Professional Documents
Culture Documents
Aar-Tank Standartları
Aar-Tank Standartları
CHAPTER 1
INTRODUCTIONS, APPROVALS, AND REPORTS
CONTENTS
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves,
Closures, and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–56
1.4.9 AAR Service Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–57
Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–61
1.4.10 Final Service Trial and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–62
Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–63
1.4.11 Certified Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–64
1.5 Certification of Independent Third Parties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
1.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
1.5.2 Requirements and Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-III–65
regulations became the DOT Hazardous Materials Regulations, effective April 1, 1967. The
Hazardous Materials Regulations currently include Title 49, Code of Federal Regulations, Parts
100–199.
The specifications in this volume also prescribe AAR specifications for tank car tanks for the
transportation of nonhazardous and DOT low-hazard commodities.
This issue of the AAR Specifications for Tank Cars dated November 2014 supersedes the issue
dated October 2007.
For current issues of the DOT Hazardous Materials Regulations, refer to Title 49, CFR, Parts 100–
199 published annually, revised each year, and available from the Government Printing Office. A
comprehensive compilation of the hazardous materials transportation regulations (all modes) is
published annually and updated quarterly as AAR Bureau of Explosives Tariff No. BOE-6000 and
can be obtained at http://www.boepublications.com.
DOT’s hazardous materials regulations are available for viewing or download from their Web site
at http://phmsa.dot.gov/regulations.
In Canada, Transport Canada, Transport Dangerous Goods Directorate, Regulatory Affairs
Branch, prepares and administers the regulations for transport of dangerous commodities. The
Transportation of Dangerous Goods Regulations and Act are available for viewing or download
from Transport Canada’s Web site at http://www.tc.gc.ca/eng/menu.htm.
1.1.2 Legal Authority
The Department of Transportation’s hazardous materials regulations are issued under the
authority of the Hazardous Materials Transportation Act as amended, 49 U.S.C. sections 1801 et
seq.
Transportation of Dangerous Goods Regulations are issued by Transport Canada under the
authority of the Transportation of Dangerous Goods Act, 1992.
DOT-105J100W 8-31-81 — — i/
DOT-105J200W 8-31-81 — — i/
DOT-105J300W 8-31-81 — — i/
DOT-105J400W 8-31-81 — — i/
DOT-105J500I 3-16-09
AWW DRAFT 09/28/18
DOT-105J500W 8-31-81 — — i/
DOT-105J600I 3-16-09
DOT-105J600W 8-31-81 — — i/
DOT105S100W 8-31-81
DOT105S200W 8-31-81
DOT-105S300W 8-31-81 — — i/
DOT-105S400W 8-31-81 — — i/
DOT-105S500W 8-31-81 — — i/
DOT-105S600W 8-31-81 — — i/
DOT-105J200ALW 8-31-81 — — i/
DOT-105J300ALW 8-31-81 — — i/
ICC-106A800XNC — — 12-19-64 —
DOT-107A 1-13-32 9-15-71 — —
ICC-108 7-1-27 — 8-31-56 —
ICC-108A 7-1-27 — 8-31-56 —
DOT-109A100ALW 6-18-57 12-31-71 — —
DOT-109A200ALW 6-25-57 12-31-71 — —
DOT-109A300ALW 9-23-57 12-31-71 — —
DOT-109A300W 6-15-51 12-31-71 — —
DOT-110A500W 8-21-51 12-19-64 — j/
DOT-110A600W 2-12-75 — — j/
DOT-110A1000W 12-19-64 — — j/
DOT-112J200W 10-16-91 — — k/
DOT-112J500I 3-16-09
DOT-112J500W 10-19-77 7-13-78 — k/
DOT-112S200W 10-16-91 — — k/
AWW DRAFT 09/28/18
DOT-112S600I 3-16-09
DOT-112T200W 10-16-91 — — k/
DOT-120A100W 10-18-94 — — —
DOT-120A200W 10-18-94 — — —
DOT-120A300W 11-10-66 — — —
DOT-120A400W 9-20-72 — — —
DOT-120A500W 3-2-72 — — —
DOT-120A600W 3-19-74 — — —
Table 1.2 Data for tank cars in interchange service not otherwise listed in these specificationsa/
Specification AAR-201A70W 113A175Wb/ 113D120Wb/
Lading temp, °F –423 –155
Material Al Alloy ASTM A240–304, –304L, or TC133
Insulation Optional 179.400–4
Burst pressure, psi (kPa) 350 (2413) 440 (3034) 300 (2068)
Tank construction Fusion-welded Fusion-welded. Impact tests
req’d. (welds and plate)
Minimum plate thickness 1/2 in. (5/8 in. bottom) 5/16 in. 3/16 in.
Shell
AWW DRAFT 09/28/18
Heads 5/8 in. or 1/2 in. (2:1) 5/16 in. 3/16 in.
Dome 1/2 in. — —
Dome expansion capacity 2% — —
Test pressure, psi (kPa) 70 (483) 175 (1207) 120 (827)
Pressure relief devices Valve Valve and vent Valve and vent
Valve S-T-D pressure, psi 35 (241) 115 (793) 75 (517)
(kPa)
Valve vapor-tight pressure, psi 28 (193) 95 (655) 60 (413)
(kPa)
Valve flow rating pressure, psi 45 (310) 125 (862) 85 (586)
(kPa)
Vent burst pressure, psi (kPa) — 175 (1207) 120 (827)
Bottom outlet Optional — —
a/ Obsolete ICC tank car specifications conform to corresponding DOT specifications except for
method of tank construction or fittings arrangement. Metric equivalents shown for pressures
only.
b/ See also M-1002, 1982
Effective seal Any flanged, threaded, or other gasket fitting design that, as tested using approved E
NDT LT procedures, meets the acceptance criteria.
Employer The corporate, private, or public entity that employs personnel for wages, salary, fees, T
or other considerations.
Environmental damage Corrosion, erosion, or other physical deterioration of an item’s strength or resistance to U
(ED) failure because of chemical interaction with its climate or environment.
Equipment, explosion Apparatus enclosed in a case that is capable of withstanding an explosion of a A
proof specified gas or vapor that may occur within it; and of preventing the ignition of a
specified gas or vapor surrounding the enclosure by sparks, flashes, or explosion of the
gas or vapor within; and that operates at such an external temperature that a
surrounding flammable atmosphere will not be ignited thereby.
Equipment, intrinsically Equipment and wiring that is incapable of releasing sufficient electrical or thermal A
safe energy under normal or abnormal conditions to cause ignition of a specific hazardous
atmospheric mixture in its most easily ignited concentration.
Equipment owner As used in this specification this term can mean tank car owner, service equipment B
owner, or interior lining/coating owner.
Essential variables, NDT Those NDT parameters considered critical, that if changed require new qualification T
and demonstration of the NDT procedure.
Essential variables, Required when notch toughness testing is part of the specification, and are in addition W
supplementary to the essential variables for each welding process.
