specified. The rectified magnetization
current shall be either three-phase (full-wave rectified) or single-phase (half-wave rectified). The
required amperage shall be verified by measuring the average current for three-phase rectified
current, and by measuring the average current output during the conducting half-cycle only for
single-phase rectified current.
5.4.10 Demagnetization of the object under examination shall be performed when required by the
referencing specification.
5.5 Evaluation
All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
5.6 Reports
5.6.1 Magnetic particle test reports shall meet the requirements of paragraph 1.20. In addition,
the following shall be either contained on the report or specifically identified in the test procedure:
• The types of magnetic particle material (dry or wet; visible or fluorescent)
• Magnetizing process
• Magnetizing current
• Direction of magnetic field
• Demagnetizing techniques, when required
• A technique sketch in accord with ASME Section V; Article 7, when multidirectional
magnetization is used
5.7 Records
Records shall be maintained as required by the referencing specification.
6.0 RADIOGRAPHIC EXAMINATION (RT)
6.1 Procedures
6.1.1 As a minimum, written procedures shall include the following:
6.1.2 Radiography
6.1.2.1 Satisfactory evidence of compliance with the written procedure may be demonstrated
when the density and image quality indicator (IQI) requirements of the written procedure on
production or technique radiographs are satisfied.
6.1.2.2 X-rays or gamma rays shall be used. All requirements for resulting radiographs shall
apply equally to X-rays or gamma rays.
6.1.2.3 Only X-rays shall be used for aluminum and its alloys.
Table T.4 Hole IQI designation, thickness, hole diameters, and corresponding wire IQI size (in.)
IQI 1T Hole Wire Size 2T Hole Wire Size 4T Hole Wire Size
Hole IQI Thickness Diameter 1T Diameter 2T Diameter 4T
Designation (in.) (in.) Equivalent (in.) Equivalent (in.) Equivalent
7 0.007 0.010 — 0.020 — 0.040 —
10 0.010 0.010 0.004 0.020 0.006 0.040 .0.010
12 0.012 0.012 0.005 0.025 0.008 0.050 0.012
15 0.015 0.015 0.0065 0.030 0.010 0.060 0.016
17 0.017 0.017 0.0076 0.035 0.012 0.070 0.020
20 0.020 0.020 0.010 0.040 0.015 0.080 0.025
25 0.025 0.025 0.013 0.050 0.020 0.100 0.032
30 0.030 0.030 0.016 0.060 0.025 0.120 0.040
35 0.035 0.035 0.020 0.070 0.032 0.140 0.050
40 0.040 0.040 0.025 0.080 0.040 0.160 0.063
45 0.045 0.045 0.030 0.090 0.045 0.180 0.071
Table T.5 Hole IQI Designation, Thickness, Hole Diameters and Corresponding Wire IQI Size (SI Units)
IQI 1T Hole Wire Size 2T Hole Wire Size 4T Hole Wire Size
Hole IQI Thickness Diameter 1T Diameter 2T Diameter 4T
Designation (mm) (mm) Equivalent (mm) Equivalent (mm) Equivalent
7 0.190 0.254 - 0.508 - 1.016 -
10 0.254 0.254 0.10 0.508 0.15 1.016 0.25
12 0.318 0.318 0.13 0.636 0.20 1.272 0.28
15 0.381 0.381 0.16 0.762 0.25 1.524 0.41
17 0.444 0.444 0.19 0.888 0.28 1.776 0.51
20 0.508 0.508 0.25 1.016 0.38 2.032 0.63
25 0.635 0.635 0.33 1.270 0.51 2.540 0.81
30 0.762 0.762 0.41 1.524 0.63 3.048 1.02
35 0.889 0.889 0.51 1.778 0.81 3.556 1.27
40 1.016 1.016 0.63 2.032 1.02 4.064 1.57
45 1.143 1.143 0.717 2.286 1.25 4.572 1.90
6.5.4 The images of the identification numbers, the IQI outline, and the essential hole or wire are
all essential indexes of image quality. They shall appear clearly on the radiograph. For fluorotapes,
the IQI shall appear clearly, both statically and at the normal scanning speed. The density
difference between the images of the holes and the IQI shall be the same as that between the edge
of the IQI and the adjacent area. Every IQI shall represent an area of uniform density. The
transmitted film density through the radiographic image of the body of the appropriate hole IQI or
adjacent to the designated wire of a wire IQI and the area of interest shall be 1.8 minimum for
single-film viewing for radiographs made with an X-ray source and 2.0 minimum for radiographs
made with a gamma ray source. For composite viewing of multiple film exposures, each film of the
composite set shall have a 1.3 minimum density. The maximum density shall not exceed 4.0 for
either single or composite viewing. A tolerance of ±0.05 in density is allowed for variation between
densitometer readings.
6.5.5 If the density of the radiograph varies anywhere in the area of interest by more than –15%
or +30% from the density through the body of the hole IQI or adjacent to the designated wire of a
wire IQI, within the minimum/maximum allowable density ranges specified in paragraph 6.5.4,
then an additional IQI shall be used for each exceptional area or areas and a new radiograph
taken. When calculating the allowable variation in density, the calculation may be rounded to the
nearest 0.1 within the range specified in paragraph 6.5.4. When shims are used, the plus 30%
density restriction may be exceeded, provided that the required IQI sensitivity is displayed and
the density limitations of paragraph 6.5.4 are satisfied.
6.5.6 The images of the identification numbers, of the IQI outline, and of the essential hole or
designated wire of the IQI are all essential indexes of image quality. These images shall appear
clearly on the radiograph. If the required hole IQI image and specified hole, or designated wire, do
not show on any film in a multiple film technique but do show in composite film viewing,
interpretation shall be permitted only by composite film viewing.
6.5.7 For fluoroscopy, the readout system variables shall be adjusted so that the resolution of the
IQI at the start of the weld seam is at maximum and shall be maintained between IQI sightings.
6.5.8 If a light image of the “B” as described in paragraph 6.4.1 appears on a darker background,
protection from backscatter is insufficient and the radiograph shall be considered unacceptable. A
dark image of the “B” on a lighter background is not cause for rejection.
6.5.9 Viewing Radiographs
6.5.9.1 When viewing radiographs, the illuminator must provide light of an intensity that will
illuminate the average density areas of the radiographs without glare. The light must be evenly
diffused over the viewing area of the film.
6.5.9.2 When necessary, masks shall be used to exclude any extraneous light from the eyes of the
viewer when viewing radiographs smaller than the viewing port of the illuminator or to cover low-
density areas of the radiograph.
6.5.9.3 High-intensity light illuminators shall be used for viewing areas of the radiographs
between 3.0 and 4.0 density.
6.5.9.4 Subdued lighting shall be available in the viewing room. Subdued lighting is preferable to
total darkness. The brightness of the surroundings should be nearly the same as the area of
interest in the radiograph. Room illumination must be arranged such that there are no reflections
from the surface of the film under examination.
6.6 Reports
Radiographic examination reports shall meet the requirements of paragraph 1.20. In addition, the
following shall be either contained on the report or technique sheet or specifically identified in the
test procedure:
• Lead number/marker locations or increments
• Material type and thickness
• X-ray voltage and mA or isotope type
• X-ray machine focal spot size or isotope physical source size
• Source-to-object distance
• Object-to-film or detector distance
• Film manufacturer and manufacturer’s type/designation
• A listing of each radiograph location
6.7 Records
A complete set of radiographs for each tank shall be retained for not less than 5 years by the tank
fabricator or by the car owner.
7.0 ULTRASONIC TESTING (UT)
7.1 Procedures
As a minimum, written procedures shall include the following:
7.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel).
7.3 Calibration
Equipment calibration shall be in accord with paragraph 1.22 above (Equipment Calibration) and
the following:
7.3.1 The proper functioning of the examination equipment shall be checked and the equipment
shall be calibrated by the use of the calibration standards (calibration blocks) at the beginning and
end of each examination; when examination personnel are changed; or at any time that
malfunctioning equipment is suspected. If, during any check, it is determined that the testing
equipment is not functioning properly, all of the material that has been tested since the last valid
equipment calibration shall be reexamined.
7.3.2 Screen height linearity and amplitude control linearity shall be evaluated in accord with
ASME Section V, Article 4.
7.4 Examination
7.4.1 Ultrasonic examination other than thickness testing shall be performed in accord with the
provisions of ASME Section V, Article 4, for the applicable material product form and the
provisions of this paragraph.
7.4.2 The technique used will depend on the thickness, surface geometry, and condition of the
workpiece. The measurement technique used and the extent of examination shall comply with the
referencing specification.
7.4.3 When continuous scanning techniques are utilized, the rate of search unit movement for
examination shall not exceed 6 in./second unless calibration is verified and documented at
scanning speed.
7.4.4 Examinations shall be conducted with a pulse-echo ultrasonic instrument capable of
generating frequencies between 1 MHz and 5 MHz. Instruments operating at other frequencies
may be used if equal or better sensitivity is demonstrated and documented.
7.4.5 Examination surfaces shall be uniform and free of loose scale and paint, discontinuities
such as pits or gouges, weld spatter, dirt, or other foreign matter that could affect the examination
results. Tightly adhering paint, scale, or coatings do not necessarily need to be removed for
examination purposes if they present uniform attenuation characteristics. The examination
surface must be adequate to permit ultrasonic examination at the sensitivity specified. If needed,
surfaces may be ground, sanded, wire brushed, scraped, or otherwise prepared for examining
purposes, if this surface preparation is not detrimental to the functioning of the item under
inspection.
7.4.6 Curved surfaces, either concave or convex, may be examined; however, the calibration
system should compensate for the effective change in search unit transmitting area between the
reference standard and the item under inspection. When practical, the reference standard should
have the same geometry as the item being examined.
7.4.7 The material shall be examined by moving the search unit over the surface such that the
scan encompasses the entire volume to be examined. Each pass of the search unit shall overlap a
minimum of 10% of the transducer element dimension perpendicular to the direction of transducer
movement.
7.5 Evaluation
7.5.1 All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
7.5.2 For all examinations, recording of indications shall be made with respect to the reference
level.
7.5.3 For examinations using a distance amplitude correction (DAC) curve, any reflector that
causes an indication greater than 20% of DAC shall be investigated to the extent that it can be
evaluated in terms of the acceptance standards of the referencing specification.
7.6 Reports
Ultrasonic test reports shall meet the requirements of paragraph 1.20. In addition, the following
shall be either contained on the report or specifically identified in the test procedure:
• Transducer size and frequency used
• Special equipment used, if applicable
• Map or description of scan locations
• Couplant manufacturer and type
• Calibration block identification
• Condition of the surfaces of the material
7.7 Records
Records shall be maintained as required by the referencing specification.
8.0 ULTRASONIC THICKNESS TESTING (UTT)
8.1 Procedures
As a minimum, written procedures shall include the following:
8.2 Personnel
8.2.1 NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel)
and the following:
8.2.2 Recommended training topics contained in ASNT SNT-TC-1A for UT may be used at the
determination of the NDT Level III.
8.3 Calibration
8.3.1 Equipment calibration shall be in accord with paragraph 1.22 above (Equipment
Calibration) and the following:
8.3.2 The proper functioning of the examination equipment shall be checked and the equipment
shall be calibrated by the use of the calibration standards (calibration blocks) at the beginning and
end of each examination; when examination personnel are changed; or at any time that
malfunctioning equipment is suspected. If, during any check, it is determined that the testing
equipment is not functioning properly, all of the material that has been tested since the last valid
equipment calibration shall be reexamined.
8.3.3 The examination system shall be calibrated on at least three calibration thicknesses
covering the thickness range to be measured. Calibration blocks are required having the same
acoustic velocity and attenuation of the material to be tested, and having thicknesses accurately
measured and in the range of the thicknesses to be measured. Calibration blocks shall have
thickness value within ±0.300 in. of the maximum of the range of interest, within ±0.300 in. of the
minimum thickness, and within ±0.200 in. of the median of the maximum and minimum
thicknesses to be tested. Calibration block temperature shall be within 50 °F of the object being
examined.
8.4 Examination
Examination shall include all of the provisions in paragraphs 7.4.2 through 7.4.6 above and the
following:
8.4.1 Where reflecting surfaces are rough, pitted, or corroded, equipment with waveform display
capabilities shall be required.
8.4.2 Time-based linearity is required on instruments used in ultrasonic thickness testing, so
that a change in the thickness of the material will produce a corresponding change in indicated
thickness.
8.5 Evaluation
All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
8.6 Reports
Ultrasonic thickness test reports shall meet the requirements of paragraph 1.20. In addition, the
following shall be either contained on the report or specifically identified in the test procedure:
• Transducer size and frequency used
• Special equipment used, if applicable
• Map or description of scan locations
• Couplant manufacturer and type
• Calibration block identification
• Condition of the surfaces of the material
8.7 Records
Records shall be maintained as required by the referencing specification.
9.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above.
9.3 Calibration
Equipment calibration shall be in accord with paragraph 1.22 above (Equipment Calibration).
9.4 Examination
9.4.1 Weld Inspection
Weld inspection should be made when access is sufficient to place the eye within 24 in. of the
surface to be examined at an angle of not less than 30° to the surface to be examined. Mirrors may
be used to improve the angle of vision, and aids such as a magnifying lens may be used to assist
examinations. The specific part, component, tank, or section thereof, under immediate
examination shall be illuminated with sufficient lighting as defined by the procedure.
9.4.2 Remote Visual Inspection
9.4.2.1 Remote visual inspection shall be performed with suitable remote equipment.
9.4.2.2 If remote inspection will include weld inspection, the remote technician shall be weld
inspection certified.
9.5 Evaluation
All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
9.6 Reports
Visual test reports shall meet the requirements of paragraph 1.20. In addition, the following shall
be either contained on the report or specifically identified in the test procedure:
• Any special equipment or techniques
9.7 Records
Records shall be maintained as required by the referencing specification.
10.2 Personnel
NDT personnel shall be in accord with paragraphs 1.4 through 1.17 above (NDT Personnel).
10.3 Calibration
Equipment calibration shall be in accord with paragraph 1.22 above (Equipment Calibration).
10.4 Examination
10.4.1 Examination shall take place after the temperature differential has been achieved and
within a timeframe that the temperature differential is maintained.
10.4.2 The test surface shall be scanned as close as possible to a normal incident angle.
10.5 Evaluation
All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
10.6 Reports
10.6.1 Reports shall be made for each examination.
10.6.2 As a minimum, the report shall contain the following information:
• All the requirements of paragraph 1.20 above (NDT Reports)
• Environmental conditions (if test performed outdoors)
• Scanning distance from test object
• Emissivity setting of test equipment
• Emissivity of test object
10.7 Record Retention
Records shall be maintained as required by the referencing specification.
12.4.2 Examination surfaces shall be uniform and free of loose scale and paint, discontinuities
such as pits or gouges, weld spatter, dirt, or other foreign matter that affect the examination
results. Tightly adhering paint, scale, or coatings do not necessarily need to be removed for
examination purposes if they present uniform attenuation characteristics. The examination
surface must be adequate to permit ultrasonic examination at the sensitivity specified. If needed,
surfaces may be ground, sanded, wire brushed, scraped, or otherwise prepared for examining
purposes, if this surface preparation is not detrimental to the functioning of the item under
inspection.
12.4.3 Phased array or multi-channel pulsed-echo focused search units utilizing zone
discrimination shall be utilized. Time of flight diffraction (TOFD) may be used in addition to the
above.
12.4.4 Couplant shall be applied utilizing an irrigated system or other suitable method that will
provide a thin consistent layer.
12.4.5 Mechanical indexing and raster scanning shall be encoded and included in the saved
examination data.
12.4.6 Data collection systems shall have the ability to electronically save collected examination
data in unchanged raw data format. The saved examination data shall clearly indicate the location
of discontinuities.
12.4.7 Data analysis may be performed utilizing A, B, or C scan presentations.
12.4.8 The material shall be examined by moving the search unit(s) over the surface such that
the scan encompasses the entire volume to be examined. Each pass of the search unit shall overlap
a minimum of 10% of the transducer element dimension perpendicular to the direction of
transducer movement.
12.5 Evaluation
12.5.1 All examinations shall be evaluated in terms of acceptance standards of the referencing
specification.
12.5.2 Time or distance amplitude corrections shall be used during calibration and examination.
Any reflector that causes an indication greater than 20%, minimum, of primary reference level
shall be investigated to the extent that it can be evaluated in terms of the acceptance standards of
the referencing specification. Evaluation of indications shall be performed at primary reference
level, at minimum.
12.6 Reports
12.6.1 Ultrasonic reports shall meet the requirements of paragraph 1.20. In addition, the
following shall be either contained on the report or specifically identified in the test procedure:
• Transducer size, frequency, angles, and modes of ultrasound used
• Scan plan of test locations and probe configuration
• Type of couplant and method of application
• Calibration block and reference standard identification
• Condition of the surfaces of the test material
• Method of scanning and scan speed
• Active elements used (phased array)
• Probe separation (TOFD)
12.7 Records
Electronically stored scan data for each tank shall be retained for not less than 5 years by the tank
fabricator or by the car owner.
Sample
NDT PROCEDURE QUALIFICATION RECORD
The NDT Level III shall be responsible for the qualification and technical approval of all NDT
procedures.
1. Qualification Specimen: The item to be examined during the qualification may be a compo-
nent or a specimen not intended for service. The specimen must contain known (actual or sim-
ulated) discontinuities.
2. Demonstration: The demonstration examination of the selected specimen shall be conducted
by a Level II or Level III who is certified in the method of the procedure being qualified. The
demonstration shall be performed in accordance with the procedure being qualified.
A minimum of one qualified individual shall perform the demonstration of the procedure. The
NDT Level III shall witness the demonstration.
Results of the procedure demonstration shall be documented using an NDT Procedure
Qualification Record having spaces to record the procedure identification, signatures, and date.
In addition, the applicable NDT report form referenced in the procedure being qualified shall be
completed and shall describe the demonstration specimen and results.
The NDT procedure is considered qualified when the results of the demonstration indicate the
ability to detect discontinuities to the satisfaction of the NDT Level III. The NDT Level III and
the witness(es) shall sign the NDT Procedure Qualification Record form.
METHOD TECHNIQUE
RESULTS
______________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________
A-end B-end
APPENDIX U
MAINTENANCE PROGRAM DEVELOPMENT
CONTENTS
APPENDIX U
MAINTENANCE PROGRAM DEVELOPMENT
1.0 GENERAL
1.1 Introduction
The content of this Appendix U was originally designated as Recommended Practice RP-263 when
it was adopted in 2003. It has been incorporated herein and is no longer a standalone document.
Federal regulations require the maintenance of tank cars to ensure that there will be no
substantial reduction in the effectiveness of the car and that there will be no identifiable release of
material to the environment. It should be emphasized that federal rules require the car owner to
manage the maintenance of its fleet of cars, to develop plans, and to set inspection intervals
consistent with the failure mode and failure rate for each component on the car. This appendix is
simply one tool to meet that end. This implies that the shipper and car owner must understand the
relationship between what might fail, how it might fail, and when it might fail for the tank and
associated equipment (e.g., understanding failure modes, failure effects, and failure rates). This is
consistent with the goal of assessing, quantitatively, the reliability of the tank and associated
equipment against lading loss during all periods of operation (i.e., reliability-centered
maintenance programs). For further information, see 49 CFR 171.2(c); 173.24(b); 173.31(a)(1) and
(3); 179.7(b)(5), (b)(10), (d), and (f); 180.2; 180.3; 180.501; 180.507(a); and 180.511.
