Shipping Lithium Batteries – Updated for 2022

Lithium batteries can be complicated to ship by air. Most people use the IATA Dangerous Goods Regulations but the lithium battery packing instructions in the IATA book are not like most of the other packing instructions.

To make it easier to ship lithium batteries by air, we’ve prepared a video that goes over the special packaging, marks, labels, and documentation commonly required when shipping lithium batteries by air.

There are changes for 2022 – including the elimination of section II options for shipping batteries under packing instruction (PI) 965! Only section IA and section IB remain in PI 965. But there are still section II instructions in other packing instructions (like PI 966 and PI 967 for batteries packed with and in equipment). So the whole process is just that much more complicated.

As always, I will warn you that the video is only a supplement to our hazmat training. There are required training elements that are covered in the class and are not addressed in the video. But our next class will be held April 19-20, 2022 and you can find out more here. [if you don’t see this until after April 19 then feel free to sign up for our next class]

You can watch the video on youtube or just watch here on our site:

Lithium Battery Shippers Video

“Dangerous Goods in Articles:” The Proper Shipping Name is ALMOST Ready to Be Used in the United States

I was looking at the list of major changes for next year’s IATA Dangerous Goods Regulations. I noticed that the major changes include expanded reliance on the new proper shipping name “Dangerous Goods in Articles.”

As a reminder, Hazmat shippers in the United States should NOT YET be using the proper shipping name “Dangerous Goods in Articles.”

This is a technical variance in what the law allows, but current use of the term in the United States as if it were a hazmat proper shipping name is not permitted, and could become the subject of an enforcement action.

The way that U.S. hazmat regulations work, is that you need to comply with the US regulations, for example, when you choose a proper shipping name for your package, it must be an authorized name. Right now, “Dangerous Goods in Articles” is not an authorized proper shipping name under U.S. law.

You are permitted to rely on the ICAO Technical Instructions when shipping things by air (except where prohibited). When US law permits reliance on an alternative source, that source must typically be incorporated by reference in the U.S. legal structure, which means that typically a specific edition or revision must be referenced. The specific edition of the ICAO Technical Instructions that is currently incorporated by reference is the 2019-2020 edition, which is incorporated at 49 C.F.R. § 171.7.

In the 2021-2022 revision, ICAO published a proper shipping name that will be quite useful to the aviation community: “Dangerous Goods in Articles.” The problem is that IATA immediately included this in the 2021 IATA Dangerous Goods Regulations, but the United States did not immediately incorporate the new ICAO edition by reference.

It is worthwhile to remind the reader that despite bearing the name “regulations” in the title, the IATA Dangerous Goods Regulations are not actually regulations. They reflect a ‘field manual’ for compliance, and they are based on the ICAO Technical Instructions.

The United States regulations still reference the 2019-2020 edition of the ICAO Technical Instructions as the edition that is currently permitted to be used for compliance.

The United States is taking steps to incorporate by reference the 2021-2022 edition (which includes the new term). The Notice of Proposed Rulemaking that will accomplish this was published on August 10, 2021. If you have a comment to share, then you may wish to submit it to the Pipeline and Hazardous Materials Safety Administration. The proposed rule is open for comments through October 12, 2021.

As far as timing goes, there is a good chance that the final rule incorporating by reference the 2021-2022 ICAO Technical Instructions will be published by the end of 2021. And when it is, we should be authorized to use “Dangerous Goods in Articles” when shipping by air. That same U.S. rule making project is also expected to add “Dangerous Goods in Articles” to the United States’ list of proper shipping names in the hazardous materials table (permitting more general use of the term). But that step hasn’t been taken yet.

So please, be patient and wait. The new proper shipping name is coming!

Looking for more hazmat compliance advice? We will be teaching a live, online, hazmat class for shippers of aviation goods next month (October 6-7). See our hazmat training webpage for more details!

Shipping Lithium Batteries

Lithium batteries can be complicated to ship by air. Most people use the IATA Dangerous Goods Regulations but the lithium battery packing instructions are not like most of the other packing instructions.

To make it easier to ship lithium batteries by air, we’ve prepared a video that goes over the special packaging, marks, labels, and documentation commonly required when shipping lithium batteries by air.

You can watch the video on youtube or just watch here on our site:

This is not a stand-alone module; this video training is meant to be a supplement to the full hazmat certification training that we offer. If you haven’t taken that training, then we recommend attending one of our classes so you can understand the scope of your compliance obligations, and then using this video to review how to follow the IATA instructions for shipping lithium batteries (in particular).