Essential variables, Those variables in which a change, as described in the specific variables, is considered W
welding to affect the mechanical properties of the weldment, and shall require requalification of
the WPS.
Evaluation A determination of the significance of a relevant indication. T
Examination Conducting the NDT methods that will be performed for the employer. For practical T
examinations, questions and answers need not be written, but observations and results
must be documented.
Excess flow valve A device designed to automatically close if the rate exceeds a specified value. 1
Experience Work activities accomplished in a specific NDT method under the direction of qualified T
supervision, including the performance of the NDT method and reports, but not
including time spent in organized training.
Exterior heater system A half pipe system welded to the exterior of the tank that uses a fluid medium to heat 1
the lading from outside the tank for the purpose of unloading.
°F Degrees Fahrenheit
Fabricate (fabrication) A form of manufacturing limited to cutting, beveling, shearing, forming, rolling, pressing, W
bending, or other allied process not defined under the term manufacturing.
Fatigue damage (FD) The initiation and subsequent propagation of a crack or cracks due to cyclic loading. U
Installation (Install) To physically connect or set an item in position or location for initial use. B
Instrument A category of service equipment used to measure the amount of lading and/or lading B
temperature.
Interior coating Any paint-type protective covering applied in one or more layers to the interior of a tank L
car tank to act as a barrier between the base metal and the commodity.
Interior heater system A piping system located within the tank that uses a thermal medium or electrical D
resistance to heat the lading within the tank for the purposes of unloading.
Interior lining Any sheet or laminated type material, glass, or fused metal applied to the interior of a L
tank car tank to act as a barrier between the base metal and the commodity.
Interpass temperature In a multipass weld, the temperature of the weld area between weld passes. R, W
Interpretation (of NDT The determination of the relevance of indications. T
test data)
ITP Independent Third Party
kPa kilopascals gauge
kPa (abs.) kilopascals absolute
Lap joint A joint between two overlapping members in parallel planes. W
Leak test A leak test of the installed valve or fitting performed below the tank test pressure. D
• Except for pressure relief devices, valves and fittings are to be tested in both the
open/plugged and non-plugged closed positions. The purpose of this test is to
determine the integrity of the fluid seal joint between a valve or fitting and the tank,
to determine pressure retention integrity of a valve, and to determine the pressure-
retention integrity of the operable valve seat by a visual inspection through the
valve port opening at the time of test.
• Pressure relief device: The purpose of this test is to determine the integrity of the
fluid seal joint between a pressure relief device and the tank, plus the integrity of
the device seals.
• Non-reclosing pressure relief device: The purpose of this test is to check for
through-wall corrosion pitting and leakage from threaded connections during
pressurization.
Leak tight An item of service equipment that shows no leakage on the downstream side when A
pressure is applied to the upstream side. All service equipment including closures must
be leak tight under loading conditions and during transit.
Liquefied compressed A gas that, under the charged pressure, is partially liquid at a temperature of 70 °F 5
gas (21.1 °C).
Liquid level control An automatic system that generates a signal to open or close valves at a A
device predetermined level.
Liquid penetrant A nondestructive test method utilizing contrasting liquids/dyes that penetrate to W
inspection (LP) highlight discontinuities open to the surface (cracks, porosity, seams, etc.).
Surface crack Separation of material extending 1/16 in. or less through the tank plate thickness. R
Surge pressure A device incorporated into the design of a tank car or attached thereto that, by design, A
reduction device reduces the internal surge pressures at the pressure relief device interface.
Tack weld A weld made to hold the parts of a weldment in proper alignment until the final welds W
are made.
Tack welder One who performs manual or semiautomatic welding to produce tack welds. W
Tank car A tank car tank mounted on or forming part of a car structure, including all components B
necessary and proper for railroad service [reference §179.1(a)].
Tank car facility An entity, at a fixed geographical location, that manufactures, repairs, inspects, tests, B
qualifies, or maintains a tank car; alters the certificate of construction of the tank car; or
performs any activities listed in or for which it otherwise has received certification or
registration under Appendix B of M-1002.
Tank car owner The party responsible for the continued qualification and maintenance of the tank car B, D, U
whose primary reporting mark is identified in the Equipment Management Information
System (Umler) element UMOW.
Tank car tank Consists of a shell, heads, nozzles, sumps, flanges, outlet saddles, any other B
attachments containing the lading, and all welds joining them. Where used in this
specification, the term “tank car tank” is synonymous with the term “tank.” Where used
in this specification, the term “tank car tank component” refers to the components listed
in this definition.
Tank design The specific designation to which the tank car is built (e.g., DOT-117A100W) as
specification identified on Form AAR 4-2 line item 7 and Umler element A072.
Tank stenciled The specific designation to which the tank car operates (e.g., DOT-117J100W) as
specification identified on Form AAR 4-2 line item 8 and Umler element A237.
Tank test date (initial The date of test of the tank on the completed car must be the same year as the built 1
stenciled) date of the car. The car builder must record the test data and provide it to the original
owner. The initial tank test date may be the same as the built date, provided the tank
test was conducted within 6 months prior to the built date.
Tanks As used in this specification means tank car tank. B
Technical performance The demonstration of competence in an NDT method or technique by a qualified T
individual. The NDT-qualified individual has demonstrated the ability to apply NDT
technical knowledge and complete NDT assignments.
Technique A specified process within an NDT method, for example magnetic particle ‘yoke T
technique.’
Temporary weld A weld made to attach a piece or pieces to a weldment for temporary use in handling, R, W
fitting, or working on the weldment.
Temperature sensing A part or parts that permit the determination of the temperature of a tank’s contents. A
equipment
11/2014 C-III [M-1002] 23
AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
CHAPTER 1 M-1002
Class DOT-104W tank cars are insulated carbon steel nonpressure cars with an expansion dome
and having a minimum expansion capacity of 2% in the dome.
Class DOT-105A, J, or S***W tank cars are insulated carbon or alloy steel pressure cars, with a
manway nozzle, designed for top loading and unloading; bottom outlet or washout prohibited.
Class 105A or J***ALW tank cars are similar except that they have aluminum alloy tanks. Class
105A***F has forge-welded tanks.
Table 1.4 Class DOT-105A, J, or S***W suffix letters
A = equipped with top-and-bottom shelf couplers
J = equipped with jacketed thermal protection, tank head puncture
resistance, and top-and-bottom shelf couplers
S = equipped with tank head puncture resistance and top-and-bottom shelf
couplers
Class DOT-106A***X tanks are uninsulated carbon steel tanks designed to be removed from the
car structure for filling or emptying and designed to a maximum stress level in the shell.
Table 1.5 Class DOT-106A***X suffix letters
X = Fusion-welded longitudinal tank seam and forge-welded head seams
XNC = Nickel clad
NCI = Nickel—chromium—iron
Class DOT-107A**** tank cars are uninsulated high-pressure service cars having several
permanently mounted seamless, forged, and drawn steel tanks designed to a maximum stress
level in the shell.
