tank inspectionsv10 (1)

8/12/2019 Tank InspectionsV10 (1)

1/39

1

Procedures for Inspection Bodies

Testing and Inspectionof

Old Tanks

Version 10 17 June 2010

VCADangerous Goods OfficeCleeve Road

Leatherhead KT22 7RU


2/39

2

Contents

1 Introduction................................................................................................................4

2

Background ...............................................................................................................5

3 Definitions and Standards .........................................................................................6

Table 1.......................................................................................................................6

Table 2.......................................................................................................................7

Sources: ....................................................................................................................7

4

Scope and Frequency...............................................................................................8

Table 3 Carriage by road...........................................................................................8

Table 4 Carriage by rail .............................................................................................8

5 Tank record and Certificates.....................................................................................9

Type Certificate .........................................................................................................9

6 Inspection Requirements ........................................................................................10

Table 5.....................................................................................................................10

Exceptional checks..................................................................................................12

Table 7.....................................................................................................................12

7

Tank Inspection Procedures ...................................................................................13

7.1

General....................................................................................................................13

7.2

Check of the design characteristics ........................................................................13

Inspection of the materials and wall thicknesses....................................................13

Examination of the manufacturing methods............................................................13

Inspection of the condition of the tank ....................................................................13

Inspection of main dimensions................................................................................14

Non-destructive testing of the welds .......................................................................14

Table 8.....................................................................................................................15

[7.3

Testing of test plates] ..............................................................................................15

7.4

Inspection of the tank interior ..................................................................................15

Inspection of protective lining or coating.................................................................16

7.5 Inspection of the tank exterior .................................................................................16

Inspection of the condition of the tank ....................................................................16

Inspection of the fastenings of the tank and its structural equipment.....................17

Inspection of marking ..............................................................................................17

Inspection of earthing terminal ................................................................................17

7.6

Hydraulic pressure test including alternative methods ...........................................17

General....................................................................................................................17

Extent of test ...........................................................................................................18

Test pressure ..........................................................................................................18

Alternatives to hydraulic testing ..............................................................................20

Table 9 - Standards for NDT...................................................................................20

7.7 Vacuum testing........................................................................................................21

Test procedure ........................................................................................................21

7.8 Leakproofness test ..................................................................................................21

General....................................................................................................................21

Extent of test ...........................................................................................................21

Leakproofness test pressure...................................................................................22


3/39

3

Leakproofness test fluid ..........................................................................................22

Pressurisation..........................................................................................................22

Test duration ...........................................................................................................22

Evaluation of the test...............................................................................................23

7.9 Determination of capacity........................................................................................23

General....................................................................................................................23

7.10 Inspection of service equipment.............................................................................23

Inspection of service equipment for the tank ..........................................................23

Inspection of service equipment for other inspections............................................23

Inspection of correct functioning of service equipment...........................................24

7.11

Inspection of the frame or other structural equipment of portable tanks and tank

containers................................................................................................................24

Inspection of frame or other structural equipment ..................................................24

Initial, periodic, intermediate inspection and exceptional check of the frame or

other structural equipment of portable tanks and tank containers..........................24

7.12

Failure at inspection ...............................................................................................25

7.13 Test report, certification and marking.....................................................................25

Certification of periodic, intermediate inspection and exceptional check ...............25

Marking....................................................................................................................25

Annex A - Provisions for particular tank types ...................................................................26

Annex B - Petroleum Road Tanker....................................................................................27

INTERMEDIATE INSPECTION ..............................................................................27

Examination of Documents. ....................................................................................27

PERIODIC INSPECTION........................................................................................28

CERTIFICATION AND MARKING ..........................................................................28

Annex C - General Chemical Road Tanker .......................................................................29


PERIODIC INSPECTION 6 YEARS........................................................................30


Annex D - General Chemical Tank Container ...................................................................31



Annex E - Vacuum Waste Tanker......................................................................................34


ANNEX F............................................................................................................................37


4/39

4

1 Introduction

The Carriage of Dangerous Goods and Use of Transportable Pressure EquipmentRegulations 2009 (CDG 2009) bring Directive 2008/68/EC on the inland transport ofdangerous goods (DG Directive) into effect in GB. The DG Directive brings together therequirements for the rail and road transport and adds requirements for inland waterways.

The DG Directive requires tanks to comply with provisions of RID and ADR for bothconstruction and for use. The DG Directive permits tanks constructed to nationalrequirements and not to the provisions of RID or ADR. These tanks known as old tanksin GB and NI, are restricted to national transport unless there is agreement betweenindividual states to allow cross border traffic. Old tanks may continue in service, providedthey are properly maintained and are safe for the remainder of their working lives.

Tanks for the carriage of dangerous goods in GB and NI that were not RID or ADR tankswere inspected by a competent person to a written scheme of examination. Thismethod of examining tanks does not require the competent person to be appointed andthe owner/ operator of the tank has the responsibility to write a suitable written schemeof examination and to ensure that it is carried out. On 2 July 2006 inspections bycompetent persons ended with inspections now being carried out by inspection bodiesappointed by the Secretary of State for Transport.

These procedures replace the individual written schemes of examination with anapproach based upon the requirements of RID and ADR but taking account of thedifferent constructional differences that may exist between old tanks and RID or ADRtanks. The requirement for old tanks to be maintained to a written scheme ofexamination is set out in the Carriage of Dangerous Goods; Approved Derogations andTransitional Provisions (Approved Derogations). These procedures and must be usedand applied in accordance with the Approved Derogations including any transitionalprovision in the Approve Derogations.

