2024 Chem-E-Car Rules Asc Final 8.2.2024

2024 Student Regional Conference Competition Official
Rules
Date Checklist of Important Deadlines
Find your Conference at www.aiche.org/conferences/student

□
Review Rules, EDP Document & Safety Training information at
www.aiche.org/chemecar
Submit questions at www.aiche.org/chemecarquestions
All teams are required to complete and submit an Engineering Documentation Package
□ (EDP) 5 weeks before competition date.
February 9th -
August 31st Teams will receive EDP Review Feedback on the safety aspects of their design so they
can prepare for the On-Site Safety Inspection.
In-Person EDP Submission Link
Bring all items to On Site Safety Inspection & Competition

 Poster
□ Competition  Printed EDP, EDP Supplement and MOC Form in binder/folder
Weekend  Printed EDP Review Feedback
 Printed Waste Tags to use at competition
 Chem-E-Car
 PPE for all team members
 Portable personal electronic device covers
Summary of Changes, February 2024 Revision

Changes to Competition Rules
a. Clarifications were added to the Chem-E-Car Competition Overview to encourage safer practices
Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions
1
before students begin working on their vehicles and to explain what resources will not be
available at the Annual Competition vs. some regional competitions.
Changes to Safety Rules

a. The following rules have been edited to enhance clarity and to provide additional safety guidance
and resources surrounding gases and pressure: 1.1.10 Hydrogen Gas Discharge Calculations ,
8.1.1 Hydrogen Discharge, 9. Reactive Materials, 18.2 Sizing Calculations
Chem-E-Car Competition Overview
The objectives of the AIChE Chem-E-Car Competition:
 To provide chemical engineering students with the opportunity to participate in a team- oriented
hands-on design and construction of a small chemical powered model car;
 To demonstrate the ability to safely control a chemical reaction by changing a chemical
reactant(s);
 To design and construct a car that is powered with a chemical energy source that will travel a
given distance and stop;
 To encourage students to become actively involved in their professional society;
 To increase awareness of the chemical engineering discipline among the general public, industry
leaders, educators and other students.
There are two general competitions. The first is held at regional conferences and the second is held at the
Annual Student Conference at the site of the AIChE Annual Student Conference.
No chemical or mechanical work should be completed on your car until an initial safety review has been
conducted by your Chem-E-Car Advisor or outside expert. The Safety Training Course & Quiz training should
also be completed before you begin work.
Please note that the Regional Competitions and Annual Competitions are separate competitions. Passing
the safety inspection at the Regional Chem-E-Car Competition does not guarantee that your team will
pass the safety inspection at the Annual Student Conference Chem-E-Car Competition. Additionally, you
will not have access to the same resources at the Annual Competition that you might have at the Regional
competitions and vice versa. Fume hoods and air compressors will not be available at the Annual
Competition. If you have any questions about what will be available to you at Annual, please reach out to
the Chem-E-Car Committee via the Questions Form.
All Chem-E-Car Teams must be from active Student Chapters that submitted a Student Chapter Annual
Report online to AIChE. Visit www.aiche.org/studentchapterannualreport to submit a report.
There is a poster session, safety inspection and a performance session at each competition, as detailed
below.
During the competition, each team will be asked to introduce its entry to the audience, giving the school
name and briefly discussing the propulsion and stopping mechanisms. Teams will also have the
2
opportunity to submit a video showcasing their team at the Annual Student Conference competition.
Regional Conference Competition
 Schools may be limited to one entry per University, at the discretion of the Regional Conference
Host Chapter and Regional Safety Coordinator
 The official rules listed apply for the regional conference competition and the Annual Student
Conference Competition.
 An AIChE-appointed safety and rules coordinator will attend each regional competition. This
coordinator is the final authority regarding Chem-E-Car Competition® rules, safety concerns,
violations, disqualifications, and the like, for that Regional Competition only.
 The coordinator's judgment applies only to the regional competition and is not binding on
judgments at the competition at the Annual Student Conference.
Regional Conference Awards
Sponsored by
 Performance Competition: 1st place: $200 & 2nd place: $100

 Poster Competition: 1st – 3rd Place: Certificates
Annual Student Conference Competition
The top teams from Regional Chem-E-Car Competitions will be awarded the opportunity to compete at
the global competition taking place at a future AIChE Annual Student Conference in the United States.
This is the only way to earn an invitation to this global event.
North America Regionals
 Mid-America: Top 3
 Mid-Atlantic: Top 5
 North Central: Top 5
 Northeast: Top 3
 Pacific Northwest: Top 2
 Rocky Mountain: Top 3
 Southern: Top 5
 Southwest: Top 2
 Western: Top 3
International Regionals
 Brazil Top 1
 China Top 3
 Latin America Top 1
 India Top 2
3
 Indonesia Top 1
 Middle East Regional Top 3
Only one entry per school, via this qualifying procedure, will be allowed at the Annual Student
Conference competition no matter how many compete at regional competitions
NOTES:
 If your team participated in a regional conference but did not qualify, or if your team is located in a
region that does not offer a regional conference, you may fill out the Chem-E-Car waitlist form,
released annually and linked here, to be added to the waitlist sometime in July or August, 2024.
Annual Student Conference Competition Awards
Sponsored by and the H. Scott Fogler Endowment Fund
The Annual Student Conference Competition associated awards are:

 The H. Scott Fogler 1st place award: $2000 USD and a trophy
 2nd place: $1000 USD and a trophy
 3rd place: $500 USD and a trophy
 4th & 5th place – trophy
 Best Use of a Biological Reaction to Power a Car sponsored by the Society for Biological
Engineers- $500 USD
 SAChE Safety Award for the best application of the principles of chemical process safety -
trophy
 Spirit of the Competition for the team displaying the most team spirit as decided by a panel
of judges- trophy
 Most Innovative Car Design to be decided by judges - trophy
 Golden Tire Award for the most creative car as decided by the teams- trophy
 Best Video – trophy
 Chem-E-Car Poster Award – 1st- 5th place- trophy
 Outstanding Sportsmanship Award- trophy
 Best Team Name- trophy
Chem-E-Car Competition Poster Session & Safety Inspection Rules
1. Poster overview:
1.1. A poster board must be displayed with the autonomous vehicle on the day of the
competition. This poster should clearly describe:
 How the car is powered by a chemical reaction
 How it stops on a chemical reaction
 Unique features of the car
4
 Environmental and safety features in the design
 Vehicle design description, drawings and testing results
2. Team Members:
2.1. The poster competition and judging will occur prior to the Chem-E-Car Performance
Session. Team members must be present during judging to answer questions from the
judges.
3. Minimum Score:
3.1. A team must achieve a passing score in the poster competition to be able to advance to the
Chem-E-Car Performance Competition. Posters will be judged according to the following
criteria:
 Quality of the poster and team member presentations (50%)