1.2 Scope
1.2.1 Appendix U describes the recommended practice for the development of a maintenance
program for tank cars. This appendix covers the application and coordination of regulatory and
industry test and inspection programs in the development of a maintenance program. To maintain
the fitness-for-service of a tank car, the maintenance program must be effective in preventing
failures.
1.2.2 This appendix requires cooperation and communication between the parties involved with a
tank car. Reliability will be greatly improved with appropriate communications. Each owner
should develop, in conjunction with each manufacturer and operator/user of a tank car, a
maintenance program and schedule.
1.2.3 The following are objectives of an efficient maintenance program:
• Maintain the fitness-for-service of the tank car.
• Obtain and analyze the data to determine appropriate action to minimize probabilities of
failures, damage, or deterioration.
• Accomplish these objectives at a minimum net cost, including maintenance costs and the
savings of avoiding failures.
• Validate inspection intervals.
1.2.4 Car owners may exceed the minimum criteria contained herein.
3.2.6 Program change: A system for changing the maintenance program, such as the methods
used to collect data or process change, or the procedures relating to reliability measurement or
performance standards.
3.3 Program and Interval Change
This section provides information on establishing maintenance policies to improve safety,
reliability, and operating performance; reduce maintenance costs; and extend the useful life of the
asset. A maintenance program consists of a continuing analysis of maintenance data to produce
documentary evidence that the program has defensible foundations that support not only
maintenance policies but also changes in the intervals of maintenance.
3.3.1 Operations: The maintenance program shall consider the operational effects on the tank
car that may lead to damage. For example, the program should consider the effects of fatigue and
incorporate a maintenance interval that allows for two opportunities for maintenance before the
car reaches its critical cycle time of failure.
3.3.2 Fleet sampling: The maintenance program may include sampling of the fleet leaders with
respect to mileage for fatigue and age for corrosion. An owner should consider the effects of the
material of construction and design to support a maintenance program based on fleet sampling.
3.3.3 Interval or content changes: To support an extended maintenance interval beyond
federal or industry requirements, or to change the mandatory content in the maintenance
program, an owner must obtain supporting evidence and approval by the governing bodies. This
can include the owner’s engineering analysis, maintenance data, pooled industry data, historical
data, benefit/cost data, and testing.
BENCH TESTING:
12. If the PRV is not a combination valve, circle “C. Not combo.” If the PRV is a combination
pressure relief valve with a needle valve, trycock, or tell-tale indicator, perform the following
test before removing the disc/diaphragm. Install the complete assembly with disc on the test
stand. Slowly raise the pressure in the test stand to one half of the valve’s labeled start-to-
discharge pressure. Check the needle valve or trycock outlet for disc leakage or the tell-tale
indicator for pressure rise. If the PRV is a combination pressure relief valve, remove the disc or
diaphragm before proceeding. The disc or diaphragm condition is recorded on line 27.
13. Put water in the outlet of the PRV. Slowly increase the pressure in the test stand and record the
pressure at the first bubble. The start-to-leak pressure is defined as “The pressure, measured
at the valve inlet of a PRV, at which the relieved fluid is first detected at the downstream side
of the seat.”
14. Continue raising the pressure in the test stand until the start-to-discharge pressure has been
observed. Record the pressure. The start-to-discharge pressure is defined as “The pressure,
measured at the valve inlet of a PRV, at which there is a measurable lift of the closure device
on a PRV or at which discharge becomes continuous as determined by seeing, feeling, or
hearing.”
15. Slowly lower the pressure in the test stand until the vapor-tight pressure has been observed by
no bubbles for a minimum of 30 seconds. Record the pressure. The vapor-tight pressure is
defined as “The pressure, measured at the valve inlet after closing, at which no further flow is
detected at the downstream side of the seat of a PRV.” Discharge the pressure in the test stand
to one half the start-to-discharge pressure or below the vapor-tight pressure, whichever is
lower.
16. Raise the pressure in the test stand until the start-to-discharge pressure has been observed a
second time. Record the pressure.
17. Slowly lower the pressure in the test stand until the vapor-tight pressure has been observed a
second time. Record the pressure. Discharge the pressure in the test stand to one half the start-
to-discharge pressure or below the vapor-tight pressure, whichever is lower.
18. Raise the pressure in the test stand until the start-to-discharge pressure has been observed a
third time. Record the pressure.
19. Slowly lower the pressure in the test stand until the vapor-tight pressure has been observed a
third time. Record the pressure. Discharge the pressure in the test stand.
20. Record any remarks out of the ordinary during bench testing of the PRV.
TEARDOWN:
Each facility should have a procedure to verify that the parts of a valve are kept together during
disassembly and assembly. Carefully inspect the PRV. Inspect the different PRV parts for cracking,
corrosion, damage, etc. Follow the PRV manufacturer’s instructions for disassembling the PRV.
21. If the spring is steel, note the condition of the plating and circle the choices that best describe
the condition of the spring. If other conditions exist, note the condition and line number in
line 29.
A. Good condition—The plating is intact and in good condition (less than 1 in.2 gone).
B. Some corrosion—The plating is no longer intact and some corrosion exists.
C. All corrosion—The plating no longer exists and the entire spring is covered with corrosion.
D. Cracked—The spring is cracked or has visible cracks or is broken.
If the spring is stainless steel, note the condition of the spring and circle the choices that best
describe the condition of the spring. If other conditions exist, note the condition and line
number in line 29.
A. Good condition—The spring has no corrosion or pitting and is in good condition.
B. Some corrosion—Some corrosion or pitting exists.
C. All corrosion—The entire spring is covered with corrosion or pitting.
D. Cracked—The spring is cracked or has visible cracks.
22. Stand the spring up on a flat surface. With a straight edge across the top of the spring, put a
ruler in the middle of the spring and measure the free height. Record the result to the nearest
1/8 in.
23. Inspect the stem seat seal area, threads, the shaft of the stem, and the transition area between
the shaft and the disc. Circle the choices that best describe the condition of the stem. If other
conditions exist, note the condition and line number in line 29.
A. Good—The stem is straight. The threads and the seat area are in good condition.
B. Dirty—The seat seal area has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean-up.
C. Cracked—The stem has visible cracks.
D. Bent—The stem is bowed or bent when rolled on a flat surface.
24. Inspect the seat seal area of the valve body and circle the choice that best describes the condition
of it. If other conditions exist, note the condition and line number in line 29.
A. Bright/clean—The seat seal area is bright and clean (like new).
B. Dirty—The seat seal area has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean up.
C. Corroded—The seat seal area has pitting that would not allow the PRV to be rebuilt.
D. Gouged—The valve body has mechanical damage (scratches, dents, galled, etc.) that would
not allow the valve to be rebuilt.
If the PRV has two O-rings, record the condition of both O-rings in lines 25 and 26. The seat
O-ring is the O-ring that seals between the stem, the cap, and the seat on the PRV body.
The plug or stem O-ring is the O-ring with the smaller outer diameter and seals between
the cap and plug or stem.
If the PRV has one O-ring, record the condition of the O-ring in line 25.
25. Inspect the seat O-ring and circle the choice that best describes the condition of it. If other
conditions exist, note the condition and line number in line 29.
A. Like new—The O-ring is still clean, soft, and pliable and seals properly in the PRV.
B. Dirty—The O-ring has contamination on it, which may not allow it to function properly.
C. Cracked—The O-ring is no longer soft and pliable. It is hard and cracks if flexed.
D. Swelled—The O-ring is swollen and over-sized for the seat area in the PRV.
E. Metal-to-Metal—The valve design does not have an O-ring, but a metal-to-metal seat.
26. Inspect the plug or stem O-ring and circle the choice that best describes the condition of it. If
other conditions exist, note the condition and line number in line 29.
A. Like new—The O-ring is still clean, soft, and pliable and seals properly in the PRV.
B. Dirty—The O-ring has contamination on it, which may not allow it to function properly.
C. Cracked—The O-ring is no longer soft and pliable. It is hard and cracks if flexed.
D. Swelled—The O-ring is swollen and over-sized for the seat area in the PRV.
E. Metal-to-Metal—The valve design does not have an O-ring, but a metal-to-metal seat.
27. Inspect the seal retainer and circle the choice that best describes the condition of it. If other
conditions exist, note the condition and line number in line 29.
A. Bright/clean—The seal retainer is bright and clean (like new).
B. Dirty—The seal retainer has surface corrosion or scale that would not allow the PRV to be
rebuilt without clean-up.
C. Corroded—The seal retainer has pitting that would not allow the PRV to be rebuilt.
D. Gouged—The seal retainer has mechanical damage (scratches, dents, galled, etc.) that
would not allow the valve to be rebuilt.
28. If the PRV is a combination device, inspect the disc or diaphragm for any manufacturer’s
markings and record them and the condition (such as like-new, burst, corroded, etc.).
29. Record any comments out of the ordinary of the physical condition of the parts during the
teardown of the PRV.
30. Record the following information for the facility that removed the valve from the car and
performed the testing and teardown:
A. Station stencil
B. Phone number
Record the date and print the name and ID# of the person performing the test.
APPENDIX W
WELDING OF TANK CAR TANKS
CONTENTS
APPENDIX W
WELDING OF TANK CAR TANKS
1.0 INTRODUCTION
1.1 Scope
Appendix W describes AAR requirements for fusion welding on tank heads, shells, sumps, and
welds attaching connections thereto. Other welding, including repairs, shall be in accord with the
American Welding Society (AWS) Railroad Welding Specification D15.1, latest revision.
1.2 Certified Facilities
Fusion welding on tank car tanks shall be performed only by facilities certified by the AAR for
fabrication or for alterations, conversions, or welded repairs. See Appendix B.
1.3 Repairs, Alterations and Conversions
For repairs, alterations, and conversions to tank car tanks, see Appendix R.
1.4 Welding Symbols
Welding symbols used shall conform to AWS Standard A2.4 (see Fig. W.21).
2.0 REQUIREMENTS FOR NONDESTRUCTIVE EXAMINATION
2.1 General
Tank car tanks, and any attachments welded directly to the tank, must be inspected by NDT
examiners qualified per Appendix T for the method employed, in accord with the following
paragraphs. For welder visual acuity requirements to check multi-pass welds, see paragraphs 14.1
and 14.2.
2.2 Tank Shell Joints
2.2.1 For manual and semiautomatic welding procedures, the weld root pass and each layer of
multi-pass weld shall be visually checked to make sure they are free from cracks, overlap,
incomplete fusion, and inclusions prior to deposition of subsequent passes. The welder making the
weld is responsible for this, which shall be monitored by the welding inspector.
2.2.2 All completed welded butt joints shall be visually inspected in accord with paragraph 14.10
below and radiographed in accord with paragraph 18.0, also below.
2.3 Welds Other than Tank Shell Joints—Attachments Welded Directly to the Tank
Shell
2.3.1 The root pass and each layer of multi-pass weld shall be visually checked to make sure they
are free from cracks, overlap, lack of fusion, and slag inclusions prior to deposition of subsequent
weld passes. The welder making the weld is responsible for this, which shall be monitored by the
welding inspector.
2.3.2 All completed welds shall be visually inspected in accord with paragraph 14.10 below.
2.3.3 In addition to the requirements in paragraphs 2.3.1 and 2.3.2, pressure car tank and
aluminum tank (pressure and nonpressure) completed fillet welds listed below shall be examined
in accord with paragraph 10.0 below. For carbon steel tanks, the completed welds shall be
examined by magnetic particle or liquid penetrant, and for aluminum tanks by liquid penetrant.
Where practical, the completed welds shall be examined after postweld heat treatment or no
sooner than 24 hours after welding.
• Tank anchor pad-to-tank, around the ends of the pad, including at least 3 in. of the
longitudinal welds
• Draft sill pad-to-tank, around the outboard end of the pad, including at least 3 in. of the
longitudinal welds
• Draft sill pad-to-tank, around the inboard end of the pad, including at least 3 in. of the
longitudinal welds, except where pads extend the full length of the tank
• For aluminum tanks only, bolster pad to tank, around the upper end of the pad, including
at least 3 in. of the circumferential welds
2.3.4 Ultrasonic testing of welds may be employed in lieu of magnetic particle or liquid
penetrant inspections. Ultrasonic testing of welds shall be performed in accord with the
requirements of paragraph 10.0 below.
3.0 TEST PLATE REQUIREMENTS
3.1 General
3.1.1 When required by DOT specifications, test plates shall be prepared, tested, and evaluated
in accordance with applicable portions of paragraphs 4.0, 5.0, 6.0, and 8.0 below.
3.1.2 A test plate shall be prepared during fabrication for each WPS used in fabrication of the
tank shell.
3.1.3 When more than one welder and/or welding operator welds on a tank, the test plates shall
be made by the welder and/or welding operator designated by the fabricator’s inspector.
3.1.4 A test plate shall be prepared as a part of the qualification requirements for each welding
procedure. See paragraph 12.1.2 below.
3.1.5 When impact tests are required, the test plate groove details shall be the same as used for
the tank fabrication.
3.2 Longitudinal Joint Test Plates
3.2.1 For each tank having a longitudinal welded joint, a test plate shall be prepared from
material of the same specification and thickness as the shell plates of the tank. Test plate material
may be taken from any part of one or more plates of the same lot of material that is used in the
fabrication of the tank without reference to the direction of mill rolling, except when impact tests
are required. When impacts are required, test plates shall be oriented the same as the shell plates
with respect to mill rolling and weld directions.
3.2.2 The test plates may be attached to a shell plate being welded, reference Fig. W.1A, so that
the weld metal shall be deposited in the test plate continuously with the weld metal deposited in
the longitudinal joint.
3.2.3 As an alternative, detached test plates may be prepared, but weld metal shall be deposited
using the same WPS used for the longitudinal joints.
6.2.2 Specimens shall pass the test if they have no cracks or other open defects exceeding 1/8 in.
(3.18 mm), measured in any direction on the convex surface of the specimen after bending, except
that cracks occurring on the corners of the specimen during testing shall not be considered, unless
there is definite evidence that they result from inclusions or other internal defects.
7.0 FILLET WELD SPECIMENS AND TESTS
7.1 Fillet Weld (Tee-Joint) Specimens
T-joint specimens, when required, shall conform to requirements of Fig. W.6.
7.1.1 The fillet weld specimen may be used for qualification test of welder performance and shall
be cut to provide a T-joint section for lateral loading and to provide a cross-section of the weldment,
to be smoothed and etched with a suitable etchant, to give a clear definition of the structure of the
weld metal and heat-affected zone. See Fig. W.6, Sketch A.
7.1.2 The fillet weld specimen shall be used for qualification test of welding procedures for ferritic
steels with their mechanical properties enhanced by quenching and tempering. It shall be cut to
provide five cross-sections of the weldment, each approximately 2 in. (50.8 mm) long. One face of
each section is to be smoothed and etched with suitable etchant to give a clear definition of
structure of the weld metal and heat-affected zone. See Fig. W.6, Sketch B.
7.2 Fillet Weld Tests
7.2.1 The T-joint specimens prepared in accord with Fig. W.6, Sketch A shall contain no visible
cracks.
7.2.2 The vertical member of the performance qualification T-joint shall be loaded laterally and
the load steadily increased until the specimen fractures or bends flat upon itself. To pass, the
specimen shall not fracture; or, if it fractures, the fractured surfaces shall show no evidence of
cracks or incomplete root fusion, and the sum of the lengths of open discontinuities visible on the
fractured surfaces shall not exceed 2 in. (50.8 mm) for ferrous materials and 3/4 in. (19.0 mm) for
nonferrous materials.
7.2.3 The performance qualification T-joint weld shall have no concavity or convexity greater
than 1/16 in. (1.59 mm) and shall have not more than 1/16 in. (1.59 mm) difference in the lengths
of the legs of the fillet weld.
7.2.4 The procedure qualification T-joint weld shall have not more than 1/8 in. (3.18 mm)
difference in the lengths of the legs of the fillet weld.
7.2.5 Visual examination of the etched cross sections of weld metal and heat-affected zones of
performance and procedure qualification T-joint welds shall show freedom from cracks and
complete fusion at the joint root, but not necessarily beyond the root.
8.0 IMPACT, CORROSION AND HARDNESS TESTS
8.1 Impact Specimens and Tests
Impact tests are required only when specified in the tank specification.
8.1.1 Material and Number Required
Test plates used to prepare specimens shall be provided for each tank and shall be from one of the
heats that provided plates for the tank. Where welding is involved, the plates shall be welded
using the same joint detail, WPS and electrodes as required for the tank. Unless otherwise
specified, at least one set of three specimens shall be taken across the weld with notch in the heat-
affected zone and one set of three with notch in the weld metal. See Fig. W.9. When two plates of
different materials are involved, an additional set of three specimens shall be taken so that there
is one set with the notch in each heat-affected zone.
8.1.5 Reports
8.1.5.1 A report of impact test results shall include identity of plate material (specification,
grade, and heat number), PQR, and welding electrodes; type and size of impact test specimens;
location and orientation of specimens and notches with respect to plate surface and rolling
direction; and weld metal and weld heat-affected zone impact value for each specimen tested.
8.1.5.2 The complete report of all impact tests shall be retained for not less than 5 years by the
tank fabricator, or by the car owner if the owner so requests.
8.2 Corrosion Specimens and Tests
Corrosion tests are required on tanks fabricated from materials listed in Table M.10.3 when
required by the tank specification.
8.2.1 Material and number required
Test plates used to prepare specimens shall be provided from each heat of material used to
fabricate tanks and each heat of filler metal that is used to weld tanks. Where welding is involved,
the plates shall be welded using the same WPS as used on the tank. At least one set of three
specimens shall be taken from the test plate, located as shown in Fig. W.1 Sketch B. Corrosion
testing of the base metal is not a requirement if the corrosion test has been conducted and certified
by the material supplier. Specimens shall be tested in accord with ASTM A262-85 Practice A. If
the results of Practice A are unacceptable, further testing with Practice B or C is required.
8.2.2 Test criteria
8.2.2.1 Corrosion test specimens shall be considered to be acceptable when each exhibits
corrosion rates not in excess of those listed in Appendix M, paragraph 3.3.2.
8.2.2.2 Weld corrosion test specimens need not be sensitized.
8.2.3 Reports
8.2.3.1 A report of corrosion test specimens shall include identity of plate material (specification,
grade, and heat number), welding procedure, welding electrodes, and corrosion rate for each
specimen tested.
8.2.3.2 The complete report of all corrosion tests shall be retained for not less than 5 years by the
tank fabricator, or by the car owner if the owner so requests.
8.3 Hardness Tests
Hardness tests of production butt welds are required for pressure tank car tanks fabricated from
materials listed in Table M.10.1.
8.3.1 On each tank, at least three points inside and three points outside shall be checked at the
centerline of the welds. Two of the inside points and two of the outside points shall be at
intersections of longitudinal and circumferential butt welds. Grind the weld metal to produce a
flat surface for hardness testing at these check points. Do not grind weld reinforcement below
joining plate surface.
8.3.2 Hardness of weld shall not exceed Brinell 225 (Rockwell C20) after postweld heat
treatment.
8.3.3 Hardness tests of butt welds on multi-unit tank car tanks shall be performed on exterior
weld seams only. One test per weld procedure is required on each tank.
9.6.5 Welders who pass the required groove or fillet weld tests listed in paragraphs 9.6.2 or 9.6.3
shall be qualified for the positions of groove welds and fillet welds shown in Table W.2. Welding
vertical down requires separate qualification.