The competent authority for the appointment of tank and pressure receptacle inspectionbodies is in GB, the Secretary of State for Transport and HSENI in Northern Ireland.Compliance with these procedures is necessary for appointment and continuation ofappointment as an inspection body. These procedures cannot cover all situations andwill be amended in the light of experience and changes in legislation.

That success in the inspections and tests conducted in accordance with theseprocedures, and the allocation of a certificate does not authorise the use of a tank forany dangerous goods. The tank instructions, published in the various modal regulationsmust also be complied with as must all other relevant requirements of the modalregulations.


5/39

5

2 Background

The UN Recommendations on the Transport of Dangerous Goods (Model Regulations)

have been developed by the United Nations Committee of Experts on the Transport ofDangerous Goods andthe Globally Harmonised system of Classification and Labellingof Chemicals. The Model Regulations continue to be developed in the light of technicalprogress, the advent of new substances and materials, the exigencies of moderntransport systems and above all the need to ensure the safety of people, property andthe environment. Amongst other aspects, the Model Regulations list the principaldangerous goods, define methods for classification, set out general packing, marking,labelling, placarding requirements, testing procedures, and specify shippingdocumentation. There are in addition special recommendations related to particularclasses of goods.

The Model Regulations are given legal entity by the provisions of a series of internationalmodal agreements and national legislation for the transport of dangerous goods. Theinternational agreements include:

The European Agreement Concerning the International Carriage of DangerousGoods by Road (ADR) (covering most of Europe)

Regulations concerning the International Carriage of Dangerous Goods by Rail(RID) (covering most of Europe, parts of North Africa and the Middle East)

The International Maritime Dangerous Goods Code (IMDG Code) (worldwide)

The International Civil Aviation Organizations Technical Instructions for the SafeTransport of Dangerous Goods by Air (ICAO TIs) (worldwide).

In each country transporting dangerous goods, a competent authority is responsible forimplementing the regulations. Amongst other things, the competent authority may set upa system for testing and certifying pressure receptacles, tanks and packagings to meetthe requirements of those regulations.

The background described above sets the context in which this document should beseen. For the purposes of old tank inspections the international regulations are notgenerally relevant although the principles adopted in ADR and RID are being usedwherever possible in this document. For the purposes of using (operating) the tank theprovisions above are applicable.


6/39

6

3 Definitions and Standards

The terms and definitions used in this document are taken as those given by the relevantregulations concerning the transport of dangerous goods unless otherwise stated in

Table 1 below.

Table 1

Term Definition

Tank record Means a file containing all the important technical informationsuch as the original design documentation, previousinspection reports and records of repairs (NOTE: see 5.2).

Inspector means individual employed by and carrying out inspectionsfor an inspection body.

Inspection body is a generic term for a body appointed by the competentauthority to perform designated inspections and tests.

Intermediateinspection

means inspection carried out between the initial and the firstperiodic inspection or between two periodic inspections

Old tank is a tank as defined in the Carriage of Dangerous GoodsApproved Derogations and Transitional provisions

Protective lining or coating means a lining or coating protecting the metallictank material against the corrosive attack by the substancesto be carried

NOTE: This does not apply to lining or coating used only toprotect the substance to be carried.

Major repair: A repair without which the safety of the tank or structurewould have been compromised. This will include any repairthat requires hotwork to the pressure containment part of thetank

Technical code means the code according to which the tank has beendesigned and constructed


7/39

7

The standards and guidance listed in Table 2 below are indispensable for the applicationof this document. For dated references, only the edition cited applies. For undatedreferences, the latest edition of the referenced document (including any amendments)applies.

Table 2

Standard Title Identif ier

EN 473 Non-destructive testing - Qualification and certification ofNDT personnel General principles

EN 8372 Pressure gauges Selection and installationrecommendations for pressure gauges

EN 1432: 1997 Swap bodies. Swap tanks. Dimensions, requirements, testmethods, operating conditions

EN1435 Non-destructive examination of welds. Radiographic

examination of welded joints

ISO 1496: 1995 Series 1 freight containers Specification and testing Part 3: Tank containers for liquids, gases and pressuriseddry bulk

EN1714 Non-destructive testing of welded joints. Ultrasonic testingof welded joints

EN 122661:2003 Industrial valves Testing of valves Part 1: Pressuretests, test procedures and acceptance criteria Mandatory

requirements

EN 12972:2007 Tanks for the transport of dangerous goods Testing,inspection and marking of metallic tanks

EN 14025 Tanks for transport of dangerous goods. Metallic pressuretanks. Design and construction

GS4 HSE Safety in Pressure Testing, which is supported by ContractResearch Report CRR168: "Pressure Test Safety", 1998(ISBN 9780717616299)

Sources:

BS, EN ISO Standards are obtainable from the British Standards Institutionhttp://www.standardsuk.com/

HSE publications are obtainable from HSE Books:http://books.hse.gov.uk/hse/public/home.jsf


8/39

8

4 Scope and Frequency

These procedures specify the testing, inspection and marking for the periodic inspection,intermediate inspection and exceptional check of old metallic tanks (shell andequipment) that are fixed tanks (tank vehicles), demountable tanks, rail tank wagons,portable tanks and tank containers for the transport of dangerous goods

These procedures are not applicable to: pressure receptacles including gas cylinders orintermediate bulk containers (IBCs).

The intervals between inspections shall not exceed those shown in Table 3 and table 4

below.