Emergency Response Guidebook is Now Available (HazMat)

The 2020 Emergency Response Guidebook (ERG) is now available for download! This book is published every four years as part of a joint effort among Argentina, Canada, Mexico, and the United States. It is intended to be a preliminary guide for first-responders who encounter an accident / spill / leak / release involving dangerous goods (hazardous materials). It is equally valuable, though, for members of the aircraft parts community who might face an accident / spill / leak / release involving dangerous goods in their own facility.

Not sure how to use the Guidebook? You can find instructions within the book, but we also include instruction on how to use the ERG as part of our hazmat class, which is offered twice a year and features discounted class fees for members of ASA (and an extra discount for those who sign up for a 2021 class before the end of 2020).

You can find the English version of the 2020 ERG online, here:

https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/2020-08/ERG2020-WEB.pdf

Also, for your reference a copy can be reviewed, below:

Hazmat: Overpacks of Mixed Materials

One of our trade association members asked whether the materials that are placed into an overpack must be the same, or if they can be different?  We received a related question about whether an overpack can consist of only one item.

An overpack

An overpack. Image from Basic Crating & Packaging, Inc.

What is an Overpack?

When shipping hazardous materials, an overpack is an enclosure used for protection or convenience in the handling of packages.  Examples of overpacks can include properly prepared packages assembled together under shrink-wrap on a wooden pallet, or a set of properly prepared packages placed together into a larger fiberboard box (used as a protective outer packaging).  One key fact here is that there are properly prepared packages of hazardous material, and each such package stands on its own for purposes of compliance to the relevant hazardous materials/dangerous goods regulations.  These properly prepared packages are then placed into another containment, and that other containment is the overpack.

Mixed Material Overpacks

The first member question was whether the materials in an overpack need to be the same substances. They do not. One may overpack different things in the same overpack, as long as no rule precludes them from being packed together.  Examples of rules that would preclude certain materials from being packed together include:

Mixing of materials is also permitted under international standards: there is an example of this in the IATA Dangerous Goods Regulations (61st Edition) at Figure 8.1.K – this figure is a sample Dangerous Good Declaration that shows motor spirits and aerosols being overpacked together.

The United States rules on overpacks are found at 49 C.F.R. § 173.25.

Single-Item Overpacks

The second question we received was about whether an overpack can consist of only one item.  It may.

There is no requirement in the United States regulations nor in the ICAO (IATA) rules that an overpack must consist of more than one properly configured package.  In fact, an overpack may contain one item, or more than one item and it may contain a combination of both properly packaged hazardous materials and also non-hazardous materials.

Examples of situations where you might want to create an overpack for a single properly packaged hazardous material include:

  • Convenience: If one needs to use a forklift to place the item on a high shelf, then one might shrink-wrap the package onto a wooden pallet in order to make it easier to manipulate with a forklift.
  • Protection: If one is expecting the package to be exposed to extreme weather, then one might place a package that is based on a fiberboard box into a plastic drum as an overpack to protect the box from getting wet.

New Hazmat Rules for Shippers

Tomorrow, the Pipeline and Hazardous Materials Safety Administration (PHMSA) will publish a new revision to the United States Hazmat rules.  The new revision is intended to better harmonize United States Hazmat rules with the ICAO Technical Instructions for Shipping Dangerous Goods.  The Technical Instructions are republished by IATA as the IATA Dangerous Goods Regulations and are widely used in the aviation community.

Those who work with standards for cylinders, and those who fill, or service/requalify, cylinders, will want to review these changes carefully.

The changes also better clarify how to identify certain types of vehicles, including remote control aircraft.

Lithium battery special conditions (e.g. special conditions 181-182) are updated.  Section 173.185, which provides the packaging instructions for lithium cells and batteries, is also updated.  Be sure you follow the new labeling and marking requirements!

The new US Lithium Battery Label is authorized for use immediately in 2017

Shippers subject to U.S. jurisdiction are permitted to voluntarily comply with the new rules as of January 1, 2017 (yes, that is three months before the final rule was published).  The mandatory compliance date will be January 1, 2018.

Where Do I Find Lithium Batteries and How Do I Ship Them?