9.6.6 A facility that does fabrication, repair, alteration, or conversion in a particular position may
make the tests in that position, but such a performance qualification is valid only for the flat
position and for the position actually tested, except that an angular deviation of ±15° is permitted
in the inclination of the weld axis and the rotation of the weld face as defined in Figs. W.7 and W.8.
10.2.3.4 In any 1 in. (25.4 mm) length of weld or 2T, whichever is smaller, rounded indications
may be clustered to a concentration four times that permitted by 0.060T in.2 (38.7T mm2). Such
clustered rounded indications shall be included in the rounded indications in any 6 in. (152 mm)
length of weld that includes the cluster.
10.2.3.5 Aligned rounded indications shall be acceptable provided the summation of the
diameters of the indications is no more than T in a length 12T or 6 in. (152 mm), whichever is less,
provided each indication is separated by a distance at least six times the diameter of the largest
adjacent indication. Aligned rounded indications shall be counted in the total area of permissible
indications in any 6 in. (152 mm) length of weld.
10.2.3.6 The maximum indication dimension shall be 0.2T or 1/8 in. (3.18 mm), whichever is
smaller, except that an isolated indication separated from an adjacent indication by 1 in.
(25.4 mm) or more may be 0.3T or 1/4 in. (6.35 mm), whichever is less.
Table W.3 Maximum permissible rounded indications in radiotapes per 6 in. length of weld—conventional units
Total Area Large Indication Size Medium Indication Size Fine Indication Size
Weld of Permitted Approx. Decimal Approx. Decimal Approx. Decimal
Thickness, Indications, Fraction, Value, Fraction, Value, Fraction, Value,
in. in.2 in. in. a/ No. in. in. a/ No. in. in. a/ No.
1/4 0.015 — — — 3/128 0.025 31 1/64 0.0138 100
1/2 0.030 3/32 0.10 4 1/32 0.031 40 3/128 0.0195 101
3/4 0.045 1/8 0.125 4 1/32 0.034 50 3/128 0.024 99
1 0.060 1/8 0.125 5 5/128 0.039 50 1/32 0.0275 101
1 1/2 0.090 1/8 0.125 7 3/64 0.048 50 1/32 0.034 99
2 0.120 1/8 0.125 10 7/128 0.055 51 5/128 0.039 100
a/ These values used for calculating total area of permitted rounded indications.
Table W.4 Maximum permissible rounded indications in radiographs per 15.2 mm length of weld—SI units
Total Area of Large Indication Size Medium Indication Size Fine Indication Size
Weld Permitted
Thickness, Indications, Decimal Value, Decimal Value, Decimal Value,
mm mm2 mma/ No. mma/ No. mma/ No.
6.35 9.68 — — 0.64 31 0.351 100
12.7 19.4 2.54 4 0.79 40 0.495 101
19.0 29.0 3.18 4 0.86 50 0.610 99
25.4 38.7 3.18 5 0.99 50 0.699 101
38.1 58.1 3.18 7 1.22 50 0.864 99
50.8 77.4 3.18 10 1.40 51 0.991 101
a/ These values used for calculating total area of permitted rounded indications.
10.2.4 Rounded Indication Charts
The rounded indication charts, Figs. W.16 through W.19, illustrate various types of assorted and
uniform, randomly dispersed rounded indications. The chart for each thickness represents the
maximum acceptable rounded indication. The charts represent full-scale 6 in. radiographs and
shall not be enlarged or reduced. The rounded indication distributions shown are not necessarily
the patterns that may appear on the radiograph, but are typical of the number and size of
indications permitted. When rounded indications differ significantly from the charts, the actual
numbers and sizes of the rounded indications may be measured and the total area of rounded
indications calculated.
10.5.2.3.2 A group of indications that have an aggregate length greater than Ta/ in a weld length
of 12T or 6 in., whichever is less, except when the distance between successive indications exceeds
6L, where L is the length of the longest indication in the group.
10.5.3 Any indication that is believed to be non-relevant shall be regarded as an imperfection
unless it is shown by reexamination that no unacceptable imperfections are present.
Reexamination shall be performed by the same method or by the use of other nondestructive
methods and/or by surface conditioning.
11.0 PERFORMANCE QUALIFICATION OF WELDERS AND WELDING OPERATORS
11.1 Qualification of Welders
Each welder shall pass the mechanical tests prescribed in paragraph 11.6 below for performance
qualification, except that welders making a groove weld with shielded metal-arc welding, flux-
cored arc welding, gas metal arc welding (except short circuiting), or gas-shielded tungsten arc
welding may alternatively be qualified by radiographic or ultrasonic examination as prescribed in
paragraph 11.6 below. The welder who welds the welding procedure qualification test plate that
results in a qualified WPS shall be performance qualified, but only within the limits of essential
variables given in paragraph 11.4 below.
11.1.1 Performance qualification tests for butt, fillet, and buildup welds, including nozzles and
other circular attachments to the shell, shall be made using butt-welded test plates (see Figs. W.3,
Sketch A, W.14, W.20, Sketch C, and W.20, Sketch D). Satisfactory qualification test results on
specimens prepared from the butt-welded test plates, or alternatively by radiographic
examinations, shall qualify a welder to make butt welds in thicknesses determined by test plate
thickness and fillet welds in all thicknesses, both within the range of essential variables as
recorded in the welder’s “Record of Welder Performance Qualification Test” (see Fig. W.13).
11.1.2 Performance qualification tests for fillet welds, only, may be made using fillet-welded test
plates (see Figs. W.6, Sketch A and W.15. Satisfactory qualification test results on specimens
prepared from the fillet-welded test plate shall qualify a welder to make fillet welds in all
thicknesses within the range of essential variables as recorded in the welder’s “Record of Welder
Performance Qualification Test” (see Fig. W.13).
a/ "T" is the thickness of the weld excluding any allowable reinforcement. For a butt weld joining
two members having different thicknesses at the weld, "T" is the thinner of these two
thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included in "T."
11/2014 C-III [M-1002] 487
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX W M-1002
11.5.5 When a welder is to be qualified for the use of F-5 filler metal of weld metal analysis A-7 or
A-8 to join P-1 or P-8 base metals to themselves or to each other, carbon steel plate may be used for
the performance qualification test. A performance qualification test made using A-8 or A-9 (F-5
filler metals) with one or a combination of P-1 or P-8 base metal will qualify for all combinations of
these base metals.
11.6 Test Specimens
11.6.1 The qualification test weld shall be visually inspected in the as-welded condition (no
grinding after completing the weld) in accordance with paragraphs 14.5 and 14.10 below, except
that reinforcement may be up to 1/8 in. For welder performance qualification by mechanical
testing, the type and number of test specimens required, together with the range of thickness of
materials for which a welder is qualified by use of a given thickness of test plate, are shown in
Table W.6. When alternative qualification by radiographic or ultrasonic examination of groove
welds is used as permitted in paragraph 11.1, the range of thickness of materials for which a
welder is qualified shall be the same as for mechanical testing in Table W.6.
11.6.2 Test specimens may be removed from the welded test plates in any order, but in a manner
similar to that shown in Figs. W.20, Sketch C, and W.20, Sketch D.
11.6.3 All test specimens shall be prepared, tested and meet the requirements as prescribed in
applicable portions of paragraphs 6.0, 7.0, and 9.0 of this appendix. When alternative qualification
by radiographic or ultrasonic examination of groove welds is used as permitted in paragraph 11.1,
the radiographic or ultrasonic acceptance standards of the applicable portions of paragraph 10.0
above shall be used.
11.6.4 The number of test plates (and sets of test specimens) required by Table W.6 shall be
prepared and tested to provide performance qualification of each welder for the “test positions”
that will be used in the fabrication, repair, alteration, or conversion of tank car tanks.
Table W.6 Performance qualification tests required
Range of Thickness of Type and Number of Tests Required
Material Qualified by
Test Plate, in. (mm) Guided-Bend Test
Side- Face- Root-
Type Bend Bend Bend
of Thickness (t) of Test Plate Fig. W.4, Fig. W.4, Fig. W.4, Fillet Tee-
Joint As-Welded, in. (mm) Min. Max. Sketch Cb/c/d/ Sketch Ac/ Sketch Bc/ Jointa/
Butt 1/16 (1.59) to 3/8 (9.5 incl.) 1/16e/
(1.59e/) 2t 1 1
Butt Over 3/8 (9.5) but less than
1/2 (12.7) 3/16 (4.76) 2t 1 1
or
Over 3/8 (9.5) but less than
1/2 (12.7) 3/16 (4.76) 2t 2
Butt 1/2 (12.7) and over Max. to be
3/16 (4.76) weldedf/ g/ 2
Fillet Fig. W.6, Sketch A Unlimited 1
a/ Required only when qualification is desired to make fillet welds only.
b/ For aluminum alloy 6061, use Fig. W.4, Sketch D.
c/ Longitudinal face-bend and longitudinal root-bend tests (Fig. W.3, Sketch B) may be used in
lieu of side-, face-, and root-bend tests only for material combinations differing markedly in
physical bending properties between the two base materials or between the weld metal and
the base materials.
d/ For groove welds made by manual shielded metal-arc welding process, flux-cored arc process,
gas-shielded tungsten arc process, or gas metal arc welding (except short circuiting),
radiography may be used in lieu of guided-bend tests. See paragraph 11.6.3 above.
e/ 0.5t for nonferrous materials, but not less than 1/16 in. (1.59 mm).
f/ When longitudinal face-bend and longitudinal root-bend tests are used in lieu of side-bend
tests, the maximum thickness of material qualified is 2t.
g/ A welder who qualified with 1/2 in. material prior to the reduction in this table may have his
WPQR changed from 2T to thickness to be welded.
11.7 Retests
A welder who fails the performance qualification tests may be retested under the following
conditions:
11.7.1 If one or more of the test specimens prescribed in Table W.6 fails to meet the requirements,
or if the qualification failed has been that of the alternative qualification by radiographic
examination of paragraph 11.6 above.
11.7.1.1 When a retest is made without further training or practice, the welder shall make two
test welds of each type for each “test position” on which the welder failed, all of which shall meet
the requirements.
11.7.1.2 When the welder has had further training or practice, a complete retest shall be made
for each “test position” on which the welder failed to meet the requirements.
11.7.2 If the performance qualification test failed was by radiographic or ultrasonic examination,
the retest shall be by the radiographic or ultrasonic examination method, respectively.
11/2014 C-III [M-1002] 491
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX W M-1002
Table W.9 F-Numbers for steel filler metals—grouping of electrodes and welding rods for qualification
F-No. AWS Specification No. AWS Classification No.
1 A-5.1 and 5.5 EXX20, EXX24, EXX27, EXX28
2 A-5.1 and 5.5 EXX12, EXX13, EXX14
3 A-5.1 and 5.5 EXX10, EXX11
4 A-5.1 and 5.5 EXX15, EXX16, EXX18, EXX48
4 A-5.4 other than austenitic EXX15, EXX16
5 A-5.4 (austenitic) EXX15, EXX16
6 A-5.17 FXX-EXX
6 A-5.9 ERXX
6 A-5.18 ERXXS-X
6 A-5.20 EXXT-X
6 A-5.22 EXXXT-X
6 A-5.23 FXX-EXXX-X, FXX-ECXXX-X, and FXX-EXXX-XN,
FXX-ECXXX-XN
6 A-5.28 ER-XXX-X and E-XXX-X
6 A-5.29 EXXTX-X
Table W.10 A-Numbers—classification of ferrous weld metal analysis for procedure qualification
Analysis, Percentagea/
A-No. Type of Weld Deposit C Cr Mo Ni Mn Si
1 Mild Steel 0.15 — — — 1.60 1.00
2 Carbon-Molybdenum 0.15 0.50 0.40–0.65 — 1.60 1.00
3 Chrome (0.4% to 2%)- 0.15 0.40–2.00 0.40–0.65 — 1.60 1.00
Molybdenum
4 Chrome (2% to 6%)-Molybdenum 0.15 2.00–6.00 0.40–1.50 — 1.60 2.00
5 Chrome (6% to 10.5%)- 0.15 6.00–10.50 0.40–1.50 — 1.20 2.00
Molybdenum
6 Chrome-Martensitic 0.15 11.00–15.00 0.70 — 2.00 1.00
7 Chrome-Ferritic 0.15 11.00–30.00 1.00 — 1.00 3.00
8 Chromium-Nickel 0.15 14.50–30.00 4.00 7.50–15.00 2.50 1.00
9 Chromium-Nickel 0.30 25.00–30.00 4.00 15.00–37.00 2.50 1.00
10 Nickel to 4% 0.15 0.55 0.80–4.00 1.70 1.00
11 Manganese-Molybdenum 0.17 — 0.25–0.75 0.85 1.25–2.25 1.00
12 Nickel-Chrome-Molybdenum 0.15 1.50 0.25–0.80 1.25–2.80 0.75–2.25 1.00
a/ Single values shown above are maximum.
Table W.11 F-Numbers for nonferrous filler metals—grouping of electrodes and welding rods for qualification
F-No. AWS Specification No. AWS Classification No.
Aluminum and Aluminum-Base Alloys
21 A-5.10 ER 1100
22 A-5.10 ER 5554, ER 5356, ER 5556, ER 5183, ER 5654
23 A-5.10 ER 4043, ER 4047, ER 4145
24 A-5.10 R-SC 51A, R356.0
Nickel and Nickel-Base Alloys,
41 A-5.11 E Ni-1
41 A-5.14 ER Ni-1
12.3 Test Joints
12.3.1 The base material, the filler metal, and the welding procedure shall comply with the
applicable WPS. Information regarding the essential variables in paragraph 12.2 above shall be
recorded in the facility’s PQRs prepared for each procedure qualified (See Fig. W.11). The
dimensions of the test plates and the length of the welds shall be sufficient to provide the required
test specimens.
12.3.2 The dimension for plates used for fillet welds shall be as noted in Fig. W.6, Sketch B.
12.3.3 When making procedure tests for butt welds, it is recommended that consideration be
given to the effect of angular, lateral, and end restraint on the weldment. This applies particularly
to material and weld metal of 80,000 psi (552 MPa) tensile strength or higher and heavy sections
of both low- and high-tensile-strength material. The addition of restraint during welding may
result in cracking that otherwise may not occur.
12.3.4 Weld grooves for thicknesses less than 5/8 in. (15.9 mm) shall be prepared by thermal
processes when such processes are to be employed during fabrication of quenched and tempered
materials. This groove preparation shall also include back gouging, back grooving, or removal of
unsound weld metal by thermal processes when this procedure is employed during fabrication.
12.4 Test Specimens
12.4.1 For procedure qualifications, the type and number of test specimens required, together
with the range of thickness qualified by a given thickness of test plate, are shown in Table W.12.
12.4.2 Test specimens shall be removed in the order shown in Figs. W.3, Sketch B, W.6, Sketch B,
W.20, Sketch A, and W.20, Sketch B.
12.4.3 All test specimens shall be prepared and tested and meet the requirements as prescribed
in applicable portions of paragraphs 5.0, 6.0, 7.0, 9.0, and 10.2 of this appendix.
12.4.4 The number of test plates (and sets of test specimens) required by Table W.12 shall be
prepared and tested to provide procedure qualification that will be used in the fabrication, repair,
alteration, or conversion of AAR-approved tanks.
12.5 Retests
When one or more of the test specimens in Table W.12 fail to meet the requirements, a retest may
be made under the following conditions:
12.5.1 When failure of specimens can be attributed to welder performance, an immediate retest
may be made.
12.5.2 When failure of specimens can be attributed to essential variables of the WPS, make
necessary changes and make a new qualification test.
12.6 Renewal of Qualification
Once a welding procedure is qualified, it shall continue in effect indefinitely, within the range of its
essential variables.
13.0 FABRICATION
13.1 Forming
Forming of plates shall be done by pressure and not by impact. This includes the edges of the
plates forming longitudinal joints.
13.2 Cutting to Size
13.2.1 Ferrous and nonferrous plates, edges of heads, and other parts may be cut to size and
shape by mechanical means such as machining, shearing, or grinding or by applicable thermal
cutting.
13.2.2 Oxygen- or arc-cut edges shall be uniform and smooth and shall be free of fins, tears,
cracks, loose or thick scale, slag, surface oxides, moisture, grease, and other foreign material that
would prevent proper welding. Detrimental oxidation of material that was molten shall also be
removed. Discoloration that may remain on oxygen-cut carbon and low-alloy-steel surfaces is not
considered detrimental to welding.
13.3 Alignment
13.3.1 Plates and heads that are being welded shall be fitted, aligned, and retained in position
during the welding operation.
13.3.2 Bars, jacks, clamps, or other appropriate devices, including tack welds, may be used to
hold in alignment the edges to be welded. Temporary tack welds shall be removed. Tack welds
shall be incorporated during final welding or removed. Temporary and/or tack welds shall be
deposited in accordance with a qualified welding procedure. Temporary tack welds shall be
removed and the surface restored to original contour. When temporary welds are deposited after
unit PWHT, the affected area shall be examined (after removal of the temporary weld) by PT or
MT to ensure soundness. Repairs shall be made in accordance with Appendix R.
13.3.3 The parts to be joined by fillet welds shall be brought into as close contact as practicable.
The root opening shall not exceed 3/16 in. (4.8 mm). If the separation is 1/16 in. (1.6 mm) or
greater, the leg of the fillet weld shall be increased by the amount of the separation, or the
manufacturer shall demonstrate that the required effective weld size has been obtained.
13.3.4 For butt welding of plates of unequal thickness, see Appendix E.
15.2.2.8 For single-pass or multipass welding in which any pass is greater than 1/2 in. (12.7 mm)
thick, an increase in base metal thickness beyond 1.1 times that of the qualification test coupon.
15.2.2.9 For the short-circuiting transfer mode of the gas metal-arc process, when the
qualification test coupon thickness is less than 1/2 in. (12.7 mm), an increase in thickness beyond
1.1 times that of the qualification test coupon.
15.2.3 Filler Metals
15.2.3.1 A change from one F-number in Tables W.9 and W.11 to any other F-number, or to any
other filler metal not listed in Tables W.9 and W.11, except qualification under any F-number up to
and including F-No. 5, shall qualify a welder for all lower F-numbers.
15.2.3.2 For the ferrous metals in Table W.10, a change in the chemical composition of the weld
deposit from one A-number to any other A-number in Table W.10. Qualification with A-No. 1 shall
qualify for A-No. 2 and vice versa. In lieu of an A-number designation, the nominal chemical
composition of the weld deposit shall be indicated on the PQR and WPS. Designation of nominal
chemical composition may also be by reference to the AWS classification (where such exists), the
manufacturer’s trade designation, or other established procurement documents.
15.2.3.3 A change from a nonferrous filler metal listed with one AWS classification number in
Table W.11 to a filler metal listed with another classification number, or to any other filler metal.
15.2.3.4 The deletion or addition of filler metal.
15.2.3.5 A change from one of the following filler metal product forms to another:
• flux cored
• bare (solid) or metal cored
• powder
15.2.3.6 The addition or deletion or change of more than 10% in volume of supplemental filler
metal as qualified.
15.2.3.7 In submerged arc welding where the alloy content of the weld metal is largely dependent
upon the composition of the flux used, any change in any part of the welding procedure that would
result in the important alloying elements in the weld metal being outside of the specification range
of chemistry given in the applicable WPS. If there is evidence that production welds are not being
made in accord with the applicable WPS, the inspector may require that a check be made on the
chemical composition of the weld metal. The check preferably shall be made on a production weld.