Table 3 Carriage by road

Tank Intermediate Periodic

Fixed tanks (tank vehicles), demountable tanks andbattery-vehicles

3 years 6 years

Tanks carrying refrigerated liquefied gases except chlorine 6 years 6 years

Tanks carrying chlorine N/A 3 years

Table 4 Carriage by rail

Tank Intermediate Periodic

fixed tanks, demountable tanks and battery-/ wagons 4 years 8 years

tanks carrying refrigerated liquefied gases except chlorine 6 years 8 years

tanks carrying chlorine N/A 3 years


9/39


10/39

10

6 Inspection Requirements

6.1 The periodic, intermediate inspection or exceptional check shall be carried out inaccordance with the relevant sections of these Procedures as set in Table 5 below andfor exceptional checks only, Table 6.

Table 5

Relevant sections

Periodic

Inspection

Intermediate

Inspection

ExceptionalCheck

See alsotable 6

Section 5 - Examination ofdocuments

x x x

Section 7.2 - Check of designcharacteristics following repair ormodification

Section 7.4 - Inspection of the tankinterior x x x

Section 7.5 - Inspection of the tankexterior

x x x

Section 7.6Hydraulic - pressuretest

x x

Section 7.8 - Leakproofness test x x x

Section 7.10 - Inspection ofservice equipment x x x

Section 7.11 - Inspection of theframe or other structuralequipment of portable tanks andtank containers where required byregulation

x x x


11/39

11

6.2 For vacuum insulated tanks the inspection of the tank interior and the hydraulic pressuretest are not required provided that a satisfactory vacuum is confirmed by measurement.

6.3 In the case of tanks intended for the carriage of powdery or granular substances, thehydraulic pressure test may be omitted and replaced by the leakproofness test

6.4 The results of the inspection shall be recorded by the inspector on a certificate or whereappropriate a notification of refusal to issue a certificate. Any defect found which canimpair the safety of the tank or the equipment and any related repairs carried out shall berecorded on the certificate or notification of refusal. Certification, including whereappropriate notification of refusal and marking shall be in accordance with 9.12.

6.5 Any inspection procedures shall take into account any relevant TE, TA, TT and TMcodes in RID/ADR Chapters 4.3, 4.4 or 6.8 that are addressed to particular tank types forparticular substances.

6.6 Where an exceptional check are required following major damage a preliminary reportcan be issued after examination of documents.


12/39

12

6.7 Exceptional checks

The required tests and inspections following checks after damage or repair are identifiedin Table 6 below.

Table 6

Relevant sections

ServiceEquipment

ServiceEquipment

wherehotworkinghas

occurred

TankAlterations

FrameorRunningGea

r

LinerorCoating

Section 5 - Examination of documents x x x x x

Section 7.2 - Check of designcharacteristics following repair ormodification

x x x x

Section 7.4 - Inspection of the tank interior x x x

Section 7.5 - Inspection of the tank exterior x x

Section 7.6 - Hydraulic pressure test x x x

Section 7.8 - Leakproofness test

x x x x

Section 7.10 - Inspection of serviceequipment x x

Section 7.11 - Inspection of frame or otherstructural equipment of portable tanks andtank containers where required byregulation

x x


13/39

13

7 Tank Inspection Procedures

7.1 GeneralWhere the interior of the tanks is to be inspected the tanks shall be empty, clean andsafe to enter (e.g. no electrical services, no heating, safe atmosphere) at the time ofinspection. Permits of work according to the legislation dealing with health and safetyat work shall be complied with. This is also a requirement when necessary for thesafety of the inspecting personnel and any other persons in the vicinity even whenother inspections are carried out.

7.2 Check of the design characteristics

NOTE:

Tanks should have full design drawings available and these should be used inconjunction with inspections. However, there may be occasions where these are notavailable and a note should be placed on the tank record with an explanation of whythe drawings are absent.

7.2.2 Inspection of the materials and wall thicknesses

The materials used for the shell, the piping and the structural and service equipmentshall correspond to the original design data or if not available or if the tank has hadsubsequent modification then tank records should be amended to record the changesand with the material certificates, where appropriate. The material certificates shall be

as required by the technical code.

The tank shall be inspected to determine the traceability between the marking of thematerials and the identification given by the material certificates.

The actual thickness of materials of the shell, the piping and the structural equipmentshall not be less than that given by the original design documents, where available.This shall be verified by appropriate measurement on completion of the tank.

7.2.3 Examination of the manufacturing methods

The manufacturing methods and data of the heat treatment, the rolling and the formingof the materials used for the shell, the piping and the structural equipment shall beexamined to ensure compliance with the design specifications of the tank.

The type of welded joints shall be examined to ensure compliance with the typespecified in the design of the tank.

7.2.4 Inspection of the condi tion of the tank

A complete visual inspection shall be performed to identify any surface defect and shalltake account of the original specification (see 5.2), where this cannot be ascertainedand explanatory note shall be added to the file.


14/39

14

7.2.5 Inspection of main dimensions

The main dimensions of the tank and if relevant of the framework shall be inspected forconformity with the dimensions given by the design drawings.

Note: It should be possible to check portable tank and tank container dimensionsagainst standards for freight containers

7.2.6 Non-destructive testing of the welds

General

NOTE: This section would normally only apply following major repairs to the tank.

The non-destructive testing of the welds may be by radiographic or ultrasonic methods.

Welds which cannot be tested by ultrasonic or radiographic methods because of thedesign or the position of the weld may be tested by dye penetrant or magnetic particleinspection.

NOTE: Where NDT testing is used the type and extent should be in accordance withthe original specifications.

The non-destructive testing of welds should be carried out in accordance with thetechnical code used for design and construction of the tank, e.g. EN 14025 forpressure tanks and carried out in accordance with EN1435 and EN1714.