 Design creativity and unique features of the vehicle and safety considerations (35%)
 Demonstration of knowledge of reactions, calibration methods by all team members, and
ability by team members to answer questions posed by the judges (15%)
4. Winners:
4.1. Winners of the poster competition will be announced at the end of the performance
competition.
5. Safety inspection:
5.1. During the poster competition, an audit team will inspect each vehicle to ensure that all of
the safety requirements have been met and that the vehicle will operate without risk to the
operators, contest staff and spectators.
5.2. If the audit team deems the vehicle safe to operate, then the vehicle will be given
permission to compete.
5.3. This permission is not automatic and must be earned by adhering to the
guidelines/procedures outlined below. If a car is deemed unsafe, then it will not be given
permission to compete.
5.4. The Chem-E-Car Competition Safety Judges at the competition site have the final say in
regard to permission to compete, regardless of whether a car was given permission to
operate at a previous Regional competition.
Chem-E-Car Competition Performance Session Rules
6. Distance
6.1. Each car will be given two opportunities to traverse a specified distance.
6.2. The required distance will be given to each team one hour prior to the start of the
performance competition. The distance will be between 15 and 30 m ± 0.005 m.
6.3. Teams may not make significant changes to their vehicle once the poster session has
concluded, unless they have prepared, and have an approved management of change
(MOC). Teams are only allowed to adjust "fuel" or chemical reactants used in the car's
5
chemical reaction.
6.4. The distance will not change for the final round.
7. Course Layout and Distance Measurement

7.1. The course will be no more than 5 meters wide in a straight line. For regional virtual
conferences the course may be less than 5 meters wide, depending on the university track location.
7.2. At the Regional Competitions only 1 track will be used. At the Annual Student Conference
Competitions, 2 identical tracks will be set up and run in parallel.
7.3. The car will start with its front end just touching the designated starting line, with the goal of
keeping the car in bounds to a designated finish line. The performance is determined by the
distance from the front-most point of the car to the finish line, whether or not the car stops
before or after the finish line.
7.4. A vehicle that goes out of bounds will be given a penalty for that run of 3 meters.
7.5. “Out of bounds” is defined as when any part of the car crosses or touches the boundary. If
tape is used to mark the side boundary or the out-of-bounds after the finish line, the inside
edge of tape is considered the course boundary (If a wall is set as track boundary then
contact with the wall is out of bounds).
7.6. If the car starts going backwards at the starting line, the score will count as 0m traveled.
7.7. The site location may also dictate an out-of-bounds region past the finish line. Vehicles
traveling across the plane of the out-of-bounds region will be disqualified for that attempt.
6
Figure 1: Performance course layout. Camera guidelines apply to Virtual Competition only.
8. Race Logistics
8.1. A Chem-E-Car Competition® judge (or MC) will announce each team just prior to the start
of their attempt.
8.2. Each car will have two (2) attempts to complete the course. Each attempt is limited to a two
(2) minute time limited for the car to start and completely stop. Any car that does not stop
within the two minutes will be disqualified for that attempt.
8.3. The best score of the two attempts will be used to determine the winner.
8.4. In the event that a team fails to show up on the starting line, or the vehicle fails to start, the
7
next team in the order of the competition will be announced and requested to proceed to the
starting line immediately.
8.5. The competition order will not change between the first and second rounds. There will be a short
15 minute break between rounds of the competition.
9. Starting Line Procedure

9.1. The car must start moving, traverse the distance, and come to a stop within a 2 minute time
interval.
9.2. At the starting line, 1 team member will be asked to head to the finish line. Team members are
responsible for picking up their car after the distance is measured.
9.3. Once the car is placed on the starting line and the 2 minute time interval begins, all wheels must
remain on the ground. Pushing the car or picking up the car/part of the car will result in a
disqualification for that attempt.
10. Competition Order Logistics

10.1. The distance and run order is announced one hour before the competition starts.
10.2. If a car is disqualified that was scheduled to start before your car, then you will move up
one position in the starting order.
10.3. Five (5) minutes before the start of the competition, the first three (3) teams for each track
are called to the start. The first team for each track will be at the starting line, the second
team at the ready table, and the third team beginning to move to the “at ready” position.
10.4. The first team is given a one-minute warning before the competition starts.
10.5. Each team is given two (2) minutes for the car to start moving from the time they are
called to the starting line.
10.6. Cars are permitted two (2) minutes to traverse the distance and stop.
10.7. The timing will also stop if the car travels out of bounds.
10.8. If the car does not stop within the two-minute period, then it is disqualified from that
round of the competition.
10.9. After the car stops, the distance traveled is measured. Once the distance measurement is
completed, the next team moves from the ready table to the starting line.
10.10. Repeat 10.5 – 10.9 for the remainder of the competition.
11. Vehicle Drive System

11.1. An objective of this contest is for students to demonstrate the ability to control a chemical
reaction.
11.2. The only energy source for the propulsion of the car is a chemical reaction.
11.3. The distance a vehicle travels must also be controlled by a chemical reaction, based on a
quantifiable change and direct control of the concentration of a chemical species.
11.4. This chemical reactant species must be a solid, liquid, or vapor.
12. Vehicle Design

12.1. Vehicles entered into the competition must have a significant and demonstrable student
design component, particularly with respect to the vehicle drive system, and the starting and
stopping mechanisms.
12.2. Both the chemical reaction propelling the vehicle and the start/stop reaction (if there is
8
one) must be physically on the vehicle during the competition (i.e., pre-loading of a drive
system such as a capacitor assembly is not allowed).
12.3. The vehicle must be powered by a chemical reaction and must be stopped by a
quantifiable change, and direct control, of the concentration of a chemical species.
12.4. This chemical reactant species must be a solid, liquid, or vapor.
12.5. Autonomous vehicle: The car must be an autonomous vehicle and cannot be controlled
remotely. Pushing to start the vehicle is not allowed. Any forward movement of the car at
the start not related to the chemical reaction will lead to disqualification. “Bleeding” the
time off at the starting line or prior to the starting line is prohibited. Raising the vehicle at
the starting line to allow the wheels to begin turning is not allowed.
12.6. On-board computer control system (ex Arduino or Raspberry Pi unit) are allowed
but must not in any way control/ measure the distance traveled. The program must be
loaded onto the controller/computer/processor prior to the competition, and the settings may
not be changed after the competition begins, which is defined as the time when the
distance is announced.
12.7. Wired or wireless communication with the on-board computer/controller is not allowed
once the competition begins and during the competition.
12.8. Teams may be asked to provide a copy of their complete programs to the rules committee
on the competition day.
12.9. Encoders: Teams are also not allowed to use an encoder to regulate the velocity of the
vehicle in order to control the distance.
12.10. No Mechanical brakes: No mechanical force can be applied to the wheel, gears,
driveshaft, etc., or ground to slow or stop the car (e.g. no brakes).
12.11. Mechanical or electronic timing devices: There can be no mechanical or electronic
timing device(s) to stop the chemical reaction or stop the car. In addition, a timing device
cannot utilize what is normally considered as an instantaneous reaction. For example, a
constant or draining liquid feed to a sensing cell that employs an instantaneous reaction
(such as acid-base or precipitation) would not be allowed. Another example would be a
liquid draining out of a vessel to serve as a stop switch. This would be considered a
mechanical timing device and would not be allowed.
12.12. ICE: Internal combustion engines using an alternative fuel (e.g., biodiesel, ethanol, etc.)
are allowed. The fuel MUST be completely synthesized by the students (no additive
blending is allowed). Succinct safety procedures for the maintenance and operation of this
engine must be demonstrated by the team, with considerations to indoor operation. Internal
combustion engines are not allowed to emit visible combustion smoke to the competition
space and are subject to sound restrictions. See the Safety Rules for a more complete
discussion.
12.13. Thermo-Electric Device (Power system): Thermo-electric thermopiles purchased from
a manufacturer must be run with at least one side (hot or cold) controlled by a chemical
reaction. NOTE: Phase changes (including melting and crystallization), mixing and
dissolutions are not considered a chemical reaction.
12.14. Fuel Cells: Any vehicle that is purchased from a vendor without major modifications to
its operation will be disqualified. For example, a team could not purchase a fuel cell car and
race this car without any modifications. Any team that purchases a commercial fuel cell or
builds their own fuel cell must synthesize the fuel that is used; example, if the team
purchases a commercial methanol fuel cell, they must synthesize the methanol and provide
9
verification of their procedure. Hydrogen for fuel cells MUST be generated by a chemical
reaction on site and or on the vehicle and not from a commercial device or pre-loaded
canister. Appropriate process safety must be followed during fuel synthesis. The synthesis
procedure must be clearly defined in the EDP.
12.15. Commercial batteries: No commercial batteries of any kind (for example, AA batteries)
are allowed as the power source. Commercial batteries are allowed for specialized
instrumentation (e.g. detectors, sensors, valves).
13. Size of Car

