[Code of Federal Regulations]
[Title 49, Volume 2]
[Revised as of October 1, 2004]
From the U.S. Government Printing Office via GPO Access
[CITE: 49CFR178.65]
[Page 854-856]
TITLE 49--TRANSPORTATION
CHAPTER I--RESEARCH AND SPECIAL PROGRAMS ADMINISTRATION, DEPARTMENT OF
TRANSPORTATION
PART 178_SPECIFICATIONS FOR PACKAGINGS--Table of Contents
Subpart C_Specifications for Cylinders
Sec. 178.65 Specification 39 non-reusable (non-refillable) cylinders.
(a) Type, size, service pressure, and test pressure. A DOT 39
cylinder is a seamless, welded, or brazed cylinder with a service
pressure not to exceed 80 percent of the test pressure. Spherical
pressure vessels are authorized and covered by references to cylinders
in this specification.
(1) Size limitation. Maximum water capacity may not exceed: (i) 55
pounds (1,526 cubic inches) for a service pressure of 500 p.s.i.g. or
less, and (ii) 10 pounds (277 cubic inches) for a service pressure in
excess of 500 p.s.i.g.
(2) Test pressure. The minimum test pressure is the maximum pressure
of contents at 130 [deg]F or 180 p.s.i.g. whichever is greater.
(3) Pressure of contents. The term ``pressure of contents'' as used
in this specification means the total pressure of all the materials to
be shipped in the cylinder.
(b) Material; steel or aluminum. The cylinder must be constructed of
either steel or aluminum conforming to the following requirements:
(1) Steel. (i) The steel analysis must conform to the following:
------------------------------------------------------------------------
Ladle Check
analysis analysis
------------------------------------------------------------------------
Carbon, maximum percent............................. 0.12 0.15
Phosphorus, maximum percent......................... .04 .05
Sulfur, maximum percent............................. .05 .06
------------------------------------------------------------------------
(ii) For a cylinder made of seamless steel tubing with integrally
formed ends, hot drawn, and finished, content percent for the following
may not exceed: Carbon, 0.55; phosphorous, 0.045; sulfur, 0.050.
(iii) For non-heat treated welded steel cylinders, adequately killed
deep drawing quality steel is required.
(iv) Longitudinal or helical welded cylinders are not authorized for
service pressures in excess of 500 p.s.i.g.
(2) Aluminum. Aluminum is not authorized for service pressures in
excess of 500 psig. The analysis of the aluminum must conform to the
Aluminum Association standard for alloys 1060, 1100, 1170, 3003, 5052,
5086, 5154, 6061, and 6063, as specified in its publication entitled
``Aluminum Standards and Data'' (IBR, see Sec. 171.7 of this
subchapter).
(3) Material with seams, cracks, laminations, or other injurious
defects not permitted.
(4) Material used must be identified by any suitable method.
(c) Manufacture. (1) General manufacturing requirements are as
follows:
(i) The surface finish must be uniform and reasonably smooth.
(ii) Inside surfaces must be clean, dry, and free of loose
particles.
(iii) No defect of any kind is permitted if it is likely to weaken a
finished cylinder.
(2) Requirements for seams:
(i) Brazing is not authorized on aluminum cylinders.
(ii) Brazing material must have a melting point of not lower than
1,000 [deg]F.
(iii) Brazed seams must be assembled with proper fit to ensure
complete penetration of the brazing material throughout the brazed
joint.
(iv) Minimum width of brazed joints must be at least four times the
thickness of the shell wall.
(v) Brazed seams must have design strength equal to or greater than
1.5 times the minimum strength of the shell wall.
(vi) Welded seams must be properly aligned and welded by a method
that provides clean, uniform joints with adequate penetration.
(vii) Welded joints must have a strength equal to or greater than
the minimum strength of the shell material in the finished cylinder.
[[Page 855]]
(3) Attachments to the cylinder are permitted by any means which
will not be detrimental to the integrity of the cylinder. Welding or
brazing of attachments to the cylinder must be completed prior to all
pressure tests.
(4) Welding procedures and operators must be qualified in accordance
with CGA Pamphlet C-3 (IBR, see Sec. 171.7 of this subchapter).
(d) Wall thickness. The minimum wall thickness must be such that the
wall stress at test pressure does not exceed the yield strength of the
material of the finished cylinder wall. Calculations must be made by the
following formulas:
(1) Calculation of the stress for cylinders must be made by the
following formula:
S = [P(1.3D2 + 0.4d2)] / (D2 -
d2)
Where:
S = Wall stress, in psi;
P = Test pressure in psig;
D = Outside diameter, in inches;
d = Inside diameter, in inches.
(2) Calculation of the stress for spheres must be made by the
following formula:
S = PD / 4t
Where:
S = Wall stress, in psi;
P = Test pressure i psig;
D = Outside diameter, in inches;
t = Minimum wall thickness, in inches.
(e) Openings and attachments. Openings and attachments must conform
to the following:
(1) Openings and attachments are permitted on heads only.
