Publication: Magyar Közlöny
Issue: MK-2011-73 (Year: 2011, Number: 73)
Era: contemporary
Section: 1. melléklet a 2011. évi LXXIX. törvényhez
Paragraph Index: 471

(5) EN 13807:2003 Transportable gas cylinders – Battery vehicles – Design, manufacture, identification and testing 6.8.3.1.4 and 6.8.3.1.5, 6.8.3.2.18 to 6.8.3.2.26, 6.8.3.4.10 to 6.8.3.4.12 and 6.8.3.5.10 to 6.8.3.5.13 Until further notice 6.8.3.7 Requirements for battery-vehicles and MEGCs which are not designed, constructed and tested according to referenced standards To reflect scientific and technical progress or where no standard is referenced in 6.8.3.6 or to deal with specific aspects not addressed in a standard referenced in 6.8.3.6, the competent authority may recognize the use of a technical code providing the same level of safety. Battery-vehicles and MEGCs shall, however, comply with the minimum requirements of 6.8.3. In the type approval the issuing body shall specify the procedure for periodic inspections if the standards referenced in 6.2.2, 6.2.4 or 6.8.2.6 are not applicable or shall not be applied. The competent authority shall transmit to the secretariat of UNECE a list of the technical codes that it recognises. The list should include the following details: name and date of the code, purpose of the code and details of where it may be obtained. The secretariat shall make this information publicly available on its website. A standard which has been adopted for reference in a future edition of the ADR may be approved by the competent authority for use without notifying the UNECE secretariat. 6.8.4 Special provisions NOTE 1: For liquids having a flash-point of not more than 60 °C and for flammable gases, see also 6.8.2.1.26, 6.8.2.1.27 and 6.8.2.2.9. NOTE 2: For requirements for tanks subjected to a pressure test of not less than 1 MPa (10 bar) or for tanks intended for the carriage of refrigerated liquefied gases, see 6.8.5. When they are shown under an entry in Column (13) of Table A of Chapter 3.2, the following special provisions apply: (a) Construction (TC) TC1 The requirements of 6.8.5 are applicable to the materials and construction of these shells. TC2 Shells, and their items of equipment, shall be made of aluminium not less than 99.5% pure or of suitable steel not liable to cause hydrogen peroxide to decompose. Where shells are made of aluminium not less than 99.5% pure, the wall thickness need not exceed 15 mm, even where calculation in accordance with 6.8.2.1.17 gives a higher value. TC3 The shells shall be made of austenitic steel. Copyright © United Nations, 2010. All rights reserved - 526 - TC4 Shells shall be provided with an enamel or equivalent protective lining if the material of the shell is attacked by UN No. 3250 chloroacetic acid. TC5 Shells shall be provided with a lead lining not less than 5 mm thick or an equivalent lining. TC6 Where the use of aluminium is necessary for tanks, such tanks shall be made of aluminium not less than 99.5% pure; the wall thickness need not exceed 15 mm even where calculation in accordance with 6.8.2.1.17 gives a higher value. TC7 The effective minimum thickness of the shell shall not be less than 3 mm. (b) Items of equipment (TE) TE1 (Deleted) TE2 (Deleted) TE3 Tanks shall in addition meet the following requirements. The heating device shall not penetrate into, but shall be exterior to the shell. However, a pipe used for extracting the phosphorus may be equipped with a heating jacket. The device heating the jacket shall be so regulated as to prevent the temperature of the phosphorus from exceeding the filling temperature of the shell. Other piping shall enter the shell in its upper part; openings shall be situated above the highest permissible level of the phosphorus and be capable of being completely enclosed under lockable caps. The tank shall be equipped with a gauging system for verifying the level of the phosphorus and, if water is used as a protective agent, with a fixed gauge mark showing the highest permissible level of the water. TE4 Shells shall be equipped with thermal insulation made of materials which are not readily flammable. TE5 If shells are equipped with thermal insulation, such insulation shall be made of materials which are not readily flammable. TE6 Tanks may be equipped with a device of a design which precludes its obstruction by the substance carried and which prevents leakage and the build-up of excess overpressure or underpressure inside the shell. TE7 The shell-discharge system shall be equipped with two mutually independent shutoff devices mounted in series, the first taking the form of a quick-closing internal stop-valve of an approved type and the second that of an external stop-valve, one at each end of the discharge pipe. A blank flange, or another device providing the same measure of security, shall also be fitted at the outlet of each external stop-valve. The internal stop-valve shall be such that if the pipe is wrenched off the stop-valve will remain integral with the shell and in the closed position. TE8 The connections to the external pipe-sockets of tanks shall be made of materials not liable to cause decomposition of hydrogen peroxide. TE9 Tanks shall be fitted in their upper part with a shut-off device preventing any buildup of excess pressure inside the shell due to the decomposition of the substances carried, any leakage of liquid, and any entry of foreign matter into the shell. Copyright © United Nations, 2010. All rights reserved - 527 - TE10 The shut-off devices of tanks shall be so designed as to preclude obstruction of the devices by the solidified substance during carriage. Where tanks are sheathed in thermally-insulating material, the material shall be of an inorganic nature and entirely free from combustible matter. TE11 Shells and their service equipment shall be so designed as to prevent the entry of foreign matter, leakage of liquid or any building up of dangerous excess pressure inside the shell due to the decomposition of the substances carried. A safety valve preventing the entry of foreign matter also fulfils this provision. TE12 Tanks shall be equipped with thermal insulation complying with the requirements of 6.8.3.2.14. If the SADT of the organic peroxide in the tank is 55 °C or less, or the tank is constructed of aluminium, the shell shall be completely insulated. The sun shield and any part of the tank not covered by it, or the outer sheathing of a complete lagging, shall be painted white or finished in bright metal. The paint shall be cleaned before each transport journey and renewed in case of yellowing or deterioration. The thermal insulation shall be free from combustible matter. Tanks shall be fitted with temperature sensing devices. Tanks shall be fitted with safety valves and emergency pressure-relief devices. Vacuum-relief devices may also be used. Emergency pressure-relief devices shall operate at pressures determined according to both the properties of the organic peroxide and the construction characteristics of the tank. Fusible elements shall not be permitted in the body of the shell. Tanks shall be fitted with spring-loaded safety valves to prevent significant pressure build-up within the shell of the decomposition products and vapours released at a temperature of 50 °C. The capacity and start-to-discharge pressure of the safetyvalve(s) shall be based on the results of the tests specified in special provision TA2. The start-to-discharge pressure shall however in no case be such that liquid could escape from the valve(s) if the tank were overturned. The emergency-relief devices may be of the spring-loaded or frangible types designed to vent all the decomposition products and vapours evolved during a period of not less than one hour of complete fire-engulfment as calculated by the following formula: 0.82 A F q × × = where: q = heat absorption [W] A = wetted area [m2] F = insulation factor F = l for non-insulated tanks, or s tank insulated for ) T - (923 U F P0 = where: K = heat conductivity of insulation layer [W·m-1·K-1] L = thickness of insulation layer [m] U = K/L = heat transfer coefficient of the insulation [W·m-2·K-1] TPO = temperature of peroxide at relieving conditions [K] Copyright © United Nations, 2010. All rights reserved - 528 - The start-to-discharge pressure of the emergency-relief device(s) shall be higher than that above specified and based on the results of the tests referred to in special provision TA2. The emergency-relief devices shall be dimensioned in such a way that the maximum pressure in the tank never exceeds the test pressure of the tank. NOTE: An example of a method to determine the size of emergency-relief devices is given in Appendix 5 of the Manual of Tests and Criteria. For tanks equipped with thermal insulation consisting of a complete cladding, the capacity and setting of the emergency-relief device(s) shall be determined assuming a loss of insulation from 1% of the surface area. Vacuum-relief devices and spring-loaded safety valves of tanks shall be provided with flame arresters unless the substances to be carried and their decomposition products are non-combustible. Due attention shall be paid to the reduction of the relief capacity caused by the flame arrester. TE13 Tanks shall be thermally