13.1. All components of the car must fit into a box of dimensions no larger than 40 cm x 30 cm
x 20 cm. The car may be disassembled to meet this requirement.
13.2. If the judges are uncertain whether the car will fit inside the box when dissembled, they
may request that the team demonstrate that they can do this.
14. Capital Cost of Vehicle:

14.1. The cost of the all vehicle components and the chemicals must not exceed $3500 USD. The
vehicle cost includes the donated cost of any equipment.
14.2. The time donated by university machine shops and other personnel will not be included in
the total price of the car. It is expected that every university has equal access to these
resources.
14.3. The cost of pressure testing is also not included in the capital cost of the car.
14.4. The method used to estimate the donated cost of the equipment must be shown. It is
expected that standard financial procedures will be used to estimate this cost.
14.5. Teams are required to include their vehicle’s capital cost in their EDP.
15. Team Member Status and Conduct

15.1. All team members must be active AIChE members and must be registered for the
Regional Conference or Annual Student Conference.
15.2. Faculty and graduate students can only act as sounding boards to student queries. The
faculty cannot be idea generators for the project.
15.3. There is no restriction on requesting assistance on vehicle safety – teams may request
safety assistance from their faculty advisor, other faculty members, other universities, and
professional practitioners in industry and elsewhere.
15.4. All questions posed by rules and safety judges at the safety inspection and poster session
must be answered by the undergraduate student team members. The ability to explain car
design, operation, safety and/or rules compliance is the responsibility of the undergraduate
students.
15.5. The students working on the project must sign a statement saying they have read,
understand, and abided by the rules. This statement must be included in the EDP.
15.6. For in-person: During the performance competition session, only five (5) team members
are allowed in the pit area at once. Team members can be swapped out during the
competition. For Virtual: During the performance competition session, teams are not limited
10
to a specific number of team members that are allowed in the pit area.
15.7. All team members and the faculty advisor MUST have completed the required safety
training course, which is available at www.aiche.org/chemecar. All participating students
must retake the course annually.
15.8. All student chapter teams that are competing in the Chem-E-Car Competition must have
submitted a Student Chapter Annual Report online to AIChE. Note: New AIChE Student
Chapter established after January 1, 2023 are exempt from this requirement.
16. Winning Team and Awards

16.1. The winning team is the car that stops closest to the competition distance. This is defined
as the absolute value of the distance between the front-most part of the car and the finish
line, whether or not the car stops before or after the finish line.
16.2. In case of ties, the team with the best average from the two attempts may be declared the
winner.
16.3. Winners of the Chem-E-Car Performance Competition will be known immediately
following the performance competition.
17. Onsite Safety Judges and Rules Coordinators: If there is any uncertainty on an issue of safety or other
judging criteria, please contact the Chem-E-Car Committee. The decisions of the onsite rules and
safety judges are final.
11
2023 Student Regional Conference Competition Safety
Rules
Chem-E-Car Safety Program Overview
The objectives of the AIChE Chem-E-Car Competition Safety Program are to ensure the safe preparation
and operation of vehicles during all phases of the competition, including construction, testing and the
competition. An audit of your system design and safety compliance will be conducted from the
documentation your team provides.
The safety audit of your vehicle will occur in two stages:
 Online audit where teams will submit a fully completed Engineering Documentation Package
(EDP) electronically and receive feedback. A member of AICHE staff will communicate EDP
instructions to all teams. Failure to meet the posted deadline and by not submitting a fully
completed EDP will result in exclusion from the competition. The EDP template is available for
download on the Chem-E-Car Competition Rules Website at www.aiche.org/chemecar.
 In Person: Onsite Audit on competition day where teams must bring printed EDP, EDP
Supplement, EDP feedback and MOC Form in a folder or binder and be ready to answer
questions from safety reviewer. In the event that a virtual competition is required: Onsite Audit
will be done ahead of the competition day by the Onsite Safety Judge; teams must provide
printed EDP, EDP Supplement, EDP Feedback and MOC Form in a folder or binder Failure to
pass this stage of the competition will result in receiving a disqualification from the competition.
Competition Safety Rules
1. Safety Audit: Online

1.1. EDP. An engineering documentation package (EDP) for your Chem-E-Car must be fully
completed and submitted by the posted deadline. A complete EDP will include the
following in the following order:
1.1.1. Job Safety Analysis: Includes a description of your car and how it works.
1.1.2. Photos: Pictures of your vehicle after construction has been completed. These
pictures must be current. The entire car must be visible in the picture. Remove the
12
top to expose electrical controls if necessary. Multiple detailed views of the car are
required. A drawing or AutoCAD document is NOT acceptable.
1.1.3. Safety Training and Rules Certifications Page: This page must be signed by all
team members and your faculty advisor. Judges will use this page to determine: (1)
If the starting and stopping mechanisms are compliant with the rules, (2) If everyone
has completed the required safety training and (3) that you have identified the major
hazards and have controlled them properly. The certification page must be signed
by the date of the competition. Note that your group must have a minimum of 10
hrs. of operating time on the car prior to the faculty member signing. Note: The
time you spend building the car cannot be counted as operating time.
1.1.4. Hazards Analysis: Complete all pages, including attaching the floor
plan/diagram of the laboratory where you are building your car.
1.1.5. Chemical Information: Includes a description of the chemistry involved, and a
list of chemicals to be sent to the competition if in person, or to be used at the
competition, if virtual
1.1.6. Chemical Hazards and Disposal: This section requires your team to conduct
chemical research related to the chemicals you handle. List the properties for every
chemical. Refer directly to the SDS for this information Resources like the NIOSH
pocket guidebook, CAMEO, and New Jersey Hazardous Substance Fact Sheets can
be used for supplemental information as needed.
1.1.7. Standard/Safe operating procedures page: Provide step-by-step details for the
safe start-up, operation, shut-down, and clean-up of your vehicle. This page should
be detailed enough so that someone unfamiliar with your vehicle should be able to
safely prepare solutions for and operate it.
1.1.8. Equipment Table: A complete list of every piece of equipment on the car in
table format, including the manufacturer of each piece of equipment. Include
operating limits (max temperature and pressure) for each piece of equipment, and
ensure material compatibility where pertinent. When manufacturing spec sheets are
absent, students should rely on the material properties for these limits.
1.1.9. Pressure: For Cars with Pressure Greater than 5 psig (0.345 barg): Please
complete and add the following to your EDP document: A quantitative design basis
for pressure relieving load; Sizing calculations for a pressure relief device; and Test
procedure and results for a pressure relief. Please see Appendix A of the Safety Rules
for full instructions on what is required for Pressure Testing.
1.1.10. Hydrogen gas discharge calculations (include for any flammable component).
If you are using hydrogen gas, and plan to discharge a small amount, you must
provide calculations demonstrating that the discharge stream is below the LEL/LFL
when mixed with ambient air. State any assumptions you make regarding the
ambient air flow rate.
1.1.11. Management of Change Form: After the online EDP review, you must complete
any changes suggested by the EDP Reviewer and document these changes in the
Management of Change (MOC) form. This MOC must be presented during the
onsite safety inspection.
13
1.2. EDP Supplement. Please combine the following information in another single, separate
PDF and should be titled “University Name EDP Supplement”.
1.2.1. Safety Data Sheets (SDS) made or revised after 2012 for all chemicals used or
generated by reaction.
1.2.2. Manufacturer’s specification documents or specifications for custom-built
components. For any commercial or custom built components, students must list
material and compatibility.
1.2.3. Safety Training Course Certificates for each team member + Advisor
1.2.4. Any additional information you need to save regarding your EDP that is not
contained within the original EDP document.
2. Safety Audit:
2.1. Onsite (In-person). On the day of the competition, an audit team will inspect each
vehicle to ensure that all of the safety requirements have been met and that the vehicle
will operate without risk to the operators, contest staff and spectators. The Safety Judges
at the competition site have the final say in regard to permission to compete, regardless
of whether a car was given permission to operate at a previous regional competition.
2.2. Virtual. During the Safety Inspection, a faculty member serving as the Onsite Safety
Judge will inspect the team’s vehicle to ensure that all of the safety requirements have
been met and that the vehicle will operate without risk to anyone present at the
competition site. The safety Judges at the competition site have the final say in regard to
permission to compete, regardless of whether a car was given permission to operate at a
previous regional competition.
2.3. Permission to compete. If the audit team deems the vehicle safe to operate, then the
vehicle will be given permission to compete. If a car is deemed unsafe, then it will not be
given permission to compete therefore rendering it unfit to run during the performance
competition.
3. Disallowed Chemical Handling/ Illegal Chemical Transport & Storage