Class DOT-109A***W tank cars are insulated or uninsulated carbon steel pressure cars with a
manway nozzle, designed for top loading and unloading, bottom washout optional.
Class DOT-109A***ALW tank cars are similar except they have aluminum alloy tanks.
Class DOT-110A***W tanks are uninsulated carbon steel tanks designed to be removed from the
car structure for filling or emptying and designed to a burst pressure.
Class DOT-111A***W* tank cars are insulated or uninsulated nonpressure cars without an
expansion dome. The expansion capacity in the tank is 2%. Class DOT-111A***W* tank cars built
for specific services or requiring special fittings or materials of construction are designated by
suffix letters or numerals. Class DOT-111A***F* have forge-welded tanks converted from
Specification ICC-105A300, 400, or 500. Suffix letters are shown in Table 1.6.
Table 1.6 Class DOT-111A***W* suffix letters
Bottom Bottom
Tank Outlet Washout
Class DOT-112A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel
pressure cars, with a manway nozzle and without bottom connections, designed for top loading and
unloading.
Table 1.8 Class DOT-112A, J, S, or T***W suffix letters
A = equipped with top-and-bottom shelf couplers
J = equipped with jacketed thermal protection, tank head puncture resistance,
and top-and-bottom shelf couplers
S = equipped with head shields and top-and-bottom shelf couplers
T = equipped with nonjacketed thermal protection system, top-and-bottom shelf
couplers, and head shields
Class DOT-113****W tank cars are vacuum-insulated cars having an inner container and carbon
steel outer shell. The insulation system is designed for a holding time. Class DOT-113 cars are
designed for specific loading and shipping temperatures and have certain materials and fittings
requirements as designated by the intermediate letter.
Table 1.9 Class DOT-113****W suffix letters
A = Minus 423 °F (–253 °C) loading; high alloy steel inner container; special
fittings and insulation for refrigerated (cryogenic) liquid hydrogen
C = Minus 260 °F (–162 °C) loading; high alloy steel inner container; special
fittings for refrigerated (cryogenic) liquid natural gas, refrigerated
(cryogenic) liquid methane (DOT exemption required), or refrigerated
(cryogenic) liquid ethylene
AWW DRAFT 09/28/18
D = Minus 155 °F (–104 °C) loading; nickel alloy steel inner container; special
fittings for refrigerated liquid ethane (DOT exemption required) or
refrigerated (cryogenic) liquid ethylene
Class DOT-114A, J, S, or T***W tank cars are insulated or uninsulated carbon or alloy steel
pressure cars with a manway nozzle and optional noncircular cross-section. An additional group of
valves and fittings may be provided in another location.
Table 1.10 Class DOT-114A, J, S, or T***W suffix letters
A = equipped with top-and-bottom shelf couplers
J = equipped with jacketed thermal protection, tank head puncture resistance,
and top-and-bottom shelf couplers
S = equipped with head shields and top-and-bottom shelf couplers
T = equipped with nonjacketed thermal protection system, top-and-bottom shelf
couplers, and head shields
Class DOT-115A***W* tank cars are insulated nonpressure cars having an inner container and
carbon steel outer shell with optional bottom connections. Suffix letters are shown in Table 1.11.
Table 1.11 Class DOT-115A***W* suffix letters
W1 = Steel inner container
W6 = Alloy steel inner container
ALW = Aluminum inner container
Class DOT-120A, J, or S***W tank cars are insulated pressure cars with a manway nozzle. An
additional group of valves and fittings may be provided in another location
Class DOT-120***ALW tank cars are similar except that they have aluminum alloy tanks.
Class AAR-204 tank cars are vacuum-insulated cars having an inner container and carbon steel
outer shell. They are designed for loading of liquid argon, nitrogen, or oxygen. Specification AAR-
204W tank cars are similar in concept to Class DOT-113****W cars. Suffix letters are shown in
Table 1.13.
Table 1.13 Class AAR-204 suffix letters
X = Conversion from XT boxed tank cars
W = Fusion-welded alloy steel inner container and carbon steel outer shell
Class AAR-207A**W* pressure-differential covered hopper cars are designed for 15 psig
(103 kPa) minimum internal pressure and are used for the transportation of granular commodities
that are unloaded pneumatically. Suffix letters are shown in Table 1.15.
Table 1.15 Class AAR-207A**W* suffix letters
W = Carbon steel fusion-welded tank
ALW = Aluminum alloy fusion-welded tank
W6 = Alloy steel fusion-welded tank
Specification AAR-208 tank cars are nonpressure cars having wood-staved metal hooped tanks
for the transportation of certain food-grade materials.
Class AAR-211A***W* tank cars are insulated or uninsulated nonpressure cars without an
expansion dome. The numeral after “W” designates specific outlet and bottom connection options.
These cars conform, with certain exceptions, to Class DOT-111A***W*. Suffix letter or numerals
are shown in Table 1.16.
Table 1.16 Class AAR-211A***W* suffix letters
W1 = Carbon steel tank
2% minimum expansion capacity in tank
Optional bottom outlet or washout
W2 = Carbon steel tank
No bottom outlet
Optional bottom washout
AWW DRAFT 09/28/18
1.3.6.5 In addition to valves and/or closures approval requirements, the fittings arrangement on
the tank car also requires approval. The fittings arrangement is identified on the Form AAR 4-2
and is approved as part of the tank car design. If the fittings arrangement is altered, the alteration
must be approved. The alteration of the fittings arrangement must be submitted using the Form
AAR 4-2.
1.3.7 Editions of Referenced Specifications
Unless a specific year is recorded after the specification number, wherever AAR, ASTM, AWS, or
other specifications are noted, the latest editions are approved.
1.3.8 Calibration and Capacity Tables
1.3.8.1 Calibration
The procedures for tank car calibration are set forth in API Standard 2554, “Measurement and
AWW DRAFT 09/28/18
Calibration of Tank Cars.” For all cars constructed after May 1, 2001, gauged or strapped
capacities shall be rounded to the nearest 10-gal and 50-L increments. Rounding is to be
performed after any conversion of units. For cars constructed prior to May 1, 2001, conformance to
this standard is optional.
1.3.8.2 Capacity Tables
For all cars constructed after May 1, 2001, capacity tables shall be provided by the car builder.
Capacity tables shall conform to the following:
1.3.8.2.1 Tables shall list outage volumes (volume of air or vapor above the surface of a liquid)
corresponding to distances measured downward from the shell-full (zero-outage) level.
1.3.8.2.2 Tables shall begin at the shell-full (zero-outage) level and continue for the full depth of
the tank.
1.3.8.2.3 If English units are used, volumes shall be whole U.S. gallons and distances shall be
inches in one-quarter-inch increments. If metric units are used, volumes shall be whole liters and
distances shall be whole centimeters.