Lithium batteries continue to be a particular concern in the aviation world.  For many aircraft parts distributors, it is important to be able to recognize the presence of lithium batteries in an article or assembly in order to be able to ensure that the article or assembly is shipped properly.

Some known uses of lithium batteries on airplanes include:

  • Flight deck and avionics systems such as displays, global positioning systems, cockpit voice recorders, flight data recorders, underwater locator beacons, navigation computers, integrated avionics computers, satellite network and communication systems, communication management units, and remote-monitor electronic line-replaceable units;
  • Cabin safety, entertainment, and communications equipment, including emergency locator transmitters, life rafts, escape slides, seat belt air bags, cabin management systems, Ethernet switches, routers and media servers, wireless systems, internet and in-flight entertainment systems, satellite televisions, remotes, and handsets;
  • Systems in cargo areas including door controls, sensors, video surveillance equipment, and security systems.

Source: Special Conditions: AmSafe; Non-Rechargeable Lithium Battery Installations, 82 F.R. 14164, 14165 (March 17, 2017).

Once you have identified a lithium battery, you need to ascertain the correct proper shipping name for the battery.  There are currently six main proper shipping names that apply to lithium battery configuration:

  • Lithium Ion Batteries
  • Lithium Ion Batteries Contained in Equipment
  • Lithium Ion Batteries Packed with Equipment
  • Lithium Metal Batteries
  • Lithium Metal Batteries Contained in Equipment
  • Lithium Metal Batteries Packed with Equipment

Each of these proper shipping names leads to a different packing instruction or packing regulation, and different standards for how to identify, package and ship the articles.  Most aircraft batteries are lithium ion, but it is important to properly classify the battery before you ship it.

The rules concerning shipping lithium batteries as hazardous materials (US term) or dangerous goods (international term) have been changing frequently in recent years.  This is meant to ensure that they are shipped safely, based on the latest knowledge.  But these changes in the standards can make compliance difficult.  In order to ensure compliance, we recommend that you always do these things:

  • Before you even consider shipping a hazardous material, make sure you are trained and that your training is current (it’s the law!);
    • We offer a live, interactive, online course for hazmat certification;
  • Pick up the current version of the relevant regulations (e.g. US DOT regulations or the ICAO Technical Instructions) and read the relevant requirements;
  • Read through the packing instruction or packing regulation carefully (yes, even though you know it, read it again, right before using it);
  • Identify what subsection of the packing instruction or packing regulation applies to your shipment (there are usually tw0 [I/II] or three [IA, IB, II] different subsections that could apply in each IATA/ICAO packing instruction – you must choose the correct subsection based shipping configuration factors like mass, watt-hour rating, number of batteries, etc.);
  • Follow the instructions carefully and don’t get mixed-up (when using the IATA DGR Packing Instructions, you should be following the instructions in your proper subsection and also the general instructions at the beginning of the packing instruction that apply to all of the subsections).

On April 5-6, 2017 we will be conducting an online class on how to ship aircraft parts when the parts are characterized as hazardous materials or dangerous goods. The class includes units and exercises designed to help you identify hazardous materials in aviation, in addition to teaching you how to package, identify and ship them.

Those who successfully pass the course will be certified in accordance with US DOT regulations and IATA/ICAO standards.  The class is inexpensive and there are additional discounts for trade association members.  It is also a live, online class.  Since it is taught online, you can participate from the comfort of your own desk, with no need to travel.  Since it is also live, you can ask the instructor questions and get answers immediately.

FAA Reauthorization Sets the Stage for 21st Century Aviation Oversight

I almost published this under the title “Congress Seeks to Privatize Air Traffic Control.”  Because that is the real headline.  And tomorrow, I expect that there will be newspapers that have headlines quite similar to that one.

But for the aviation parts community, the devil is always in the details.  Details like properly completed 8130-3 tags, Spec 106 parts/material certifications, and unusual occurrence statements.

Today, Congress published proposed legislation (known as the AIRR Act) to reauthorize the FAA and the biggest headline in that bill is air traffic control.  But there is plenty in this bill that could affect the rest of the industry.  Here is a quick summary of some items that may affect members of the ASA community:

Sec. 302. Safety Oversight and Certification Advisory Committee.  Congress is establishing an advisory committee that will be responsible for advising the Secretary of Transportation on policy-level issues related to FAA safety certification and oversight programs and activities.