3.1.1. Transport Chemicals. Teams are not allowed to transport hazardous chemicals
by car to the competition site. No chemicals should be transported in private,
university or rental vehicles to and from the competition site, even over short
distances.
3.1.1.1. Household Chemicals. Common household chemicals, in the
concentration in which they are sold, such as baking soda, vinegar, etc., are
exempt from this rule. To qualify as a common household chemical, the
chemical must be available for purchase and pickup from a retail location such
as a grocery or hobby store.
3.1.2. Shipping Chemicals. Chem-E-Car teams should work with their University EHS
department to make sure everything is shipped according to all DOT Hazardous
Material Shipping laws. Make sure everything is properly labeled.
14
3.1.3. Illegal Chemical Storage. Chemicals must not be stored in hotel rooms or other
facilities not rated for chemical storage. The exception to this rule is common
household items such as baking soda and salt.
4. No Compressed Hydrogen Gas Cylinder Usage

4.1. Hydrogen Generation. All hydrogen used on the vehicles (for instance with fuel cells)
must be generated on-site or on the vehicle keeping the pressure below 5 psig (0.345
barg). Appropriate safety precautions and safe operation must be demonstrated.
Hydrogen generation cannot begin until chemicals are given out on competition day.
4.2. Commercial Hydrogen Storage Canisters. Filling of vessels from a compressed
hydrogen gas cylinder or commercial hydrogen storage canisters (such as hydrostiks or
solid–core hydrogen cartridges) will not be allowed.
5. Illegal Testing of Vehicles

5.1. Testing Location. Testing of vehicles must only be done in a laboratory or other
facility with chemical handling capability. Testing in hotel or dorm hallways,
warehouses, or other facilities that are not designed for chemical handling is not allowed.
No mixing of chemicals, including common household chemicals is allowed in the hotel
or in dorm hallways.
6. Disposal of Chemicals. Disposal of waste represents both significant risk and cost to the
competition. Teams are expected to be knowledgeable in all of their generated waste streams.
All chemicals shipped to and waste generated from the competition site must be disposed of
in a safe and environmentally friendly fashion in compliance with all local, state and national
regulatory measures. Please minimize chemicals shipped to the competition site in order to
reduce disposal costs.
6.1. On-Site Disposal. Teams are responsible to make each of their waste streams safe for
disposal in one of the following available waste streams: Acid, Base, Organic, Aqueous,
Solid Waste. All team assembled items disposed in solid waste must be separated into
their individual components with a neutral pH (pH 6-8) and contained in their own water
tight container with a copy of their Team Waste Tag securely attached to the container.
6.2. Team Waste Tags. Team Waste Tags must be completed ahead of the competition
based on anticipated waste streams and included at the end of the teams Engineering
Design Package. Team Waste Tags must accompany all discharges of waste into AIChE
waste containers and include at a minimum: Description of waste, Concentration,
Volume, Team name, Table number.
6.3. Illegal Disposal. Failure to follow these rules on chemical handling may result in a
safety incident being attributed to your team and possible suspension from future
competitions. See 28, Accidents/Incidents.
7. Flames/smoke/noise. All cars are restricted from having any open flames or emitting any
smoke. Cars shall not have internal flames. Any team that generates any open flame or
smoke in the prep area or on the track will be disqualified.
15
7.1.1. Internal combustion engines (ICE). The only exception to this rule is that an
internal flame is allowed in a commercial internal combustion engine (ICE) that
uses an alternative fuel that is synthesized by students. Cars with ICEs are not
allowed to produce smoke during the attempt. Succinct safety procedures for the
maintenance and operation of this engine must be demonstrated by the team. In
addition, cars with an ICE must show a demonstrable and significant student design
component.
7.1.2. Noise. Noise from internal combustion engines must not exceed 90 db (as
measured from a distance of 1 meter).
7.1.3. Gas Discharge. Gas discharge from an ICE shall be permitted when the exhaust
has been properly filtered by a catalytic converter or other filter media to remove
hazardous exhaust materials with including soot, obnoxious odor, and smoke.
7.1.4. Gas Discharge from a reaction: Any byproducts with an NFPA health rating of
3 or 4 must be scrubbed or removed prior to discharge.
8. Liquid/Vapor/Odor Discharge. No liquid discharge, including water, is allowed. No