1.3.8.2.4 All tables must show an effective date.
1.3.8.2.5 For reference, the following conversion factors are to be used:
• Multiply U.S. gallons by 3.785 to convert to liters.
• Multiply imperial gallons by 1.201 to convert to U.S. gallons.
• Multiply imperial gallons by 4.545 to convert to liters.
• Multiply inches by 2.540 to convert to centimeters.
1.3.8.2.6 Tank cars may be grouped when assigning capacity tables if the measured (water
gauged or strapped) shell-full capacity of the tank is within 0.1% of the shell-full capacity used in
the gauge table.
1.3.9 Gauging
Tank car tanks can be gauged by built-in gauge marker, tell-tale valve, or electronic or magnetic
gauging device as may be in accordance with the specification. Gauging can alternatively be
accomplished by scale weighing, liquid metering, or by use of poles and outage/innage tables,
depending upon the commodity and class of car involved. Procedures for gauging tank car tanks
are detailed in API Measurement Standard 3.2, “Tank Gauging—Gauging Petroleum and
Petroleum Product in Tank Cars.”
Effective August 1, 2005, tank cars equipped with slip tube gauging devices must have them
removed no later than the next tank qualification event. Cars altered under this rule need not
meet the capping kit requirements of Appendix E, paragraph 3.1.6.
1.3.16.3.3 Existing cars may have gross rail load increased above 263,000 lb if originally
designed for the higher load and so noted on the Certificate of Construction.
1.3.16.3.4 Tank cars that exceed 263,000 lb due to the addition of approved safety features must
be in compliance with paragraph 1.3.16.3.1 but need not comply with paragraph 1.3.16.3.3.
1.3.17 Maintenance Program
The provisions of Appendix U apply to the following entities:
• Tank car owner
• Service equipment owner
• Lining or coating owner
• Tank car manufacturing facility
• Tank car repair facility
• Operator/User
• Subcontractor
1.4 Procedures for Securing Approval
1.4.1 General
Paragraph 1.3.6 of this specification and U.S. Department of Transportation (DOT) and Transport
Canada (TC) regulations require AAR Tank Car Committee (Committee) approval of designs and
materials used for the construction, conversion, alteration, or welded repair of tank car tanks. The
Committee has delegated to the AAR Safety and Operations Department the authority on its
behalf to approve applications provided that
• they have been reviewed and deemed to be in accord with AAR, DOT, and TC requirements
by an independent third party (ITP) that has been certified by the Committee in accord
with paragraph 1.5, or,
• they meet the requirements for precedent approval outlined in paragraph 1.4.2.3.
The AAR may elect to request a Committee ballot on any application for approval. Such a request
should be made within 10 days of receipt of the application.
Applications for approval of service equipment will continue to be approved by the Tank Car
Committee in accord with paragraphs 1.4.6 and 1.4.7.
1.4.1.1 AAR Tank Car Application for Approval and Certificate of Construction
Web-Based System
Effective January 1, 2015, applicants are required to use the AAR Tank Car Application for
Approval and Certificate of Construction Web-Based System for submittal of applications for tank
car designs. This system encompasses the entire process of seeking approval of tank car designs.
Tank car design applicants, AAR, and certified ITPs are required to obtain access to this system
and will use it in processing applications through the approval process, including the certificate of
construction submittal. A system user guide is available to those who obtain access.
To obtain access to the Tank Car Application for Approval and Certificate of Construction
Web-Based System, contact Railinc’s Customer Support Center (CSC) where the application is
hosted and maintained on behalf of the AAR. Customer support can be reached at 877-724-5462 or
via email to csc@railinc.com.
Subject to the limitations outlined in paragraph 1.4.2.3, permitted design differences from
previously approved designs may include the following:
• Changes in tank length only, provided that the rail load limit is not increased
• A reduction in rail load limit
• A change in arrangement or number of heater coils, including deletion of the entire system
or application of a previously approved system
• Changes to appurtenances used for loading and unloading, provided that they are in
compliance with Appendix S and the AAR Interchange Rules
• Changes to trucks, braking systems, or draft systems, provided that they are in compliance
with the AAR Interchange Rules
• Use of previously approved tank opening reinforcements, nozzles, and protective housings,
provided that the approved design and application were for tanks of equal or greater test
pressure
• Application or rearrangement of previously approved fittings, provided that they had been
approved for tank cars of equal or greater test pressure
• Changes to materials of previously approved fittings that are necessary for compatibility
with lading, provided the changes do not reduce the strength of the fitting or its
components (see paragraph 1.4.5.3.3)
• Application of previously approved head shields, thermal protection systems, or insulation
systems or the deletion of such systems
• Changes to approved head shields, thermal protection systems, or insulation systems
necessary to conform to changes in tank geometry
• Changes to car structure that are not in violation of paragraph 1.4.2.5
• Changes necessary to accommodate tank geometry that do not reduce the strength of a
previously approved underframe
Applications that are referred to the Tank Car Committee pursuant to paragraph 1.4.1 or
paragraph 1.4.2.3 will be handled by mail ballot and will be approved by majority vote unless
advised by any member of the Committee or by AAR staff that approval appears to be in violation
of the specifications or will represent a hazardous condition. In the event such advice is received,
all committee members will be notified, and those members previously voting to approve the
application will be asked to reconsider their vote.
A Committee member having comments on any application being considered must, within 15 days
of receipt of the application, direct his or her comments to the applicant with copies to the balance
of the Committee and to the Director. The applicant must respond to Committee comments within
30 days, directing his or her response to each member of the Committee and to AAR staff. Failure
to respond will be cause for disapproval of the application.
Once an applicant has furnished all additional information requested in Committee comments, all
Committee member(s) initially commenting on the application must resubmit a ballot within
15 days of the applicant’s response. A Committee member having taken exception to an
application and then approving it based on satisfactory applicant response to comments must
direct approval to the Director with copies to the applicant and the balance of the Committee.
If sufficient ballots to constitute action have not been received within 45 days from receipt of the
application by AAR, staff will poll each member of the Committee to expedite response. AAR staff
must notify the applicant of the status of his or her application within 60 days of receipt of the
application. A written explanation must be provided for any application that is disapproved or
held pending additional information.
1.4.2.12 Disapproved Applications
If an application is disapproved pursuant to action of the Tank Car Committee, the applicant may,
by written notice to the Director, petition the Committee for review of the application at a regular
or special meeting of the Committee to be held not later than 90 days from receipt of the notice.
The applicant must attend any such meeting and will be granted the right to present additional
information is support of the application. AAR must notify the applicant of the action of the
Committee within seven business days following the meeting.
If tank cars covered by formally disapproved applications are subsequently offered for interchange
service, the Director will notify all AAR member railroads and appropriate movement restrictions
will be placed in the Universal Machine Language Equipment Register (UMLER) file.