insulated and fitted with a heating device on the outside. TE14 Tanks shall be equipped with thermal insulation. The thermal insulation directly in contact with the shell shall have an ignition temperature at least 50 °C higher than the maximum temperature for which the tank was designed. TE15 (Deleted) TE16 (Reserved) TE17 (Reserved) TE18 Tanks intended for the carriage of substances filled at a temperature higher than 190 ºC shall be equipped with deflectors placed at right angles to the upper filling openings, so as to avoid a sudden localized increase in wall temperature during filling. TE19 Fittings and accessories mounted in the upper part of the tank shall be either: - inserted in a recessed housing; or - equipped with an internal safety valve; or - shielded by a cap, or by transverse and/or longitudinal members, or by other equally effective devices, so profiled that in the event of overturning the fittings and accessories will not be damaged. Fittings and accessories mounted in the lower part of the tank: Copyright © United Nations, 2010. All rights reserved - 529 - Pipe-sockets, lateral shut-off devices, and all discharge devices shall either be recessed by at least 200 mm from the extreme outer edge of the tank or be protected by a rail having a coefficient of inertia of not less than 20 cm3 transversally to the direction of travel; their ground clearance shall be not less than 300 mm with the tank full. Fittings and accessories mounted on the rear face of the tank shall be protected by the bumper prescribed in 9.7.6. Their height above the ground shall be such that they are adequately protected by the bumper TE20 Notwithstanding the other tank-codes which are permitted in the hierarchy of tanks of the rationalized approach in 4.3.4.1.2, tanks shall be equipped with a safety valve. TE21 The closures shall be protected with lockable caps. TE22 (Reserved) TE23 Tanks shall be equipped with a device of a design which precludes its obstruction by the substance carried and which prevents leakage and the build-up of excess overpressure or underpressure inside the shell. TE24 If tanks, intended for the carriage and handling of bitumen, are equipped with a spray bar at the end of the discharge pipe, the closing device, as required by 6.8.2.2.2, may be replaced by a shut-off valve, situated on the discharge pipe and preceding the spray bar. TE25 (Reserved) (c) Type approval (TA) TA1 Tanks shall not be approved for the carriage of organic substances. TA2 This substance may be carried in fixed or demountable tanks or tank-containers under the conditions laid down by the competent authority of the country of origin, if, on the basis of the tests mentioned below, the competent authority is satisfied that such a transport operation can be carried out safely. If the country of origin is not party to ADR, these conditions shall be recognized by the competent authority of the first ADR country reached by the consignment. For the type approval tests shall be undertaken: - to prove the compatibility of all materials normally in contact with the substance during carriage; - to provide data to facilitate the design of the emergency pressure-relief devices and safety valves taking into account the design characteristics of the tank; and Copyright © United Nations, 2010. All rights reserved - 530 - - to establish any special requirements necessary for the safe carriage of the substance. The test results shall be included in the report for the type approval. TA3 This substance may be carried only in tanks with the tank code LGAV or SGAV; the hierarchy in 4.3.4.1.2 is not applicable. TA4 The conformity assessment procedures of section 1.8.7 shall be applied by the competent authority, its delegate or inspection body conforming to 1.8.6.2, 1.8.6.4, 1.8.6.5 and 1.8.6.8 and accredited to EN ISO/IEC 17020:2004 type A. (d) Tests (TT) TT1 Tanks of pure aluminium need to be subjected to the initial and periodic hydraulic pressure tests at a pressure of only 250 kPa (2.5 bar) (gauge pressure). TT2 The condition of the lining of shells shall be inspected every year by an expert approved by the competent authority, who shall inspect the inside of the shell. TT3 By derogation from the requirements of 6.8.2.4.2, periodic inspections shall take place at least every eight years and shall include a thickness check using suitable instruments. For such tanks, the leakproofness test and check for which provision is made in 6.8.2.4.3 shall be carried out at least every four years. TT4 (Reserved) TT5 The hydraulic pressure tests shall take place at least every 3 years. 2½ years. TT6 The periodic tests, including the hydraulic pressure test, shall be carried out at least every 3 years. TT7 Notwithstanding the requirements of 6.8.2.4.2, the periodic internal inspection may be replaced by a programme approved by the competent authority. TT8 Tanks on which the proper shipping name required for the entry UN 1005 AMMONIA, ANHYDROUS is marked in accordance with 6.8.3.5.1 to 6.8.3.5.3 and constructed of fine-grained steel with a yield strength of more than 400 N/mm2 in accordance with the material standard, shall be subjected at each periodic test according to 6.8.2.4.2, to magnetic particle inspections to detect surface cracking. For the lower part of each shell at least 20% of the length of each circumferential and longitudinal weld shall, together with all nozzle welds and any repair or ground areas, be inspected. If the marking of the substance on the tank or tank plate is removed, a magnetic particle inspection shall be carried out and these actions recorded in the inspection certificate attached to the tank record. TT9 For inspections and tests (including supervision of the manufacture) the procedures of section 1.8.7 shall be applied by the competent authority, its delegate or inspection body conforming to 1.8.6.2, 1.8.6.4, 1.8.6.5 and 1.8.6.8 and accredited according to EN ISO/IEC 17020:2004 type A. Copyright © United Nations, 2010. All rights reserved - 531 - (e) Marking (TM) NOTE: These particulars shall be in an official language of the country of approval, and also, if that language is not English, French or German, in English, French or German, unless any agreements concluded between the countries concerned in the transport operation provide otherwise. TM1 Tanks shall bear in addition to the particulars prescribed in 6.8.2.5.2, the words: "Do not open during carriage. Liable to spontaneous combustion" (see also the Note above). TM2 Tanks shall bear in addition to the particulars prescribed in 6.8.2.5.2, the words: "Do not open during carriage. Gives off flammable gases on contact with water" (see also the Note above). TM3 Tanks shall also bear, on the plate prescribed in 6.8.2.5.1, the proper shipping names of the approved substances and the maximum permissible load of the tank in kg. TM4 For tanks the following additional particulars shall be marked by stamping or by any other similar method on the plate prescribed in 6.8.2.5.2 or directly on the shell itself, if the walls are so reinforced that the strength of the tank is not impaired: the chemical name with the approved concentration of the substance concerned. TM5 Tanks shall bear, in addition to the particulars referred to in 6.8.2.5.1 the date (month, year) of the most recent inspection of the internal condition of the shell. TM6 (Reserved) TM7 The trefoil symbol, as described in 5.2.1.7.6, shall be marked by stamping or any other equivalent method on the plate described in 6.8.2.5.1. This trefoil may be engraved directly on the walls of the shell itself, if the walls are so reinforced that the strength of the shell is not impaired. Copyright © United Nations, 2010. All rights reserved - 532 - 6.8.5 Requirements concerning the materials and construction of fixed welded tanks, demountable welded tanks, and welded shells of tank-containers for which a test pressure of not less than 1 MPa (10 bar) is required, and of fixed welded tanks, demountable welded tanks and welded shells of tank-containers intended for the carriage of refrigerated liquefied gases of Class 2 6.8.5.1 Materials and shells 6.8.5.1.1 (a) Shells intended for the carriage of : - compressed, liquefied gases or dissolved gases of Class 2; - UN Nos. 1380, 2845, 2870, 3194 and 3391 to 3394 of Class 4.2; and - UN No. 1052 hydrogen fluoride, anhydrous and UN No.1790 hydrofluoric acid with more than 85% hydrogen fluoride of Class 8 shall be made of steel; (b) Shells constructed of fine-grained steels for the carriage of: - corrosive gases of Class 2 and UN No. 2073 ammonia solution; and - UN No. 1052 hydrogen fluoride, anhydrous and UN No.1790 hydrofluoric acid with more than 85% hydrogen fluoride of Class 8 shall be heat-treated for thermal stress relief; (c) Shells intended for the carriage of refrigerated liquefied gases of Class 2, shall be made of steel, aluminium, aluminium alloy, copper or copper alloy (e.g. brass). However, shells made of copper or copper alloy shall be allowed only for gases containing no acetylene; ethylene, however, may contain not more than 0.005% acetylene; (d) Only materials appropriate to the lowest and highest working temperatures of the shells and of their fittings and accessories may be used. 6.8.5.1.2 The following materials shall be allowed for the manufacture of shells: (a) Steels not subject to brittle fracture at the lowest working temperature (see 6.8.5.2.1): - mild steels (except for refrigerated liquefied gases of Class 2); - fine-grained steels, down to a temperature of -60 ºC; - nickel steels (with a nickel content of 0.5 to 9%), down to a temperature of –196 ºC, depending on the nickel content; - austenitic chrome-nickel steels, down to a temperature of -270 ºC; (b) Aluminium not less than 99.5% pure or aluminium alloys (see 6.8.5.2.2); (c) Deoxidized copper not less than 99.9% pure, or copper alloys having a copper content of over 56% (see 6.8.5.2.3). 