obnoxious odor is allowed either through discharge or during use. All liquid products of
reaction should be properly collected and contained within the vehicle, and properly disposed
of (example, use of a scrubber/ holding tank). Discharge should only occur during emergency
relief situations to protect the equipment from rupture and/or explosion.
8.1.1. Hydrogen Discharge. An exception to the 'no gas discharge' rule is that a small
amount of hydrogen discharge is allowed. Students should provide calculations in
the EDP to prove to the reviewer that any discharged hydrogen stream is diluted to
below 25% of the LFL/LEL, as discussed in Section 1.1.10 of the Safety Rules.
8.1.2. Release of Pressurized Gas. Although pressure relief devices are required as a
means of protection, the release of pressurized gas during the competition (greater
than 5 psig [0.345 barg]) is not allowed. If a PRV functions during the attempt for
any reason that attempt will be disqualified.
8.1.3. Gas Discharge Unpressurized, untreated gas discharge as a reaction byproduct is
allowed without filtration for gases containing an NFPA health rating of 0, 1, or 2.
(Example - water vapor, or CO2 are OK, H2S and SO2 are not OK). The onsite
safety personnel may disqualify any entry where the gas discharged by a vehicle is
deemed improper. Disqualification due to excessive gas production is at the
discretion of the observing safety committee, and the ruling is final and cannot be
challenged
9. Reactive Materials. Teams using any chemicals with potential air/oxygen reactivity (e.g.,
flammable gases) MUST purge the system with an appropriate inert gas before the reactive
gas is introduced in to the system. The volume of inert gas used to purge the system must be
at least three (3) times the volume of the system. Purging may be accomplished through the
use of a small inert gas canister.
16
10. Open and/or Improperly Secured Containers. All containers on the vehicle containing
chemicals (including water) must be securely attached to the vehicle to prevent the container
from tipping over during the competition. The lid to this container must also be securely
attached to the container and must be capable of preventing escape of the chemical during
any phase of the competition, including an accident involving tipping over of the vehicle.
11. No Open containers, pipetting, or chemical pouring at the Starting Line or at the ready
table. No open containers or manual pouring/pipetting of chemicals is permitted at the
starting line or ready table. Built-in chemical reservoirs must be filled at the team’s
preparation table and securely attached to the car prior to moving to the ready table and
starting line. Manual or automatic valves or switches can be used at the starting line.
Violations will result in that run being disqualified – built-in chemical reservoir is still
subject to containment requirements, MOC compatibility, double containment, lid, etc., if
necessitated based on the chemical(s) contained.” All containers on the vehicle must have a
secure lid and must be properly managed to prevent spillage.
11.1. Starting Line Procedure. All chemicals must be on the car and secured in fixed
containment on the vehicle before walking to the starting line. Nothing may be carried
away from the start line or left at the ready table. If any parts fall off the car either at the
starting line or in competition will result in disqualification of that attempt. All
containers, packets, etc. must be properly labeled and contained.
11.2. No Manually Plunged Syringes at the Starting Line or at the ready table.
Teams cannot manually plunge a syringe at the starting line or the ready table. Manually
plunged syringes cannot be included in the car design. This rule change is also to
promote better and safer design. Labeled syringes or pipettes can be used at the team’s
preparation table, but sharp needles are not permitted.
12. No Sharp Needles. Sharp needles cannot be used in any capacity (including, but not limited
to in the operation and preparation of the vehicle) in Regional or Annual competitions.
13. No Specially Regulated Carcinogenic Chemicals. A number of carcinogenic chemicals are
listed by OSHA as a special carcinogenic hazard. The handling of these chemicals is outside
the scope of the management systems available during the competition. Such chemicals are
therefore not permitted. See www.osha.gov for details. These regulated chemicals include:
1,2-Dibromo-3-chloropropane Beta-propiolactone
1,3-Butadiene Bis-chloromethyl ether
2-Acetylaminofluorene Chromium (VI)
3,3'-Dichlorobenzidine Cadmium
4,4'-Methylenedianiline Coal tar pitch volatiles
4-Aminodiphenyl Ethylene oxide
4-Dimethylaminoazo-benezene Ethyleneimine
4-Nitrobiphenyl Formaldehyde
Acrylonitrile Inorganic arsenic
Alpha-napthylamine Methyl chloromethyl ether
Asbestos Methylene chloride
17
Benzene Methylenedianiline
Benzidine N-nitrosodimethylamine
Beryllium Respirable Crystalline Silica
Beta-naphthylamine Vinyl chloride
14. No Highly Reactive/Unstable Chemicals. No chemical, raw material, intermediate or

product that is highly reactive or unstable will be permitted. This includes chemicals with
any of the following GHS hazard classifications: explosives, flammable liquids (Category 1),
flammable solids (Category 1), self-reactive chemicals (Type A or B), pyrophoric solids,
pyrophoric liquids, self-heating substances, substances which in contact with water emit
flammable gases, oxidizing liquids (Category 1), oxidizing solids (Category 1), organic
peroxides (Type A or B), acute toxicity (Category 1), and carcinogenicity (Category 1). This
also includes any chemical on the extremely hazardous substances list published by EPA, as
well as the following chemicals specifically.
Banned chemical list includes (not exhaustive):
0-Dinitrobenzene
3-Bromopropyne
Acetyl peroxide
Cumene hydroperoxide
Diethyl peroxide
Diisopropyl peroxydicarbonate
Di-tert-butyl-peroxide
Divinyl acetylene
Ethyl nitrite
Nitroglycerin
Nitromethane
Paracetic acid
Ammonia
15. No Liquid Hydrogen Peroxide Concentrations Greater than 30%. Liquid hydrogen
peroxide is very unstable and difficult to handle at concentrations greater than 30%.
16. Pressure Restrictions. Pressurized vessels and vehicle components represent a significant
explosion hazard due to the substantial energy contained in the pressure. The student team
must also demonstrate that the proper safety systems have been installed to prevent an
explosion.
18
16.1.1. The maximum allowable working pressure (MAWP) should be the highest
pressure the weakest component of your pressurized system can handle. No vehicle
is permitted to have a MAWP greater than 200 psig (13.8 barg). Note that the
MAWP for the ‘car system’ may be less than the MAWP the manufacturer listed for
the pressure vessel.
16.1.2. The maximum operating pressure (MOP) may not exceed 90% of the MAWP
for the reaction vessel, and should be 90% of the operating pressure of the weakest
pressure rated component in the system. For initial design purposes, the maximum
operating pressure (MOP) can be estimated from stoichiometry; however, the actual
pressure must be measured once the car is operational. Student teams must
demonstrate through appropriate pressure measurements that the pressures during
normal operations do not exceed equipment specifications.
17. Pressure Gauge. All vessels and equipment with pressures greater than 5 psig (0.345 barg)
must have a pressure gauge that reads from 0 gauge pressure to 2 times the MOP.
18. Emergency Relief Devices. All vehicles with pressures greater than 5 psig (0.345 barg) must
have an industry-standard relief valve set at no more than 1.1 times the MOP of the vehicle.
18.1. Relief Device Testing. This valve must be tested and evidence must be provided
in the safety documentation. If using a fixed set point PRV, the manufacturer
specifications must be included in the EDP document. If using adjustable set point PRV,
proof that the PRV has been tested to that set point with a faculty member signature
must be included in the EDP.
18.2. Sizing Calculations. All Emergency Relief Devices must be properly sized.
Emergency relief system calculations must be included in the EDP documentation and
they must be reviewed and approved by your faculty advisor. In addition, the following
design specifications for the emergency relief device must be clearly stated in the EDP:
 Total quantity of reacting material assumed
 Concentration of the reactant(s) and
 Initial temperature
An example of pressure relief device sizing is included in the Chem-E-Car Safety Training Course.
Additionally, an online copy of Crowl and Tipler’s “Sizing Pressure-Relief Devices” is available in
the Resources section below and may be used as a reference for sizing pressure relief devices. Note
the important clarification below the resource hyperlink regarding a typo in the online copy.
18.3. Emergency Relief Device in Proper Location. The relief device must be
properly located. For vessels, the relief valve must be located at the top of the vessel
without any valves between the vessel and the relief. Consideration must also be given
for any entrained liquid or solids that might carry over from the vessel and prevent
proper relief function. If a pressure reduction valve (pressure regulator) reduces pressure
downstream to a value above atmospheric pressure, ALL piping and equipment
19
downstream of the pressure reduction valve/regulator must be rated for that pressure or
protected by an appropriate relief valve/frangible/rupture disk.
18.4. Piping. The piping connecting the relief to the vessel must be of appropriate size
and must be as short as possible to prevent pressure drop during relief conditions.
Pressure Restrictions Example
A vehicle system has the following components.