NOTE: The following Table 7 should only be used where there are complete recordsof design and original construction of the tank.


15/39

15

Table 7

Weldefficiency

factor

Extent of examination

() of 08

All weld "Tee" junctions with the total length of weld examined to be

not less than 10 % of the sum of the length of all longitudinal,circumferential and radial (e.g. in tank ends) welds shall be tested.

() of 09

The total length of all longitudinal welds, all "Tee" junctions and 25 %of the total length of circumferential and radial (e.g. in tank ends) weldsshall be tested.

() of 10The total length of all longitudinal, circumferential and radial (e.g. intank ends) welds shall be tested.

[7.3 Testing of test plates]

The test plates shall be tested in accordance with the applicable regulation or technicalcode.

7.4 Inspection of the tank interior

7.4.1 Interior

A complete visual inspection shall be performed (provided no protective lining or

coating is used) to identify any surface defect.

The wall thickness shall be verified where possible against that given by the originaldesign documents by appropriate measurement if the tank shows indication ofreduction of wall thickness.

Any lining or coating not falling under the definition of protective lining or coating givenin this document shall be visually inspected for integrity. In particular bonding defectsor delaminations shall be identified and recorded in the report.

When it is necessary to verify wall thickness, or there is concern that there may becracking of welds, the tank shell shall be subjected to non-destructive testing e.g.radiographic or ultrasonic. The person undertaking such testing shall be appropriately

qualified personnel (to the requirements of EN 473).

Welds that cannot be tested by these methods, may be examined with the use of a dyepenetrant or magnetic particle examination.

NOTE: where such testing is carried out it shall be recorded and retained by the tankowner/operator.


16/39

16

The tank shell shall be examined internally to identify any of the following defects:

Surface corrosion, weld defects, linings that may be damaged or be delaminated, to anextent, which could affect the integrity of the tank.

This inspection may be carried out visually through a manhole (other openings such asfill holes will not be adequate) the inspection performed from the manhole shall be ableto detect any foreseeable defects that would otherwise be detected from closeexamination from inside of the tank. To make a though inspection it may be necessaryto use remote visual inspection equipment.

The method for the inspection of the tank interior may be replaced by an equivalentmethod based on non-invasive inspection (NII). Any such procedures shall be includedin the inspection bodys accreditation.

Non Invasive Inspection (NII) is an assessment regime that may use a combination ofnon-destructive testing (NDT) techniques such as ultrasonics, acoustic emission,radiography, dye penetrant, magnetic particle, electromagnetic, leaking testing or othersuitable non-destructive test method.

Suitable methods may be found in the following Standards:

radiographic techniques in accordance with EN 444 and EN 1435;

ultrasonic techniques in accordance with EN 1714;

magnetic particle techniques in accordance with EN 1290;

dye penetrant techniques in accordance with EN 571-1.

NOTE: non destructive testing systems may be used but the conditions of EN 473shall be met.

7.4.2 Inspection of protective lining or coating

The condition of the protective lining or coating shall be inspected by appropriatemethods, e.g. spark test, and in accordance with the manufacturer's recommendations.In particular bonding defects shall be identified and recorded in the report.

7.5 Inspection of the tank exterior

7.5.1 Inspection of the condi tion of the tank

A complete visual inspection shall be performed to identify any surface defect.

The wall thickness shall be verified where possible against that given by the originaldesign documents by appropriate measurement if the tank shows indication ofreduction of wall thickness.

Sheathing, thermal or other insulation shall be removed only to the extent required toachieve a reliable appraisal of the condition of the tank.


17/39

17

7.5.2 Inspection of the fastenings of the tank and its structuralequipment

The following elements shall be inspected by an appropriate method to ensure thatthey are in good condition:

structures supporting and reinforcing the tank;

means of attachment to the frame or chassis;any structural protective equipment e.g. the cover assembly, the sun shield.

Sheathing, thermal or other insulation shall be removed only to the extent required toachieve a reliable appraisal.

7.5.3 Inspection of marking

The marking of the tank shall be verified against the requirements of 5.11.2.

7.5.4 Inspection of earthing terminal

Shells which are required to be fitted with an earth connection shall be inspected forconformity of the earth connection with the design requirements. The electricalresistance between the earth connection and the metallic parts of the tank andequipment, including any frame and where applicable between the earth connection

and the vehicle chassis, shall not exceed 10.

7.6 Hydraulic pressure test including alternativemethods

7.6.1 General

Before the beginning of the test the tank shall be dry and clean on its outside so thatany leakage can be detected. If the ambient temperature is below 7C a hydraulicpressure test with water is only allowed if the contents of the tank, of the measuringequipment and of the piping systems cannot freeze.

NOTE: Tests should not be carried out when the ambient temperature is less than7C unless precautions are taken against fracture.

The use of an antifreeze mixture is permitted. Any other method shall be included in

the inspection bodies accreditation.

The hydraulic pressure test may be omitted for tanks designed for the carriage ofpowdery or granular substances and replaced by a leakproofness test (see 9.8).

NOTE: where pneumatic pressure testing is undertaken inspection bodies should takeaccount of the following publication:

HSE Safety in Pressure testing GS4 published by the HSE.


18/39

18

7.6.2 Extent of test

The whole tank and each self-contained compartment including the partitions shall betested as prescribed in 9.6.3 9.6.8.

During the test of a compartment, the adjacent compartment(s) shall be empty andunpressurised.

All service equipment and the whole piping system with the exception of ventingdevices, safety valves and bursting discs shall be included in the hydraulic pressuretest.