Sec. 311. Aircraft certification performance objectives and metrics.  The FAA shall establish metrics for progress toward increasing certification efficiency, increasing accountability, “achieving full utilization of FAA delegation and designation authorities,” implementing risk management and systems safety principles, increasing transparency, training personnel in auditing systems and maintaining the leadership of the United States in international aviation and aerospace.

Sec. 312. Organization designation authorizations.  Establishes a new provision in the US Code for ODAs.  ODAs shall have a procedures manual, shall be entitled to full delegation of functions approved in the manual, but shall be subject to regular FAA inspection.  ODA holders shall cooperate fully with the FAA oversight activities.  FAA shall establish an ODA Office to coordinate ODA policy and oversight.
Sec. 314. Type certification resolution process.  Requires FAA to set policies and timelines for resolving type certification issues, and for elevating them when they cannot be resolved at the lower levels of the FAA.

Sec. 315. Safety enhancing equipment and systems for small general aviation
airplanes.  Requires FAA to streamline the installation of safety enhancing equipment and systems for small general aviation airplanes in a manner that reduces regulatory delays and significantly improves safety. This is something that the FAA has been working on already so they should be prepared to meet Congressional deadlines.

Sec. 317. Additional certification resources.  If the FAA needs to travel to a foreign country to help expedite the process of acceptance or validation of a US certificate, then the US applicant can reimburse the FAA for travel expenses (which makes it easier for the FAA to contribute to such efforts).  The FAA will have to keep metrics on this, including how often requests from US applicants to enter into such an arrangement were denied.

Sec. 331. Flight standards performance objectives and metrics.  The FAA shall establish metrics for progress toward eliminating delays in flight standards activities, increasing accountability, increasing use of delegation, increasing use of risk management principles, eliminating inconsistencies, and creating a streamlined appeal process for interpretations.

Sec. 332. FAA task force on flight standards reform.  Establishes a task force to study ways to make the Flight Standards Service better, including achieving more consistent regulatory interpretations.
Sec. 333. Centralized safety guidance database.  Create a database of aviation safety documents, with links to the regulations that they interpret.  This will include “acceptable means of compliance” documents.

Sec. 334. Regional Consistency Communications Board.  Establishes a Board that will help harmonize the guidance given by different offices.

Sec. 351. Promotion of united states aerospace standards, products, and services abroad.  This section gives the FAA promotion responsibilities, which were taken out of the law a number of years ago.  This limited promotion authorization is focused on international promotion, like promoting United States aerospace safety standards abroad, and facilitating and vigorously defending approvals of United States aerospace products and services abroad.  It will also reiterate our commitment to working with bilateral partners.

Sec. 352. Bilateral exchanges of safety oversight responsibilities.  Includes a requirement for the FAA to accept foreign airworthiness directives (ADs) issued by bilateral partners.  This could impose an unworkable burden on smaller US companies to track foreign AD proposals, because it will mean that the US companies will have to comment on the foreign AD, because it will have no reasonable opportunity to comment on a US version if the FAA is required to accept foreign ADs.

Sec. 353. FAA leadership abroad.  This will require the FAA to better support US companies in foreign acceptance or validation projects.  one clear element of this will be through increased US engagement with foreign authorities.

Sec. 613. Aircraft registration.  Increase the term of an aircraft registration for a noncommercial general aviation aircraft to 10 years.

Sec. 615. Air transportation of lithium cells and batteries.  The government will establish a committee, and try to make sure that people actually comply with lithium battery shipping requirements.

Reauthorization is often a slow process, but the last reauthorization bill was a six month extension that went into effect October 1, 2015.  That means that the new reauthorization bill is needed by April 1, 2016.  It is possible that this ATC privatization may be contentious (General Aviation groups contend that it is an effort to shift the expense of maintaining the system into their pockets) and that could slow down the progress of the AIRR Act.  If the AIRR Act cannot be passed by April then we could see another temporary reauthorization (e.g. for another six months).  But it is possible that the AIRR Act could move on a fast track, and become law, later this Spring.

Can Factory New Parts Be Hazmat?

Recently, an ASA member asked me whether factory new parts could be hazardous materials.  This is an important question because if the parts are treated as hazardous materials, then they must be shipped in compliance with the hazardous materials regulations.

The answer to the question depends on whether the units have hazardous materials (or dangerous goods) in them when they are shipped.

