(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. VerDate 15<DEC>99 10:04 Dec 21, 1999 Jkt 183197 PO 00000 Frm 00753 Fmt 8010 Sfmt 8010 Y:\SGML\183197T.XXX pfrm03 PsN: 183197T 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 VerDate 15<DEC>99 10:04 Dec 21, 1999 Jkt 183197 PO 00000 Frm 00754 Fmt 8010 Sfmt 8010 Y:\SGML\183197T.XXX pfrm03 PsN: 183197T 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 VerDate 15<DEC>99 10:04 Dec 21, 1999 Jkt 183197 PO 00000 Frm 00755 Fmt 8010 Sfmt 8010 Y:\SGML\183197T.XXX pfrm03 PsN: 183197T 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 VerDate 15<DEC>99 10:04 Dec 21, 1999 Jkt 183197 PO 00000 Frm 00756 Fmt 8010 Sfmt 8010 Y:\SGML\183197T.XXX pfrm03 PsN: 183197T