6.8.5.1.3 (a) Shells made of steel, aluminium or aluminium alloys shall be either seamless or welded; (b) Shells made of austenitic steel, copper or copper alloy may be hard-soldered. Copyright © United Nations, 2010. All rights reserved - 533 - 6.8.5.1.4 The fittings and accessories may either be screwed to the shells or be secured thereto as follows: (a) Shells made of steel, aluminium or aluminium alloy: by welding; (b) Shells made of austenitic steel, of copper or of copper alloy: by welding or hardsoldering. 6.8.5.1.5 The construction of shells and their attachment to the vehicle, to the underframe or in the container frame shall be such as to preclude with certainty any such reduction in the temperature of the load-bearing components as would be likely to render them brittle. The means of attachment of shells shall themselves be so designed that even when the shell is at its lowest working temperature they still possess the necessary mechanical properties. 6.8.5.2 Test requirements 6.8.5.2.1 Steel shells The materials used for the manufacture of shells and the weld beads shall, at their lowest working temperature, but at least at -20 ºC, meet at least the following requirements as to impact strength: - The tests shall be carried out with test-pieces having a V-shaped notch; - The minimum impact strength (see 6.8.5.3.1 to 6.8.5.3.3) for test-pieces with the longitudinal axis at right angles to the direction of rolling and a V-shaped notch (conforming to ISO R 148) perpendicular to the plate surface, shall be 34 J/cm2 for mild steel (which, because of existing ISO standards, may be tested with test-pieces having the longitudinal axis in the direction of rolling); fine-grained steel; ferritic alloy steel Ni < 5%, ferritic alloy steel 5% ≤ Ni ≤ 9%; or austenitic Cr - Ni steel; - In the case of austenitic steels, only the weld bead need be subjected to an impactstrength test; - For working temperatures below -196ºC the impact-strength test is not performed at the lowest working temperature, but at -196 ºC. 6.8.5.2.2 Shells made of aluminium or aluminium alloy The seams of shells shall meet the requirements laid down by the competent authority. 6.8.5.2.3 Shells made of copper or copper alloy It is not necessary to carry out tests to determine whether the impact strength is adequate. 6.8.5.3 Impact-strength tests 6.8.5.3.1 For sheets less than 10 mm but not less than 5 mm thick, test-pieces having a cross-section of 10 mm × e mm, where "e" represents the thickness of the sheet, shall be used. Machining to 7.5 mm or 5 mm is permitted if it is necessary. The minimum value of 34 J/cm2 shall be required in every case. NOTE: No impact-strength test shall be carried out on sheets less than 5 mm thick, or on their weld seams. Copyright © United Nations, 2010. All rights reserved - 534 - 6.8.5.3.2 (a) For the purpose of testing sheets, the impact strength shall be determined on three testpieces. Test-pieces shall be taken at right angles to the direction of rolling; however, for mild steel they may be taken in the direction of rolling. (b) For testing weld seams the test-pieces shall be taken as follows: when e ≤ 10 mm: three test-pieces with the notch at the centre of the weld; three test-pieces with the notch in the centre of the heat affected zone (the V-notch to cross the fusion boundary at the centre of the specimen); when 10 mm < e ≤ 20 mm: three test-pieces from the centre of the weld; three test-pieces from the heat affected zone (the V-notch to cross the fusion boundary at the centre of the specimen); Center of the weld Heat affected zone Heat affected zone e e e Center of the weld Copyright © United Nations, 2010. All rights reserved - 535 - when e > 20 mm two sets of three test-pieces, one set on the upper face, one set on the lower face at each of the points indicated below (the V-notch to cross the fusion boundary at the centre of the specimen for those taken from the heat affected zone) 6.8.5.3.3 (a) For sheets, the average of the three tests shall meet the minimum value of 34 J/cm2 indicated in 6.8.5.2.1; not more than one of the individual values may be below the minimum value and then not below 24 J/cm2; (b) For welds, the average value obtained from the three test-pieces taken at the centre of the weld shall not be below the minimum value of 34 J/cm2; not more than one of the individual values may be below the minimum value and then not below 24 J/cm2; (c) For the heat affected zone (the V-notch to cross the fusion boundary at the centre of the specimen) the value obtained from not more than one of the three test-pieces may be below the minimum value of 34 J/cm2, though not below 24 J/cm2. 6.8.5.3.4 If the requirements prescribed in 6.8.5.3.3 are not met, one retest only may be done if: (a) the average value of the first three tests is below the minimum value of 34 J/cm2; or (b) more than one of the individual values is less than the minimum value of 34 J/cm2 but not below 24 J/cm2. 6.8.5.3.5 In a repeated impact test on sheets or welds, none of the individual values may be below 34 J/cm2. The average value of all the results of the original test and of the retest should be equal to or more than the minimum of 34 J/cm2. On a repeated impact strength test on the heat-affected zone, none of the individual values may be below 34 J/cm2. e Center of the weld Heat affected zone Copyright © United Nations, 2010. All rights reserved - 536 - 6.8.5.4 Reference to standards The requirements of 6.8.5.2 and 6.8.5.3 shall be deemed to have been complied with if the following relevant standards have been applied: EN 1252-1:1998 Cryogenic vessels - Materials - Part 1: Toughness requirements for temperature below - 80 °C. EN 1252-2: 2001 Cryogenic vessels - Materials - Part 2: Toughness requirements for temperature between - 80 °C and - 20 °C. Copyright © United Nations, 2010. All rights reserved - 537 - CHAPTER 6.9 REQUIREMENTS FOR THE DESIGN, CONSTRUCTION, EQUIPMENT, TYPE APPROVAL, TESTING AND MARKING OF FIBRE-REINFORCED PLASTICS (FRP) FIXED TANKS (TANK-VEHICLES), DEMOUNTABLE TANKS, TANK-CONTAINERS AND TANK SWAP BODIES NOTE: For portable tanks and UN multiple-element gas containers (MEGCs) see Chapter 6.7; for fixed tanks (tank-vehicles), demountable tanks and tank-containers and tank swap bodies, with shells made of metallic materials, and battery-vehicles and multiple element gas containers (MEGCs) other than UN MEGCs see Chapter 6.8; for vacuum operated waste tanks see Chapter 6.10. 6.9.1 General 6.9.1.1 FRP tanks shall be designed, manufactured and tested in accordance with a quality assurance programme recognized by the competent authority; in particular, lamination work and welding of thermoplastic liners shall only be carried out by qualified personnel in accordance with a procedure recognized by the competent authority. 6.9.1.2 For the design and testing of FRP tanks, the provisions of 6.8.2.1.1, 6.8.2.1.7, 6.8.2.1.13, 6.8.2.1.14 (a) and (b), 6.8.2.1.25, 6.8.2.1.27, 6.8.2.1.28 and 6.8.2.2.3 shall also apply. 6.9.1.3 Heating elements shall not be used for FRP tanks. 6.9.1.4 For the stability of tank-vehicles, the requirements of 9.7.5.1 shall apply. 6.9.2 Construction 6.9.2.1 Shells shall be made of suitable materials, which shall be compatible with the substances to be carried in a service temperature range of between -40°C and +50°C, unless temperature ranges are specified for specific climatic conditions by the competent authority of the country where the transport operation is performed. 6.9.2.2 Shells shall consist of the following three elements : - internal liner, - structural layer, - external layer. 6.9.2.2.1 The internal liner is the inner shell wall zone designed as the primary barrier to provide for the long-term chemical resistance in relation to the substances to be carried, to prevent any dangerous reaction with the contents or the formation of dangerous compounds and any substantial weakening of the structural layer owing to the diffusion of products through the internal liner. The internal liner may either be a FRP liner or a thermoplastic liner. Copyright © United Nations, 2010. All rights reserved - 538 - 6.9.2.2.2 FRP liners shall consist of: (a) surface layer ("gel-coat"): adequate resin rich surface layer, reinforced with a veil, compatible with the resin and contents. This layer shall have a fibre mass content of not more than 30% and have a thickness between 0.25 and 0.60 mm; (b) strengthening layer(s): layer or several layers with a minimum thickness of 2 mm, containing a minimum of 900 g/m² of glass mat or chopped fibres with a mass content in glass of not less than 30% unless equivalent safety is demonstrated for a lower glass content. 