Line Instruction
1. Indicate by an “X” in the appropriate block whether nonprecedent or precedent approval,
based on a precedent already approved by the Committee, is requested. AAR staff will
assign nonprecedent requests to the Committee or to an ITP, as appropriate.
2. Indicate if the application concerns construction, conversion, alteration, repair, or other
(provide description for “other”).
In the event that the method of approval changes after submission, the AAR staff will
revise the prefix to correspond to the proper code.
4. Enter the date of the original application. Dates of revisions to the application must be
shown under “Revisions.”
4.1 Enter the date the order was made with the Tank Car Builder. MM/DD/YYYY
5. Enter a file number or builder lot number.
6. Enter the name of the applicant. For new construction, the applicant must be the tank car
builder. For conversion, alteration, or repair, the applicant must be the car owner or the
facility authorized to perform such work.
7. Enter the tank specification to which the tank is to be built (e.g., DOT-111A100W1).
8. If the car is to be operated under a specification other than the one shown on Line 7, the
stenciled specification must be entered here (e.g., AAR-211A100W1).
9. The reporting marks and car numbers entered here must be those that are or will be
recorded in the “Official Railway Equipment Register” covering the car or cars in question.
10. Enter the total number of cars represented by the car numbers or series shown on Line 9.
11. If the car is designed for a specific commodity, enter its proper shipping name. If the car
is not designed for a specific commodity or is limited to certain commodities, enter the
words “(Initial lading) and products authorized by DOT Part 173 for which there are no
special commodity requirements and nonregulated commodities compatible with this
class of car.” If special commodity stenciling is required, it must be shown under “Notes.”
Line Instruction
12. If the car is designed for a specific commodity, enter the weight of the commodity in
pounds per gallon or pounds per gallon and kilograms per liter. When Line 11 shows “DOT
Part 173” and an initial commodity, show the weight of the initial commodity.
13. Enter the tank capacity in U.S. gallons or U.S. gallons and liters. For nonpressure cars,
record shell-full volume. For pressure cars, record shell-full volume plus volume of
manway nozzle.
14. Enter the as-designed outage in U.S. gallons or U.S. gallons and liters.
15. Enter the material specifications for tank shell and heads and their respective
through specifications and thicknesses.
16.
17.
18.
AWW DRAFT 09/28/18
15.1 Indicate whether or not the tank head material is normalized. (Yes= normalize; No=not
normalized)
15.2 Indicate whether or not the tank head is spliced. (Yes or No)
15.3 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the
impact test temperature.
16.1 Indicate whether or not the tank shell material is normalized. (Yes= normalize; No=not
normalized)
16.2 When transverse Charpy impact tests are required per paragraph 2.2.1.2, indicate the
impact test temperature.
19. Where linings are required by the specification, the lining material and thicknesses must
be shown.
20. Enter tank inside diameter, in inches, at center and at tank ends. May also be submitted
21. in both inches and millimeters.
22. This item refers to dished heads and, when such heads are used, the main radius in inches
or inches and millimeters must be entered.
23. Enter the actual test pressure for which the tank is designed, including maximum
pressure relief device setting permitted by 49 CFR 179.15. Use psi or psi and kPa.
24. Enter the type of insulation used (e.g., fiberglass, cork, polyurethane, etc.)
25. Enter the thickness of insulation in inches, or inches and millimeters, for all insulated
tanks.
26. The thermal conductivity of the insulation must be shown in the units indicated at 60 °F
(15.6 °C). (Mineral wool, ceramic fiber, or other thermal protection materials are not
considered insulation.) SI equivalent units are kJ•mm/h•m2•°C.
27. These items must indicate whether the pressure relief device is a valve, vent, or breather
28. vent. The number of such devices and the start-to-discharge pressure or bursting pressure
must be shown in psi or psi and kPa.
27.1 Enter the number of safety relief devices.
29. For pressure relief devices, the required flow capacity in cubic feet per minute, or cubic
feet per minute and cubic meters per second, must be entered.
30. When pressure relief devices are used, enter the actual flow capacity provided.
31. Enter the exterior tank surface area in square feet or square feet and square meters.
32. For tank cars with an underframe, enter “full.” For stub sill cars, enter the code for the
stub sill style (see Appendix R, Exhibit R-2, fourth page, for builder and sill codes).
Line Instruction
33. Enter the height from top of rail to the center of gravity of the tank car in inches or inches
and millimeters. If the center of gravity height exceeds 84 in. (2130 mm) on cars with four-
wheel trucks having 6 1/2 in. × 12 in. journals or larger, an asterisk must be used to refer
to a comment under “Notes,” indicating car truck centers or truck spring travel.
34. Enter the estimated light weight of the completed car in pounds or pounds and kilograms.
35. Indicate if car is constructed to AAR Clearance Diagram Plate B, C, E, or F.
36. The rail load limit must be shown and must be compatible with the truck capacity for the
number and size of axles used. If gross weight on rail exceeds 263,000 lb with
6 1/2 in. × 12 in. journals, approval of the AAR Equipment Engineering Committee is
required (see paragraph 1.4.2.6).
1.4.3.1.2 Application for approval of new tanks to be mounted on existing car structures must be
accompanied by a statement under “Notes” that “Car structure complies with all requirements of
the AAR Interchange Rules and is suitable for continued service.”
1.4.3.1.3 Applications for conversion, alteration, or repair must indicate current specification,
former lading, date built new, and previous certificate number(s) under “Notes” and must show
specification and new commodity on Line 7 and Line 11, respectively. Supply a supplemental
sheet, if necessary, to associate the car numbers with their previous certificate numbers.
1.4.3.1.4 For applications covering welded repairs on tanks using procedures or materials that
have not been previously approved, fill in Lines 1 through 38, inclusive. Description of damage to
tank, date, place, and circumstances of damage, together with proposed method of making repairs,
must also be submitted under “Notes” on a continuation sheet.
AWW DRAFT 09/28/18
1.4.3.1.5 For applications covering reconditioning of manway covers for tank cars covered by
DOT 179.100, submit data on original construction, certificate numbers, and car specification,
with drawing numbers used in original construction. Application must include drawings and a
detailed explanation of how repairs are to be made.
1.4.3.1.6 Applications submitted by facilities other than the fabricator of tank shell and heads for
assembly of new tank cars must be accompanied by a statement under “Notes” that “Tank shell
and head fabrication by... (certified facility). Completed car will comply with all applicable AAR
and DOT requirements.”
1.4.3.1.7 Certain car designs, appurtenances, valves, fittings, or attachments may be declared by
the Tank Car Committee to be subject to service trials before general acceptance for new
construction. Such service trials and their restrictions must be identified by the applicant or AAR
under “Notes.” Service trial numbers are assigned by the Director. See paragraph 1.4.9.
1.4.3.1.8 DOT exemptions, special approvals (SAs), or Canadian special permits applicable to the
car or commodity must be identified under “Notes.” A copy of the latest revision must be submitted
with the application.