Single items of the equipment and of the piping system may be tested separately.

Safety valves and vents shall be sealed or be removed and replaced by blankingplates before testing begins.

7.6.3 Test pressure

7.6.3.1 Test pressure of the whole tank

The hydraulic pressure test of the whole tank shall be carried out at the test pressuregiven by the tank plate or original design documents. The test pressure shall relate tothe highest point of the tank.

7.6.3.2 Test pressure of compartments

Each compartment of subdivided tank containers, portable tanks and tanks of rail tankwagons shall be tested with the hydraulic pressure required by 5.5.3.1.

Each compartment of fixed tanks or demountable tanks shall be tested with a hydraulic

pressure of 1.3 times the maximum working pressure.

Partitions of compartments of tanks having a maximum working pressure originatingonly from hydrostatic pressure shall be tested with a hydraulic pressure of 2 times thestatic pressure of the heaviest goods to be carried, but not less than a hydraulicpressure of 2 times the static pressure of water, in both cases referred to the bottom ofthe tank. Hydraulic pressure means the pressure arising from the highest possiblecolumn of fluid in the tank.

The test pressure shall be related to the highest point of the compartment.

NOTE: Tanks should be subjected to individual compartment tests unless the

original design of the compartments makes this unsuitable in which case the wholetank may be pressurised. The Inspection body report should note where they deviatefrom the preferred method and record their reasons.

7.6.3.3 Test flu id

The fluid normally used for hydraulic pressure testing shall be water.


19/39

19

Other liquids may be used with agreement of the inspection body. Any suchprocedures shall be included in the inspection bodies accreditation. The flash point ofalternative test liquids shall be above 61 C. Toxic or corrosive liquids shall not beused.

Gases may be used for pressure testing only in special cases and with agreement ofthe inspection body. Flammable or toxic gases shall not be used.

In particular when using gas as the test fluid, precautions given in Annex C ofEN12972 should be observed.

7.6.3.4 Pressurisation

The tank may be filled with the test fluid and gradually pressurised before the inspectorcommences witnessing the test. The tank shall be filled with the test liquid to not lessthan 99 % of the water capacity.

When using a standpipe for pressurizing the tank, only water shall be used as a testfluid.

For tanks having a maximum working pressure not exceeding 05 bar an alternativetest procedure may be carried out using water or another liquid as follows:

the tank shall be filled with the test liquid to not less than 99 % of the water capacity. Anon-flammable, non-toxic gas shall be used to pressurize the space above the liquid;

a safety device shall be included in the gas pressurizing system. The device shallensure that the pressure in the shell cannot exceed 105 % of the required testpressure.

7.6.3.5 Test duration

The test pressure shall be held for the time necessary for the inspector to carry out theinspection of the shell or a compartment but not less than 15 min for a non-insulatedtank and not less than 30 min for an insulated tank.

7.6.3.6 Measurement

The test pressure may be measured either by the height of the column of test liquidstanding in the standpipe or U-tube, or by other pressure gauges.

The accuracy of the measuring equipment shall be equal to or less than 1 % of full

scale deflection; this accuracy shall be attested by a calibration certificate. Forselection and installation of pressure gauges EN 837-2 shall be used.

When only a gas is used as test fluid the pressure in the tank shall be indicated in away that it may be seen from a safe location (see Annex C of EN12972).

7.6.3.7 Evaluation of the test

The tank fails the hydraulic pressure test if any of the following occur:

a leak is detected;

there is an unaccountable fall in pressure during the test period;


20/39


21/39

21

7.7 Vacuum testing

7.7.1 Test procedure

The tank shall start the test empty and at atmospheric pressure.

All openings of the tank shall be closed except the discharge openings. A pressure of

15 times more severe than the external design pressure shall be created inside thetank and held for 5 min.

7.7.1.2 Measurement

The accuracy of the measuring equipment shall be equal to or less than 1% of fullscale deflection; this accuracy shall be attested by a calibration certificate. Forselection and installation of pressure gauges EN 837-2 shall be used.

7.7.1.3 Evaluation of the test

The tank fails the test if any of the following occur:

a leak is detected;

there is an unaccountable rise of pressure at the pressure gauge;

there is visible permanent deformation.

7.8 Leakproofness test

7.8.1 General

Before the beginning of the test the tank shall be dry and clean on its outside so that

any leakage can be detected. If the ambient temperature is below 7 C aleakproofness test with water is only allowed if the contents of the tank, of themeasuring equipment and of the piping system cannot freeze.

NOTE:

Tests should not be carried out when the ambient temperature is less than 7C unlessprecautions are taken against fracture.

7.8.2 Extent of test

The leakproofness test shall be carried out on the tank and service equipment whichwill be used with the tank including any permanently attached hoses after assembly inaccordance with the requirements of 7.8.3-7.8.7.

This testing shall include each compartment partition.

During the test of a compartment the adjacent compartment(s) shall be empty andunpressurised.


22/39

22

Where shut-off valves are fitted in series they shall be tested separately to ensure thatwith the pressure on the tank side of the device the leakage does not exceed the rategiven in 7.8.7.

When the device is a valve, the test is to determine the leak-tightness of the valve seat

and the glands of the valve operating mechanism.

7.8.3 Leakproofness test pressure

The leakproofness test shall be carried out with the pressure given by the relevantregulation. The test pressure shall be related to the highest point of the tank orcompartment.

If there is no specific regulation, a pressure of not less than 25 % of the maximum

working pressure with a minimum of 02 bar shall be applied. The leakproofness testfor refrigerated liquefied gases shall be carried out with a pressure of not less than 90% of the maximum working pressure.