6.9.2.2.3 Thermoplastic liners shall consist of thermoplastic sheet material as referred to in 6.9.2.3.4, welded together in the required shape, to which the structural layers are bonded. Durable bonding between liners and the structural layer shall be achieved by the use of an appropriate adhesive. NOTE: For the carriage of flammable liquids the internal layer may require additional measures in accordance with 6.9.2.14, in order to prevent the accumulation of electrical charges. 6.9.2.2.4 The structural layer of the shell is the zone specially designed according to 6.9.2.4 to 6.9.2.6 to withstand the mechanical stresses. This part normally consists of several fibre reinforced layers in determined orientations. 6.9.2.2.5 The external layer is the part of the shell which is directly exposed to the atmosphere. It shall consist of a resin rich layer with a thickness of at least 0.2 mm. For a thickness larger than 0.5 mm, a mat shall be used. This layer shall have a mass content in glass of less than 30% and shall be capable of withstanding exterior conditions, in particular the occasional contact with the substance to be carried. The resin shall contain fillers or additives to provide protection against deterioration of the structural layer of the shell by ultra-violet radiation. 6.9.2.3 Raw materials 6.9.2.3.1 All materials used for the manufacture of FRP tanks shall be of known origin and specifications. 6.9.2.3.2 Resins The processing of the resin mixture shall be carried out in strict compliance with the recommendations of the supplier. This concerns mainly the use of hardeners, initiators and accelerators. These resins can be: - unsaturated polyester resins; - vinyl ester resins; - epoxy resins; - phenolic resins. The heat distortion temperature (HDT) of the resin, determined in accordance with ISO 75-1:1993 shall be at least 20°C higher than the maximum service temperature of the tank, but shall in any case not be lower than 70 °C. Copyright © United Nations, 2010. All rights reserved - 539 - 6.9.2.3.3 Reinforcement fibres The reinforcement material of the structural layers shall be a suitable grade of fibres such as glass fibres of type E or ECR according to ISO 2078:1993. For the internal surface liner, glass fibres of type C according to ISO 2078:1993 may be used. Thermoplastic veils may only be used for the internal liner when their compatibility with the intended contents has been demonstrated. 6.9.2.3.4 Thermoplastic liner material Thermoplastic liners, such as unplastified polyvinyl chloride (PVC-U), polypropylene (PP), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), etc. may be used as lining materials. 6.9.2.3.5 Additives Additives necessary for the treatment of the resin, such as catalysts, accelerators, hardeners and thixotropic substances as well as materials used to improve the tank, such as fillers, colours, pigments etc. shall not cause weakening of the material, taking into account lifetime and temperature expectancy of the design. 6.9.2.4 Shells, their attachments and their service and structural equipment shall be designed to withstand without loss of contents (other than quantities of gas escaping through any degassing vents) during the design lifetime: - the static and dynamic loads in normal conditions of carriage; - the prescribed minimum loads as defined in 6.9.2.5 to 6.9.2.10. 6.9.2.5 At the pressures as indicated in 6.8.2.1.14 (a) and (b), and under the static gravity forces caused by the contents with maximum density specified for the design and at maximum filling degree, the design stress σ in longitudinal and circumferential direction of any layer of the shell shall not exceed the following value: K R m ≤ σ where: Rm = the value of tensile strength given by taking the mean value of the test results minus twice the standard deviation of the test results. The tests shall be carried out, in accordance with the requirements of EN 61:1977, on not less than six samples representative of the design type and construction method; K = S × K0 × K1 × K2 × K3 where K shall have a minimum value of 4, and S = the safety coefficient. For the general design, if the tanks are referred to in Column (12) of Table A of Chapter 3.2 by a tank code including the letter "G" in its second part (see 4.3.4.1.1), the value for S shall be equal to or more than 1.5. For tanks intended for the carriage of substances which require an increased safety level, i.e. if the tanks are referred to in Column (12) of Table A of Chapter 3.2 by a tank code including the number "4" in its second part (see 4.3.4.1.1), the value Copyright © United Nations, 2010. All rights reserved - 540 - of S shall be multiplied by a factor of two, unless the shell is provided with protection against damage consisting of a complete metal skeleton including longitudinal and transverse structural members; K0 = a factor related to the deterioration in the material properties due to creep and ageing and as a result of the chemical action of the substances to be carried. It shall be determined by the formula: αβ = 1 Ko where "α" is the creep factor and "β" is the ageing factor determined in accordance with EN 978:1997 after performance of the test according to EN 977:1997. Alternatively, a conservative value of K0 = 2 may be applied. In order to determine α and β the initial deflection shall correspond to 2σ; K1 = a factor related to the service temperature and the thermal properties of the resin, determined by the following equation, with a minimum value of 1: K1 = 1.25 - 0.0125 (HDT - 70) where HDT is the heat distortion temperature of the resin, in ºC; K2 = a factor related to the fatigue of the material; the value of K2 = 1.75 shall be used unless otherwise agreed with the competent authority. For the dynamic design as outlined in 6.9.2.6 the value of K2 = 1.1 shall be used; K3 = a factor related to curing and has the following values: - 1.1 where curing is carried out in accordance with an approved and documented process; - 1.5 in other cases. 6.9.2.6 At the dynamic stresses, as indicated in 6.8.2.1.2 the design stress shall not exceed the value specified in 6.9.2.5, divided by the factor α. 6.9.2.7 At any of the stresses as defined in 6.9.2.5 and 6.9.2.6, the resulting elongation in any direction shall not exceed 0.2% or one tenth of the elongation at fracture of the resin, whichever is lower. 6.9.2.8 At the specified test pressure, which shall not be less than the relevant calculation pressure as specified in 6.8.2.1.14 (a) and (b) the maximum strain in the shell shall not be greater than the elongation at fracture of the resin. 6.9.2.9 The shell shall be capable of withstanding the ball drop test according to 6.9.4.3.3 without any visible internal or external defects. 6.9.2.10 The overlay laminates used in the joints, including the end joints, the joints of the surge plates and the partitions with the shell shall be capable of withstanding the static and dynamic stresses mentioned above. In order to avoid concentrations of stresses in the overlay lamination, the applied tapper shall not be steeper than 1:6. Copyright © United Nations, 2010. All rights reserved - 541 - The shear strength between the overlay laminate and the tank components to which it is bonded shall not be less than: K l Q R τ τ ≤ = where: τR is the bending shear strength according to EN ISO 14125:1998 (three points method) with a minimum of τR = 10 N/mm2, if no measured values are available; Q is the load per unit width that the joint shall carry under the static and dynamic loads; K is the factor calculated in accordance with 6.9.2.5 for the static and dynamic stresses; l is the length of the overlay laminate. 6.9.2.11 Openings in the shell shall be reinforced to provide at least the same safety factors against the static and dynamic stresses as specified in 6.9.2.5 and 6.9.2.6 as that for the shell itself. The number of openings shall be minimized. The axis ratio of oval-shaped openings shall be not more than 2. 6.9.2.12 For the design of flanges and pipework attached to the shell, handling forces and the fastening of bolts shall also be taken into account. 6.9.2.13 The tank shall be designed to withstand, without significant leakage, the effects of a full engulfment in fire for 30 minutes as specified by the test requirements in 6.9.4.3.4. Testing may be waived with the agreement of the competent authority, where sufficient proof can be provided by tests with comparable tank designs. 6.9.2.14 Special requirements for the carriage of substances with a flash-point of not more than 60 °C FRP tanks used for the carriage of substances with a flash-point of not more than 60°C shall be constructed so as to ensure the elimination of static electricity from the various component parts so as to avoid the accumulation of dangerous charges. 6.9.2.14.1 The electrical surface resistance of the inside and outside of the shell as established by measurements shall not be higher than 109 ohms. This may be achieved by the use of additives in the resin or interlaminate conducting sheets, such as metal or carbon network. 