15.2.3.8 Where the alloy content of the weld metal is largely dependent upon the composition of
the supplemental powdered filler metal, any change in any part of the welding procedure that
would result in the important alloying elements in the weld metal being outside of the
specification range of chemistry given in the procedure specification.
15.2.3.9 Qualification with an F-No. 2X aluminum filler metal shall qualify to weld with any
other F-No. 2X filler metal.
15.2.3.10 If filler metal does not have an AWS classification that defines chemical limits, a
change in weld wire brand name or grade.
15.2.3.11 A change from one F-number in Table W.9 to any other F-number, or to any other filler
metal not listed in Table W.9, except that deposited weld metal using a bare rod not covered by an
AWS specification that conforms to an analysis listed in Table W.10, shall be considered to be
classified as F-No. 6.
15.2.3.12 A change in the nominal diameter of the electrode to over 1/4 in. (6.35 mm).
15.2.3.13 A change in the AWS specification filler metal classification, or to a weld metal or filler
metal composition not covered by these specifications.
Exception: For carbon steel, low alloy steel, and stainless steel, a change in low hydrogen coating
type having the same minimum tensile strength and chemical analysis.
15.2.3.14 A change in FCAW filler metal brand name or grade, unless the AWS specification
requires Charpy properties equal to the required values in the relevant postweld heat treated
condition.
15.2.3.15 A change in
• the indicator for minimum tensile strength (e.g., the “7” in F7A2-EM12K) when the
flux/wire combination is classified by AWS specifications.
• either the flux trade name or wire trade name when neither the flux nor the wire is
classified by AWS specifications.
• the flux trade name for A-No. 8 deposits.
15.2.3.16 When a filler metal with a minimum required tensile strength less than the base metal
is used, the filler metal brand and grade must be essential variables.
15.2.3.17 The omission or addition of consumable inserts.
15.2.4 Positions
15.2.4.1 The addition of welding positions other than those already qualified. See paragraph 9.6
above.
15.2.4.2 A change from any position to the vertical position, uphill progression. Vertical-uphill
progression qualifies for all positions. In uphill progression, a change from stringer bead to weave
bead.
15.2.4.3 A change from uphill to downhill, or from downhill to uphill, in the progression specified
for any pass of a vertical weld.
15.2.5 Preheat
15.2.5.1 A decrease of 100 °F (37.8 °C) or more in the minimum specified preheating temperature
of the qualification test. The minimum temperature for welding shall be specified in the WPS. See
paragraph 13.4.1 in this appendix.
15.2.5.2 An increase of more than 100 °F (37.8 °C) in the maximum interpass temperature
recorded on the PQR.
15.2.5.3 For a preheat temperature of 32 °F (0 °C) or lower, the PQR test temperature is the
minimum.
15.2.6 Postweld Heat Treatment
A separate procedure qualification is required for each of the following:
• No PWHT (Note: Alternate PWHT times and temperatures listed in Table W.16 may be
used without welding procedure requalification.)
• PWHT within a specified temperature range
Heat input (J/in.) = Voltage × Amperage × 60 Heat input (J/cm) = Voltage × Amperage × 60
-------------------------------------------------------------- --------------------------------------------------------------
Travel Speed (in./min) Travel Speed (cm/min)
15.2.7.3.2 A change in volume of weld metal means an increase in bead size, or a decrease in
length of weld bead, per unit length of electrode.
The requirement for measuring the heat input or volume of deposited weld metal does not apply
when the procedure specification is qualified with a grain refining austenitizing heat treatment
after welding.
15.2.8 Shielding Gas or Flux
15.2.8.1 A change from a single gas to any other single gas or to a mixture of gases, or a change in
specified percentage composition of gas mixture.
15.2.8.2 In gas-shielded arc welding processes, the omission of gas backing.
15.2.8.3 A change in flux brand name or designation.
15.2.8.4 A change in flux involving either addition or deletion of any material of screen size finer
than 200 mesh (79 per 10 mm).
15.2.8.5 A change in flux involving the use of recrushed flux.
15.2.9 Technique
15.2.9.1 A change in width, frequency, or dwell time of oscillation for machine or automatic
welding only.
15.2.9.2 In machine welding, a change from single arc to multiple arc, or vice versa.
15.2.9.3 A change from single electrode to multiple electrode, or vice versa, for machine or
automatic welding only.
15.2.9.4 A change from one welding process to any other welding process or combination of
welding processes.
TEST PLATES
TANK SHELL
REINFORCING BARS
TANK
SHELL
THIS PIECE
THIS PIECE
TEST
GUIDED-BEND SPECIMEN
GUIDED-BEND SPECIMEN
CORROSION
Sufficient length to
provide required specimens
T
Guided-Bend Specimens
Allow additional material as shown in
Fig. W.3, Sketch A, when dissimilar
materials used permit longitudinal face-
and root-bend specimens.
TEST PLATES
TANK SHELL
REINFORCING BARS
TANK
SHELL
THIS PIECE
THIS PIECE
TEST
GUIDED-BEND SPECIMEN
GUIDED-BEND SPECIMEN
CORROSION
Sufficient length to
provide required specimens
T
Guided-Bend Specimens
Allow additional material as shown in
Fig. W.3, Sketch A, when dissimilar
materials used permit longitudinal face-
and root-bend specimens.
Note: All dimensions in mm. Appendix H must be followed when using SI units.
10'' approximately t
¼"
¼"
Weld reinforcement shall
2'' R be machined flush with
W = 1 1/2'' ± 0.01'', if t base material
does not exceed 1''
¼" Minimum This section machined,
W = 1'' ± 0.01'', if t preferably by milling
exceeds 1''
D R
C
WELD
B A B
L
SKETCH B: TURNED, REDUCED-SECTION TENSION SPECIMEN
D R
C
WELD
B A B
L
SKETCH B: TURNED, REDUCED-SECTION TENSION SPECIMEN
Note: All dimensions in mm. Appendix H must be followed when using SI units.
WELD
TENSION SPECIMEN
REDUCED-SECTION
TENSION SPECIMEN
REDUCED-SECTION
THIS
THIS
corrosion test specimens are required,
LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
LONGITUDINAL
ROOT-BEND
ROOT-BEND
FACE-BEND
FACE-BEND
SPECIMEN
SPECIMEN
SPECIMEN
SPECIMEN provide additional material as shown in
DISCARD
DISCARD
SKETCH A: SUGGESTED ORDER OF REMOVAL OF TEST SPECIMENS
FACE-BEND ROOT-BEND
R = 1/8 in. max
T (in.)
WELD 1 ½" Materials in All Other
R R t (in.) Table M.10.2 Materials
1/16–1/8 t t
T T
6" MINIMUM 1/8–3/8 1/8 t
t t
Over 3/8 1/8 3/8
Weld reinforcement and backing strip, if any, shall LF LR
be removed flush with the surface of the specimen.
SKETCH B: LONGITUDINAL FACE-BEND AND LONGITUDINAL ROOT-BEND SPECIMENS
Fig. W.3 Test plate and guided-bend test specimens for dissimilar metals
WELD
TENSION SPECIMEN
REDUCED-SECTION
TENSION SPECIMEN
REDUCED-SECTION
THIS
THIS
LONGITUDINAL
LONGITUDINAL
corrosion test specimens are required,
LONGITUDINAL
LONGITUDINAL
ROOT-BEND
ROOT-BEND
FACE-BEND
FACE-BEND
SPECIMEN
SPECIMEN
SPECIMEN
SPECIMEN
DISCARD
FACE-BEND ROOT-BEND
R = 3.18 max
T (mm)
WELD 38.1 Materials in All Other
R R t (mm) Table M.10.2 Materials
1.59 to 3.18 t t
T T
152 MINIMUM 3.18 to 9.52 3.18 t
t t
Over 9.52 3.18 9.52
Weld reinforcement and backing strip, if any, shall LF LR
be removed flush with the surface of the specimen.
SKETCH B: LONGITUDINAL FACE-BEND AND LONGITUDINAL ROOT-BEND SPECIMENS
Fig. W.3.1 Test plate and guided-bend test specimens for dissimilar metals—SI units
SKETCH D SIDE-BEND SPECIMEN FOR ASTM B 209 ALLOY 6061: This specimen to be the same as Sketch C
except for specimen thickness and corner radius. The finished thickness shall
be 1/8'' rather than 3/8'' and the radius shall be 1/16'' max. rather than 1/8'' max.
For longitudinal-face bend and
longitudinal-root bend types of
guided-bend specimens, see
Fig. W.3, Sketch B.
SKETCH D SIDE-BEND SPECIMEN FOR ASTM B 209 ALLOY 6061: This specimen to be the same as Sketch C
except for specimen thickness and corner radius. The finished thickness shall
be 3.18 rather than 9.52 and the radius shall be 1.59 max. rather than 3.18 max.
For longitudinal-face bend and
longitudinal-root bend types of
guided-bend specimens, see Fig. W.3,
Sketch B.
Thickness of A B C D
Specimen, (in.) (in.) (in.) (in.) (in.)
3/8a/ 1 1/2 3/4 2 3/8 1 3/16a/
ta/ 4t 2t 6t + 1/8 3t + 1/16a/
1/8b/ 2 1/16 1 1/32 2 3/8 1 3/16b/
3/8c/ 2 1/2 1 1/4 3 3/8 1 11/16c/
td/ 6 2/3t 3 1/3t 8 2/3t + 1/8 4 1/3t + 1/16d/
a/ Use for all materials not otherwise indicated.
b/ Use only for P-23 aluminum alloys.
c/ Use only for P-25 aluminum alloys.
d/ Use only for P-25 aluminum alloys where thickness, t, is less than 3/8 in.
To determine
SI dimensions,
see
Thickness of A B C D
Specimen, (mm) (mm) (mm) (mm) (mm)
9.52a/ 38.1 19.0 60.3 30.2a/
ta/ 4t 2t 6t + 3.18 3t + 1.59a/
3.18b/ 52.4 26.2 60.3 30.2b/
9.52c/ 63.5 31.8 85.7 42.9c/
td/ 6 2/3t 3 1/3t 8 2/3t + 3.18 4 1/3t + 1.59d/
a/ Use for all materials not otherwise indicated.
b/ Use only for P-23 aluminum alloys.
c/ Use only for P-25 aluminum alloys.
d/ Use only for P-25 aluminum alloys where thickness, t, is less than 9.52 mm.
MACRO TEST
DIRECTION OF LOADING
NOTES: T
1. FOR FERROUS MATERIALS:
L = 10" STOP AND RESTART
W = 3" WELDING NEAR THE 1"
T = 16" to 2 " CENTER
3 1
MACRO TEST
12" MIN.
NOTE:
T = MAXIMUM THICKNESS OF 1"
BASE MATERIAL IN TANK AT POINT 6" MIN.
OF WELDING OR 1", WHICHEVER IS
SMALLER
FIVE EQUAL SECTION
MACRO TEST
MACRO TEST
NOTE:
T = MAXIMUM THICKNESS OF
BASE MATERIAL IN TANK AT POINT
OF WELDING OR 25.4 MM, WHICHEVER IS
SMALLER
FIVE EQUAL SECTION
80° 90°
Axis
limits
for E
125° 0°
Axis limits for D D 360°
235°
150° C
A 0° 360°
B 210° Vertical
125° B plane
15° 235°
P
Axis limits
for A and B
0° C 360° Horizontal plane
0°
Notes:
1. The horizontal reference plane is always taken to lie below the weld under consideration.
2. The inclination of axis is measured from the horizontal reference plane toward the vertical reference plane.
3. The angle of rotation of the face is determined by a line perpendicular to the theoretical face of the weld which passes through the axis of
the weld. The reference position (0°) of rotation of the face invariably points in the direction opposite to that in which the axis angle increases.
When looking at point P, the angle of rotation of the face of the weld is measured in a clockwise direction from the reference position (0°).
80° 90°
Axis
limits
for E
D 0°
Axis limits for D 360°
80°
280°
0° C 360° Vertical
150° A plane
210°
B
15° B
80° P
Notes:
1. The horizontal reference plane is always taken to lie below the weld under consideration.
2. The inclination of axis is measured from the horizontal reference plane toward the vertical reference plane.
3. The angle of rotation of the face is determined by a line perpendicular to the theoretical face of the weld which passes through the axis of the
weld. The reference position (0°) of rotation of the face invariably points in the direction opposite to that in which the axis angle increases.
When looking at point P, the angle of rotation of the face of the weld is measured in a clockwise direction from the reference position (0°).
LONGITUDINAL SPECIMEN
TRANSVERSE
SPECIMEN
WELD
PLATE SURFACE
LOCATE SPECIMEN WITHIN 16" (1.59) OF PLATE
1
NOTES:
1. ALL NOTCHES CUT PERPENDICULAR TO
PLATE SURFACE.
CUT TO FINISHED LENGTH AFTER NOTCHING
2. ALL COMMENTS APPLY TO FULL SIZE OR
SUBSIZE SPECIMENS.
3. ALL COMMENTS APPLY TO TYPE A
(CHARPY V-NOTCH), TYPE B (CHARPY
KEYHOLE NOTCH), OR TYPE C (CHARPY
U-NOTCH) SPECIMENS
WELD
8 mm.
(0.315'')
0.25 mm.
(0.010'') rad.
10 mm.
(0.394'') VEE-NOTCH
L/2
55 mm
(2.165'') 10 mm. 45°
L (0.394'')
D = 8 mm
(0.315'') D 10 mm. D 10 mm. D
(0.394'') (0.394'')
Fig. W.10 Type A Charpy (simple beam) impact test specimen dimensions
ELECTRICAL CHARACTERISTICS
Current AC or DC __________ Polarity _________________________
Amps (Range) ___________________ Volts (Range) _______________
(Amps and volts range should be recorded for each electrode size, position and thickness, etc.
This information may be listed in a tabular form similar to that shown below)
Tungsten Electrode Size & Type_________________________________________________________________
(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW ______________________________________________________________
(Spray, arc, short-circuited arc, etc.)
Electrode Wire Feed Speed Range _______________________________________________________________
TECHNIQUE
String or Weave Bead __________________________________________________________________________
Orifice or Gas Cup Size _________________________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding, etc.) __________________________________________
_______________________________________________________________________________________________
Method of Back Gouging________________________________________________________________________
Oscillation ____________________________________________________________________________________
Contact Tube to Work Distance _________________________________________________________________
Multiple or Single Pass (per side)________________________________________________________________
Multiple or Single Electrodes ___________________________________________________________________
Travel Speed (Range)___________________________________________________________________________
Peening _______________________________________________________________________________________
Other _________________________________________________________________________________________
_____________________________________________________________________________________________
Filler Metal Current OTHER
Travel (e.g. Remarks, Comments,
Weld Type Amperage Voltage Speed Hot Wire Addition, Tech-
Layer(s) Process Class Diameter Polarity Range Range Range nique, Torch Angle, etc.)
Fig. W.11 Suggested format for welding procedure specification (WPS) (concluded)
POSITION TECHNIQUE
Position of Groove _______________________________ Travel Speed____________________________________
Weld Progression (Upward, Downward) ___________ String of Weave Bead ____________________________
Other __________________________________________ Oscillation______________________________________
________________________________________________ Multipass or Single Pass (per side)________________
________________________________________________ Single or Multiple Electrodes_____________________
Other __________________________________________
PREHEAT ________________________________________________
Preheat Temperature ____________________________ ________________________________________________
Interpass Temperature __________________________ ________________________________________________
Other __________________________________________ ________________________________________________
________________________________________________ ________________________________________________
ULTIMATE TENSILE
STRENGTH
YIELD
Type & STRENGTH REDUCTION
Figure Diameter Area Total Load Unit Stress (0.2% offset) ELONGA- OF AREA
No. in. sq. In. lb. psi psi TION (%) (%)
Manufacturer: _________________________________________________________________________________________
Date ____________________________________________ By: __________________________________________________
Revised 3/16/88 Page 2 of 2
Fig. W.12 Suggested format for procedure qualification record (PQR) (concluded)
Backing (metal, weld metal, welded from both sides, flux, etc.)
P-No. to P-No.
Filler metal specification (AWS) / Classification
Filler metal F-No.
Consumable insert
Weld thickness
Welding position (1G, 5G, etc.)
Progression (uphill/downhill)
Backing gas for GTAW
GMAW transfer mode
GTAW welding current type/polarity
Type (Side, Root, Face) Result Type (Side, Root, Face) Result
Visual examination (see paragraphs W15.3, 15.4, 15.5, and 15.9) Acceptable
Yes
No
Radiographic test results
Macro test fusion Fillet leg size in. × in. Concavity/convexity in.
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in
accordance with the requirements of Appendix W.
Organization
Date By
Plate horizontal. Axis of weld horizontal. Plate vertical. Axis of weld horizontal.
FLAT POSITION 1G HORIZONTAL POSITION 2G
Plate vertical.
Axis of weld vertical.
Axis of Weld
Horizontal
Throat of Weld
Vertical
45°
ASSORTED
0.10 4
LARGE
0.031 40
MEDIUM
0.0195 101
FINE
ASSORTED
2.54 4
LARGE
0.787 40
MEDIUM
0.495 101
FINE
0.024 35
0.034 19
0.125 1
ASSORTED
0.125 4
LARGE
0.034 50
MEDIUM
0.024 99
FINE
0.610 35
0.864 19
3.18 1
ASSORTED
3.18 4
LARGE
0.864 50
MEDIUM
0.610 99
FINE
0.0275 38
0.039 21
0.125 1
ASSORTED
0.125 5
LARGE
0.039 50
MEDIUM
0.0275
101
FINE
0.698 38
0.991 21
3.18 1
ASSORTED
3.18 5
LARGE
0.991 50
MEDIUM
0.698 101
FINE
0.039 38
0.055 21
0.125 2
ASSORTED
0.125 10
LARGE
0.055 51
MEDIUM
0.039 100
FINE
0.991 38
1.40 21
3.18 2
ASSORTED
3.18 10
LARGE
1.40 51
MEDIUM
0.991 100
FINE
WELD WELD
SKETCH AFOR PLATES 1/16" TO 3/4" (1.59 TO 19.0) THICK SKETCH BFOR PLATES 3/8" (9.52) AND OVER THICK
WELDING PROCEDURE QUALIFICATION SPECIMEN
WELD WELD
SKETCH CFOR PLATES 1/16" TO 3/4" (1.59 TO 19.0) THICK SKETCH DFOR PLATES 3/8" (9.52) AND OVER THICK
APPENDIX X
DOT REGULATIONS
CONTENTS
APPENDIX X
DOT REGULATIONS
1.0 INTRODUCTION
DOT requirements for tank cars are set forth in the Code of Federal Regulations, Title 49, Sections
173.31, 173.314, 173.319, and 173.320 and Parts 179 and 180.
Published in DOT Notice 93-12 is a list of thermal protection systems that may be used, without
further test verification, on DOT Specification 105, 111, 112, and 114 tank cars to satisfy thermal
protection requirements.
APPENDIX Y
SELECTED AAR CIRCULAR LETTERS
CONTENTS
APPENDIX Y
SELECTED AAR CIRCULAR LETTERS
1.0 INTRODUCTION
Certain letters to members and private car owners contain information not found in the
Specifications for Tank Cars, but are believed to be of long-term relevance. These are copied in this
appendix for reference.