Internal leakproofness of shut-off devices shall be tested at the leakproofness test

pressure as well as at a pressure of not more than 02 bar.

7.8.4 Leakproofness test fluid

The test fluid shall be compatible with the materials of the tank and the goods to betransported.

The test fluid shall in no case create a hazard to the inspecting personnel or any otherpersons in the vicinity. In particular when using gas as the test fluid, precautions givenin Annex C of EN12972 should be observed.

7.8.5 Pressurisation

The tank may be filled with the test fluid and gradually pressurised before the inspectorcommences witnessing the test.

The tank shall be filled with the test liquid to not less than 99 % of the water capacity.

When using a standpipe for pressurizing the tank, only water may be used as a testfluid.

For tanks having a working pressure not exceeding 0 5 bar an alternative testprocedure may be carried out using water or another liquid as follows:

tank shall be filled with the test liquid to not less than 95 % of the water capactiy, anon-flammable, non-toxic gas shall be used to pressurize the space above the liquid;

a safety device shall be included in the gas pressurizing system. The device shall

ensure that the pressure in the shell does not exceed 105 % of the requiredleakproofness test pressure.

7.8.6 Test duration

The test pressure shall be held for the time necessary for the inspector to carry out theinspection of the shell, a compartment or the equipment but not less than 5 min in eachcase.


23/39

23

7.8.7 Evaluation of the test

The maximum allowable leakage rate shall be in accordance with Table A.5 of EN12266-1:2003 Rate A.

NOTE "No visually detectable leakage" means no visible weeping or formationof drops or bubbles and is a lower leakage rate than Rate B.

For this purpose it is not necessary to enter adjacent compartments.

Where PRV's with frangible discs (bursting discs) are fitted, the 'tell-tale' shall bechecked for evidence of use. Test of relief valves, on a calibrated test bench to beverified, valve must close at a point not more than 10% below the pressure at whichopening begins, and remain closed at all lower pressures

7.9 Determination of capacity

7.9.1 General

For rail wagons determination of capacity is only required for inspection for typeapproval and initial inspection in certain circumstances (see EN 12972:2007 section4.1.2 8thindent and section 4.2.1 7 thindent)

The determination of capacity shall be carried out using an appropriate calculation (ifnot forbidden), volumetric or gravimetric method. For volumetric and gravimetricmethods any error shall be less than 1 %. If not otherwise required the capacity of thetank shall be determined for a reference temperature of 20 C.

The volumetric or gravimetric determination of capacity of the tank and, whereappropriate, each compartment shall be carried out by completely filling the tank orcompartment with a suitable liquid.

NOTE an appropriate method of determination of capacity can be foundin the Recommendation of the Organisation Internationale de MtrologieLgale OIML R80: Road and rail tankers.

7.10 Inspection of service equipment

7.10.1 Inspection of service equipment for the tank

The inspection shall determine that the service equipment and its marking conforms tothe requirements of the applicable regulations. The inspection shall also determine thatall the service equipment is suitable for the operating conditions of the tank.

7.10.2 Inspection of service equipment for other inspections

The inspection shall determine that the service equipment is in accordance with thatgiven in the original design documentation, where possible.


24/39

24

7.10.3 Inspection of correct functioning of service equipment

All service equipment including any permanently attached hoses shall be inspected inthe mounted position for correct functioning. Where it is not possible to inspect theequipment in the mounted position, e.g. in the case of venting devices, the equipmentshall be tested separately.

The parts of venting devices which are open during transport (e.g. breathing valve)shall be tested to ensure that they are leaktight in the 90, 180 and 270 positions.

The test pressure shall be at least 1.1 times the static pressure of the substances to betransported (e.g. petrol, diesel-, heating-oil) which arises from the possible fluid columnon the venting device. If the venting devices need a relief pressure to open duringtransport they shall be tested for correct opening at this relief pressure.

The adjustment of the start-to-discharge-pressure of safety valves shall be inspectedfor conformity with the relevant regulations.

If bursting discs are installed, they shall be inspected for integrity and correct rating.

Flexible joints and fixed hoses as part of the filling and/or discharging system shall bevisually inspected. Paint or coating shall be removed where necessary.

Where the bursting disc is to be replaced, the rating and type should be checked toconfirm it is correct.

Bolted flanges, caps to valves at bottom outlets shall be checked for worn threads anddamaged gaskets.

7.11 Inspection of the frame or other structuralequipment of portable tanks and tank containers

7.11.1 Inspection of frame or other structural equipment

The frame or other structural equipment of a portable tank or tank container which hasnot been designed or constructed in accordance with a standard (e.g. ISO 668 or EN1432) or other requirements (e.g. UIC 592-4) shall be shown to be suitable for the

intended purpose either by calculation or, if required, by testing (e. g. the appropriatetests specified in ISO 1496-3).

In addition, the applicable requirements of the CSC shall be fulfilled by any portable

tank that meets the definition of a "container" within the terms of that Convention.

7.11.2 Initial, periodic, intermediate inspection and exceptional checkof the frame or other structural equipment of portable tanksand tank containers

The framework, supports and arrangements for lifting the portable tank are in asatisfactory condition. This inspection shall include a visual inspection of the weldedjoints and the surface of all structural parts. Where necessary, the insulation shall beremoved to the extent required to achieve a reliable appraisal of the condition of theframe or other structural equipment.

Any damage or corrosion which could influence the safety or function of the frame shallbe repaired.