 Reactor with MAWP = 1800 psi
 Steel tubing with MAWP = 150 psig.
The MAWP of the Vehicle system = 150psig (weakest component in system)
MOP = 135 psig (90% of 150psig)
PRV maximum set point = 149 psig (1.1 x 135psig)
Appropriate pressure gauge range= 0 to 270 psig.( 2 x MOP)
19. Pressure Testing. All components, including vessels, piping and fittings, valves, gauges, filters,
must be certified to operate at a pressure greater than your vehicle’s maximum operating pressure
(MOP). For most components, the pressure specifications can be obtained directly from the
manufacturer. This information must be provided with your engineering documentation package. For
vessels, the pressure certification might not be known. In this case, you will need to either have
someone test the vessel for you, or complete the pressure test yourself under the supervision of a
faculty member. See Appendix A on Pressure Vessel Test Protocol and Procedure.
20. Proper Management System to Prevent Over or Mis-Charging Pressure System. Student teams
must also be aware that the internal pressure in the vessel is dependent on the amount of reactant(s)
charged. Students must demonstrate that proper management systems and controls are in place to
ensure that the proper quantity of reactant is charged to the vehicle.
20.1. Standard Operating Procedures. The following steps must be included in the Standard
Operating Procedures of your vehicle to ensure proper charging:
20.1.1. The quantity to be charged should be agreed upon by all team members and must be
supported by data obtained from operating the vehicle.
20.1.2. At least one team member should observe both the measuring and charging operation to
ensure that it is done properly.
20.1.3. The car should be tagged once the charging is completed. This tag should remain until the
attempt is finished.
21. No Plastic in pressure service. No plastics such as: PVC, Tygon Tubing, cPVC, polyethylene
terephthalate (PETE), ABS, PC, etc. are permitted for pressurized vessels or piping systems or for
20
gases or liquids above manufacturer’s temperature recommendations. NO exceptions to this rule will
be allowed.
21.1. Documentation. If plastics are used on the vehicle they must be certified by
manufacture’s data for the particular temperature, pressure, and fluid or gas being used by the
team and the data must be available at the safety inspection.
22. Chemical Containment

22.1. Primary Containment. The primary containment must be adequate to prevent leakage of
any chemicals during normal transport of the vehicle to the starting line and during vehicle
operation during the contest. The lid must be stout enough to provide no more than very limited
release of chemicals during emergency conditions, such as a vehicle tip over or collision.
22.1.1. Lids. All lids on containers containing chemicals must be securely attached to the
container and should cover the entire container opening. Please ensure that any holes in the
lid or container are just big enough to accommodate the “through hole item” — seal if
possible. Saran™ wrap, Parafilm™, aluminum foil and other similar materials are not
adequate for use as container covers. However, caution must be exercised to ensure no
pressure build up occurs in a vessel not rated for pressure.
22.2. Secondary Containment. Secondary Containment is required for all liquids on the car.
The secondary containment on the vehicle must be of suitable durability and size to hold the
contents of any spilled chemicals on the vehicle. It is not required to have a lid for the second
containment however it is good practice. Proper measures must be taken during chemical
handling in the vehicle preparation area to prevent human exposure to these chemicals – see
Appendix B on Chemical Handling and Disposal.
23. Temperature Hazards. All exposed surfaces on your vehicle with temperatures greater than 150oF
(65.5oC) or under 32oF (0oC) must either be insulated or covered to prevent contact with human skin.
24. Electrical Hazards

24.1. Preventing Electrical Shock or Ignition. All wiring and exposed electrical components
must be insulated or covered to prevent the possibility of electrical shock or ignition of any
component of a vehicle.
24.2. No Alligator Clips. Alligator clips and twisted wires represent both an electrical shock
hazard and an ignition source for flammable vapors and/or liquids and are not allowed. Use more
robust electrical connectors such as banana plugs or binding posts.
24.3. Charging Batteries. The charging of student-made batteries must be done in a safe way
and documented within the EDP.
25. Mechanical Hazards Guards must be present for any moving parts and pinch points. This includes
gears, belts, linkages, actuator arms and any other part that may present a pinch point.
26. Oxygen Service All components in oxygen service must be compatible with oxygen at elevated
concentrations. This includes vessels, piping, filters, regulators and valves. Electronic components
and regulators in oxygen service must be rated by the manufacturer for oxygen service. Metallic
21
components are preferred because nonmetals are more susceptible to oxygen ignition. The equipment
must not have been used previously for another chemical service that could leave residual ignitable
material. In particular, gas regulators used for hydrocarbon gas service can ignite and potentially
explode when placed into oxygen service.
26.1. Cleaning. All equipment in oxygen service must be thoroughly cleaned before being placed into
service. Effective cleaning will: (1) remove particles, films, greases, oils, and other unwanted
matter, (2) prevent loose scale, rust, dirt, mill scale, weld spatter, and weld flux deposited on
moving and stationary parts from interfering with the component function and clogging flow
passages, and (3) reduce the concentration of finely divided contaminants, which are more easily
ignited than bulk material. Cleaning of the oxygen system must be done by disassembling all
components to their individual parts
27. Biohazards If any biological organisms are used during any phase of the design, development,
operation, competition and preparation of your Chem-E-Car, they must be no more than Level 1
biological hazards (also called biosafety level 1). This would include any bacterial, fungal, viral, or
yeast organisms. Proper handling procedures must be followed to minimize human exposure. All
leftover cultures, stocks, and other regulated wastes must be collected, packaged and decontaminated
according to local, state and federal regulations.
28. Accidents/Incidents. If a safety incident occurs during the competition, the AICHE student chapter
advisor of that team will be informed that an incident analysis report must be submitted to
[email protected]. This safety incident report must be approved by the Chem-E-Car
Competition® Student Chapters Subcommittee before any team from that university is allowed to
compete in Regional or Annual Student Conference Chem-E-Car competitions.
29. Competition Day Rules