1.4.3.1.9 Applications for increased truck capacity must be supported by justification (with
calculations if necessary) to verify the structural adequacy of the car for increased capacity and
braking requirements.
1.4.3.1.10 Valves are to be identified by manufacturer, size, and identification number on the
drawings or application, whether or not supplied by the proponent.
1.4.3.1.11 The method of anchoring the jacket of an insulated car must be submitted with Form
AAR 4-2.
1.4.3.2 Approval
AAR staff complete the “Approval” section of Form AAR 4-2 based on action taken on the
application.
1.4.3.3 Certification
The “Certification” section of Form AAR 4-2 is to be completed only after the approved application
has been received from AAR and the referenced construction, alteration, conversion, or repair has
been completed. Certification is accepted only from a responsible Quality Control representative
acting for the facility performing the work, from an officer of the company performing the work, or
from the car owner. When signed by all parties, the completed Form AAR 4-2 is recognized as the
Certificate of Construction for the car or cars identified thereon.
SIGNATURE
TITLE
CERTIFICATION: The cars enumerated below conform to the above approved description and to all applicable DOT and AAR requirements, including specifications,
regulations, rules of interchange, and the DOT Railroad Safety Appliance Standards. Copy of this Certificate of Construction will be furnished to the owner and others as
required by 49 CFR Part 179.5 before these cars are placed in service.
Initials and Car Numbers
Name Date
Title
Fig. 1.1 Form AAR 4-2 Application for Approval and Certificate of Construction
Date _____________________________
AWW DRAFT 09/28/18
1.4.5.1.6 Metallic fittings require Tank Car Committee approval unless all of the following
conditions are met:
• Parts are manufactured in accordance with a nationally recognized standard (e.g., SAE,
ASME, ANSI, MIL) or Appendix M.
• Parts are designed to meet or exceed the operating pressure rating of a tank car.
• Parts are designed to be leak tight.
• Parts must be joined in accordance with Appendix E, as specified by the tank car
manufacturer or owner, or ASME Section 8, Division 1.
• Fitting must be marked with the name of the manufacture and pressure rating and with
additional markings as agreed to by purchaser and manufacturer.
• Approval is granted for the application of the fitting to the tank car when the Form AAR
4-2 for the tank car is approved for a specific application for new construction, alteration,
AWW DRAFT 09/28/18
conversion, or repair.
1.4.5.2 Approval of Service Equipment
Tank car service equipment must be approved by the Tank Car Committee. Approvals of service
equipment must be renewed every 10 years. Approvals will be marked with the expiration date,
which shall be the end of the month in which the approval was executed plus 10 years. Table 1.17
outlines the devices by group, committee approval, and what form is to be used. The application
process, instructions, and forms are provided within this chapter.
Note: All submitted materials must be marked with an assigned AAR number.
1.4.6.1.2 The application package for pressure relief devices shall consist of the following:
• Form AAR 4-35
• Test results required in Appendix A, paragraph 5.3
• Drawings (assembly drawing and any additional drawing necessary to describe the device
including a Bill of Material)
• Flow test facility’s report, if applicable
• Supplemental information as applicable
• Application fee per Appendix E of the Office Manual of the AAR Interchange Rules
1.4.6.2 Instructions
1.4.6.2.1 The following instructions must be followed by the applicant when completing the
application and certification portions of the form:
• The applicant must request an AAR number from the Executive Director.
• The applicant must be the valve manufacturer or its agent.
• The date must be that on which the application is completed.
• The applicant’s number blank is for the convenience of the applicant.
• The device identification number is for the convenience of the applicant (e.g., catalog
number).
1.4.6.2.1.1 The numbered items must be entered as follows:
16.
a. If a drawing has been previously approved by the Tank Car Committee, enter the
certificate number of the approval in the third column and leave the second column
blank. Prints need not be submitted.
b. If a new drawing is submitted for Committee consideration, leave the second and third
columns blank. Prints must be furnished and an explanation provided by letter or
separate sheet.
c. If a new drawing is submitted for Committee consideration and a precedent drawing
is appropriate, enter the precedent drawing and its application or certificate number
in columns two and three. If the precedent is pending before the Committee, indicate
“Pend” after the application number. Prints of the new drawing must be furnished and
deviations must be explained by letter or separate sheet.
d. If a precedent is pending before the Committee, indicate “Pend” after the application
number. Prints of the new drawings are not required to be submitted, but deviations
must be explained by letter or separate sheet.
e. Under b, c, or d above, if the same new drawing and precedent are shown on another
pending application, this information must also be indicated by letter or separate
sheet. The first approval received must be the approval of record for the drawing.
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Specifications for Tank Cars
M-1002 CHAPTER 1
Line Instruction
f. All drawings submitted with Form AAR 4-3 must carry a current approval signature
or initial by the proponent.
14 Note: When the design of a pressure relief device is such that the spring follower is guided
by the mounting nozzle, the mounting nozzle shall be considered as a required part of the
application and a drawing of the nozzle in sufficient detail to show critical dimensions
shall be included. When the pressure relief device design does not require the mounting
nozzle to act as a guide for the spring follower, the word “None” can be used in the space
for this item.
1.4.6.2.2 Certification
The applicant signs the form under “Certification” attesting to the above entries.
AWW DRAFT 09/28/18
1. Manufacturer
Address
2. Test facility name 3. Test facility location
4. Test date 5. Observer
11. Official flow capacity (air) scfm ( std. m3/s) at flow rating pressure psi ( kPa)
Test medium
12. Commodity: Regulated Commodity Nonregulated Commodity Specific Commodity
Precedent
The following drawings apply Drawing number Application/
Latest revision Drawing number Certificate
13. Valve Assembly……………………………………..
14. Valve Mounting Nozzle……………………………..
15. ……………………………………………………….
16. ……………………………………………………….
REVISIONS:
CERTIFICATION: The above data is correct. The capacity test complies with AAR Specifications for Tank Cars, Appendix A and
the devices tested conform with the drawings listed above.
By: Title
APPROVAL of Service Trial by AAR Tank Car Committee
AAR Service Trial Required Service Trial Number: ST-__________
Fig. 1.3 Form AAR 4-3 Application for Approval of Pressure Relief Device
1.4.7.1.2 The application package for valves, closures, and fittings shall consist of the following:
• Form AAR 4-5
• Drawings (assembly drawing and any additional drawing necessary to describe the device
including a Bill of Material)
• Flow test facility’s report, if applicable
• Supplemental information as applicable
• Application fee per Appendix E of the Office Manual of the AAR Interchange Rules
Note: All submitted materials must be marked with an assigned AAR number.
1.4.7.2 Instructions
1.4.7.2.1 The following instructions must be followed by the applicant when completing the
application and certification portions of the form.
• The applicant must request an AAR number from the Executive Director.
• Applicant must be the manufacturer of the device or its agent.
• The date must be that on which the application is completed.