25/39

25

7.12 Failure at inspectionA tank that fails one or more units of inspection shall, once the failure has beeninvestigated and corrected, be retested in accordance with the requirements of thoseunits. If, in the opinion of the inspector, the repair may have affected the validity of anyprevious tests these tests shall be repeated. Depending on the result of the inspectionsadditional inspections may be necessary.

7.13 Test report , certif ication and marking7.13.1 Certification of periodic, intermediate inspection and

exceptional check

Wherever defects or deficiencies are identified during the inspection, they shall benoted in the report. Wherever a defect could be considered a safety issue e.g. severecorrosion, leaking joints etc, in the judgement of the inspector, and a report along witha Notification of Refusal shall be issued.

Following the successful completion of the, periodic or intermediate inspection or theexceptional check a certificate shall be issued. An example for the certificate is given inAnnex B of this document.

Additional requirements or remarks, which can influence the next regular inspection orexceptional check, shall be stated on the certificate.

7.13.2 Marking

The tank plates for fixed tanks (tank vehicles) and demountable tanks shall contain theinformation required by Annex D of EN12972. For tank plates for rail tank wagons EN12561-1 refers. The tank plates for portable tanks and tank containers shall contain theinformation required by Annex E of EN12972.

The minimum height of the letters shall be 3 mm.

Any modification to any data on the tank plate required by this Procedure shall beattested by the inspector's stamp close to the modified information.

Markings not necessarily required to be given on the tank plate shall comply with therelevant regulation. If information is given on the tank plate as well as in other places(e.g. on the shell) this information shall be identical. In each case, the information shallcomply with the valid documents.


26/39


27/39

27

Annex B Petroleum Road Tanker

INTERMEDIATE INSPECTION

Examination of Documents.

Documents relating to the tank and previous inspections shall be examined prior tocommencement of the inspection.

The tank shall be identified against the documents and details on tanker name plate.

Documentary evidence that all residues of product have been removed (eg. tanker washcertificate).

External Visual Examination

A visual check of all accessible external surfaces.

Areas of corrosion and damage that may affect the tank integrity and safe operation shall benoted on the report.

Check shell mounting supports and attachment points for items of equipment fitted directly totanker shell for cracks or deformation.

Remove paint from surfaces showing signs of peeling or blistering to determine condition ofshell beneath.

Internal Visual Examination

A visual check of internal surfaces.

Areas not directly visible from the point of inspection, such as reverse sides of surge platesonly be subject to further investigation if the overall condition of the interior is belowacceptable criteria.

Areas of thinning, tramlining around welds and areas of corrosion shall be investigated byappropriate measurement.

Evidence of blistering, cracking or incomplete areas of linings or coatings on internal

surfaces, used to protect the material of the shell shall be:

recorded

investigated and

assessed

before issuing any certificate.


28/39

28

Service Equipment

Service equipment, including any permanently attached hoses, shall be inspected forsatisfactory operation.

PERIODIC INSPECTION

All inspections as Intermediate Inspection and in addition :-

Hydraulic pressure test

A hydraulic test pressure of 36 kPa shall be applied to the tank as a whole.

For multi-compartment tanks each compartment shall also be tested to 1.3 times the MWP.

For multi-compartment tanks each compartment shall be tested individually.

CERTIFICATION AND MARKING

The results of Intermediate and Periodic inspections shall be recorded on a certificate.

The corrosion resistant metal plate fitted to the tank shall be stamped with the date of theinspection and stamp of the inspector.

Dates for periodic inspections shall be followed by the letter "P" and intermediate inspectionsby "L".

The letter "P" signifies that all required inspections have been carried out.

The letters "P" and "L" must not appear together against the same date

The inspector shall ensure that the inspection date and inspection code (P or L) has beenentered on the nameplate before applying his stamp

The certificate shall comply with the model given in Annex B.


29/39

29

Annex C General Chemical Road TankerINTERMEDIATE INSPECTION











A visual check of internal surfaces

Areas not directly visible from the point of inspection, such as reverse sides of surge plates,need only be subject to further investigation if the overall condition of the interior is belowacceptable criteria.

Areas of thinning, tram lining around welds and areas of corrosion shall be investigated byappropriate measurement.

Evidence of blistering, cracking or incomplete areas of linings or coatings on internalsurfaces, used to protect the material of the shell, shall berecordedinvestigated and

assessedBefore issuing any certificate.

Where PRV's with frangible discs (bursting discs) are fitted, the 'tell-tale' shall be checked forevidence of use

Leakproofness Test

A leakproofness test shall be carried out on the tanker with all service equipment in place


30/39

30

Where individual compartments are tested in a multi-compartment tanker, the compartmentsadjoining the one being tested shall be empty and at atmospheric pressure.

The test pressure shall be at 25% of the MAWP (unless otherwise identified on thedocumentation).

The pressure shall be maintained for a minimum of 5 minutes.

Service Equipment


Openings below the liquid level shall be inspected at the transition between shell and outlet


Where PRV's with frangible discs (bursting discs) are fitted, the 'tell-tale' shall be checked for

evidence of use.

PERIODIC INSPECTION - 6 YEARS

All inspections as Intermediate Inspection and in addition :-

Hydraulic pressure test

A hydraulic test pressure as indicated on the tanker plate shall be applied to the tank.

The test pressure shall be at least 1.3 times the design pressure.

The test pressure shall be applied for a minimum of 15 minutes without any measurabledecay.

Any evidence of leakage or loss of pressure shall be investigated, identified and recorded.




Dates for periodic inspections shall be followed by the letter "P" and intermediate inspectionsby "L".The letter "P" signifies that all required inspections have been carried out.