6.9.2.14.2 The discharge resistance to earth as established by measurements shall not be higher than 107 ohms. 6.9.2.14.3 All components of the shell shall be electrically connected to each other and to the metal parts of the service and structural equipment of the tank and to the vehicle. The electrical resistance between components and equipment in contact with each other shall not exceed 10 ohms. 6.9.2.14.4 The electrical surface-resistance and discharge resistance shall be measured initially on each manufactured tank or a specimen of the shell in accordance with a procedure recognized by the competent authority. 6.9.2.14.5 The discharge resistance to earth of each tank shall be measured as part of the periodic inspection in accordance with a procedure recognized by the competent authority. Copyright © United Nations, 2010. All rights reserved - 542 - 6.9.3 Items of equipment 6.9.3.1 The requirements of 6.8.2.2.1, 6.8.2.2.2 and 6.8.2.2.4 to 6.8.2.2.8 shall apply. 6.9.3.2 In addition, when they are shown under an entry in Column (13) of Table A of Chapter 3.2, the special provisions of 6.8.4 (b) (TE) shall also apply. 6.9.4 Type testing and approval 6.9.4.1 For any design of a FRP tank type, its materials and a representative prototype shall be subjected to the design type testing as outlined below. 6.9.4.2 Material testing 6.9.4.2.1 The elongation at fracture according to EN ISO 527-5:1997 and the heat distortion temperature according to ISO 75-1:1993 shall be determined for the resins to be used. 6.9.4.2.2 The following characteristics shall be determined for samples cut out of the shell. Samples manufactured in parallel may only be used, if it is not possible to use cutouts from the shell. Prior to testing, any liner shall be removed. The tests shall cover: - Thickness of the laminates of the central shell wall and the ends; - Mass content and composition of glass, orientation and arrangement of reinforcement layers; - Tensile strength, elongation at fracture and modulus of elasticity according to EN ISO 527-5:1997 in the direction of stresses. In addition, the elongation at fracture of the resin shall be established by means of ultrasound; - Bending strength and deflection established by the bending creep test according to ISO 14125:1998 for a period of 1000 hours using a sample with a minimum width of 50 mm and a support distance of at least 20 times the wall thickness. In addition, the creep factor α and the ageing factor β shall be determined by this test and according to EN 978:1997. 6.9.4.2.3 The interlaminate shear strength of the joints shall be measured by testing representative samples in the tensile test according to EN ISO 14130:1997. 6.9.4.2.4 The chemical compatibility of the shell with the substances to be carried shall be demonstrated by one of the following methods with the agreement of the competent authority. This demonstration shall account for all aspects of the compatibility of the materials of the shell and its equipment with the substances to be carried, including chemical deterioration of the shell, initiation of critical reactions of the contents and dangerous reactions between both. - In order to establish any deterioration of the shell, representative samples taken from the shell, including any internal liners with welds, shall be subjected to the chemical compatibility test according to EN 977:1997 for a period of 1 000 hours at 50°C. Compared with a virgin sample, the loss of strength and elasticity modulus measured by the bending test according to EN 978:1997 shall not exceed 25%. Cracks, bubbles, pitting effects as well as separation of layers and liners and roughness shall not be acceptable. Copyright © United Nations, 2010. All rights reserved - 543 - - Certified and documented data of positive experiences on the compatibility of the filling substances in question with the materials of the shell with which they come into contact at given temperatures, times and any other relevant service conditions. - Technical data published in relevant literature, standards or other sources, acceptable to the competent authority. 6.9.4.3 Type testing A representative prototype tank shall be subjected to tests as specified below. For this purpose service equipment may be replaced by other items if necessary. 6.9.4.3.1 The prototype shall be inspected for compliance with the design type specification. This shall include an internal and external visual inspection and measurement of the main dimensions. 6.9.4.3.2 The prototype, equipped with strain gauges at all locations where a comparison with the design calculation is required, shall be subjected to the following loads and the strains shall be recorded: - Filled with water to the maximum filling degree. The measuring results shall be used to calibrate the design calculation according to 6.9.2.5; - Filled with water to the maximum filling degree and subjected to accelerations in all three directions by means of driving and braking exercises with the prototype attached to a vehicle. For comparison with the design calculation according to 6.9.2.6 the strains recorded shall be extrapolated in relation to the quotient of the accelerations required in 6.8.2.1.2 and measured; - Filled with water and subjected to the specified test pressure. Under this load, the shell shall exhibit no visual damage or leakage. 6.9.4.3.3 The prototype shall be subjected to the ball drop test according to EN 976-1:1997, No. 6.6. No visible damage inside or outside the tank shall occur. 6.9.4.3.4 The prototype with its service and structural equipment in place and filled to 80% of its maximum capacity with water, shall be exposed to a full engulfment in fire for 30 minutes, caused by an open heating oil pool fire or any other type of fire with the same effect. The dimensions of the pool shall exceed those of the tank by at least 50 cm to each side and the distance between fuel level and tank shall be between 50 cm and 80 cm. The rest of the tank below liquid level, including openings and closures, shall remain leakproof except for drips. 6.9.4.4 Type approval 6.9.4.4.1 The competent authority or a body designated by that authority shall issue in respect of each new type of tank an approval attesting that the design is suitable for the purpose for which it is intended and meets the construction and equipment requirements of this chapter as well as the special provisions applicable to the substances to be carried. 6.9.4.4.2 The approval shall be based on the calculation and the test report, including all material and prototype test results and its comparison with the design calculation, and shall refer to the design type specification and the quality assurance programme. 6.9.4.4.3 The approval shall include the substances or group of substances for which compatibility with the shell is provided. Their chemical names or the corresponding collective entry (see 2.1.1.2), and their class and classification code shall be indicated. Copyright © United Nations, 2010. All rights reserved - 544 - 6.9.4.4.4 In addition, it shall include design and threshold values (such as life-time, service temperature range, working and test pressures, material data) specified and all precautions to be taken for the manufacture, testing, type approval, marking and use of any tank, manufactured in accordance with the approved design type. 6.9.5 Inspections 6.9.5.1 For every tank, manufactured in conformity with the approved design, material tests and inspections shall be performed as specified below. 6.9.5.1.1 The material tests according to 6.9.4.2.2, except for the tensile test and for a reduction of the testing time for the bending creep test to 100 hours shall be performed with samples taken from the shell. Samples manufactured in parallel may only be used, if no cutouts from the shell are possible. The approved design values shall be met. 6.9.5.1.2 Shells and their equipment shall either together or separately undergo an initial inspection before being put into service. This inspection shall include: - a check of conformity to the approved design; - a check of the design characteristics; - an internal and external examination; - a hydraulic pressure test at the test pressure indicated on the plate prescribed in 6.8.2.5.1; - a check of operation of the equipment; - a leakproofness test, if the shell and its equipment have been pressure tested separately. 6.9.5.2 For the periodic inspection of tanks the requirements of 6.8.2.4.2 to 6.8.2.4.4 shall apply. In addition, the inspection in accordance with 6.8.2.4.3 shall include an examination of the internal condition of the shell. 6.9.5.3 The inspections and tests in accordance with 6.9.5.1 and 6.9.5.2 shall be carried out by the expert approved by the competent authority. Certificates shall be issued showing the results of these operations. These certificates shall refer to the list of the substances permitted for carriage in this shell in accordance with 6.9.4.4. 6.9.6 Marking 6.9.6.1 The requirements of 6.8.2.5 shall apply to the marking of FRP tanks, with the following amendments: - the tank plate may also be laminated to the shell or be made of suitable plastics materials; - the design temperature range shall always be marked. 