• Describe the device and its function in accord with the definitions and requirements of
Appendix A.
• Spaces for the applicant’s number and the device identification number are for the
convenience of the applicant (e.g., index, catalog, or type numbers).
1.4.7.2.2 The numbered items must be entered as follows:
Line Instruction
1. Identify the manufacturer of the device.
2. Record the test facility that tested the device, if other than the manufacturer’s.
3. Record the date testing was completed for subject device.
4. Indicate the applicant’s observer’s name and title.
5. Indicate the procedure used to test the prototype device and the number of devices tested.
6. Indicate the number of cycles to which a device was subjected at high and low
temperatures and at the given pressure, as well as the specific test medium used (e.g., air,
water, etc.).
7. Indicate the commodity or commodity type.
8. Indicate the flow rate of the device in gallons per minute, or gallons per minute and liters
per minute, if applicable.
9. Indicate the drawing number showing the application of the device to the car and the basic
material. When applicable, reference a precedent drawing with AAR application number.
Line Instruction
10. Indicate the drawing number of the device assembly and basic material and, when
applicable, reference a precedent drawing with AAR application number.
11. Indicate the drawing number and material specification of individual parts.
12. Provide a basic statement that the facility has a quality control program to provide
compliance with drawings and specifications.
1.4.7.2.3 Revisions/Certification
• The “Revisions” space is provided to indicate any revisions to the original application.
• The applicant signs the form under “Certification,” attesting to the above entries.
1.4.7.2.4 Approval by AAR Tank Car Committee
1. Manufacturer
2. Address City State Zip
3. Test facility if other than the manufacturer Address
4. Test date 4. Observer
AWW DRAFT 09/28/18
Title: .
TEST PROCEDURE
5. Description of prototype testing:
6. Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
Cycles Min. Temp. @ Pressure Cycles Max. Temp. @ Pressure Test Medium Remarks
ºF psi ºF _psi
ºC _kPa ºC kPa
7. Commodity: Regulated Commodity___ Non Regulated Commodity ___ Specific Commodity
8. Flow rate (if applicable) gpm ( L/min)
Drawing Number Precedent
Applicable drawings Material latest revision Drawing Number Application/Certificate
9. Device application . . . . . .
10. Device assembly . . . . . . . .
11. Device details . . . . . . . . . .
12. Quality Control Statement
REVISIONS:
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars, Appendix A. The devices
tested conform with drawings listed above.
By Title
APPROVAL AAR Tank Car Committee Service Trial Required
Date Approved for Service Trial
Service Trial Number
(Signature) on behalf of Tank Car Committee
APPROVAL AAR Tank Car Committee Service Completed / Not Required
Date Service Trial Completed Date AAR Received Form AAR 4-6 .
Date Approved _____________________________________
Expiration Date ____________________________________ ________________________________________________
(Signature) on behalf of Tank Car Committee
Form AAR 4-5 Revised 10/2014
Fig. 1.4 Form AAR 4-5 Application for Approval of Valves and Fittings
1.4.8 Renewal of Approval for Pressure Relief Devices, Valves, Closures, and Fittings
1.4.8.1 Procedures for Renewal—Application Form AAR 4-7
1.4.8.1.1 To secure approval for renewal of approval for pressure relief devices, valves, closures,
and fittings as required by paragraph 1.3.6, the completed application package as defined in
paragraph 1.4.8.1.2 must be submitted to the following:
Executive Director—Tank Car Safety
Association of American Railroads
425 Third Street SW, Suite 1000
Washington, DC 20024
Line Instruction
1. Enter the AAR Number assigned by the Executive Director.
2. Enter the date which the application is completed.
3. Enter the previous AAR approval number under which the device was approved by the
Tank Car Committee.
4. Enter the applicant’s name.
5. Enter the applicant’s Address, City, State, and ZIP.
6. Provide an applicable drawing number.
7. Enter the latest revision.
8. Enter the date of the latest revision.
9. Enter detail description of the device.
10. For convenience of the applicant, enter the device ID No. (e.g., index, catalog, type
numbers).
11. If the subject device is unchanged, the applicant signs the certification attesting to the
entries on the form and enters the applicant’s title.
12. Identify the previous and current drawings, and if on service trial the service trial number.
Line Instruction
13. Indicate whether or not the change supersedes the drawings.
14. Describe the changes and the reasons for making the changes.
15. Provide a statement about the operational effect of the changes.
16. Identify the drawing submitted with this application.
17. If the device has changed, then the applicant signs the certification that the data is correct
and conforms with AAR Specifications for Tank Cars and the device conforms with
drawing listed on the form
1.4.8.3 Certification
The applicant signs the “Certification,” attesting to the entries. Enter the applicant’s title. Applies
AWW DRAFT 09/28/18
13. New drawing supersedes previous one or does not obsolete it
CHANGES REASONS FOR CHANGES
14. a. a.
b. b.
c. c.
d. d.
(if needed use supplemental sheet)
CERTIFICATION: The above data is correct and conforms with AAR Specifications for Tank Cars,
Appendix A. The device conforms with drawing listed above.
Date Approved:
(Signature) on behalf of Committee
Form AAR 4-7 8/1/2014
Fig. 1.5 Form AAR 4-7 Application for Renewal of Approval for Pressure Relief Devices, Valves, Closures, and
Fittings
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AAR Manual of Standards and Recommended Practices
Specifications for Tank Cars
M-1002 CHAPTER 1
build.
1.4.9.1.3 The following requirements apply to tank cars under service trial:
• Notification to the AAR of the date the cars are placed in service
• Minimum 100,000 miles or 10 years, first qualification
• Annual visual inspection of draft sill and bolster
• Annual report by tank car giving, miles and trips for the year, and results of annual
inspection
• Stub sill inspection at the conclusion of the service trial
• Final report by tank car having total mileage, trips, and results of stub sill inspection
1.4.9.2 Authorization for Service Trials for Service Equipment
1.4.9.2.1 All new devices may be subjected to service trials. Service trials, when required by the
Tank Car Committee, must be reported on Form AAR 4-4. The service trial may be waived by the
Tank Car Committee after considering the supporting material in the application.
The applicant has 30 days to appeal the request for service trial. In its challenge appeal, the
applicant must provide reasons why a service trial in unnecessary. The appeal must be filed with
the Executive Director for disposition by the Tank Car Committee.
1.4.9.2.2 The requirements for a service trial are as follows:
1.4.9.2.2.1 The sample size and post-trial teardown requirements are provided in Table 1.18.
1.4.9.2.2.2 The maximum number of units that can be applied to tank cars may be exceeded if
authorized by the Executive Director or his designee. After receipt of approval for non-regulated
service, the maximum number of units that may be applied in regulated service is no longer
restricted.
1.4.9.2.2.3 The devices in the service trial must average 5,000 loaded miles and 10 loaded trips
per year. If at the 1-year anniversary one or both of these averages are not being met, the applicant
may apply to the Tank Car Committee for modification of these averages.