The inspector shall ensure that the inspection date and inspection code (P or L) has beenentered on the nameplate before applying his stamp



31/39

31

Annex D General Chemical Tank Container












A visual check of internal

Areas not directly visible from the point of inspection, such as reverse sides of surge plates,only be subject to further investigation if the overall condition of the interior is belowacceptable criteria.


Evidence of blistering, cracking or incomplete areas of linings or coatings on internalsurfaces, used to protect the material of the shell shall berecordedinvestigated andassessedbefore issuing any certificate.


32/39


33/39

33




Dates for periodic inspections shall be followed by the letter "P" and intermediate inspectionsby "L".The letter "P" signifies that all required inspections have been carried out.


Details of failure to comply to any "Units used for tank inspection" (see 5) shall also berecorded

The certificate shall comply to the model given in Annex B.

If the certificate examined as part of the documentation check does not comply to that

prescribed, a new certificate shall be completed


34/39

34

Annex E Vacuum Waste Tanker









Check shell mounting supports and attachment points for items of equipment fitted directly totanker shell.

Rear doors on tanks fitted with openable ends shall be checked for signs of damage orleaking.

Pivots, hinges and securing clamps etc shall be examined for evidence of wear or damage.

Suction boom attachment points and rotation crown wheels, if fitted, shall be checked forevidence of wear or damage.



A v isual check of internal sur faces


Evidence of blistering, cracking or incomplete areas of linings or coatings on internalsurfaces, used to protect the material of the shell, shall be recorded.

Internal pistons, if fitted, shall be checked for free movement and peripheral seals shall be ingood condition.

Rear door seals shall be checked for evidence of deterioration or damage.


35/39

35

Leakproofness Test

A leakproofness test shall be carried out on the tanker with all service equipment in place

Where individual compartments are tested in a multi-compartment tanker, the compartmentsadjoining the one being tested shall be empty and at atmospheric pressure.

The test pressure shall be not less than 20% of the MAWP (unless otherwise identified on

the documentation).

The pressure shall be maintained for a minimum of 15 minutes.

Service Equipment


Vacuum/pressure pump pipework and spark/flame arresters, where fitted, shall be checkedfor good condition.


PERIODIC INSPECTION

All inspections as Intermediate Inspection and in addition:-

Vacuum test

A vacuum test shall be applied to the tank as a whole.

A test pressure at least 1.5 times the external design pressure shall be applied internally.

For multi-compartment tanks each compartment shall be tested individually.

The test pressure shall be applied for a minimum of 5 minutes without any measurabledecay.

Any evidence of leakage or loss of pressure shall be investigated, identified and recorded




Dates for periodic inspections shall be followed by the letter "P" and intermediate inspectionsby "L".The letter "P" signifies that all required inspections have been carried out.The letters "P" and "L" must not appear together against the same date


36/39

36

Details of failure to comply to any "Units used for tank inspection" (see 5) shall also berecorded


If the certificate examined as part of the documentation check does not comply to thatprescribed, a new certificate shall be completed.


37/39

37

ANNEX F

TANK INSPECTION CERTIFICATE FOR OLD TANK INSPECTIONS


38/39

38

United Kingdom of Great Britain and Northern Ireland

Carriage of Dangerous Goods by Rail and Road - RID/ADR and Old tanks

CERTIFICATE No. ISSUED TYPE P

Type P Periodic; I Intermediate; R Repair/Retest; F FailDetails of Tank

INSPECTION SCHEDULE

Documents relating to previous inspections/cleaning have beenexamined

YES Date

A visual check of all accessible external surfaces was carried out YES DateA visual check of internal surfaces was carried out YES Date

A leakproofness test was carried out YES Date

Service equipment was examined YES Date

A hydraulic test at a pressure of was carried out YES Date

A vacuum test at an internal pressure of was carried out YES Date

Date of expiry of this certificate. The date Month, Yearand the letter P or L must appear on the tank plate.

Date Letter P

Signed: Date:

Name and Address of authorised inspecting body :-

Stamp of Inspecting Body approved by the Department for Transport

Type-approval NumberGB/FT/TC

Initial ApprovalCertificate No.

Name of Manufacturer and Serial No:

Owners Serial Number: Year of Manufacture:

Vehicle Registration Mark or Chassis Number (FixedTanks)

Tare MASS (including fittings) (kg):

Maximum Gross MASS (kg): Capacity (litres):

Design Temperature (if above +50C or below -20C)

Pressure Relief Devices: First Device Second Device

Description ( make, type):

Operating pressure (bar):

Capacity (m/hr):

Working pressure of tank [bar]


39/39

Notification of Refusal

United Kingdom of Great Britain and Northern IrelandCarriage of Dangerous Goods by Rail and Road - RID/ADR and Old tanks

CERTIFICATE No. ISSUED TYPE P

Type P Periodic; I Intermediate; R Repair/Retest; F FailDetails of Tank

Reasons for refusal

Signed: Date:

Name and Address of authorised inspecting body :-

Stamp of Inspecting Body approved by the Department for TransportM

Type-approval NumberGB/FT/TC

Initial ApprovalCertificate No.

Name of Manufacturer and Serial No:

Owners Serial Number: Year of Manufacture:

Vehicle Registration Mark or Chassis Number (FixedTanks)

Tare MASS (including fittings) (kg):Maximum Gross MASS (kg): Capacity (litres):

Design Temperature (if above +50C or below -20C)

Pressure Relief Devices: First Device Second Device

Description ( make, type):

Operating pressure (bar):

Capacity (m/hr):

Working pressure of tank [bar]