(2) All openings and their reinforcements must be within an
imaginary circle, concentric to the axis of the cylinder. The diameter
of the circle may not exceed 80 percent of the outside diameter of the
cylinder. The plane of the circle must be parallel to the plane of a
circumferential weld and normal to the long axis of the cylinder.
(3) Unless a head has adequate thickness, each opening must be
reinforced by a securely attached fitting, boss, pad, collar, or other
suitable means.
(4) Material used for welded openings and attachments must be of
weldable quality and compatible with the material of the cylinder.
(f) Pressure tests. (1) Each cylinder must be tested at an internal
pressure of at least the test pressure and must be held at that pressure
for at least 30 seconds.
(i) The leakage test must be conducted by submersion under water or
by some other method that will be equally sensitive.
(ii) If the cylinder leaks, evidences visible distortion, or any
other defect, while under test, it must be rejected (see paragraph (h)
of this section).
(2) One cylinder taken from the beginning of each lot, and one from
each 1,000 or less successively produced within the lot thereafter, must
be hydrostatically tested to destruction. The entire lot must be
rejected (see paragraph (h) of this section) if:
(i) A failure occurs at a gage pressure less than 2.0 times the test
pressure;
(ii) A failure initiates in a braze or a weld or the heat affected
zone thereof;
(iii) A failure is other than in the sidewall of a cylinder
longitudinal with its long axis; or
(iv) In a sphere, a failure occurs in any opening, reinforcement, or
at a point of attachment.
(3) A ``lot'' is defined as the quantity of cylinders successively
produced per production shift (not exceeding 10 hours) having identical
size, design, construction, material, heat treatment, finish, and
quality.
(g) Flattening test. One cylinder must be taken from the beginning
of production of each lot (as defined in paragraph (f)(3) of this
section) and subjected to a flattening test as follows:
(1) The flattening test must be made on a cylinder that has been
tested at test pressure.
(2) A ring taken from a cylinder may be flattened as an alternative
to a test on a complete cylinder. The test ring may not include the heat
affected zone or any weld. However, for a sphere, the test ring may
include the circumferential weld if it is located at a 45 degree angle
to the ring, 5 degrees.
(3) The flattening must be between 60 degrees included-angle, wedge
shaped knife edges, rounded to a 0.5 inch radius.
(4) Cylinders and test rings may not crack when flattened so that
their outer surfaces are not more than six
[[Page 856]]
times wall thickness apart when made of steel or not more than ten times
wall thickness apart when made of aluminum.
(5) If any cylinder or ring cracks when subjected to the specified
flattening test, the lot of cylinders represented by the test must be
rejected (see paragraph (h) of this section).
(h) Rejected cylinders. Rejected cylinders must conform to the
following requirements:
(1) If the cause for rejection of a lot is determinable, and if by
test or inspection defective cylinders are eliminated from the lot, the
remaining cylinders must be qualified as a new lot under paragraphs (f)
and (g) of this section.
(2) Repairs to welds are permitted. Following repair, a cylinder
must pass the pressure test specified in paragraph (f) of this section.
(3) If a cylinder made from seamless steel tubing fails the
flattening test described in paragraph (g) of this section, suitable
uniform heat treatment must be used on each cylinder in the lot. All
prescribed tests must be performed subsequent to this heat treatment.
(i) Markings. (1) The markings required by this section must be
durable and waterproof. The requirements of Sec. 178.35(h) do not apply
to this section.
(2) Required markings are as follows:
(i) DOT-39.
(ii) NRC.
(iii) The service pressure.
(iv) The test pressure.
(v) The registration number (M****) of the manufacturer.
(vi) The lot number.
(vii) The date of manufacture if the lot number does not establish
the date of manufacture.
(viii) With one of the following statements:
(A) For cylinders manufactured prior to October 1, 1996: ``Federal
law forbids transportation if refilled-penalty up to $25,000 fine and 5
years imprisonment (49 U.S.C. 1809)'' or ``Federal law forbids
transportation if refilled-penalty up to $500,000 fine and 5 years
imprisonment (49 U.S.C. 5124).''
(B) For cylinders manufactured on or after October 1, 1996:
``Federal law forbids transportation if refilled-penalty up to $500,000
fine and 5 years imprisonment (49 U.S.C. 5124).''
(3) The markings required by paragraphs (i)(2)(i) through (i)(2)(v)
of this section must be in numbers and letters at least \1/8\ inch high
and displayed sequentially. For example:
DOT-39 NRC 250/500 M1001.
(4) No person may mark any cylinder with the specification
identification ``DOT-39'' unless it was manufactured in compliance with
the requirements of this section and its manufacturer has a registration
number (M****) from the Associate Administrator.
[Amdt. 178-114, 61 FR 25942, May 23, 1996, as amended at 65 FR 58631,
Sept. 29, 2000; 66 FR 45389, Aug. 28, 2001; 67 FR 51654, Aug. 8, 2002;
68 FR 75748, 75749, Dec. 31, 2003]