1. Type A bottom outlet valves (Fisher and Rego internal valves with vertical lift seats)
must be protected in accordance with Appendix E, paragraph 8.0, of the AAR Tank Car Spec-
ifications. Such fittings will be exempted from this requirement if the shear groove can be
relocated, in an approved manner, to the bottom of the tank flange providing the maximum
projection of the tank outlet flange from the shell envelope does not exceed 2 inches. This will
apply only to Type A valves with the closure seat above the shear groove and attached so that
the seat will remain intact if the outlet leg is sheared off at the tank flange face. Relocating
the shear groove will mean eliminating the tongue and groove connection between the tank
flange and the valve and reducing the strength of the bolted joint.
2. Type B (Jamesbury internal ball valve) bottom outlets must be protected in accor-
dance with Appendix E, paragraph 8.0, of the AAR Tank Car Specifications except that the
Tank Car Committee will be receptive to proposals of alternate protection schemes when sub-
mitted by car owners.
3. Sumps on existing cars, not exceeding 5 inches in depth, are exempt from require-
ments of Appendix E, paragraph 8.0,. Sump reference here is to weld cap type of pressed steel
sumps (pressed into tank shell or a separate pressing welded into or onto the tank shell). The
exemption does not include sumps formed of straight nozzles with essentially flat cover
plates, bolted or welded in place. Sumps not referred to above or sumps of 5 inches or greater
depth are subject to additional review by the Tank Car Committee for design features.
4. Blind flanged outlets must be protected in accord with one of the following three
options:
a. Protection in accordance with Appendix E, paragraph 8.0,
b. Provide an internal closure similar to those required for washouts. Remove the tongue
from the appropriate flange to provide a shear groove at the bottom of the tank flange.
The maximum allowable projection of the tank outlet flange from the shell envelope is
2 in. Reinstall the blind flange with proper gasketing to provide a secondary closure
and hydrostatically retest the assembly. Maximum protrusion of the outlet, including
studs, is not to exceed 4 5/8 in. from the shell envelope.
c. Weld a steel plug into the shell, thus sealing the outlet, remove the blind flange and
hydrostatic test. Radiographing any butt weld involved will be waived since it is not
practical. No protrusion will be allowed below the plane of the tank flange and the
protrusion of the tank flange beyond the shell envelope is not to exceed two inches.
Exhibit 2
Association of American Railroads
Mechanical Division Circular D.V. 2007
of heat.
(4)Group 9 commodities are evaluated on an individual basis and protection levels are assigned as deemed
appropriate. See Fig. Y5 for Group 9 commodities which have been assigned protection levels.
Exhibit 2
Association of American Railroads
Mechanical Division Circular D.V. 2007
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D)
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Acetal 6 C Alcohol, n.o.s. (alcohol, contaminated,
Acetaldehyde 3 A suitable only for blending or redistilling
purposes) 6 C
Acetic acid 3 C
Alcohol, n.o.s. (ethyl alcohol, anhydrous,
Acetic anhydride 3 B denatured in part with petroleum
Acetone 6 C products and/or chemicals, petroleum
Acetone cyanohydrin 1 A products and/or chemicals not to
Acetone oil 6 C exceed five percent) 6 C
Acetonitrile 2 B Alcohol, n.o.s. (denatured alcohol solvent) 6 C
Acetyl Bromide 3 B Alcohol, n.o.s. (denaturing alcohol, nec)
(flammable) 6 C
Acetyl chloride 3 B
Alcohol, n.o.s. (denaturing alcohol, nec)
Acetyl iodide 7 B (combustible) 8 C
Acid butyl phosphate 7 C Alcohol, n.o.s. (isopropanol and methanol
Acid, glacial methacrylic (corrosive liquid, mixture) 6 C
n.o.s.) 7 C Alcohol, n.o.s. (methanol, contaminated,
Acid, liquid, n.o.s. (acids, inorganic, nec, value only for refining) 6 C
liquid) 7 D Alcohol distillates, synthetic (alcohol, n.o.s.)
Acid, liquid, n.o.s. (acid, nec, liquid, (flammable) 6 C
organic) 7 D Alcohol distillates, synthetic (alcohol, n.o.s.)
Acrylamide solution (combustible liquid, (combustible) 8 C
n.o.s.) 8 C Alcoholic beverage (flammable) 6 C
Acrylamide solution (flammable liquid, Alcoholic beverage (combustible) 8 C
n.o.s.) 6 C
Alcohols, fatty or cyclic, ethoxylated
Acrylic acid 7 C (alcohol, n.o.s.) (combustible) 8 C
Acrylonitrile 1 A Alcohols, fatty or ethoxylated (alcohol,
Active sec-amyl alcohol (alcohol, n.o.s.) 6 C n.o.s.) (flammable) 6 C
Additives, fuel oil, gasoline, or lubricating Aldol (combustible liquid, n.o.s.) 8 C
oil, containing less than 50% by weight Aldrin 1 A
of petroleum (combustible liquid, n.o.s.) 8 C
Alkaline battery fluid 7 C
Additives, fuel oil, gasoline, or lubricating
oil, containing less than 50% by weight Alkaline (corrosive) liquid, n.o.s. 7 D
of petroleum (flammable liquid, n.o.s.) 6 C Alkaline (corrosive) liquid, n.o.s. (fatty
Adhesive, n.o.s. (flammable) 6 C alcohols, aliphatic or cyclic,
cyanoethylated and hydrogenated, and
Adhesive, n.o.s. (combustible) 8 C derivatives thereof, such as salts,
Adhesive, n.o.s. (insecticide adhesives, diamines, oxyalkylates and quarternary
liquid) (combustible) 8 C ammonium compounds) 7 C
Adhesive, n.o.s. (insecticide adhesives, Alkanesulfonic acid 7 C
liquid) (flammable) 6 C Allyl alcohol 1 A
Alcohol, n.o.s. (flammable) 6 C Allyl bromide 2 C
Alcohol, n.o.s. (combustible) 8 C Allyl chloride 2 C
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–554 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Allyl trichlorosilane 7 B Antifreeze compound, liquid (combustible) 8 C
Aluminum liquid (or) paint 6 C Antifreeze preparation, liquid (flammable) 6 C
Aluminum phosphate solution 7 C Antifreeze preparation, liquid (combustible) 8 C
Aluminum sulfate 3 C Antimony pentachloride 3 C
2-(2-aminoethoxy) ethanol 7 C Antimony tribromide 3 C
Aminoethylethanolamine (corrosive liquid, 7 C Antimony trichloride 3 C
n.o.s.) Antimony trifluoride 3 B
N-aminoethylpiperazine 7 C Aromatic concentrates, suitable only for 6 C
Aminopropyldiethanolamine 7 C further processing (flammable liquid,
N-aminopropylmorpholine 7 C n.o.s.)
Ammonium bifluoride 3 C Arsenic trichloride 3 A
Ammonium bisulfite 3 C Arsenic acid solution 5 A
Ammonium hydroxide 3 C Arsenical dip, liquid (sheep dip) 5 A
Ammonium sulfide 3 C Arsenical pesticide (compounds and 6 D
preparations), liquid (flammable)
Ammonium thiocyanate 3 C
Arsenical pesticide (compounds and 5 D
Ammonium thiosulfate 3 C
preparations), liquid (poison)
Amyl acetate 3 C
Asphalt, cut back 6 C
Active primary amyl alcohol (alcohol, n.o.s.) 8 C
Asphalt, cut back (asphalt petroleum, liquid 8 C
n-sec-amyl alcohol (alcohol, n.o.s.) 6 C and tall oil pitch, mixed)
Amyl acid phosphate 7 C Asphalt pavement surface sealer, asphalt, 8 C
Primary n-amyl alcohol (alcohol, n.o.s.) 6 C coal tar or petroleum base (combustible
Tert-amyl alcohol (alcohol, n.o.s.) 6 C liquid, n.o.s.)
Amylamine 6 C Asphalt pavement surface sealer, asphalt, 6 C
coal tar or petroleum base (flammable
Amyl chloride 6 C
liquid, n.o.s.)
Amylene, (normal) 6 C
Asphalt tile plasticizer (combustible liquid, 8 C
Amyl formate 6 C n.o.s.)
Amyl mercaptan 6 C Asphalt tile plasticizer (flammable liquid, 6 C
Amyl nitrate (combustible liquid, n.o.s.) 8 C n.o.s.)
Amyl nitrite (flammable) 6 C Belt dressing (combustible liquid, n.o.s.) 8 C
Amyl phenol (corrosive liquid, n.o.s.) 7 A Belt dressing (flammable liquid, n.o.s.) 6 C
Amyl trichlorosilane 7 B Benzaldehyde 8 C
Aniline 3 B Benzene 3 A
Anisoyl chloride 7 B Benzene phosphorus dichloride 7 B
Antifreeze alcohols (alcohol, n.o.s.) 6 C Benzene phosphorus thiodichloride 7 B
(flammable) Benzidine 5 C
Antifreeze alcohols (alcohol, n.o.s.) 8 C Benzine 6 C
(combustible)
Benzoic derivative pesticide (compounds 6 D
Antifreeze compound, liquid (flammable) 6 C and preparations), liquid (flammable)
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III–555
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Benzoic derivate pesticide (compounds 5 D Butyl methacrylate (combustible liquid, 8 C
and preparations), liquid (poison) n.o.s.)
Benzol fore-runnings, crude, not benzol 6 C Butyl phenol (corrosive solid, n.o.s.) 7 A
(flammable liquid, n.o.s.) n-Butyl phthalate 1 A
Benzonitrile 3 A Butyl trichlorosilane 7 B
Benzoyl chloride 3 B Butyraldehyde 6 B
Benzyl chloride 1 A Butyric acid (Isobutyric acid) 3 C
Beta-propiolacetone (combustible liquid, 8 C Butyronitrile (flammable liquid, n.o.s.) 6 C
n.o.s.)
Calcium dodecylbenzenesulfonate 3 B
Biphenyl (diphenyl) (combustible liquid, 8 C
Calcium hydrogen sulfite solution 7 C
n.o.s.)
Camphor oil 8 C
Bipyridilium pesticide (compounds and 6 D
preparations), liquid (flammable) Carbamate pesticide (compounds and 6 D
preparations), liquid (flammable)
Bipyridilium pesticide (compounds and 5 D
preparations), liquid (poison) Carbamate pesticide (compounds and 5 D
preparations), liquid (poison)
Bis-(aminopropyl) piperazine 7 C
Carbon black oil (combustible liquid, n.o.s.) 8 C
Boiler compound, liquid 7 D
Carbon black oil (flammable liquid, n.o.s.) 6 C
Bordeau arsenite, liquid 5 A
Carbon disulfide 3 D
Boron tribromide 7 C
Carbon remover, liquid 6 C
Boron trichloride 7 C
Carbon tetrachloride 3 C
Boron trifluoride acetic acid complex 7 C
Cement, leather 6 C
Box toe gum (flammable) 6 C
Cement, linoleum, tile, wallboard or 6 C
Box toe gum (combustible) 8 C
container, liquid
Bromoacetic acid solution 7 C
Cement, liquid, n.o.s. (flammable) 6 C
Bromobenzene 8 C
Cement, liquid, n.o.s. (combustible) 8 C
Butyl acetate (Isobutyl acetate) 3 C
Cement or concrete waterproofing 8 C
Butyl alcohol (isobutyl alcohol) 6 C compound, liquid or paste (combustible
Butyl alcohol (n-butyl alcohol) 6 C liquid, n.o.s.)
Butyl alcohol (2-butanol) 6 C Cement or concrete waterproofing 6 C
Butyl alcohol (tert-butyl alcohol) 6 C compounds, liquid or paste (flammable
liquid, n.o.s.)
Butylamine (Isobutylamine) 3 C
Cement, pyroxylin 6 C
Butyl bromide, (normal) 6 C
Cement, roofing, liquid 6 C
Butyl chloride 6 C
Cement, rubber 6 C
Butyl ether 6 C
Chemical plant waste, nec (combustible 8 D
n-Butyl isocyanate, (flammable liquid, 2 C
liquid, n.o.s.)
n.o.s.)
Chemical plant waste, nec (corrosive liquid, 7 D
Butyl lactate (combustible liquid, n.o.s.) 8 C
n.o.s.)
Butyl mercaptan 6 C
Chemical plant waste, nec (flammable 6 D
liquid, n.o.s.)
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–556 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Chemical plant waste, nec (poisonous 5 D Coal tar light oil (combustible) 8 C
liquid, n.o.s.) Coal tar naphtha (flammable) 6 C
Chloral (corrosive liquid, n.o.s.) 7 C Coal tar naphtha (combustible) 8 C
Chlorinated lime, liquid (corrosive liquid, 7 C Coal tar nephtha and light oil of coal tar 8 C
n.o.s.) crude (combustible liquid, n.o.s.)
Chloroacetic acid, liquid (or) solution 7 C Coal tar naphtha and light oil of coal tar, 6 C
Chloroacetic acid, solid 7 C crude (flammable liquid, n.o.s.)
Chloroacetyl chloride 7 B Coal tar oil (flammable) 6 C
Chlorobenzene 1 A Coal tar oil (combustible) 8 C
Chloroform 3 C Coal tar oil, crude, nec (corrosive liquid, 7 C
Chloropentanes (combustible liquid, n.o.s.) 8 C n.o.s.)
Chloropentanes (flammable liquid, n.o.s.) 6 C Coal tar oil, crude, nec (corrosive solid, 7 C
n.o.s.)
Chlorophenyl trichlorosilane 7 B
Coal treating compounds, other than 8 D
Chloroprene 2 B
petroleum, nec, liquid (combustible
2-chloropropene 6 C liquid, n.o.s.)
Chlorosulfonic acid (Chlorosulfonic acid 3 B Coal treating compounds, other than 6 D
sulfur trioxide mixture) petroleum, nec, liquid (flammable liquid,
Chrome chloride solution (corrosive liquid, 7 C n.o.s.)
n.o.s.) Coating solution 6 C
Chromic acid 3 B Collidine (combustible liquid, n.o.s.) 8 C
Chromic fluoride solution 7 C Collodion 6 C
Chromic sulfate 3 C Combustible liquid, n.o.s. 8 D
Chromium oxychloride (or) chromyl 7 B Combustible liquid, n.o.s. (absorption oil, 8 C
chloride belt oil, compression oil, cordage oil,
Chromous chloride 3 C floor oil, harness oil, leather oil,
Coal briquette binder (combustible liquid, 8 C neatsfoot oil, putty oil, tanners oil,
n.o.s.) tobacco oil, transformer oil or wood oil,
petroleum)
Coal briquette binder (flammable liquid, 6 C
n.o.s.) Combustible liquid, n.o.s. (alcohol, 8 C
contaminated, suitable only for blending
Coal spraying oil, petroleum (combustible 8 C
or redistilling purposes)
liquid, n.o.s.)
Combustible liquid, n.o.s. (aromatic 8 C
Coal tar distillate (flammable) 6 C
concentrates, suitable only for further
Coal tar distillate (combustible) 8 C processing)
Coal tar dye, liquid (not otherwise 7 D Combustible liquid, n.o.s. (bond breaking 8 C
specifically named in section 172.101) compound, consisting of naphtha,
Coal tar fibre saturant, liquid (combustible 8 C petroleum resins and vegetable oils)
liquid, n.o.s.) Combustible liquid, n.o.s. (fungicides, 8 D
Coal tar fibre saturant liquid (flammable 6 C agricultural, nec, liquid)
liquid, n.o.s.) Combustible liquid, n.o.s. (lubricating oil, 8 C
Coal tar light oil (flammable) 6 C nec)
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III–557
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Combustible liquid, n.o.s. (lubricating 8 C Compounds, hectograph (combustible 8 D
system sight feed fluid) liquid, n.o.s.)
Combustible liquid, n.o.s. (petroleum 8 C Compounds, hectograph (flammable liquid, 6 D
lubricating oil) n.o.s.)
Combustible liquid, n.o.s. (petroleum 8 C Compounds, leather finishing, nec 8 D
partially refined, for further processing) (combustible liquid, n.o.s.)
Combustible liquid, n.o.s. (petroleum oil 8 C Compounds, leather finishing, nec 6 D
residuum) (flammable liquid, n.o.s.)
Combustible liquid, n.o.s. (rubber tire 8 C Copper based pesticide (compounds and 6 D
lacquer, paint or shellac) preparations), liquid (flammable)
Combustible liquid, n.o.s. (smoke flue 8 D Copper based pesticide (compounds and 5 D
cleaning compounds) preparations), liquid (poison)
Combustible liquid, n.o.s. (wallpaper 8 D Copper naphthenate petroleum solution, 8 C
remover, liquid) not more than 8% copper naphthenate
Compound, cleaning, liquid (corrosive)) 7 C (combustible liquid, n.o.s.)
Compound, cleaning, liquid (flammable) 6 C Copper naphthenate petroleum solution, 6 C
not more than 8% copper naphthenate
Compound, cleaning, liquid (combustible) 8 C
(flammable liquid, n.o.s.)
Compound, cleaning, liquid (smoke flue 6 D
Corrosive liquid, n.o.s. 7 D
cleaning compounds)
Corrosive liquid, poisonous, n.o.s. 7 D
Compound, enamel 6 C
Corrosive solid, n.o.s. 7 D
Compound, lacquer, paint (or) varnish 7 C
removing, liquid Cosmetics, n.o.s., liquid 7 D
Compound, lacquer, paint, (or) varnish 6 C Cosmetics, n.o.s. (flammable) 6 D
removing, reducing (or) thinning, liquid Cosmetics, n.o.s. (combustible) 8 D
(flammable) Cresol 3 A
Compound, lacquer, paint (or) varnish, 8 C Creosote, coal tar 8 B
removing, reducing, (or) thinning, liquid
Crotonaldehyde 1 A
(combustible)
Crotonic acid 7 C
Compound, polishing, liquid 6 C
Crotonylene 6 C
Compound, rust preventing (or) compound, 7 C
rust removing Crude oil, petroleum (flammable) 6 C
Compound, tree (or) weed killing, liquid 8 D Crude oil, petroleum (combustible) 8 C
(combustible) Cumene (combustible liquid, n.o.s.) 8 C
Compound, tree (or) weed killing 7 D Cupriethylene-diamine solution 7 C
(corrosive) Cutch, catechu or japonica extract, liquid 8 C
Compound, vulcanizing, liquid (corrosive) 7 D (combustible liquid, n.o.s.)
Compound, vulcanizing, liquid (flammable) 6 C Cutch, catechu, or japonica extracts, liquid 6 C
Compounds, calking or glazing 8 C (flammable liquid, n.o.s.)
(combustible liquid, n.o.s.) Cyanide solution, n.o.s. 5 B
Compounds, calking or glazing (flammable 6 C Cyclohexane 3 C
liquid, n.o.s.) Cyclohexanone (combustible liquid, n.o.s.) 8 C
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–558 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Cyclohexenyl trichlorosilane 7 B Dichloropropene 3 B
Cyclohexyl trichlorosilane 7 B Dichloropropene (Dichloropropane 3 B
Cyclohexylamine 6 C Mixture)
Cyclopentane 6 C 2, 2-Dichloropropionic acid 3 C
Cyclopentane, methyl 6 C Diethylamine 3 B
Decahydronaphthalene 8 C Diethylaminoethanol (combustible liquid, 8 C
n.o.s.)
Decyl alcohol, other than perfumery grade 8 C
(alcohol, n.o.s.) Diethylbenzene (combustible liquid, 8 C
n.o.s.)