29.1. PPE: Each team must provide the appropriate personal protective equipment (PPE) for use in
the chemical prep area, as identified in their JSA, and must use them properly. This includes lab
coats, safety glasses, gloves, masks, face shields, and hearing protection. The personal
protective equipment must be used appropriately by all team members depending on the hazards
encountered during the chemical preparation.
29.2. Electronics in prep area: All portable personal electronic devices must be covered while in
the prep area. Smaller portable personal electronic devices such as calculators and especially
cell phones must be kept in clear plastic bags (e.g. Ziploc bags) throughout the competition.
Teams will also be required to place screen covers and disposable keyboard covers over laptop
and tablet touch screens and keyboards. The purpose of this rule is to prevent contamination of
portable personal electronic devices. Teams are responsible for providing clear plastic bags,
screen covers, and keyboard covers for their portable personal electronic devices. Failure to
follow this rule will result in all team electronic devices being removed for the remainder of the
competition from the prep area.
22
29.3. Labeling Containers. All containers with chemicals, including bottles, beakers, and plastic
bags must be properly labeled. The label must minimally include the name of the chemical(s),
and the name of the Chem-E Car team.
29.4. Spill Containment at Table. All chemical pouring or mixing in the preparation area must be
done with spill containment. Your team must use a large tray compatible with your chemicals,
with a volume large enough to hold your chemical quantities.
29.5. Chemical Distribution. All chemicals will be made available to the teams in the chemical
preparation area at least two (2) hours prior to the performance competition. Absolutely no
chemicals will be available for any team prior to three (3) hours before start of the competition.
This includes battery-operated cars. Any requests to charge batteries overnight or longer than
three (3) hours before the competition starts will not be granted.
29.6. One Car in chemical prep area. Each team is only permitted to have the car that passed the
onsite safety inspection in the chemical prep area during the competition.
29.7. Testing of vehicles in chemical prep area. Once the distance is announced, teams can only
test their reactions if the cars are held or supported on a stationary stand. The car wheels are not
allowed to touch a solid surface (table or floor) under power.
30. Requesting Assistance. There is no restriction on requesting assistance for vehicle safety. Teams are
encouraged to request additional safety assistance from their faculty advisor, other faculty members,
other universities, other teams, and professional practitioners in industry and elsewhere.
Resources
National Fire Protection Association (NFPA). This method assigns a numerical value to the
degree of hazard based on three major hazard groups: toxicity, flammability and
instability/reactivity. The numerical values range from 0 to 4, with 0 representing the lowest
degree of hazard and 4 representing the highest. See www.nfpa.org for more details on this.
National Institute for Occupational Safety and Health (NIOSH). An excellent source of
information on the hazardous properties of chemicals. www.cdc.gov/niosh. In particular,
they support a free, on-line guide to chemical hazards called the NIOSH Pocket Guide to
Chemical Hazards. This is available at http://www.cdc.gov/niosh/npg/default.html.
Occupational Safety and Health Administration (OSHA) Information about Hazard

Communication Standard (HDS), which is now aligned with the Globally Harmonized
System of Classification and labeling of Chemical (GHS). Information on Safety Dara
Sheets, & labeling can be found at https://www.osha.gov/dsg/hazcom/.
Information on GHS can be found at https://www.osha.gov/dsg/hazcom/ghsguideoct05.pdf
Crowl and Tipler, “Sizing Pressure-Relief Devices”:

23
https://www.aiche.org/sites/default/files/cep/20131068_r.pdf
NOTE: Equations (5) and (6) in Crowl and Tipler’s “Sizing Pressure-Relief Devices” have
a typo. The exponent (y+1)*(y-1) is incorrect, and instead should read (y+1)/(y-1)
SACHE module: Emergency Relief system Design for Single and Two-Phase Flow
AIChE Chem-E-Car Competition Safety Training Course: www.aiche.org/chemecar
Appendix A: Pressure Vessel Test Protocol and Procedure
The test pressure is the target pressure specified for the hydrotest. This specification depends on
whether the MAWP of the vessel is known or not. See the Pressure Vessel Test Protocol shown
below. The manufacturer recommendations for the use of all pressurized components, especially
plastic components, for a vehicle must be thoroughly researched and documented. This includes
following manufacturer’s recommendations for use of materials.
No plastics such as: PVC, Tygon Tubing, cPVC, polyethylene terephthalate (PETE), ABS,
PC, etc. are permitted for pressurized vessels or piping systems or for gases or liquids
above manufacturer’s temperature recommendations. All plastics have microscopic
defects called crazes that grow into cracks as a result of hoop stresses, which can over time
cause failure and therefore represent a hazard. NO exceptions to this rule will be allowed.
A.1 Pressure Vessel Test Protocol

There are three cases involving different protocols:
1. You already know the MAWP of the vessel, and the vessel is less than 5 years old or has been
retested within the last five years, and does not show any corrosion, wear or abuse. In this case the
vessel is already certified and all that is required is to obtain information related to this certification.
There are two ways to get this information:
i. The pressure vessel is already stamped with the MAWP or contains a plate indicating the
MAWP. This indicates that it has been hydrostatically tested previously. Submit
documentation that supports the MAWP rating, or a clear photograph of the name plate or
the MAWP stamp and date of testing. See documentation requirements below.
ii. The manufacturer of the vessel supplies the pressure rating of the vessel via technical
specifications. In this case provide copies of this specification. The age of the vessel must
also be certified. See documentation requirements below.
24
The documentation is all that is required for the pressure certification for this case.
2. You already know the MAWP of the vessel, and the vessel is more than 5 years old, or has not
been retested within 5 years, or shows corrosion, wear or abuse. There are two options available
for this case:
i. Use a commercial firm to recertify the MAWP via hydrotest. Provide documentation on this
recertification with your JSA, including the name of the contractor and the date.
ii. Recertify the vessel yourself using the hydrotesting procedure shown below. The test
pressure in this case is 1.5 times the MAWP. See documentation requirements below.
3. The MAWP is not known. This case applies to unlabeled/undocumented vessels as well as custom-
built pressure vessels. There are two options available for this case:
i. Use a commercial firm to certify the MAWP of the vessel and perform the hydrotest.
Provide documentation on this certification with your JSA, including the name of the
contractor. See documentation requirements below.
ii. Certify the vessel yourself using the hydrotesting procedure shown below. Use a test
pressure of 1.3 times the maximum operating pressure. See documentation requirements
below.
A.2 Hydrotesting Procedure
Hydrostatic testing (using water) is the standard for pressure vessel testing. Pneumatic tests using air,
nitrogen, carbon dioxide or other gases is not permitted due to the explosive nature of rapidly
expanding gases.
Pressure Gauge Requirements
The pressure gauge must have an indication range of not less than 1.5 and not more than 4 times the
test pressure. The gauge must be able to be read to increments of at least 5 psig.
Measurement of Vessel Deformation
During pressure testing a gauge must be configured to measure any deformation of the vessel. This
gauge must be visible to the operator applying pressure. Use a dial gauge accurate to at least 0.001 inch
25
(0.0254 mm). Ensure that the dial gauge is in good working condition and properly calibrated.
To confirm that plastic yielding (expansion) has not occurred during pressurization, the vessel must be
measured along its centerline in three directions (x, y, z) both before and after hydrostatic testing.
Measurements shall be taken using a caliper or mechanical gauge accurate to 0.001 inch or less.
Test Area
The test area should be restricted and barricaded. The vessel being pressure-tested should be oriented
so that bolts, flanges, and other possible missiles point away from people and other equipment. All
pressure tests must be conducted remotely. A barrier (sand bags, lumber) must be used to limit the
potential from flying projectiles should the vessel fail the test. The barrier should be around all four
sides of the vessel and should extend above the vessel.
Test Procedure
1. Provide a vent to allow air to leave the vessel while filling with water. You might consider
providing a bottom drain to remove water when the testing is done.
2. Fill the vessel with water and remove the air. Make sure the vessel is completely filled with
liquid prior to the test.
3. First, increase the pressure to a maximum of one-half of the test pressure. Then, raise the
pressure in increments of 0.1 times the test pressure until the test pressure is reached. The final
test pressure must be held for a minimum of 30 minutes. Pressure should hold steady and not
change significantly during the test. A change of 10% of the test pressure or 5 psig is significant.
No water leaks or drips should be observed.
4. The pressure should then be lowered to the operating pressure of the vessel and held for a
visual inspection of all joints and connections. No water leaks or drips should be observed.
5. Take appropriate vessel measurements, accurate to within 0.001inch (0.0254mm), both before
and after testing to show that detectable plastic yielding has not occurred during pressurization.
Documentation of Test
Provide the following documentation in support of the hydrotest.
1. Identification of vessel(s) or system..