6.9.6.2 In addition, when they are shown under an entry in Column (13) of Table A of Chapter 3.2, the special provisions of 6.8.4 (e) (TM) shall also apply. Copyright © United Nations, 2010. All rights reserved - 545 - CHAPTER 6.10 REQUIREMENTS FOR THE CONSTRUCTION, EQUIPMENT, TYPE APPROVAL, INSPECTION AND MARKING OF VACUUM-OPERATED WASTE TANKS NOTE 1: For portable tanks and UN multiple-element gas containers (MEGCs) see Chapter 6.7; for fixed tanks (tank-vehicles), demountable tanks and tank containers and tank swap bodies, with shells made of metallic materials, and battery-vehicles and multiple element gas containers (MEGCs) other than UN MEGCs see Chapter 6.8; for fibre-reinforced plastic tanks see Chapter 6.9. NOTE 2: This Chapter applies to fixed tanks, demountable tanks, tank-containers and tank swap bodies. 6.10.1 General 6.10.1.1 Definition NOTE: A tank which fully complies with the requirements of Chapter 6.8 is not considered to be a "vacuum-operated waste tank". 6.10.1.1.1 The term "protected area" means the areas located as follows: (a) The lower part of the tank in a zone which extends over a 60o angle on either side of the lower generating line; (b) The top part of the tank in a zone which extends over a 30° angle on either side of the top generating line; (c) On the end front of the tank on motor vehicles; (d) On the rear end of the tank inside the protection volume formed by the device stipulated in 9.7.6. 6.10.1.2 Scope 6.10.1.2.1 The special requirements of 6.10.2 to 6.10.4 complete or modify Chapter 6.8 and are applied to vacuum-operated waste tanks. Vacuum-operated waste tanks may be equipped with openable ends, if the requirements of Chapter 4.3 allow bottom discharge of the substances to be carried (indicated by letters "A" or "B" in Part 3 of the tank code given in Column (12) of Table A of Chapter 3.2, in accordance with 4.3.4.1.1). Vacuum-operated waste tanks shall comply with all requirements of Chapter 6.8, with the exception of requirements overtaken by a special provision in this Chapter. However the requirements of 6.8.2.1.19, 6.8.2.1.20, and 6.8.2.1.21 shall not apply. 6.10.2 Construction 6.10.2.1 Tanks shall be designed for a calculation pressure equal to 1.3 times the filling or discharge pressure but not less than 400 kPa (4 bar) (gauge pressure). For the carriage of substances for which a higher calculation pressure of the tank is specified in Chapter 6.8, this higher pressure shall apply. 6.10.2.2 Tanks shall be designed to withstand a negative internal pressure of 100 kPa (1 bar). Copyright © United Nations, 2010. All rights reserved - 546 - 6.10.3 Items of equipment 6.10.3.1 The items of equipment shall be so arranged as to be protected against the risk of being wrenched off or damaged during carriage or handling. This requirement can be fulfilled by placing the items of equipment in a so called "protected area" (see 6.10.1.1.1). 6.10.3.2 The bottom discharge of shells may be constituted by external piping with a stop-valve fitted as close to the shell as practicable and a second closure which may be a blank flange or other equivalent device. 6.10.3.3 The position and closing direction of the stop-valve(s) connected to the shell, or to any compartment in the case of compartmented shells, shall be unambiguous, and be able to be checked from the ground. 6.10.3.4 In order to avoid any loss of contents in the event of damage to the external filling and discharge fittings (pipes, lateral shut-off devices), the internal stop-valve, or the first external stop-valve (where applicable), and its seatings shall be protected against the danger of being wrenched off by external stresses or shall be so designed as to withstand them. The filling and discharge devices (including flanges or threaded plugs) and protective caps (if any) shall be capable of being secured against any unintended opening. 6.10.3.5 The tanks may be equipped with openable ends. Openable ends shall comply with the following conditions: (a) The ends shall be designed to be secured leaktight when closed; (b) Unintentional opening shall not be possible; (c) Where the opening mechanism is power operated the end shall remain securely closed in the event of a power failure; (d) A safety or breakseal device shall be incorporated to ensure that the openable end cannot be opened when there is still a residual over pressure in the tank. This requirement does not apply to openable ends which are power-operated, where the movement is positively controlled. In this case the controls shall be of the dead-man type and be so positioned that the operator can observe the movement of the openable end at all times and is not endangered during opening and closing of the openable end; and (e) Provisions shall be made to protect the openable end and prevent it from being forced open during a roll-over of the vehicle, tank-container or tank swap body. 6.10.3.6 Vacuum-operated waste tanks which are fitted with an internal piston to assist in the cleaning of the tank or discharging shall be provided with stop-devices to prevent the piston in every operational position being ejected from the tank when a force equivalent to the maximum working pressure of the tank is applied to the piston. The maximum working pressure for tanks or compartments with pneumatic operated piston shall not exceed 100 kPa (1.0 bar). The internal piston shall be constructed in a manner and of materials which will not cause an ignition source when the piston is moved. The internal piston may be used as a compartment provided it is secured in position. Where any of the means by which the internal piston is secured is external to the tank, it shall be placed in a position not liable to accidental damage. Copyright © United Nations, 2010. All rights reserved - 547 - 6.10.3.7 The tanks may be equipped with suction booms if: (a) The boom is fitted with an internal or external stop-valve fixed directly to the shell, or directly to a bend that is welded to the shell; a rotation crown wheel can be fitted between the shell or the bend and the external stop valve, if this rotation crown wheel is located in the protected area and the stop-valve control device is protected with a housing or cover against the danger of being wrenched off by external loads; (b) The stop-valve mentioned in (a) is so arranged that carriage with the valve in an open position is prevented; and (c) The boom is constructed in such a way that the tank will not leak as a result of accidental impact on the boom. 6.10.3.8 The tanks shall be fitted with the following additional service equipment: (a) The outlet of a pump/exhauster unit shall be so arranged as to ensure that any flammable or toxic vapours are diverted to a place where they will not cause a danger; (b) A device to prevent immediate passage of flame shall be fitted to both the inlet and outlet of a vacuum pump/exhauster unit which may create sparks and which is fitted on a tank used for the carriage of flammable wastes; (c) Pumps which can deliver a positive pressure shall have a safety device fitted in the pipework which can be pressurised. The safety device shall be set to discharge at a pressure not exceeding the maximum working pressure of the tank; (d) A stop-valve shall be fitted between the shell, or the outlet of the overfill prevention device fitted to the shell, and the pipework connecting the shell to the pump/exhauster unit; (e) The tank shall be fitted with a suitable pressure/vacuum manometer which shall be mounted in a position where it can be easily read by the person operating the pump/exhauster unit. A distinguishing line shall be marked on the scale to indicate the maximum working pressure of the tank; (f) The tank, or in case of compartmented tanks, every compartment, shall be equipped with a level indicating device. Sight glasses may be used as level indicating devices provided: (i) they form a part of the tank wall and have a resistance to the pressure comparable to that of the tank; or they are fitted external to the tank; (ii) the top and bottom connections to the tank are equipped with shut-off valves fixed directly to the shell and so arranged that carriage with the valves in an open position is prevented; (iii) are suitable for operation at the maximum working pressure of the tank; and (iv) are placed in a position where they will not be liable to accidental damage. 6.10.3.9 The shells of vacuum-operated waste tanks shall be fitted with a safety valve preceded by a bursting disc. Copyright © United Nations, 2010. All rights reserved - 548 - The valve shall be capable of opening automatically at a pressure between 0.9 and 1.0 times the test pressure of the tank to which it is fitted. The use of dead weight or counterweight valves is prohibited. The bursting disc shall burst at the earliest when the initial opening pressure of the valve is reached and at the latest when this pressure reaches the test pressure of the tank to which it is fitted. Safety devices shall be of such a type as to resist dynamic stresses, including liquid surge. The space between the bursting disc and the safety valve shall be provided with a pressure gauge or suitable tell-tale indicator for the detection of disc rupture, pinholing or leakage wich could cause a malfunction of the safety valve. 