Defoaming compound, nec, liquid 8 C
(combustible liquid, n.o.s.) Diethyl dichlorosilane 6 B
Defoaming compound, nec, liquid 6 C Diethylenetrimine (corrosive liquid, n.o.s.) 7 C
(flammable liquid, n.o.s.) Diethylhydroxylamine (combustible liquid, 8 C
Degumming compounds, fabric or fibre 8 C n.o.s.)
(combustible liquid, n.o.s.) Diethyl ketone 6 C
Degumming compounds, fabric or fibre 6 C Dihydropyran 6 C
(flammable liquid, n.o.s.) Diisobutylamine (flammable liquid, n.o.s.) 6 C
De-inking compounds, liquid, used in 7 C Diisobutyl carbinol (alcohol, n.o.s.) 8 C
recycling paper (corrosive liquid, n.o.s.)
Diisobutylene (flammable liquid, n.o.s.) 6 C
Denatured alcohol 6 C
Diisobutyl ketone 8 C
Detergent intermediates, other than cyclic 8 C
Diisooctyl acid phosphate 7 C
or petroleum (combustible liquid, n.o.s.)
Diisopropylamine 6 C
Detergent intermediates, other than cyclic 6 C
or petroleum (flammable liquid, n.o.s.) Diisopropylether 6 C
Diacetone alcohol 6 C Dimethylamine, aqueous solution 3 B
Diacetyl 6 C Dimethylaminoethanol (combustible liquid, 8 C
n.o.s.)
Dicamba 3 C
Dimethylaminoethyl methacrylate 8 C
Dichlobenil 3 C
(combustible liquid, n.o.s.)
Dichlorobenzene 1 A
2, 3-dimethylbutane 6 C
Dichloroacetic acid 7 C
Dimethyl carbonate 6 C
Dichloroacetyl chloride 7 B
Dimethyl chlorothiophosphate (or) dimethyl 7 B
Dichlorobutene (corrosive) 7 C phosphorochloridothioate
Dichlorobutene (flammable) 2 C 1, 4-dimethylcyclohexane 6 C
Dichloroethyl ether (poisonous liquid, 5 C Dimethylethylamine (flammable liquid, 6 C
n.o.s.) n.o.s.)
Dichlorethylene 6 C Dimethylhydrazine, unsymmetrical 2 A
Dichloroisopropyl ether 7 C Dimethyl sulfate 7 B
Dichloropentane 6 C Dimethyl sulfide 6 C
Dichlorophenyl trichlorosilane 7 B Dinitrobenzene 3 C
Dichloropropane 3 B Dinitrochlorobenzene 5 C
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III–559
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Dinitrophenol 3 B Enamel (enamel, other than watch dial) 6 C
Dinitrotoluene 3 C (flammable)
Dioxane 6 C Enamel (enamel other than watch dial) 8 C
(combustible)
Dioxolane 6 C
Enamel whitening compounds, nec 8 C
Diphenyl dichlorosilane 7 B
(combustible liquid, n.o.s.)
Diphenylmethylbromide, solution 7 C
Enamel whitening compounds, nec 6 C
Di-n-propylamine (flammable liquid, n.o.s.) 6 C (flammable liquid, n.o.s.)
Diquat 3 C Epichlorohydrin 2 A
Disinfectant, liquid (corrosive) 7 D Eradicator, paint (or) grease, liquid 6 C
Disinfectant, liquid (poison) 5 D Ethyl acetate 6 C
Disinfectant, liquid, n.o.s. 8 D Ethyl acrylate 2 B
Distillate 6 C Ethyl alcohol 6 C
Dithiocarbamate pesticide (compounds and 6 D Ethyl benzene 3 C
preparations), liquid (flammable)
Ethyl butyl acetate 8 C
Dithiocarbamate pesticide (compounds and 5 D
Ethyl-n-butylamine (flammable liquid, 6 C
preparations), liquid (poison)
n.o.s.)
Divinyl ether 6 C
Ethyl butyl ether 6 C
Dodecylbenzenesulfonic acid 3 B
Ethyl butyraldehyde 6 C
Dodecyltrichlorosilane 7 B
Ethyl butyrate 6 C
Drugs, n.o.s. (flammable) 6 D
Ethyl chloride 6 C
Drugs, n.o.s. (combustible) 8 D
Ethyl chloroacetate 8 C
Drugs, n.o.s., liquid (poison) 5 D
Ethyl crotonate 6 C
Drugs, n.o.s., liquid (corrosive) 7 D
Ethyl-N-cyclohexylamine (flammable liquid, 6 C
Drugs, n.o.s., solid 7 D n.o.s.)
Dye intermediate, liquid 7 D Ethyl dichlorosilane 6 B
Electric wire saturating or finishing 8 C Ethylene diamine 3 C
compound, asphalt or pitch base
Ethylene dibromide 3 B
(combustible liquid, n.o.s.)
Ethylene dichloride 3 B
Electric wire saturating or finishing 6 C
compound, asphalt or pitch base Ethylene glycol diethyl ether 8 C
(flammable liquid, n.o.s.) Ethylene glycol monoethyl ether 8 C
Electric wire saturating or finishing 8 C Ethylene glycol monoethyl ether acetate 8 C
compound, paraffine base (combustible Ethylene glycol monomethyl ether 8 C
liquid, n.o.s.)
Ethylene glycol monomethyl ether acetate 8 C
Electric wire saturating or finishing 6 C
Ethylene imine 2 A
compound, paraffine base (flammable
liquid, n.o.s.) Ethylene oxide 6 B
Electrolyte (acid), battery fluid (not over 7 C Ethyl ether 6 C
47% acid) Ethyl formate 6 C
Ethylhexaldehyde 8 C
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–560 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Ethylhexyl acrylate (combustible liquid, 8 C Fireproofing compounds, liquid, nec 7 C
n.o.s.) (corrosive liquid, n.o.s.)
Ethyl lactate 8 C Flame retardant compound, liquid 7 C
Ethyl mercaptan 6 C Flammable liquid, n.o.s. 6 D
n-ethyl-metatoluidine (combustible liquid, 8 C Flammable liquid, n.o.s. (bond breaking 6 C
n.o.s.) compound consisting of naphtha,
Ethyl methyl ether 6 C petroleum resins and vegetable oils)
Ethyl nitrate 2 C Flammable liquid, n.o.s. (petroleum oil 6 C
additive, containing more than 50
Ethyl nitrite 2 C
percent by weight of petroleum)
Ethyl phenyl dichlorosilane 7 B
Flammable liquid, corrosive, n.o.s. 6 D
Ethyl phosphonothioic dichloride, 7 B
Flammable liquid, poisonous, n.o.s. 6 D
anhydrous
Floor covering underlayment compounds, 8 C
Ethyl phosphonous dichloride, anhydrous 7 B
nec (combustible liquid, n.o.s.)
Ethyl phosphorodichloridate 7 B
Floor covering underlayment compounds, 6 C
Ethyl propionate 6 C nec (flammable liquid, n.o.s.)
Ethyl silicate 8 C Fluorosulfonic acid (or) fluosulfonic acid 7 B
Extract, liquid, flavoring 6 C Formaldehyde 3 A
Extracts, chestnut or quebracho, liquid 8 C Formic acid 3 C
(combustible liquid, n.o.s.)
Fuel oil 8 C
Extracts, chestnut or quebracho, liquid 6 C
Fuel, aviation, turbine engine (flammable) 6 C
(flammable liquid, n.o.s.)
Fuel, aviation, turbine engine (combustible) 8 C
Extracts, fustic or logwood, liquid or paste 8 C
(combustible liquid, n.o.s.) Fuel oil treating compounds (corrosive 7 D
liquid, n.o.s.)
Extracts, fustic or logwood, liquid or paste 6 C
(flammable liquid, n.o.s.) Fumaryl chloride 7 B
Extracts, hypernic, liquid or paste 8 C Fungicides, agricultural, nec, liquid 6 D
(combustible liquid, n.o.s.) (flammable liquid, n.o.s.)
Extracts, hypernic, liquid or paste 6 C Furan 6 C
(flammable liquid, n.o.s.) Furfural 3 C
Extracts, tanning, nec, liquid or paste 8 C Furfuryl alcohol (alcohol, n.o.s.) 8 C
(combustible liquid, n.o.s.) Fusel oil 8 C
Extracts, tanning, nec, liquid or paste 6 C Gambier extracts, liquid (combustible 8 C
(flammable liquid, n.o.s.) liquid, n.o.s.)
Ferric chloride 3 B Gambier extracts, liquid (flammable liquid, 6 C
Ferrous chloride 1 A n.o.s.)
Ferrous sulfate 3 C Gas drips, hydrocarbon (flammable) 6 C
Fertilizer solution, consisting of water, free 7 C Gas drips, hydrocarbon (combustible) 8 C
ammonia and sulphur, total ammonia Gas odorants, not compressed gas 8 C
content not to exceed 30 percent by (combustible liquid, n.o.s.)
weight (corrosive liquid, n.o.s.)
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III–561
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Gas odorants, not compressed gas 6 C Hydrobromic acid (more than 49% 7 C
(flammable liquid, n.o.s.) strength)
Gasohol (gasoline mixed with ethyl alcohol) 6 C Hydrobromic acid not more than 49% 7 C
(gasolines, blended, consisting of motor strength
fuels containing 50% or more of Hydrochloric acid 3 A
gasolines) Hydrochloric acid
Gasoline 6 C Hydrochloric acid mixture
Gasoline preservative, nec, liquid 8 D Hydrochloric acid solution inhibited
(combustible liquid, n.o.s.) Hydrochloric acid (muriatic acid, spent)
Gasoline preservative, nec, liquid 6 D Hydrofluoric acid 3 C
(flammable liquid, n.o.s.) Hydrofluosilicic acid 7 A
Geraniol-nerol mixture (combustible liquid, 8 C Hydroxyethyl acrylate (corrosive liquid, 7 C
n.o.s.) n.o.s.)
Glue catalyst, nec (combustible liquid, 8 D Hydroxypropyl acrylate (corrosive liquid, 7 B
n.o.s.) n.o.s.)
Glue catalyst, nec (flammable liquid, n.o.s.) 6 D Iminobispropylamine 7 C
Glycerine, crude, (spent lye) concentrated 7 C Ink (flammable) 6 C
(corrosive liquid, n.o.s.) Ink (combustible) 8 C
Glycol ethers (combustible liquid, n.o.s.) 8 C Ink materials, nec (flammable liquid, n.o.s.) 6 C
Heptane 6 C Ink materials, nec (combustible liquid, 8 C
Hexachlorocyclopentadiene 1 A n.o.s.)
Hexadecyltrichlorosilane 7 B Insecticide adhesives, spreaders or 7 C
Hexadiene 6 C stickers, liquid (corrosive liquid, n.o.s.)
Hexaldehyde 6 C Insecticide, liquid, n.o.s. (insecticides, 8 D
agricultural, nec, liquid) (combustible)
Hexamethylene diamine, solid 7 C
Insecticide, liquid, n.o.s. (insecticides, 6 D
Hexamethylene diamine, solution 7 A
agricultural, nec, liquid) (flammable)
Hexamethylene imine 7 B
Insecticide, liquid, n.o.s. (vermin 6 D
Hexane 6 C exterminator) (flammable)
Hexanoic acid 7 C Insecticide, liquid, n.o.s. (vermin 8 D
Hexyl alcohol, other than perfumery grade 8 C exterminator) (combustible)
(alcohol, n.o.s.) Isoamyl alcohol (alcohol, n.o.s.) 8 C
Hexyl trichlorosilane 7 B Isobutyl acrylate (flammable liquid, n.o.s.) 2 C
Hydroxy aldehydes, waste (combustible 8 C Isobutyraldehyde (flammable liquid, n.o.s.) 6 C
liquid, n.o.s.)
Isobutyric anhydride 7 C
Hydroxy aldehydes, waste (flammable 6 C
Isobutyronitrile (flammable liquid, n.o.s.) 6 C
liquid, n.o.s.)
Isoheptyl alcohol (alcohol, n.o.s.) 8 C
Hydrazine, anhydrous 2 A
Isooctane 6 C
Hydrazine, aqueous solution 7 A
Isooctene 6 C
Hydriodic acid 7 C
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–562 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Isooctyl alcohol, other than perfumery 8 C Methallyl chloride (flammable liquid, n.o.s.) 6 C
grade (alcohol, n.o.s.) Methyl aceto-acetate (combustible liquid, 8 C
Isooctyl alcohol, perfumery grade (alcohol, 8 C n.o.s.)
n.o.s.) Methyl acrylate 2 B
Isopentane 6 C Methyl amyl ketone 8 C
Isopentanoic acid 7 C Methanol (methyl alcohol) 6 C
Isoprene 2 C Methyl acetone 6 C
Isopropanol 6 C Methyl acetate 6 C
Isopropyl acetate 6 C Methylal 6 C
Isopropylamine 6 C Methyl amyl acetate 6 C
Isopropyl nitrate 2 C Methyl butene 6 C
Isopropyltoluene (combustible liquid, n.o.s.) 8 C Methyl butyl ketone (flammable liquid, 6 C
Kelthane 3 B n.o.s.)
Kerosene 8 C Methyl butyrate 6 C
Lacquer thinning compound (lacquer 6 C Methyl chloroformate 6 C
thinning compounds, used) (flammable) Methylcyclohexane 6 C
Lacquer thinning compound (lacquer 8 C Methyl dichloroacetate 7 C
thinning compounds, used)
Methyl dichlorosilane 6 B
(combustible)
Methylethanolamine (combustible liquid, 8 C
Leather bleach (flammable) 6 D
n.o.s.)
Leather bleach (combustible) 8 D
Methyl ethyl ketone 6 C
Leather dressing (flammable) 6 D
Methyl ethyl pyridine 7 B
Leather dressing (combustible) 8 D
Methyl formate 6 C
Lighter fluid 6 C
Methylfuran 6 C
Lutidene (flammable liquid, n.o.s.) 6 C
Methylhydrazine 6 A
Maleic anhydride 3 C
Methyl isobutyl carbinol (alcohol, n.o.s.) 8 C
Medicines, n.o.s. 6 D
Methyl isobutyl ketone (flammable liquid, 6 C
Medecine, n.o.s. 8 D n.o.s.)
Medicines, n.o.s., liquid (corrosive) 7 D Methyl isopropenyl ketone 2 C
Medicines, n.o.s., liquid (poison) 5 D Methyl methacrylate monomer 2 A
Medicines, n.o.s., solid 7 D Methyl methoxy pentanone (combustible 8 C
Mercaptan mixture, aliphatic (flammable) 6 C liquid, n.o.s.)
Mercaptan mixture, aliphatic (combustible) 8 C Methylpentadiene 6 C
Mercuric iodide solution 5 B Methyl pentane 6 C
Mercury based pesticide (compounds and 6 D Methyl phosphonothioic dichloride, 7 B
preparations), liquids (flammable) anhydrous
Mercury based pesticide (compounds and 5 D Methyl propionate 6 C
preparations), liquids (poison) Methyl propyl ketone 6 C
Mesityloxide 6 C Methyltrichlorosilane 6 B
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III–563
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Methyl vinyl ketone inhibited 2 B Nicotine, liquid 5 B
Mexacarbate 3 B Nicotine salicylate 5 B
Mining reagent, liquid (containing 20% or 7 B Nicotine sulfate, liquid 5 B
more cresylic acid) Nicotine tartrate 5 B
Mixed chlorosilanes (flammable liquid, 6 B Nitric acid 3 B
corrosive, n.o.s.) Nitric acid (over 40%)
Mono-tert-butyl-meta-cresol (combustible 8 B Nitric acid, fuming
liquid, n.o.s.) Nitric acid, 40% or less
Monoethanolamine 7 C Nitroaniline 5 C
Monoethylamine 3 B Nitrobenzene 3 B
Monomethylamine, aqueous solution 3 B Nitrochlorobenzene, ortho, liquid 5 C
Monoisopropanolamine (corrosive liquid, 7 C Nitrophenol 3 B
n.o.s.) Nitrotoluene 3 C
Morpholine 6 C Nitroxylol 5 C
Morpholine, aqueous, mixture (corrosive) 7 C Nonyl trichlorosilane 7 B
Morpholine, aqueous, mixture (flammable) 6 C Octane 6 C
Mortar stain, liquid (flammable) 6 C Octadecyltrichlorosilane 7 B
Mortar stain, liquid (combustible) 8 C Octyl alcohol, other than perfumery grade 8 C
Motor fuel, n.o.s. (flammable) 6 C (alcohol, n.o.s.)
Motor fuel, n.o.s. (combustible) 8 C Octyl alcohol, perfumery grade (alcohol, 8 C
Mud treating compounds, nec, gas or oil 8 C n.o.s.)
well drilling (combustible liquid, n.o.s.) Octyl trichlorosilane 7 B
Mud treating compounds, nec, gas or oil 6 C Oil, n.o.s., petroleum oil, (or) petroleum oil, 6 C
well drilling (flammable liquid, n.o.s.) n.o.s. (flammable)
Naphtha (flammable) 6 C Oil, n.o.s., petroleum oil, (or) petroleum oil, 8 C
Naphtha (combustible) 8 C n.o.s. (combustible)
Naphtha distillate (flammable) 6 C Organic phosphate, organic phosphate 5 D
compound, (or) organic phosphorus
Naphtha distillate (combustible) 8 C
compound, liquid
Naphtha, solvent (flammable) 6 C
Organochlorine pesticide (compounds and 6 D
Naphtha, solvent (combustible) 8 C preparations), liquid (flammable)
Naphthalene 3 C Organochlorine pesticide (compounds and 5 D
Neohexane 6 C preparations), liquid (poison)
Neo pentanoic acid (combustible liquid, 8 C Organophosphorus pesticide (compounds 6 D
n.o.s.) and preparations), liquid (flammable)
Nickel plating solution (corrosive liquid, 7 C Organophosphorus pesticide (compounds 5 D
n.o.s.) and preparations), liquid (poison)
Nickel plating solution (poisonous liquid, 5 B Organotin pesticide (compounds and 6 D
n.o.s.) preparations), liquid (flammable)
Nicotine hydrochloride 5 B
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–564 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Organotin pesticide (compounds and 5 D Petroleum oil, n.o.s. (petroleum oil 6 C
preparations), liquid (poison) residuum)
Paint (asphaltum or coal tar paint) 6 C Petroleum oil, n.o.s. (petroleum, partially 6 C
(flammable) refined, for further processing)
Paint (asphaltum or coal tar paint) 8 C Petroleum propylene tetramer (combustible 8 C
(combustible) liquid, n.o.s.)
Paint drier, liquid (flammable) 6 C Petroleum propylene trimer (flammable 6 C
Paint drier, liquid (combustible) 8 C liquid, n.o.s.)
Paint, lacquer or shellac (rubber tire 6 C Petroleum refinery sulfide waste (corrosive 7 B
lacquer, paint or shellac) liquid, n.o.s.)