1.4.9.2.2.4 For non-regulated commodities, each car set of the device must be subjected to a trial
of 1 year minimum duration.
1.4.9.2.2.5 For regulated commodities, each car set of the device must be subjected to a trial of
2 years minimum duration.
1.4.9.2.3.3 Documentation
Copies of any tests and notes of conditions found shall be kept. Photographs of each step of the
teardown process and each individual component must be kept.
A copy of the test and inspection procedure and copies of each bench test and appropriate
photographs shall be included with the submission of the Form AAR 4-6.
1.4.9.2.3.4 At the conclusion of a service trial, Form AAR 4-6 “Final Service Trial Inspection
Report,” with any design changes the service trial indicates are necessary must be submitted to
the Tank Car Committee for approval with a copy of the original application. The Tank Car
Committee may request additional tests to supplement the manufacturer’s tests or service trials
prior to acceptance of the device.
1.4.9.3 Service Trial Report Form AAR 4-4
AWW DRAFT 09/28/18
Service trial data must be submitted to the Executive Director on Form AAR 4-4, AAR Tank Car
Service Trial Report, at 6 month intervals before the April and October meetings of the Tank Car
Committee, no later than April 1 and October 1. Failure to submit the report may result in
cancellation of service trial authorization and revocation of all approvals. The Executive Director
shall be notified when the service trial starts; 90 days before the 2-year service trial ends; and
90 days before teardown is planned.
1.4.9.3.1 Instructions
1.4.9.3.1.1 The following instructions must be followed by the proponent when completing the
Service Trial Report.
• AAR number is the same number used on Forms AAR 4-2, AAR 4-3, or AAR 4-5.
• AAR docket number is the number assigned by the Director to review a specific item when
requested by the Tank Car Committee.
• AAR service trial number is the number issued by the Director at the time the application
is processed.
• Reporting company is the applicant or applicant’s representative having knowledge of the
performance and service of the device.
• The date must be the date on which the report is completed.
• Period covered is the period from the date of application or date of last report to the
required reporting date as specified above.
1.4.9.3.1.2 Enter the numbered items as follows:
Line Instruction
1. The applicant’s number blank is for the convenience of the applicant.
2. The device identification number is for the convenience of the applicant (e.g., catalog
number).
3. Record the date the device was initially installed on the car.
4. Describe the device as it was described on Form AAR 4-2, 4-3, or 4-5, giving function in
accord with the definitions and requirements of Appendix A.
5. Record the total number of cars authorized by the Tank Car Committee to have device
applied and the number of cars covered by the individual report.
6. Record the specific car numbers.
7. Indicate the commodity or commodity type.
8. Indicate the date of initial installation of the device.
9. Indicate the number of loaded trips and total miles the car moved in the period covered by
the report.
Line Instruction
10. Show the total number of loaded trips and the total distance for each car to date for this
service trial. Indicate the average trips and distance for all cars.
11. Indicate the loading temperature of commodity, if known and applicable.
12. Indicate the unloading temperature of commodity, if known and applicable.
13. Indicate the loading pressure, if applicable.
14. Indicate the unloading pressure, if applicable.
15. Indicate the operational or performance difficulties encountered. Specify by car number.
16. These items provide recommendations to the Tank Car Committee.
through
18.
AVERAGES
Fig. 1.6 Form AAR 4-4 AAR Tank Car Service Trial Report
Line Instruction
1. Enter the name and address of the applicant to whom service trial is assigned.
2. Enter the name and address of the device manufacturer, if different than that of the
applicant.
3. The description designation and/or model number of the device should be the same as
4. shown on Form AAR 4-3 (see Fig. 1.3) or Form AAR 4-5 (see Fig. 1.4).
5. Enter the total number of devices of this description or model number in the service trial
sample.
6. Enter the number of devices from the service trial sample that are included in the tests
and inspections reported.
7. Enter the total load/unload cycles, total loaded mileage, and total service time for the
service trial sample and average for the devices to be torn down. (Details for each device
or car should be available on Form AAR 4-4 submitted during the service trial.)
8. Enter actual test conditions to which each teardown sample is subjected (see Chapter 1,
paragraph 1.4.9 for teardown sample size). Comment on test results, physical condition,
corrosion, wear, etc. Compare critical dimensions to original.
9. Show drawing numbers and indicate revisions made during service trial.
10. Conclusions are those of the proponent after the tear down.
11. Recommendations are those of the designated Tank Car Committee observer.
12. The form is signed by the applicant or manufacturer (or agent) performing the tests and
inspections. The signature of the independent observer (if designated by the Committee)
also appears.
13. Upon successful completion based on the comments in Lines 10 and/or 11, the Executive
Director will approve the Final Service Trial Inspection Report and complete the approval
of the Form AAR 4-3 or 4-5, as appropriate.
1.4.10.2.3 The samples examined must have had the full range of service trial experience.
3. Description of device
4. Device designation or model no.
5. Total number of devices in service 6. Number of devices for teardown
7. Service data for service equipment under this inspection
Total load/unload cycles and average Total loaded mileage and average
Total service time and average
AWW DRAFT 09/28/18
Test remarks……………...
Physical condition…….….
Compare critical final
dimensions to original.…..
9. Drawing numbers…….…....
(Ref. Form AAR 4-3 or AAR 4-5)
Revisions made…….….....
Revision date…….….........
10. Conclusions
12. CERTIFICATION
The above data is correct and complies with the AAR Specifications for Tank Cars, Appendix A. Devices tested
conform to the drawings listed above.
(Signature) (Signature)
Title Title
Company Company
Date approved
(Signature) on behalf of Tank Car Committee
Fig. 1.7 Form AAR 4-6 Final Service Trial Inspection Report
1.6.4.1 Table 1.20 lists the documents that must be retained by each certified and registered tank
car facility:
AWW DRAFT 09/28/18
Table 1.20 Documents retained by certified and registered tank car facility
Document Retention Period
Certification/registration of facilities 6 years
Welding procedure and procedure qualification While valid
Performance qualification of welders and operators While valid, plus 90 days
Procedure qualification While valid
NDT written practice While valid
NDT certification records While valid, plus 90 days
NDT procedure requirements While valid
Results of radiographic examinations (radiographs may be retained or discarded) 5 years
Exhibit B-1 Subcontractor’s evaluation sheet (requires an annual review) While valid
1.6.4.2 Table 1.21 lists the documents that must be retained by each registered manufacturer of a
tank car pressure relief device, and service equipment:
Table 1.21 Documents retained by registered manufacturer of tank car pressure relief device and service equipment
Document Retention Period
Final service trial inspection report 2 years
Service trial report Duration of trial
Approval of pressure relief devices 10 years
Approval of valves and fittings 10 years
1.6.4.3 Table 1.22 lists the documents that must be retained by each lining or coating owner: