753

Research and Special Programs Admin., DOT 178.50

(1) F l atteni ng requi red to 50 percent
of the ori gi nal outsi de di ameter wi th-
out cracki ng.
(2) Burst pressure must be at l east 3
ti mes the servi ce pressure.
(o) Rejected containers. Repai r of wel d-
ed seams by wel di ng pri or to process
treatment i s authori zed. Subsequent
thereto, contai ners must be heat treat-
ed and pass al l prescri bed tests.
(p) Duties of inspector. I n addi ti on to
the requi rements of 178.35, the i nspec-
tor must veri fy that al l tests are con-
ducted at temperatures between 60 F
and 90 F .
(q) Marking. Marki ngs must be
stamped pl ai nl y and permanentl y on a
permanent attachment or on a metal
namepl ate permanentl y secured to the
contai ner by means other than soft sol -
der.
178.50 Specification 4B welded or
brazed steel cylinders.
(a) Type, size, and service pressure. A
DOT 4B i s a wel ded or brazed steel cyl -
i nder wi th l ongi tudi nal seams that are
forged l ap-wel ded or brazed and wi th
water capaci ty (nomi nal ) not over 1,000
pounds and a servi ce pressure of at
l east 150 but not over 500 pounds per
square i nch. Cyl i nders cl osed i n by
spi nni ng process are not authori zed.
(b) Steel. Open-hearth, el ectri c or
basi c oxygen process steel of uni form
qual i ty must be used. Content percent
may not exceed the fol l owi ng: Carbon,
0.25; phosphorus, 0.045; sul phur, 0.050.
(c) I dentification of material. Materi al
must be i denti fi ed by any sui tabl e
method except that pl ates and bi l l ets
for hotdrawn cyl i nders must be marked
wi th the heat number.
(d) Manufacture. Cyl i nders must be
manufactured usi ng equi pment and
processes adequate to ensure that each
cyl i nder produced conforms to the re-
qui rements of thi s subpart. No defect i s
permi tted that i s l i kel y to weaken the
fi ni shed cyl i nder appreci abl y. A rea-
sonabl y smooth and uni form surface
fi ni sh i s requi red. Exposed bottom
wel ds on cyl i nders over 18 i nch l ong
must be protected by footri ngs. Wel d-
i ng procedures and operators must be
qual i fi ed i n accordance wi th CGA Pam-
phl et C3. Seams must be made as fol -
l ows:
(1) Welded or brazed circumferential
seams. Heads attached by brazi ng must
have a dri vi ng fi t wi th the shel l , unl ess
the shel l i s cri mped, swedged, or curl ed
over the ski rt or fl ange of the head,
and be thoroughl y brazed unti l com-
pl ete penetrati on by the brazi ng mate-
ri al of the brazed j oi nt i s secured.
Depth of brazi ng from end of shel l must
be at l east four ti mes the thi ckness of
shel l metal .
(2) L ongitudinal seams in shells. L ongi -
tudi nal seams must be forged l ap wel d-
ed, by copper brazi ng, by copper al l oy
brazi ng, or by si l ver al l oy brazi ng. Cop-
per al l oy composi ti on must be: Copper,
95 percent mi ni mum; Si l i con, 1.5 per-
cent to 3.85 percent; Manganese, 0.25
percent to 1.10 percent. The mel ti ng
poi nt of the si l ver al l oy brazi ng mate-
ri al must be i n excess of 1000 F . When
brazed, the pl ate edge must be l apped
at l east ei ght ti mes the thi ckness of
pl ate, l aps bei ng hel d i n posi ti on, sub-
stanti al l y metal to metal , by ri veti ng
or el ectri c spot-wel di ng; brazi ng must
be done by usi ng a sui tabl e fl ux and by
pl aci ng brazi ng materi al on one si de of
seam and appl yi ng heat unti l thi s ma-
teri al shows uni forml y al ong the seam
of the other si de.
(e) Welding or brazing. Onl y the at-
tachment of neckri ngs, footri ngs, han-
dl es, bosses, pads, and val ve protecti on
ri ngs to the tops and bottoms of cyl -
i nders by wel di ng or brazi ng i s author-
i zed. Such attachments and the porti on
of the contai ner to whi ch they are at-
tached must be made of wel dabl e steel ,
the carbon content of whi ch may not
exceed 0.25 percent except i n the case
of 4130X steel whi ch may be used wi th
proper wel di ng procedure.
(f) Wall thickness. The wal l thi ckness
of the cyl i nder must compl y wi th the
fol l owi ng requi rements:
(1) F or cyl i nders wi th outsi de di ame-
ters over 6 i nches the mi ni mum wal l
thi ckness must be 0.090 i nch. I n any
case, the mi ni mum wal l thi ckness
must be such that cal cul ated wal l
stress at mi ni mum test pressure (para-
graph (i )(4) of thi s secti on) may not ex-
ceed the fol l owi ng val ues:
(i ) 24,000 pounds per square i nch for
cyl i nders wi thout l ongi tudi nal seam.
(i i ) 22,800 pounds per square i nch for
cyl i nders havi ng copper brazed or si l -
ver al l oy brazed l ongi tudi nal seam.
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754
49 CFR Ch. I (10199 Edition) 178.50
(i i i ) 18,000 pounds per square i nch for
cyl i nders havi ng forged l apped wel ded
l ongi tudi nal seam.
(2) Cal cul ati on must be made by the
formul a:
S = [P(1.3D
2
+ 0.4d
2
)] / (D
2
d
2
)
Where:
S = wal l stress i n pounds per square i nch;
P = mi ni mum test pressure prescri bed for
water j acket test or 450 pounds per square
i nch whi chever i s the greater;
D = outsi de di ameter i n i nches;
d = i nsi de di ameter i n i nches.
(g) Heat treatment. Cyl i nder body and
heads, formed by drawi ng or pressi ng,
must be uni forml y and properl y heat
treated pri or to tests.
(h) Opening in cylinders. Openi ngs i n
cyl i nders must conform to the fol -
l owi ng:
(1) Each openi ng i n cyl i nders, except
those for safety devi ces, must be pro-
vi ded wi th a fi tti ng, boss, or pad, se-
curel y attached to cyl i nder by brazi ng
or by wel di ng or by threads. F i tti ng,
boss, or pad must be of steel sui tabl e
for the method of attachment em-
pl oyed, and whi ch need not be i denti -
fi ed or veri fi ed as to anal ysi s except
that i f attachment i s by wel di ng, car-
bon content may not exceed 0.25 per-
cent. I f threads are used, they must
compl y wi th the fol l owi ng:
(i ) Threads must be cl ean cut, even
wi thout checks, and tapped to gauge.
(i i ) Taper threads to be of l ength not
l ess than as speci fi ed for Ameri can
Standard taper pi pe threads.
(i i i ) Strai ght threads, havi ng at l east
4 engaged threads, to have ti ght fi t and
cal cul ated shear strength at l east 10
ti mes the test pressure of the cyl i nder;
gaskets requi red, adequate to prevent
l eakage.
(i v) A brass fi tti ng may be brazed to
the steel boss or fl ange on cyl i nders
used as component parts of hand fi re
exti ngui shers.
(2) The cl osure of a fi tti ng, boss, or
pad must be adequate to prevent l eak-
age.
(i ) Hydrostatic test. Cyl i nders must
wi thstand a hydrostati c test as fol l ows:
(1) The test must be by water-j acket,
or other sui tabl e method, operated so
as to obtai n accurate data. The pres-
sure gauge must permi t readi ng to an
accuracy of 1 percent. The expansi on
gauge must permi t readi ng of total ex-
pansi on to an accuracy ei ther of 1 per-
cent or 0.1 cubi c centi meter.
(2) Pressure must be mai ntai ned for
at l east 30 seconds and suffi ci entl y
l onger to ensure compl ete expansi on.
Any i nternal pressure appl i ed after
heat-treatment and previ ous to the of-
fi ci al test may not exceed 90 percent of
the test pressure. I f, due to fai l ure of
the test apparatus, the test pressure
cannot be mai ntai ned, the test may be
repeated at a pressure i ncreased by 10
percent or 100 pounds per square i nch,
whi chever i s the l ower.
(3) Permanent vol umetri c expansi on
may not exceed 10 percent of total vol -
umetri c expansi on at test pressure.
(4) Cyl i nders must be tested as fol -
l ows:
(i ) At l east one cyl i nder sel ected at
random out of each l ot of 200 or l ess
must be tested as outl i ned i n para-
graphs (i )(1), (i )(2), and (i )(3) of thi s sec-
ti on to at l east two ti mes servi ce pres-
sure.
(i i ) Al l cyl i nders not tested as out-
l i ned i n paragraph (i )(4)(i ) of thi s sec-
ti on must be exami ned under pressure
of at l east two ti mes servi ce pressure
and show no defect.
(j ) Flattening test. After the hydro-
stati c test, a fl atteni ng test must be
performed on one cyl i nder taken at
random out or each l ot of 200 or l ess, by
pl aci ng the cyl i nder between wedge
shaped kni fe edges havi ng a 60 i n-
cl uded angl e, rounded to
1
2-i nch radi us.
The l ongi tudi nal axi s of the cyl i nder
must be at a 90-degree angl e to kni fe
edges duri ng the test. F or l ots of 30 or
l ess, fl atteni ng tests are authori zed to
be made on a ri ng at l east 8 i nches l ong
cut from each cyl i nder and subj ected to
same heat treatment as the fi ni shed
cyl i nder.
(k) Physical test. A physi cal test must
be conducted to determi ne yi el d
strength, tensi l e strength, el ongati on,
and reducti on of area of materi al as
fol l ows:
(1) The test i s requi red on 2 speci -
mens cut from 1 cyl i nder, or part
thereof heat-treated as requi red, taken
at random out of each l ot of 200 or l ess.
F or l ots of 30 or l ess, physi cal tests are
authori zed to be made on a ri ng at
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755
Research and Special Programs Admin., DOT 178.50
l east 8 i nches l ong cut from each cyl -
i nder and subj ected to same heat treat-
ment as the fi ni shed cyl i nder.
(2) Speci mens must conform to the
fol l owi ng:
(i ) A gauge l ength of 8 i nches wi th a
wi dth of not over 1
1
2 i nches, a gauge
l ength of 2 i nches wi th a wi dth of not
over 1
1
2 i nches, or a gauge l ength at
l east 24 ti mes the thi ckness wi th a
wi dth not over 6 ti mes the thi ckness i s
authori zed when a cyl i nder wal l i s not
over
3
16 i nch thi ck.
(i i ) The speci men, excl usi ve of gri p
ends, may not be fl attened. Gri p ends
may be fl attened to wi thi n one i nch of
each end of the reduced secti on.
(i i i ) When si ze of cyl i nder does not
permi t securi ng strai ght speci mens,
the speci mens may be taken i n any l o-
cati on or di recti on and may be
strai ghtened or fl attened col d, by pres-
sure onl y, not by bl ows. When speci -
mens are so taken and prepared, the i n-
spectors report must show i n connec-
ti on wi th record of physi cal tests de-
tai l ed i nformati on i n regard to such
speci mens.
(i v) Heati ng of a speci men for any
purpose i s not authori zed.
(3) The yi el d strength i n tensi on
must be the stress correspondi ng to a
permanent strai n of 0.2 percent of the
gauge l ength. The fol l owi ng condi ti ons
appl y:
(i ) The yi el d strength must be deter-
mi ned by ei ther the offset method or
the extensi on under l oad method as
prescri bed i n ASTM Standard E8.
(i i ) I n usi ng the extensi on under
l oad method, the total strai n (or ex-
tensi on under l oad) correspondi ng to
the stress at whi ch the 0.2 percent per-
manent strai n occurs may be deter-
mi ned wi th suffi ci ent accuracy by cal -
cul ati ng the el asti c extensi on of the
gauge l ength under appropri ate l oad
and addi ng thereto 0.2 percent of the
gauge l ength. El asti c extensi on cal -
cul ati ons must be based on an el asti c
modul us of 30,000,000. I n the event of
controversy, the enti re stress-strai n
di agram must be pl otted and the yi el d
strength determi ned from the 0.2 per-
cent offset.
(i i i ) F or the purpose of strai n meas-
urement, the i ni ti al strai n must be set
whi l e the speci men i s under a stress of
12,000 pounds per square i nch, and
strai n i ndi cator readi ng must be set at
the cal cul ated correspondi ng strai n.
(i v) Cross-head speed of the testi ng
machi ne may not exceed
1
8 i nch per
mi nute duri ng yi el d strength deter-
mi nati on.
(l ) Acceptable results for physical and
flattening tests. Ei ther of the fol l owi ng
i s an acceptabl e resul t:
(1) An el ongati on of at l east 40 per-
cent for a 2-i nch gauge l ength or at
l east 20 percent i n other cases and
yi el d strength not over 73 percent of
tensi l e strength. I n thi s i nstance, a
fl atteni ng test i s not requi red.
(2) When cyl i nders are constructed of
l ap wel ded pi pe, fl atteni ng test i s re-
qui red, wi thout cracki ng, to 6 ti mes
the wal l thi ckness. I n such case, the
ri ngs (crop ends) cut from each end of
pi pe, must be tested wi th the wel d 45
or l ess from the poi nt of greatest
stress. I f a ri ng fai l s, another from the
same end of pi pe may be tested.
(m) Rejected cylinders. Reheat treat-
ment i s authori zed for rej ected cyl -
i nder. Subsequent thereto, cyl i nders
must pass al l prescri bed tests to be ac-
ceptabl e. Repai r of brazed seams by
brazi ng and wel ded seams by wel di ng i s
authori zed.
(n) Markings. Marki ngs must be
stamped pl ai nl y and permanentl y i n
any of the fol l owi ng l ocati ons on the
cyl i nder:
(1) On shoul ders and top heads when
they are not l ess than 0.087-i nch thi ck.
(2) On si de wal l adj acent to top head
for si de wal l s whi ch are not l ess than
0.090 i nch thi ck.
(3) On a cyl i ndri cal porti on of the
shel l whi ch extends beyond the re-
cessed bottom of the cyl i nder, consti -
tuti ng an i ntegral and non-pressure
part of the cyl i nder.
(4) On a metal pl ate attached to the
top of the cyl i nder or permanent part
thereof; suffi ci ent space must be l eft on
the pl ate to provi de for stampi ng at
l east si x retest dates; the pl ate must be
at l east
1
16-i nch thi ck and must be at-
tached by wel di ng, or by brazi ng. The
brazi ng rod must mel t at a tempera-
ture of 1100 F . Wel di ng or brazi ng
must be al ong al l the edges of the
pl ate.
(5) On the neck, neckri ng, val ve boss,
val ve protecti on sl eeve, or si mi l ar part
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756
49 CFR Ch. I (10199 Edition) 178.51
permanentl y attached to the top of the
cyl i nder.
(6) On the footri ng permanentl y at-
tached to the cyl i nder, provi ded the
water capaci ty of the cyl i nder does not
exceed 25 pounds.
[Amdt. 178114, 61 F R 25942, May 23, 1996, as
amended at 62 F R 51561, Oct. 1, 1997]
178.51 Specification 4BA welded or
brazed steel cylinders.
(a) Type, size, and service pressure. A
DOT 4BA cyl i nder i s a cyl i nder, ei ther
spheri cal or cyl i ndri cal i n shape, wi th
a water capaci ty of 1,000 pounds or l ess
and a servi ce pressure of at l east 225
and not over 500 pounds per square
i nch. Cl osures made by the spi nni ng
process are not authori zed.
(1) Spheri cal type cyl i nders must be
made from two seaml ess hemi spheres
j oi ned by the wel di ng of one ci rcum-
ferenti al seam.
(2) Cyl i ndri cal type cyl i nders must be
of ci rcumferenti al l y wel ded or brazed
constructi on.