Some factory new parts are intrinsically hazardous materials.  A factory new self-inflating life raft is likely to be considered a hazardous material because it has a compressed gas cylinder in it, and this makes it a “life saving appliance, self inflating” which is regulated under UN number 2990.

Other articles, though, may be conditional hazmats.  That is, the article may or may not be a hazardous material depending on whether the unit has yet had hazardous material introduced into it.  Fuel system components can be a good example.  After they have had fuel run through them, the fuel residue generally makes the fuel system component a hazardous material (known as “dangerous goods in apparatus”).  But before fuel has ever run through the fuel system component, it may not be a hazardous material.

Reading that last sentence, you may be expressing frustration over a lawyer’s unwillingness to commit.  “[I]t may not be a hazardous material”?  How about taking a stand?

But with some engine components, even a factory new and unused part might be a hazardous material.  Even without fuel residue, new parts and overhauled parts may contain a preservative or calibration fluid that is a hazardous material.  The preservative may be treated as a “petroleum distillate” that is regulated under UN 1268.  Even if the amount that remains is only a tiny residue, this residue in an engine part will cause the engine part to be treated as a “dangerous goods in apparatus.”

One important rule of thumb is that if you can smell a substance in the aircraft part, then there is at least an appreciable residue that remains (that’s what you are smelling).  And if that residue is a hazardous material then the larger article is likely to be regulated as a hazardous material if it is shipped with the hazardous residue.

The best source of information about what is in you parts is going to be the manufacturer, who can tell you what chemicals or other hazards might be found in their part.

Once you’ve identified the chemical(s), the best source of information about the chemical is the manufacturer of the chemical (and their MSDS).  This is usually idfferent from the “OEM of the part.  I once encountered a calibration fluid that the engine OEM said was not a hazmat, but the label on the chemical’s packaging specified that the chemical was, in fact, a hazmat.  We double-checked with the chemical manufacturer and confirmed that the fluid was a hazmat.  So research carefully, and be sure to check what you learn!

Late Civil Penalty Payments Could Halt Your Business

The FAA issues civil penalties.  Sometimes the amount is low and the company agrees to pay the civil penalty even in cases where the penalty is undeserved.  But what happens if you are late paying a civil penalty?  In the past, the U.S. government would become a creditor like any other (albeit one with a lot of lawyers on staff); but after September 7, 2014, the regulations will prevent you from engaging in certain activities if you fail to pay your civil penalty in a timely fashion:

49 C.F.R. Sec. 109.101
* * *
(b) Failure to pay civil penalty in full. A respondent that fails to pay a hazardous material civil penalty in full within 90 days after the date specified for payment by an order of the … Federal Aviation Administration … is prohibited from conducting hazardous materials operations and shall immediately cease all hazardous materials operations beginning on the next day (i.e., the 91st). The prohibition shall continue until payment of the penalty has been made in full or at the discretion of the agency issuing the order an acceptable payment plan has been arranged.

This means that if you are late paying a civil penalty, shipping a hazmat aircraft part would become a violation that warrants a separate civil penalty (even if the shipment is otherwise proper)!

How broad is this limit?  For some aircraft parts distributors, this could be very broad indeed because many aircraft parts are regulated as hazmats.  The preamble to the new rule clarifies that this is intended to halt any activity regulated under the hazardous materials regulations.  This would include shipping of aircraft parts that are regulated as hazmats (also known as dangerous goods).  This includes obvious hazmats like explosive squibs and chemical oxygen generators  but it also includes less obvious articles like:

  • compressed gas cylinders
  • engine and fuel system parts with fuel residue
  • passenger service units with installed oxygen generators
  • avionics or data recorders with back-up batteries
  • batteries
  • self-inflating articles like slides, rafts and life preservers
  • many first aid kits

This highlights the importance of (1) mounting an effective defense to proposed hazmat civil penalties, and also (2) paying civil penalties that have become final in a timely fashion.  Note that appealing the ruling DOES NOT stay the execution of this provision, so if you appeal the ruling, then you will have to ask the appellate court to grant a stay.

49 C.F.R. Sec. 109.101
* * *
(d) Appeals to Federal Court. If the respondent appeals an agency order issued pursuant to Sec. 109.103 to a Federal Circuit Court of Appeals, the terms and payment due date of the order are not stayed unless the Court so specifies.

The new provisions are published in today’s Federal Register at http://www.gpo.gov/fdsys/pkg/FR-2014-08-07/html/2014-18617.htm