Paint, lacquer, stain, (or) varnish, bronze, or 6 C Phenol (Carbolic acid) 3 A
gold, liquid (or) lacquer base, liquid Phenoxy pesticide (compounds and 6 D
(flammable) preparations), liquid (flammable)
Paint, lacquer, stain, (or) varnish, bronze, or 8 C Phenoxy pesticide (compounds and 5 D
gold, liquid (or) lacquer base, liquid preparations), liquid (poison)
(combustible) Phenyl trichlorosilane 7 B
Paint oil compounds (combustible liquid, 8 C Phenylurea pesticide (compounds and 6 D
n.o.s.) preparations), liquid (flammable)
Paint oil compounds (flammable liquid, 6 C Phenylurea pesticide (compounds and 5 D
n.o.s.) preparations), liquid (poison)
Paint oils, nec (combustible liquid, n.o.s.) 8 C Phosphoric acid 3 C
Paint oils, nec (flammable liquid, n.o.s.) 6 C Phosphorus 1 A
Paraldehyde 6 B Phosphorus oxybromide 7 B
Pentane 6 C Phosphorus oxychloride 3 B
Perchloro-methyl-mercaptan 5 B Phosphorus tribromide 7 B
Petroleum distillate (flammable) 6 C Phosphorus trichloride 3 A
Petroleum distillate (combustible) 8 C Phthalimide derivative pesticide 6 D
Petroleum ether 6 C (compounds and preparations), liquid
Petroleum ether (polyethylligroin) 6 C (flammable)
Petroleum naphtha (flammable) 6 C Phthalimide derivative pesticide 5 D
(compounds and preparations), liquid
Petroleum naphtha (combustible) 8 C
(poison)
Petroleum oil additive, containing more 8 C
Picoline (combustible liquid, n.o.s.) 8 C
than 50 percent by weight of petroleum
(combustible liquid, n.o.s.) Picoline (flammable liquid, n.o.s.) 6 C
Petroleum oil, n.o.s. (absorption oil, belt oil, 6 C Pinene 6 C
compression oil, cordage oil, floor oil, Pine Oil 8 C
harness oil, leather oil, neatsfoot oil, Plastic solvent, n.o.s. (flammable) 6 C
putty oil, tanners oil, tobacco oil,
Plastic solvent, n.o.s. (combustible) 8 C
transformer oil or wood oil, petroleum)
Plasticizer alcohol (alcohol, n.o.s.) 6 C
Petroleum oil, n.o.s. (coal spraying oil, 6 C
(flammable)
petroleum)
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III–565
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Plasticizer alcohol (alcohol, n.o.s.) 8 C Pulp mill liquid (combustible liquid, n.o.s.) 8 C
(combustible) Pulp mill liquid (flammable liquid, n.o.s.) 6 B
Plasticizers, paint, lacquer or varnish 8 C Pyridine 6 B
(combustible liquid, n.o.s.)
Pyroligneous acid (combustible liquid, 8 C
Plasticizers, paint, lacquer or varnish 6 C n.o.s.)
(flammable liquid, n.o.s.)
Pyroligneous acid (flammable liquid, n.o.s.) 6 C
Poisonous liquid, n.o.s. (animal or poultry 5 D
Pyro sulfuryl chloride 7 B
dip, nec, liquid)
Pyroxylin solution (flammable) 6 C
Poisonous solid, corrosive, n.o.s. 5 D
Pyroxylin solution (combustible) 8 C
Polish, metal, stove, furniture (or) wood, 8 C
liquid (combustible) Pyroxylin solvent, n.o.s. (flammable) 6 C
Polish, metal, stove, furniture (or) wood, 6 C Pyroxylin solvent, n.o.s. (combustible) 8 C
liquid (flammable) Pyrrolidine 6 C
Polishing wheel cement thinner 8 C Quinaldine (combustible liquid, n.o.s.) 8 C
(combustible liquid, n.o.s.) Quinoline 3 C
Polishing wheel cement thinner (flammable 6 C Refinery cracking stock (combustible liquid, 8 C
liquid, n.o.s.) n.o.s.)
Polychlorinated biphenyls 1 A Refinery cracking stock (flammable liquid, 6 C
Polyethylbenzene (combustible liquid, 8 C n.o.s.)
n.o.s.) Resin solution (resin compound, liquid) 6 C
Polyethylligroin (combustible liquid, n.o.s.) 8 C (flammable)
Potassium cyanide 1 A Resin solution (resin compound, liquid) 8 C
Potassium fluoride solution 7 C (combustible)
Potassium hydrogen fluoride solution 7 C Road asphalt or tar, liquid 6 C
Potassium hydroxide (Caustic Potash) 3 C Road asphalt (or) tar, liquid (petroleum road 8 C
oil)
1-propanol (alcohol, n.o.s.) 6 C
Road oil (petroleum road oil) 8 C
Propargyl alcohol 6 B
Rosin gloss or ester gum (combustible 8 C
Propionaldehyde (propyl aldehyde) 6 C
liquid, n.o.s.)
Propionic acid 3 C
Rosin gloss or ester gum (flammable liquid, 6 C
Propionic anhydride 3 C n.o.s.)
Propyl acetate 6 C Rosin liquor, consisting of rosin and not 8 C
Propyl chloride 6 C more than 40% alcohol or mineral
Propylamine (mono-n-propylamine) 6 C spirits (combustible liquid, n.o.s.)
Propylenediamine 6 C Rosin liquor (flammable liquid, n.o.s.) 6 C
Propylene dichloride 3 B Rosin residue (combustible liquid, n.o.s.) 8 C
Propylene imine 2 A Rosin residue (flammable liquid, n.o.s.) 6 C
Propylene oxide 2 A Rosin solution (combustible liquid, n.o.s.) 8 C
Propyl mercaptan 6 C Rosin solution (flammable liquid, n.o.s.) 6 C
Propyl trichlorosilane 7 B
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–566 11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Rubber accelerators or softeners, other 8 D Sodium nitrite 1 A
than petroleum, nec (combustible Sodium phenolate, solid 7 C
liquid, n.o.s.)
Sodium solution waste (corrosive liquid, 7 C
Rubber accelerators or softeners, other 6 D n.o.s.)
than petroleum, nec (flammable liquid,
Solution, copper plating (corrosive liquid, 7 C
n.o.s.)
n.o.s.)
Rubber preservative, nec (combustible 8 D
Solution, copper plating (poisonous liquid, 5 B
liquid, n.o.s.)
n.o.s.)
Rubber preservative, nec (flammable liquid, 6 D
Solvent, n.o.s. (flammable) 6 D
n.o.s.)
Solvent, n.o.s. (combustible) 8 D
Rubbing alcohol compounds (alcohol, 8 C
n.o.s.) (combustible) Solvent, n.o.s. (solvents, paint, lacquer, 6 C
varnish or resin) (flammable)
Rubbing alcohol compounds (alcohol, 6 C
n.o.s.) (flammable) Solvent, n.o.s. (solvents, paint, lacquer, 8 C
varnish or resin) (combustible)
Rum, denatured 6 C
Solvent refined coal, liquid (combustible 8 C
Rust preventive coating (pipe line rust 8 C
liquid, n.o.s.)
preventive coating)
Spirits of turpentine (combustible liquid, 8 C
Selenic acid, liquid 7 B
n.o.s.)
Selenium oxychloride (poisonous liquid, 5 B
Spirits of turpentine (flammable liquid, 6 C
n.o.s.)
n.o.s.)
Shellac, liquid (flammable) 6 C
Styrene monomer 2 A
Shellac, liquid (combustible) 8 C
Substituted nitrophenol pesticide 6 D
Silicon chloride (or) silicon tetrachloride 7 B (compounds and preparations), liquid
Sludge acid 7 B (flammable)
Sludge acid (sludge, acid, containing not 7 C Substituted nitrophenol pesticide 5 D
less than 75% water) (compounds and preparations), liquid
Sludge, alkali, containing not less than 75% 7 C (poison)
water (corrosive liquid, n.o.s.) Sulfur trioxide 7 B
Sodium aluminate solution 7 C Sulfuric acid 3 A
Sodium arsenite 3 B Nitrating acid
Hydrofluoric and sulfuric acid mixture
Sodium chlorite solution (not exceeding 42 7 C
Oleum
percent sodium chlorite)
Sulfuric acid
Sodium chromate 3 B Sulfuric acid, spent
Sodium bifluoride 3 C Nitrating acid, spent
Sodium bisulfite 3 C Sulfur monochloride 3 A
Sodium cyanide 1 A Sulfurous acid 7 C
Sodium fluoride 3 C Sulfuryl chloride 7 B
Sodium hydrogen sulfate solution 7 C Sulphates, mixed ethyl, consisting of 7 C
Sodium hydroxide (Caustic Soda) 3 C monoethyl sulphate and diethyl
sulphate (corrosive liquids, n.o.s.)
Sodium methylate 3 C
Fig. Y.4 D.V. 2007 Exhibit 2, Bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
11/2014 C-III–567
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
APPENDIX Y M-1002
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Sulphide waste (corrosive liquid, n.o.s.) 7 B Trichloroethylene 3 C
Tallow alcohol (alcohol, n.o.s.) (flammable) 6 C Trichlorophenol 1 A
Tallow alcohol (alcohol, n.o.s.) 8 C Trichlorosilane 6 B
(combustible) Triethylamine 3 B
Tanners depilatory, nec (corrosive liquid, 7 D Triethylenetetramine (corrosive liquid, 7 C
n.o.s.) n.o.s.)
Tar, liquid (flammable) 6 C Triethyl phosphite (combustible liquid, 8 C
Tar, liquid (combustible) 8 C n.o.s.)
1,2,3,6-tetrahydrobenzaldehyde 7 C Trimethyl acetylchloride 7 B
Tetrahydrofuran 6 C Trimethylamine, aqueous solution 3 B
Tetrahydrofurfuryl alcohol (combustible 8 C Trimethylchlorosilane 6 B
liquid, n.o.s.) Trimethyl phosphite (flammable liquid, 6 C
Tetramethylammonium hydroxide, liquid 7 C n.o.s.)
Textile treating compound (or) mixture, 7 D Turpentine (flammable) 6 C
liquid Turpentine (combustible) 8 C
Thinner for rust preventive coating 6 C Turpentine residue, liquid (flammable 6 C
(flammable) liquid, n.o.s.)
Thinner for rust preventive coating 8 C Turpentine residue, liquid (combustible 8 C
(combustible) liquid, n.o.s.)
Thioglycolic acid 7 C Turpentine substitute (flammable) 6 C
Thionyl chloride 7 B Turpentine substitute (combustible) 8 C
Thiophosphoryl chloride 7 B Uranyl acetate 3 A
Tin tetrachloride, anhydrous 7 B Uranyl nitrate (Uranyl nitrate hexahydrate 3 A
Titanium tetrachloride 7 B solution)
Titanium sulfate solution (containing not 7 C Valeric acid 7 C
more than 45% sulfuric acid) Valeryl chloride 7 D
Toluene 3 C Vanadium oxytrichloride 7 B
Toluene diisocyanate 5 A Vanadium tetrachloride 7 B
Toluene sulfonic acid, liquid 7 C Varnish (asphaltum or coal tar varnish) 6 C
Toluidene (combustible liquid, n.o.s.) 8 C (flammable)
Toxaphene 1 A Varnish (asphaltum or coal tar varnish) 8 C
Triazine pesticide (compounds and 6 D (combustible)
preparations), liquid (flammable) Vinyl acetate 3 A
Triazine pesticide (compounds and 5 D Vinylidene chloride, inhibited 3 C
preparations), liquid (poison) Vinyl isobutyl ether 2 C
Tri-n-butylamine (combustible liquid, n.o.s.) 8 C Vinyl ethyl ether 2 C
Trichlorfon 3 B Vinyl toluene, inhibited, liquid (combustible 8 C
Trichloroacetic acid, solid 7 C liquid, n.o.s.)
Trichloroacetic acid solution 7 C Vinyl trichorosilane 6 B
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (continued)
C-III–568 11/2014
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 APPENDIX Y
Protection
Required
Group
Commodity
Wallpaper remover liquid (flammable liquid, 6 D
n.o.s.)
Waste, chemical plant, zinc chloride 7 C
(corrosive liquid, n.o.s.)
Waste etchant solution, suitable only for 7 C
reclamation of metallic content
(corrosive liquid, n.o.s.)
Waste liquor, consisting of not less than 50 8 C
percent by weight of water, resulting
from sulphate or soda pulping process
(combustible liquid, n.o.s.)
Waste liquor, consisting of not less than 50 7 C
percent by weight of water, resulting
from sulphate or soda pulping process
(corrosive liquid, n.o.s.)
Waste liquor, consisting of not less than 50 6 C
percent by weight of water, resulting
from sulphate or soda pulping process
(flammable liquid, n.o.s.)
Water treatment compounds, liquid 7 C
Wax, liquid 8 C
Wood bleach (corrosive liquid, n.o.s.) 7 D
Wood turpentine (corrosive liquid, n.o.s.) 8 C
Wood turpentine (flammable liquid, n.o.s.) 6 C
Xylene 3 C
Xylenol 3 B
Zinc arsenate 5 A
Zinc chloride 3 C
Fig. Y.4 D.V. 2007 Exhibit 2, bottom fittings protection—protection requirements (Levels A, B, C, and D) (concluded)
Exhibit 2
Addendum—September 1, 1990
Association of American Railroads
Mechanical Division Circular D.V. 2007
The following commodities have been reviewed since the publication of D.V. 2007
Protection
Protection
Required
Required
Group
Group
Commodity Commodity
Adipic acid solution 3 C Hazardous waste, liquid, n.o.s. 9 C
Alpha methyl styrene 8 C Hexamethylene diamine solution 7 C*
Aluminum sulfate solution 9 C Lasso 8 A
Ammonium chloride 3 C Maleic acid 3 C
Ammonium fluoride 3 C Methyl butynol 6 C
Ammonium hydroxide (less than 12% NH3) 9 C 2-Methyl cyclohexylamine 2 B
Ammonium oxalate 9 C Methyl pentynol 6 C
Ammonium sulfite 3 C Methyl styrene 8 C
Benzoic acid 3 C Paraquat 1 A
Bis-para-aminocyclohexyl methane 7 C N-Pentanol 6 C
Butyl acrylate 8 C Petroleum distillate engine fuel 8 C
Diazo-bicyclo-undecane 7 A Other regulated substances, liquid, n.o.s. 9 C
N-Dibutylamine 8 C (hazardous substances)
Dichloromethane (Methylene chloride) 9 A Piperidine 2 A
Dicyclohexylamine 7 C Propyl acetate 6 C
N-N diethylaniline 5 B Sodium chlorate solution — C
Dimethyl aminopropylamine 2 A Sodium dichromate (bichromate) 9 B
Dimethyl cyclohexylamine 7 C Sodium hydrosulfide solution 3 C
Dimethyl formamide 8 C Sodium nitrite 40% solution 1 A
Dioctyl phthalate 1 B Tetrachloroethylene (Perchloroethylene) 9 A
Dowanol (propylene glycol methyl ether) 6 C Toluenediamine 3 B
Environmentally hazardous substances, 9 C Tri-n-propylamine 8 B
liquid, n.o.s. 1,1,1,-Trichloroethane (Methyl chloroform) 9 A
Ethyl cyclohexylamine 7 C Vapam (sodium methyldithiocarbamate) 7 B
Ethyl octynol 8 C Zinc bromide 3 C
Ferric sulfate 3 C Zinc sulfate 3 C
Formaldehyde solution (50-54%) 3 A
ASSOCIATION
OF AMERICAN
RAILROADS
P. G. Kinnecom
Executive Director - Tank Car Safety
September 7, 1999
(CPC-1097)
SUBJECT: New Requirements for Inspections of Stub Sills on Tank Cars T79.20.20-98
Please refer to circular letter no. CPC-1094, dated April 15, 1999, wherein the new stub sill
inspection program was introduced, to become effective July 1, 1999 for all stub sill tank cars.
At their July 1999 Executive Session, the Tank Car Committee approved two actions to modify
that program. First, the committee approved a new Form SS-3 (attached), to be used by
proponents to record inspection information for their cars. It is expected that Windows-based
software will be available for distribution by October. In the meantime, cars can be inspected
and the inspection results recorded using Form SS-3. When the SS-3 software is available,
proponents can enter their inspection data for transmission to AAR’s designated agent.
Please be advised that initial inspections of cars subject to O&M Circular No. 1 (stub sill
cars built prior to January 1, 1984) must be reported to the “old” SS-2 database using the SS-2
form and the SILSPEC program. Use of the SS-3 form is required for all other stub sill
inspections.
The Committee also addressed the situation where stub sill tank cars built since January 1,
1984 may be overdue for inspection in accord with CPC-1094, based on time or mileage. The
Committee agreed that a 3-year catch-up period until July 1, 2002 should be allowed for such
overdue cars. This date coincides with the deadline for initial Rule 88B inspections for tank cars.
Sincerely,
P. G. Kinnecom
Fig. Y.6 CPC-1097 stub sill inspection program—new Form SS-3 (page 1 of 5)
Form SS-3
13. Total Mileage to Nearest 1,000 Miles Note: Lines 10 - 13 Provided By Car Owner
(actual cumulative mileage required)
SS-3 9/1/99
Fig. Y.6 CPC-1097 stub sill inspection program—new Form SS-3 (page 2 of 5)
SS-3 9/1/99
Fig. Y.6 CPC-1097 stub sill inspection program—new Form SS-3 (page 3 of 5)
Form SS-3 is intended to facilitate collection of data during the stub sill inspection process. Written reports
must be completed and then transferred to the computer file format specified by AAR. A record of each
stub sill inspection is then submitted in electronic format to the designated AAR contractor as well as the
car owner. The following instructions must be followed in filling out the report (item numbers represent
line numbers on the form):
Items 14-30 are for recording crack measurements in specified areas of the stub sill and adjacent tank shell.
Each location has six fields available, which are to be completed for the specified area.
The fields are: A-end inspection technique, A-end number of cracks, A-end maximum crack length, B-end
inspection technique, B-end number of cracks, and B-end maximum crack length.
A key for the Inspection Technique codes can be found at the bottom of page 2 of the SS-3 Form. An entry
for inspection method is required on Line 14. The database program will assume that the same inspection
technique is used for Lines 15 – 30 unless an entry is made on those lines indicating a different inspection
method.
If there is more than one crack present in the indicated area, the longest crack is to be recorded. All
recorded cracks are to be measured to the nearest ¼ inch and recorded in decimal format (e.g.: 3 ¾=3.75).
The field locations are as follows:
Fig. Y.6 CPC-1097 stub sill inspection program—new Form SS-3 (page 4 of 5)
Form SS-3 contains six reserved fields for special data collection purposes. Lines 8, 9, 18, 23, 30, and 33
should not be used unless specified by the car builder. The car builder may customize Form SS-3 to collect
data specific to a particular stub sill design using these fields.
9/1/99
Fig. Y.6 CPC-1097 stub sill inspection program—new Form SS-3 (page 5 of 5)
ASSOCIATION
OF AMERICAN
RAILROADS
P. G. Kinnecom
Executive Director - Tank Car Safety
(CPC-1114)
SUBJECT: Requirements for SS-3 Inspections of Tank Car Stub Sills T79.20.20
Please refer to circular letter no. CPC-1094, dated April 15, 1999, wherein the new stub sill
inspection program was introduced, effective July 1, 1999 for all stub sill tank cars. Refer also to
circular letter no. CPC-1097, dated September 7, 1999, wherein Form SS-3 was introduced to
capture the inspection data from the new program.
The stub sill inspection interval defined in CPC-1094 is conditionally tied to the interval for the
Federal qualification time, reference 49 CFR Part 180. In accord with the provisions of CPC-
1094, the stub sill inspection can be due before the Part 180 tank qualification time if the car
exceeds 200,000 miles (in the case of cars that are not designed to a one-million mile fatigue life
requirement; 500,000 for cars that are so designed) since any of the following:
1) built date
2) last Rule 88.B.2 inspection, or
3) last stub sill inspection.
It is believed that some cars that received a hydrostatic tank retest shortly before the new Part
180 rules took effect may not have received stub sill inspections, based on the erroneous
assumption that stub sills did not have to be inspected until the car’s qualification time under the
terms of 49CFR Part 180. This circular is intended to clarify this and serve as a reminder of the
requirements of CPC-1094.