(b) Steel. The steel used i n the con-
structi on of the cyl i nder must be as
speci fi ed i n tabl e 1 of appendi x A to
thi s part.
(c) I dentification of material. Materi al
must be i denti fi ed by any sui tabl e
method except that pl ates and bi l l ets
for hotdrawn cyl i nders must be marked
wi th the heat number.
(d) Manufacture. Cyl i nders must be
manufactured usi ng equi pment and
processes adequate to ensure that each
cyl i nder produced conforms to the re-
qui rements of thi s subpart. No defect i s
permi tted that i s l i kel y to weaken the
fi ni shed cyl i nder appreci abl y. A rea-
sonabl y smooth and uni form surface
fi ni sh i s requi red. Exposed bottom
wel ds on cyl i nders over 18 i nches l ong
must be protected by footri ngs.
(1) Seams must be made as fol l ows:
(i ) Mi ni mum thi ckness of heads and
bottoms must be not l ess than 90 per-
cent of the requi red thi ckness of the
si de wal l .
(i i ) Ci rcumferenti al seams must be
made by wel di ng or by brazi ng. Heads
must be attached by brazi ng and must
have a dri vi ng fi t wi th the shel l , unl ess
the shel l i s cri mped, swedged or curl ed
over the ski rt or fl ange of the head and
must be thoroughl y brazed unti l com-
pl ete penetrati on by the brazi ng mate-
ri al of the brazed j oi nt i s secured.
Depth of brazi ng from end of the shel l
must be at l east four ti mes the thi ck-
ness of shel l metal .
(i i i ) L ongi tudi nal seams i n shel l s
must be made by copper brazi ng, cop-
per al l oy brazi ng, or by si l ver al l oy
brazi ng. Copper al l oy composi ti on
must be: Copper 95 percent mi ni mum,
Si l i con 1.5 percent to 3.85 percent, Man-
ganese 0.25 percent to 1.10 percent. The
mel ti ng poi nt of the si l ver al l oy braz-
i ng materi al must be i n excess of 1,000
F . The pl ate edge must be l apped at
l east ei ght ti mes the thi ckness of
pl ate, l aps bei ng hel d i n posi ti on, sub-
stanti al l y metal to metal , by ri veti ng
or by el ectri c spot-wel di ng. Brazi ng
must be done by usi ng a sui tabl e fl ux
and by pl aci ng brazi ng materi al on one
si de of seam and appl yi ng heat unti l
thi s materi al shows uni forml y al ong
the seam of the other si de. Strength of
l ongi tudi nal seam: Copper brazed l on-
gi tudi nal seam must have strength at
l east
3
2 ti mes the strength of the steel
wal l .
(2) Wel di ng procedures and operators
must be qual i fi ed i n accordance wi th
CGA Pamphl et C3.
(e) Welding and brazing. Onl y the
wel di ng or brazi ng of neckri ngs,
footri ngs, handl es, bosses, pads, and
val ve protecti on ri ngs to the tops and
bottoms of cyl i nders i s authori zed.
Provi ded that such attachments and
the porti on of the contai ner to whi ch
they are attached are made of wel dabl e
steel , the carbon content of whi ch may
not exceed 0.25 percent except i n the
case of 4130 steel whi ch may be used
wi th proper wel di ng procedure.
(f) Wall thickness. The mi ni mum wal l
thi ckness of the cyl i nder must meet
the fol l owi ng condi ti ons:
(1) F or any cyl i nder wi th an outsi de
di ameter of greater than 6 i nches, the
mi ni mum wal l thi ckness i s 0.078 i nch.
I n any case the mi ni mum wal l thi ck-
ness must be such that the cal cul ated
wal l stress at the mi ni mum test pres-
sure may not exceed the l esser val ue of
any of the fol l owi ng:
(i ) The val ue shown i n tabl e I of ap-
pendi x A to thi s part, for the parti cul ar
materi al under consi derati on;
(i i ) One-hal f of the mi ni mum tensi l e
strength of the materi al determi ned as
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