2. MOP or test pressure of vessel(s) or system, if known.
3. Planned test pressure.
4. Supporting calculations.
5. Date and time that test started.
6. Date and time that test was completed or failed.
26
7. Maximum pressure attained.
8. Chart of test-pressure sequence (optional).
9. Test liquid.
10. External temperature of system.
11. Temperature of test liquid.
12. Organization conducting test.
13. Signature of Chem-E Car Advisor Certify the completion of the test.
Vessel Labeling
At the completion of the test a pressure test label must be affixed to the pressure vessel. Information on
the label must include:
1. Identification of the Vessel (Car Name, Vessel Purpose)

2. MOP or test pressure, and temperature
3. Working fluid
4. Test engineer
5. Test Date
Appendix B: Chemical Handling and Disposal
B.1 Introduction
All ChemE car students who handle chemicals either at their host institution or at a regional or Annual
Student Conference competition must understand the hazardous properties of these chemicals. Before
using a specific chemical, safe handling methods must always be reviewed. Faculty advisers are
responsible for ensuring that the equipment needed to work safely with chemicals is provided.
B.2 General Rules for Chemical Safety
A. Safety Data Sheets (SDS) must be available in the laboratory for all chemicals, including those in
storage in the laboratory.
B. When purchasing chemicals, purchase the smallest quantity necessary to complete the
planned experiments. The cost of disposal of unused chemicals far exceeds the savings
from quantity purchases.
C. Skin contact with chemicals must be generally avoided.
27
D. No more than 2-gallons of flammable solvent should be out in the laboratory at any one time.
Store bulk flammable containers in a flammable storage cabinet.
E. All containers (including those in storage) must be labeled – see the section on labeling below.
Any unlabeled container must be treated as a hazardous substance.
F. Wear compatible gloves and apron when handling strong acids and bases.
G. Use a grounding strap and/or dip leg when transferring flammable chemicals into a storage tank.
H. Transport all chemicals using a safety carrier. The chemical must be in a closed container.
I. Chemical containers must be kept away from high temperatures, the edge of the lab bench, and
other areas where an incident might lead to loss of containment.
J. Mouth suction for pipetting or starting a siphon is not allowed.
K. Unknown substances must be treated as toxic and flammable.
L. Do not taste or smell any chemicals.
M. Operations involving chemicals should generally be done in a laboratory hood.
B.3 Chemical Storage
A. SDS's must be available for all chemicals stored.
B. ALL chemicals stored must be properly labelled.
C. No chemicals shall be stored on the top of lab benches or out in the open. Chemicals must not
be stored over eye level height to prevent accidents from dropping containers.
D. Flammable and volatile chemicals must be stored in a cabinet designated for flammable storage.
See the discussion of flammable storage cabinets in the Safety Equipment section. Refrigerated
storage of these chemicals requires a refrigerator rated for storing flammables.
E. Acids and bases should be stored separately.
F. Acid-resistant trays shall be placed under stored acid containers.
G. Acid-sensitive materials such as cyanides and sulfides must be separated from acids.
H. Oxidizable materials should be stored away from acids/bases and flammables.
I. Stored chemicals must be examined on a regular basis by the laboratory personnel (at least
annually) to inspect for deterioration, container integrity, and expired dates. Chemicals which
28
are not being used should be disposed of or returned to Chem Stores for recycling.
J. An inventory of stored chemicals must be maintained by the laboratory owner at all times.
Leftover items shall be properly discarded or returned to Chemical Stores. Store only what you
are using.
B.4 Chemical Labeling
All chemicals must be labeled, even during temporary transport. This includes lab samples, temporary
containers, etc. A proper chemical label must include:
▸ Name, address and telephone number

▸ Product Identifier
▸ Signal word
▸ Hazard statement(s)
▸ Precautionary statements
▸ Pictograms
Pictograms are required on labels to alert users of the chemical hazards to which they may be exposed.
Each pictogram consists of a symbol on a white background framed within a red border and represents a
distinct hazard. Here are examples of pictograms you may encounter.
29
30
B.5 Chemical Disposal
All chemicals must be disposed of in a safe and environmentally friendly manner. Any chemical
substance which is corrosive, flammable, reactive, toxic, radioactive, infectious, phytotoxic, mutagenic,
or acutely hazardous must be treated as hazardous waste. Do not dispose of chemicals by evaporation
in a fume hood or in the sink! Do not hesitate if any questions occur about the hazards of a material.
Collect and store chemical waste in containers which are clearly labeled. Do not combine containers
unless the contents in each container are known, compatible, and it is safe to do so. Combined wastes
are much more difficult and costly to dispose of properly.
Ordinary waste such as paper, cardboard, etc., may be placed in the wastebasket. However,
contaminated waste must be disposed of separately in a labeled container.
Empty chemical containers must also be disposed of in an acceptable fashion. They must first be
cleaned and then either returned to Chemical Stores or disposed through normal trash.
31

2024 Chem-E-Car Rules Asc Final 8.2.2024

Uploaded by

Copyright:

Available Formats

2024 Chem-E-Car Rules Asc Final 8.2.2024

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2024 Chem-E-Car Rules Asc Final 8.2.2024

Uploaded by

Copyright:

Available Formats

2024 Student Regional Conference Competition Official

Find your Conference at www.aiche.org/conferences/student

Submit questions at www.aiche.org/chemecarquestions

In-Person EDP Submission Link

Bring all items to On Site Safety Inspection & Competition

Summary of Changes, February 2024 Revision

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

Changes to Safety Rules

Chem-E-Car Competition Overview

The objectives of the AIChE Chem-E-Car Competition:

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

Regional Conference Competition

Regional Conference Awards

 Performance Competition: 1st place: $200 & 2nd place: $100

Annual Student Conference Competition

North America Regionals

Annual Student Conference Competition Awards

Sponsored by and the H. Scott Fogler Endowment Fund

The Annual Student Conference Competition associated awards are:

Chem-E-Car Competition Poster Session & Safety Inspection Rules

 Quality of the poster and team member presentations (50%)

Chem-E-Car Competition Performance Session Rules

7. Course Layout and Distance Measurement

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

9. Starting Line Procedure

10. Competition Order Logistics

11. Vehicle Drive System

12. Vehicle Design

13. Size of Car

14. Capital Cost of Vehicle:

15. Team Member Status and Conduct

16. Winning Team and Awards

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

Chem-E-Car Safety Program Overview

The safety audit of your vehicle will occur in two stages:

Competition Safety Rules

1. Safety Audit: Online

3. Disallowed Chemical Handling/ Illegal Chemical Transport & Storage

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

4. No Compressed Hydrogen Gas Cylinder Usage

5. Illegal Testing of Vehicles

8. Liquid/Vapor/Odor Discharge. No liquid discharge, including water, is allowed. No

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

14. No Highly Reactive/Unstable Chemicals. No chemical, raw material, intermediate or

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

Pressure Restrictions Example

A vehicle system has the following components.

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

22. Chemical Containment

24. Electrical Hazards

29. Competition Day Rules

Updated February 2024 Questions? Visit www.aiche.org/chemecarquestions

Occupational Safety and Health Administration (OSHA) Information about Hazard

Information on GHS can be found at https://www.osha.gov/dsg/hazcom/ghsguideoct05.pdf

Crowl and Tipler, “Sizing Pressure-Relief Devices”:

AIChE Chem-E-Car Competition Safety Training Course: www.aiche.org/chemecar

Appendix A: Pressure Vessel Test Protocol and Procedure

A.1 Pressure Vessel Test Protocol