To address this situation, the Tank Car Committee has agreed to modify the SS-3 inspection
program to include a maximum 10-year interval for stub sill inspections for cars that are not
designed to the one-million mile fatigue life criteria.
CPC-1097 also addressed a potential conflict in which stub sill tank cars built since January 1,
1984 could, on the basis of accumulated mileage, be immediately overdue for inspection under
the provisions of CPC-1094. The Tank Car Committee rectified that by allowing a three-year
catch-up period until July 1, 2002 for such cars. Since cars can now become immediately
overdue on either a time or mileage basis, the Committee agreed to extend the catch-up period
until July 1, 2003.
Fig. Y.7 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 1 of 4)
CPC-1114
May 10, 2001
Page 2
Sincerely,
P. G. Kinnecom
Fig. Y.7 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 2 of 4)
Page 1 of 2
(Attachment to Circular Letter No. CPC-1114 dated May 10, 2001)
AAR Circular letter CPC-1082 stipulated that, effective July 1, 1999, each tank car stub sill would be
inspected in accord with a plan based on a damage tolerance analysis (DTA) or at a default inspection
interval of five years or 75,000 miles. That proposal was based on the anticipation that DTA would then
be fully developed as a tool to establish tank car inspection intervals. At present, the DTA method is not
providing reliable or consistent results when applied to railcar structures. More development work is
required to establish DTA as a tool that is effective in driving inspection and maintenance processes for
railcars.
The following is an alternate inspection plan that provides an equivalent level of safety, includes
provisions for reporting inspection results and monitoring ongoing stub sill performance, provides
information required for enforcement, prioritizes inspections, and is in harmony with the qualification
requirements of 49 CFR180. Note that established accelerated inspection programs in effect at the time
of its adoption will continue under their existing schedules.
The Stub Sill Working Group (SSWG) is committed to continuing the development of DTA and considers
the following plan to be an interim measure until such time that DTA has been sufficiently developed for
use in establishing tank car inspection intervals. The SSWG is committed to achieving success in
utilization of the DTA method. The success of this program will be dependent, in part, on the continued
commitment of railcar owners, shippers and regulatory agencies to funding and supporting the
continuation of DTA research.
Effective July 1, 1999, the following interim inspection program will be required for all stub sill tank cars:
A. Inspection Requirements
1. All cars of stub sill design must receive inspections of the stub sills to ensure structural
integrity of the sills, using inspection procedures specified in Section B.
2. Inspection is due at the time of the next 49 CFR 180.509 tank qualification or AAR
Appendix D tank qualification, except:
a. not to exceed 10 years or 200,000 miles (whichever occurs first) from built date,
Rule 88.B.2 inspection or last stub sill inspection unless stub sills are designed to one
million mile fatigue life requirement.
b. not to exceed 500,000 miles from built date, Rule 88.B.2 inspection or last stub sill
inspection for cars with sills that do meet the one million mile fatigue life requirement.
3. Any extensions to the inspection interval allowed by 49 CFR 180.509 (or DOT-E 12095)
will not be cause for extension of the stub sill inspection interval unless approved under
the alternate inspection provisions set forth in Section C.
4. For the purpose of Paragraph 2, actual mileage shall be used whenever possible. When
actual mileage of the car is not known, mileage may be estimated using an assumed
20,000 miles per year as established in AAR O&M Circular No. 1.
Fig. Y.7 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 3 of 4)
Page 2 of 2
(Attachment to Circular Letter No. CPC-1094 dated April 15, 1999)
B. Inspection Procedures
2. Until August 31, 1999, inspections will be documented on Form SS-2. Inspection data
will be submitted to AAR’s designated database administrator according to the
procedures defined for the program prescribed under FRA Emergency Order 17 and AAR
O&M Circular No. 1.
1. The AAR Tank Car Committee may establish inspection intervals that are shorter than
the requirements set forth in Section A and may require more extensive inspections when
the performance history of a design merits such action. Established accelerated
inspection programs in effect at the time of adoption of this program will continue under
their existing schedules.
2. Car owners may use alternate inspection intervals when an alternate inspection protocol
has been approved by the AAR Tank Car Committee (e.g. DTA or other analytic tool).
Fig. Y.7 CPC-1114 requirements for SS-3 inspections of tank car stub sills (page 4 of 4)
ASSOCIATION
OF AMERICAN
RAILROADS
P. G. Kinnecom
Executive Director - Tank Car Safety
(CPC-1116)
SUBJECT: Shop Practices for Installation and Maintenance of Bottom Outlet Ball Valves
on Tank Cars T10.29
This Circular Letter is intended to provide guidance on shop practices for installation and maintenance of
bottom outlet ball valves on tank cars equipped with linings or coatings.
Tank car owners and shops that apply bottom outlet ball valves or provide maintenance services for tank
cars are reminded that replacement of components in valves must be a replacement in-kind. Seals used in
valves should be selected to match the valve manufacturer’s design and performance criteria.
Assembled valves are to be used only in the configuration for which they were granted AAR approval.
Likewise, the application of a valve to a tank car must reflect the configuration shown in the applicable
arrangement drawing specified on the certificate of construction. Failure to return a valve to its approved
configuration after a maintenance activity may cause the valve to be in non-compliance with its approval.
Tank car owners and shops are advised to discontinue the following practices effective upon the issue
date of this Circular Letter.
Some car owners have adopted the practice of lining or coating the interior surface of bottom outlet valves
on tank cars equipped with linings or coatings. Unless the valve was specifically designed to accept a
lining or coating, the application of such material to a valve changes the configuration of the valve with
respect to its AAR approval. The presence of a lining or coating may alter the operating characteristics of
the valve and may adversely impact the ability of the seals to perform as intended.
Tank car owners and shippers who operate lined or coated cars should consider the use of bottom outlet
valves with stainless steel bodies or use valves already approved for lining or coating application.
Individuals who wish to obtain AAR approval for a valve with a lining or coating applied may apply for
approval through established procedures. During service trial, the proponent will demonstrate that the
presence of the material in the valve body does not reduce the effectiveness of the seals and does not
adversely impact the ability of the valve to operate as intended.
Fig. Y.8 CPC-1116 Shop practices for installation and maintenance of bottom outlet valves (page 1 of 2)
CPC-1116
May 30, 2001
Page 2
Some shops have adopted the practice of using shims in conjunction with ball seals to compensate for
variations in the dimensions of the seals. This practice is intended to assist in obtaining a leak-tight seal
and often occurs after the interior of the valve body has been lined or coated.
The practice of using shims is an undesirable practice that alters the configuration of the valve relative to
its approval. Valves applied to tank cars must be configured in accord with their approved designs.
Sincerely,
P. G. Kinnecom
Fig. Y.8 CPC-1116 Shop Practices for Installation and Maintenance of Bottom Outlet Valves (page 2 of 2)
SIGNATURE
TITLE
CERTIFICATION: The cars enumerated below conform to the above approved description and to all applicable DOT and AAR requirements, including specifications,
regulations, rules of interchange, and the DOT Railroad Safety Appliance Standards. Copy of this Certificate of Construction will be furnished to the owner and others as
required by 49 CFR Part 179.5 before these cars are placed in service.
Initials and Car Numbers
Name Date
Title
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Approval AAR Tank Committee
Date _____________________________
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Application for Approval of Pressure Relief Device
1. Manufacturer
Address
2. Test facility name 3. Test facility location
4. Test date 5. Observer
6. Device 7. Start-to-discharge 8. Flow rating 9. Vapor-tight 10. Flow capacity
Number psi kPa psi kPa psi kPa SCFM std.m3/s
11. Official flow capacity (air) scfm ( std. m3/s) at flow rating pressure psi ( kPa)
Test medium
12. Commodity: Regulated Commodity Nonregulated Commodity Specific Commodity
Precedent
The following drawings apply Drawing number Application/
Latest revision Drawing number Certificate
13. Valve Assembly……………………………………..
14. Valve Mounting Nozzle……………………………..
15. ……………………………………………………….
16. ……………………………………………………….
REVISIONS:
CERTIFICATION: The above data is correct. The capacity test complies with AAR Specifications for Tank Cars, Appendix A and
the devices tested conform with the drawings listed above.
By: Title
APPROVAL of Service Trial by AAR Tank Car Committee
AAR Service Trial Required Service Trial Number: ST-__________
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AAR Tank Service Trial Report
AVERAGES
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Application for Approval of Valves, Closures, and Fittings
1. Manufacturer
2. Address City State Zip
3. Test facility if other than the manufacturer Address
4. Test date 4. Observer
Title: .
TEST PROCEDURE
5. Description of prototype testing:
6. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
7. Commodity: Regulated Commodity___ Non Regulated Commodity ___ Specific Commodity
8. Flow rate (if applicable) gpm ( L/min)
Drawing Number Precedent
Applicable drawings Material latest revision Drawing Number Application/Certificate
9. Device application . . . . . .
10. Device assembly . . . . . . . .
11. Device details . . . . . . . . . .
12. Quality Control Statement
REVISIONS:
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars, Appendix A. The devices
tested conform with drawings listed above.
By Title
APPROVAL AAR Tank Car Committee Service Trial Required
Date Approved for Service Trial
Service Trial Number
(Signature) on behalf of Tank Car Committee
APPROVAL AAR Tank Car Committee Service Completed / Not Required
Date Service Trial Completed Date AAR Received Form AAR 4-6 .
Date Approved _____________________________________
Expiration Date ____________________________________ ________________________________________________
(Signature) on behalf of Tank Car Committee
Form AAR 4-5 Revised 10/2014
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Final Service Trial Inspection Report
3. Description of device
4. Device designation or model no.
5. Total number of devices in service 6. Number of devices for teardown
7. Service data for service equipment under this inspection
Total load/unload cycles and average Total loaded mileage and average
Total service time and average
Test remarks……………...
Physical condition…….….
Compare critical final
dimensions to original.…..
9. Drawing numbers…….…....
(Ref. Form AAR 4-3 or AAR 4-5)
Revisions made…….….....
Revision date…….….........
10. Conclusions
12. CERTIFICATION
The above data is correct and complies with the AAR Specifications for Tank Cars, Appendix A. Devices tested
conform to the drawings listed above.
(Signature) (Signature)
Title Title
Company Company
Date approved
(Signature) on behalf of Tank Car Committee
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Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings
CERTIFICATION: The subject device is unchanged from the previous approval, and conforms with the
latest revision of AAR Specifications for Tank Cars, Appendix A. The device conforms
with drawing listed above.
13. New drawing supersedes previous one
or does not obsolete it
CHANGES REASONS FOR CHANGES
14. a. a.
b. b.
c. c.
d. d.
(if needed use supplemental sheet)
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars,
Appendix A. The device conforms with drawing listed above.
Date Approved:
(Signature) on behalf of Committee
Form AAR 4-7 8/1/2014
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Exhibit B-1 Subcontractor Evaluation Sheet
EXHIBIT B–1
2 Address 3 City
7 Name 8 Title
12 Email Address
Part 3: Subcontractor Activity
13 Select the applicable activities provided to the Certified Facility :
For each activity identified above, explain how the company representative responsible for that activity verifies that the
subcontractor understands and conforms to the requirements of the Association of American Railroads Manual of
Standards and Recommended Practices, Section C Part III, Specification for Tank Cars (M-1002).
14 Personnel
15 Processes
16 Equipment
17 Service
18 Product
20 Name 21 Title
25 Address 26 City
30 Signature (Attesting)
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Exhibit B-2 AAR Tank Car Committee Shop Evaluation
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This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
Exhibit B-3 Registration for Class F, G, and L Facilities
EXHIBIT B–3
APPLICATION FOR TANK CAR FACILITY TECHNICAL CERTIFICATION
AND CHANGE NOTIFICATION FORM
This form is both the application for AAR Technical Certification for a single tank car facility and used as change
notification as required by paragraph 3.10. This application must be accompanied by an initial payment as required by
paragraph 3.13. This form is part of the application package (see paragraph 3.1.2), which must be submitted to
7 Company Name
8 Address 9 City
10 State/Province 11 ZIP/Postal Code 12 Country
Part 3: Primary Contact at Facility
13 Name 14 Title
15 Office Phone 16 Cell Phone 17 Fax
18 Email Address
Part 4: Applicant
19 Is the applicant the contact identified in Part 3 and located as identified in Part 2?
Yes (if so, skip this part) No
20 Company Name
21 Name 22 Title
23 Address 24 City
25 State/Province 26 ZIP/Postal Code 27 Country
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
EXHIBIT B–3
APPLICATION FOR TANK CAR FACILITY TECHNICAL CERTIFICATION
AND CHANGE NOTIFICATION FORM
Part 6: Facility Certification Information
NOTE: Certified facility must be capable of performing, or arrange to have performed, all associated tank car activities for
which the facility is certified.
33 Select activity codes that apply:
A19 Manufacturer of tank cars
B82 Manufacture of tank car tanks, including support structure, that are moved to and from the facility without trucks
(running gear)
B83 Repair tank car tanks that are moved to and from the facility without trucks (running gear)
B84 Qualification of tank car tanks that are moved to and from the facility without trucks (running gear)
B85 Manufacturer of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
B86 Repair of pressure-retaining tank components that are moved to and from the facility without trucks (running gear)
C6 Removal and replacement of tank car service equipment (including changing of gaskets)
RL2—Demonstrate proficiency in performing welding to tank car tank material, NDT, and postweld heat treatment. This level
includes repairing a through-the-tank-car tank defect (insert or through-the-shell/head crack). This demonstration must be
performed on a tank car tank or test plate and must be performed on a material from a material group for which the facility
seeks certification.
11/2014
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
EXHIBIT B–3
APPLICATION FOR TANK CAR FACILITY TECHNICAL CERTIFICATION
AND CHANGE NOTIFICATION FORM
37 Comments
This is to attest that the information provided in this application meets all requirements of M-1002, Appendix B, and that
all information required by M-1002, Appendix B, Form B-3A, has been included.
38 Applicant’s Name 39 Applicant’s Signature
42 Title
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
Certification Additional Information Form
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Certification Additional Information Form
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This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
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Certification Additional Information Form
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This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
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Certification Additional Information Form
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This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
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Certificate of Test Form
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Exhibit R-1 Report of Tank Repairs, Alteration, or Conversion
15. For alterations, conversions, pressure relief devices, or other, list procedure and materials:
The cars listed above conform to all approvals mentioned and to all applicable DOT and AAR requirements, including
specifications, regulations, rules of interchange, and the DOT safety appliance standards.
FACILITY
Company name: __________________________________ Location (City/State): _______________________________
Management Representative (Name): __________________________________________ Title: __________________
Management Representative Signature: ________________________________________ Date: __________________
Rev. 04/2010
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This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
11/2014
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Exhibit R-2 Report of Nonaccident-Related Buckles, Corrosion, and Crack Repairs
A1
A2
D2 A1 A2
A1 A2
C2 D1 B1
A1 C1
A2
D1 C2
C1 B1
B2 B2 B2
CL LONG CL LONG
NON-STRUCTURAL
A2 A2 SEAL WELD.
NOT REPORTABLE
A1
A2
A2
A2
B2 B2 B2
CL LONG C
A1 L LONG
SEAL WELD
A2
A1 A1
B1
A1
B1
B2
A2 CL LONG
CL LONG
11/2014
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Form SS-1 Report of Tank Car Stub Sill Inspection
FORM SS-1
REPORT OF TANK CAR STUB SILL INSPECTION
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Form SS-3 Report of Tank Car Stub Sill Inspection
13. Total Mileage to Nearest 1,000 Miles Note: Lines 10 - 13 Provided By Car Owner
(actual cumulative mileage required)
SS-3 9/1/99
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REPORT OF TANK CAR STUB SILL INSPECTION Form SS-3
SS-3 9/1/99
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This publication is licensed solely to Panamerican Technology Group (compraspma@ptglatina.com) and may not be copied or redistributed without an AAR enterprise license
Suggested Format for Welding Procedure Specification (WPS)
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WPS No. ____________ Rev. _________________
ELECTRICAL CHARACTERISTICS
Current AC or DC __________ Polarity _________________________
Amps (Range) ___________________ Volts (Range) _______________
(Amps and volts range should be recorded for each electrode size, position and thickness, etc.
This information may be listed in a tabular form similar to that shown below)
Tungsten Electrode Size & Type_________________________________________________________________
(Pure Tungsten, 2% Thoriated, etc.)
Mode of Metal Transfer for GMAW ______________________________________________________________
(Spray, arc, short-circuited arc, etc.)
Electrode Wire Feed Speed Range _______________________________________________________________
TECHNIQUE
String or Weave Bead __________________________________________________________________________
Orifice or Gas Cup Size _________________________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding, etc.) __________________________________________
_______________________________________________________________________________________________
Method of Back Gouging________________________________________________________________________
Oscillation ____________________________________________________________________________________
Contact Tube to Work Distance _________________________________________________________________
Multiple or Single Pass (per side)________________________________________________________________
Multiple or Single Electrodes ___________________________________________________________________
Travel Speed (Range)___________________________________________________________________________
Peening _______________________________________________________________________________________
Other _________________________________________________________________________________________
_____________________________________________________________________________________________
Filler Metal Current OTHER
Travel (e.g. Remarks, Comments,
Weld Type Amperage Voltage Speed Hot Wire Addition, Tech-
Layer(s) Process Class Diameter Polarity Range Range Range nique, Torch Angle, etc.)
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Suggested Format for Procedure Qualification Record (PQR)
POSITION TECHNIQUE
Position of Groove _______________________________ Travel Speed____________________________________
Weld Progression (Upward, Downward) ___________ String of Weave Bead ____________________________
Other __________________________________________ Oscillation______________________________________
________________________________________________ Multipass or Single Pass (per side)________________
________________________________________________ Single or Multiple Electrodes_____________________
Other __________________________________________
PREHEAT ________________________________________________
Preheat Temperature ____________________________ ________________________________________________
Interpass Temperature __________________________ ________________________________________________
Other __________________________________________ ________________________________________________
________________________________________________ ________________________________________________
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PQR No. _______________________
REDUCED SECTION TENSILE SPECIMEN TESTS
Ultimate Ultimate Type of
Specimen Total Load Unit Stress Failure &
No. Width Thickness Area lb. psi Location
ULTIMATE TENSILE
STRENGTH
YIELD
Type & STRENGTH REDUCTION
Figure Diameter Area Total Load Unit Stress (0.2% offset) ELONGA- OF AREA
No. in. sq. In. lb. psi psi TION (%) (%)
Manufacturer: _________________________________________________________________________________________
Date ____________________________________________ By: __________________________________________________
Revised 3/16/88 Page 2 of 2
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Record of Welder Performance Qualification Test
Backing (metal, weld metal, welded from both sides, flux, etc.)
P-No. to P-No.
Filler metal specification (AWS) / Classification
Filler metal F-No.
Consumable insert
Weld thickness
Welding position (1G, 5G, etc.)
Progression (uphill/downhill)
Backing gas for GTAW
GMAW transfer mode
GTAW welding current type/polarity
Type (Side, Root, Face) Result Type (Side, Root, Face) Result
Visual examination (see paragraphs W15.3, 15.4, 15.5, and 15.9) Acceptable
Yes
No
Radiographic test results
Macro test fusion Fillet leg size in. × in. Concavity/convexity in.
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in
accordance with the requirements of Appendix W.
Organization
Date By
11/2014
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