6.10.4 Inspection Vacuum-operated waste tanks shall be subject every three years for fixed tanks or demountable tanks and at least every two and a half years for tank-containers and tank swap bodies to an examination of the internal condition, in addition to the tests according to 6.8.2.4.3. Copyright © United Nations, 2010. All rights reserved - 549 - CHAPTER 6.11 REQUIREMENTS FOR THE DESIGN, CONSTRUCTION, INSPECTION AND TESTING OF BULK CONTAINERS 6.11.1 Definitions For the purposes of this section: Closed bulk container means a totally closed bulk container having a rigid roof, sidewalls, end walls and floor (including hopper-type bottoms). The term includes bulk containers with an opening roof, side or end wall that can be closed during carriage. Closed bulk containers may be equipped with openings to allow for the exchange of vapours and gases with air and which prevent under normal conditions of carriage the release of solid contents as well as the penetration of rain and splash water; Sheeted bulk container means an open top bulk container with rigid bottom (including hopper-type bottom), side and end walls and a non-rigid covering; 6.11.2 Application and general requirements 6.11.2.1 Bulk containers and their service and structural equipment shall be designed and constructed to withstand, without loss of contents, the internal pressure of the contents and the stresses of normal handling and carriage. 6.11.2.2 Where a discharge valve is fitted, it shall be capable of being made secure in the closed position and the whole discharge system shall be suitably protected from damage. Valves having lever closures shall be able to be secured against unintended opening and the open or closed position shall be readily apparent. 6.11.2.3 Code for designating types of bulk container The following table indicates the codes to be used for designating types of bulk containers: Types of bulk containers Code Sheeted bulk container BK1 Closed bulk container BK2 6.11.2.4 In order to take account of progress in science and technology, the use of alternative arrangements which offer at least equivalent safety as provided by the requirements of this chapter may be considered by the competent authority. 6.11.3 Requirements for the design, construction, inspection and testing of containers conforming to the CSC used as bulk containers 6.11.3.1 Design and construction requirements 6.11.3.1.1 The general design and construction requirements of this sub-section are deemed to be met if the bulk container complies with the requirements of ISO 1496-4:1991 "Series 1 Freight containers- Specification and testing – Part 4: Non pressurized containers for dry bulk" and the container is siftproof. Copyright © United Nations, 2010. All rights reserved - 550 - 6.11.3.1.2 Containers designed and tested in accordance with ISO 1496-1:1990 "Series 1 Freight containers- Specification and testing - Part 1: General cargo containers for general purposes" shall be equipped with operational equipment which is, including its connection to the container, designed to strengthen the end walls and to improve the longitudinal restraint as necessary to comply with the test requirements of ISO 1496-4:1991 as relevant. 6.11.3.1.3 Bulk containers shall be siftproof. Where a liner is used to make the container siftproof it shall be made of a suitable material. The strength of material used for, and the construction of, the liner shall be appropriate to the capacity of the container and its intended use. Joins and closures of the liner shall withstand pressures and impacts liable to occur under normal conditions of handling and carriage. For ventilated bulk containers any liner shall not impair the operation of ventilating devices. 6.11.3.1.4 The operational equipment of bulk containers designed to be emptied by tilting shall be capable of withstanding the total filling mass in the tilted orientation. 6.11.3.1.5 Any movable roof or side or end wall or roof section shall be fitted with locking devices with securing devices designed to show the locked state to an observer at ground level. 6.11.3.2 Service equipment 6.11.3.2.1 Filling and discharge devices shall be so constructed and arranged as to be protected against the risk of being wrenched off or damaged during carriage and handling. The filling and discharge devices shall be capable of being secured against unintended opening. The open and closed position and direction of closure shall be clearly indicated. 6.11.3.2.2 Seals of openings shall be so arranged as to avoid any damage by the operation, filling and emptying of the bulk container. 6.11.3.2.3 Where ventilation is required bulk containers shall be equipped with means of air exchange, either by natural convection, e.g. by openings, or active elements, e.g. fans. The ventilation shall be designed to prevent negative pressures in the container at all times. Ventilating elements of bulk containers for the carriage of flammable substances or substances emitting flammable gases or vapours shall be designed so as not to be a source of ignition. 6.11.3.3 Inspection and testing 6.11.3.3.1 Containers used, maintained and qualified as bulk containers in accordance with the requirements of this section shall be tested and approved in accordance with the CSC. 6.11.3.3.2 Containers used and qualified as bulk containers shall be inspected periodically according to the CSC. 6.11.3.4 Marking 6.11.3.4.1 Containers used as bulk containers shall be marked with a Safety Approval Plate in accordance with the CSC. Copyright © United Nations, 2010. All rights reserved - 551 - 6.11.4 Requirements for the design, construction and approval of bulk containers other than containers conforming to the CSC NOTE: When containers conforming to the provisions of this section are used for the carriage of solids in bulk, the following statement shall be shown on the transport document: "Bulk container BK(x) approved by the competent authority of ……". (see 5.4.1.1.17)". 6.11.4.1 Bulk containers covered in this section include skips, offshore bulk containers, bulk bins, swap bodies, trough shaped containers, roller containers, and load compartments of vehicles. NOTE: These bulk containers also include containers conforming to the UIC leaflets 591 and 592-2 to 592-4 as mentioned in 7.1.3 which do not conform to the CSC. 6.11.4.2 These bulk containers shall be designed and constructed so as to be strong enough to withstand the shocks and loadings normally encountered during carriage including, as applicable, transhipment between modes of transport. 6.11.4.3 (Reserved) 6.11.4.4 These bulk containers shall be approved by the competent authority and the approval shall include the code for designating types of bulk containers in accordance with 6.11.2.3 and the requirements for inspection and testing as appropriate. 6.11.4.5 Where it is necessary to use a liner in order to retain the dangerous goods it shall meet the provisions of 6.11.3.1.3. Copyright © United Nations, 2010. All rights reserved - 553 - CHAPTER 6.12 REQUIREMENTS FOR THE CONSTRUCTION, EQUIPMENT, TYPE APPROVAL, INSPECTIONS AND TESTS, AND MARKING OF TANKS, BULK CONTAINERS AND SPECIAL COMPARTMENTS FOR EXPLOSIVES OF MOBILE EXPLOSIVES MANUFACTURING UNITS (MEMUs) NOTE 1: For portable tanks, see Chapter 6.7; for fixed tanks (tank-vehicles), demountable tanks, tank-containers and tank swap bodies, with shells made of metallic materials, see Chapter 6.8; for fibre-reinforced plastics tanks see Chapter 6.9; for vacuum operated waste tanks see Chapter 6.10; for bulk containers see Chapter 6.11. NOTE 2: This Chapter applies to fixed tanks, demountable tanks, tank-containers, tank swap bodies, which do not comply with all requirements of the Chapters mentioned in Note 1 as well as bulk containers and special compartments for explosives. 6.12.1 Scope The requirements of this Chapter are applicable to tanks, bulk containers and special compartments intended for the carriage of dangerous goods on MEMUs. 6.12.2 General provisions 6.12.2.1 Tanks shall meet the requirements of Chapter 6.8, notwithstanding the minimum capacity defined in section 1.2.1 for fixed tanks, as modified by the special provisions of this Chapter. 6.12.2.2 Bulk containers intended for the carriage of dangerous goods on MEMUs shall comply with the requirements for bulk containers of type BK2. 6.12.2.3 Where a single tank or bulk container contains more than one substance each substance shall be separated by at least two walls with drained air space between. 6.12.3 Tanks 6.12.3.1 Tanks with a capacity of 1 000 litres or more 6.12.3.1.1 These tanks shall meet the requirements of section 6.8.2. 6.12.3.1.2 Where a safety valve is required by the provisions of section 6.8.2, a tank shall also have a bursting disc, or other suitable means of pressure relief, approved by the competent authority. 6.12.3.1.3 For shells not of a circular cross-section, for example box-shaped or elliptical shells, which cannot be calculated according to 6.8.2.1.4 and standards or technical code mentioned therein, the ability to withstand the permissible stress may be demonstrated by a pressure test specified by the competent authority. These tanks shall meet the requirements of sub-section 6.8.2.1 other than 6.8.2.1.3, 6.8.2.1.4 and 6.8.2.1.13 to 6.8.2.1.22. Copyright © United Nations, 2010. All rights reserved - 554 - The thickness of these shells shall not be less than the values given in the table below: Material Minimum thickness Stainless austenitic steels 2.5 mm Other steels 3 mm Aluminium alloys 4 mm Pure aluminium of 99.80% 6 mm Protection of the tank against damage through lateral impact or overturning shall be provided. Protection shall be provided according to 6.8.2.1.20 or the competent authority shall approve alternative protection measures. 6.12.3.1.4 By derogation from the requirements of 6.8.2.5.2 tanks do not need to be marked with the tank code and the special provisions, as applicable. 6.12.3.2 Tanks with a capacity of less than 1 000 litres 6.12.3.2.1 The construction of these tanks shall meet the requirements of sub-section 6.8.2.1 other than 6.8.2.1.3, 6.8.2.1.4, 6.8.2.1.6, 6.8.2.1.10 to 6.8.2.1.23 and 6.8.2.1.28. 6.12.3.2.2 The equipment of these tanks shall meet the requirements of 6.8.2.2.1. Where a safety valve is required by the provisions of 6.8.2, a tank shall also have a bursting disc, or other suitable means of pressure relief, approved by the competent authority. 6.12.3.2.3 The thickness of these shells shall not be less than the values given in the table below: Material Minimum thickness Stainless austenitic steels 2.5 mm Other steels 3 mm Aluminium alloys 4 mm Pure aluminium of 99.80% 6 mm 6.12.3.2.4 Tanks may have constructional parts that are without a radius of convexity. Alternative supportive measures may be curved walls, corrugated walls or ribs. In at least one direction the distance between parallel supports on each side of the tank shall not be greater than 100 times the wall thickness. 6.12.3.2.5 Welds shall be skilfully made and shall afford the fullest safety. Welding shall be performed by skilled welders using a welding process whose effectiveness (including any heat treatments required) has been demonstrated by test. 6.12.3.2.6 The requirements of 6.8.2.4 do not apply. However, the initial and periodic inspections of these tanks shall be carried out under the responsibility of the user or owner of the MEMU. Shells and their equipment shall be subject to visual examination of their external and internal condition and a leakproofness test to the satisfaction of the competent authority at least every three years. 6.12.3.2.7 The requirements for type approval of 6.8.2.3 and for marking of 6.8.2.5 do not apply. 6.12.4 Items of equipment 6.12.4.1 Tanks with bottom discharge for UN 1942 and UN 3375 shall have at least two closures. One of these closures may be the product mixing or discharge pump or auger. Copyright © United Nations, 2010. All rights reserved - 555 - 6.12.4.2 Any piping after the first closure shall be of a fusible material (i.e. rubber hose) or have fusible elements. 6.12.4.3 In order to avoid any loss of contents in the event of damage to the external pumps and discharge fittings (pipes), the first closure and its seatings shall be protected against the danger of being wrenched off by external stresses or shall be so designed as to withstand them. The filling and discharge devices (including flanges or threaded plugs) and protective caps (if any) shall be capable of being secured against any unintended opening. 6.12.4.4 Venting systems in accordance with 6.8.2.2.6 on tanks for UN 3375 may be substituted by "goose necks". Such equipment shall be protected against the danger of being wrenched off by external stresses or shall be so designed as to withstand them. 6.12.5 Special compartments for explosives Compartments for packages of explosives containing detonators and/or detonator assemblies and those containing substances or articles of compatibility group D shall be designed to provide effective segregation such that there is no danger of transmission of detonation from the detonators and/or detonator assemblies to the substances or articles of compatibility group D. Segregation shall be achieved by the use of separate compartments or by placing one of the two types of explosive in a special containment system. Either method of segregation shall be approved by the competent authority. If the material used for the compartment is metal, the complete inside of the compartment shall be covered with materials providing suitable fire resistance. The explosives compartments shall be located where they are protected from impact and from damage on rough terrain and dangerous interaction with other dangerous goods on board and from ignition sources on the vehicle e.g. exhausts etc. NOTE: Materials classified as class B-s3-d2 according to standard EN 13501-1:2002 are deemed to fulfil the fire resistance requirement. Copyright © United Nations, 2010. All rights reserved - 557 - PART 7 Provisions concerning the conditions of carriage, loading, unloading and handling Copyright © United Nations, 2010. All rights reserved - 559 - CHAPTER 7.1 GENERAL PROVISIONS 7.1.1 The carriage of dangerous goods is subject to the mandatory use of a particular type of transport equipment in accordance with the provisions of this Chapter and Chapter 7.2 for carriage in packages, Chapter 7.3 for carriage in bulk and Chapter 7.4 for carriage in tanks. In addition, the provisions of Chapter 7.5 concerning loading, unloading and handling shall be observed. Columns (16), (17) and (18) of Table A of Chapter 3.2 show the particular provisions of this Part that apply to specific dangerous goods. 7.1.2 In addition to the provisions of this Part, vehicles used for the carriage of dangerous goods shall, as regards their design, construction and, if appropriate, their approval, conform to the relevant requirements of Part 9. 7.1.3 Large containers, portable tanks and tank-containers which meet the definition of "container" given in the CSC (1972), as amended, or in UIC leaflets 591 (status at 01.10.2007, 3rd edition), 592-2 (status at 01.10.2004, 6th edition), 592-3 (status at 01.01.1998, 2nd edition) and 592-4 (status at 01.05.2007, 3rd edition) may not be used to carry dangerous goods unless the large container or the frame of the portable tank or tank-container satisfies the provisions of the CSC or of UIC leaflets 591 and 592-2 to 592-4. 7.1.4 A large container may be presented for carriage only if it is structurally serviceable. "Structurally serviceable" means that the container is free from major defects in its structural components, e.g. top and bottom side rails, doorsill and header, floor cross members, corner posts, and corner fittings. "Major defects" are dents or bends in structural members greater than 19 mm in depth, regardless of length; cracks or breaks in structural members; more than one splice or an improper splice (e.g. a lapped splice) in top or bottom end rails or door headers or more than two splices in any one top or bottom side rail or any splice in a door sill or corner post; door hinges and hardware that are seized, twisted, broken, missing or otherwise inoperative; non-closing gaskets and seals; any distortion of the overall configuration sufficient to prevent proper alignment of handling equipment, mounting and securing on a chassis or vehicle. In addition, deterioration in any component of the container, such as rusted metal in side walls or disintegrated fibreglass is unacceptable, regardless of the material of construction. Normal wear, including oxidization (rust), slight dents and scratches and other damage that do not affect serviceability or weather-tightness are, however, acceptable. Prior to loading the container shall also be checked to ensure that it is free from any residue of a previous load and that the interior floor and walls are free from protrusions. 7.1.5 Large containers shall meet the requirements concerning the body of the vehicle laid down in this Part and, if appropriate, those laid down in Part 9 for the load in question; the body of the vehicle need not then satisfy those provisions. However, large containers carried on vehicles whose platforms have insulation and heatresistant qualities which satisfy those requirements need not then satisfy the said requirements. This provision also applies to small containers for the carriage of explosive substances and articles of Class 1. 7.1.6 Subject to the provisions of the last part of the first sentence of 7.1.5, the fact that dangerous goods are contained in one or more containers shall not affect the conditions to be met by the vehicle by reason of the nature and quantities of the dangerous goods carried. Copyright © United Nations, 2010. All rights reserved - 561 - CHAPTER 7.2 PROVISIONS CONCERNING CARRIAGE IN PACKAGES 7.2.1 Unless otherwise provided in 7.2.2 to 7.2.4, packages may be loaded: (a) in closed vehicles or in closed containers; or (b) in sheeted vehicles or in sheeted containers; or (c) in open vehicles or in open containers. 7.2.2 Packages comprising packagings made of materials sensitive to moisture shall be loaded on to closed or on to sheeted vehicles or into closed or sheeted containers. 7.2.3 (Reserved) 7.2.4 When they are shown under an entry in Column (16) of Table A of Chapter 3.2, the following special provisions apply: V1 Packages shall be loaded on to closed or sheeted vehicles or into closed or sheeted containers. V2

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