CODES & STANDARDS

PIPING
• Codes, Standards & Regulations
– ASME
– DIN
– TRD
– BS
– IBR
• Codes and Standards:
•  
• Several groups have written codes and standards for
materials, inspection, design, stress analysis, fabrication,
heat treatment, welding and construction of pipes and
piping components. Regulations, practices, rules and laws
are also available for use of piping. Certain aspects are
mandatory and certain aspects are recommendatory. The
commonly used American Codes and Standards on piping
are given below:
• 1. ASME B31.1 - Power Piping
• 2.          ASME B31.2 - Fuel Gas Piping
• 3.          ASME B31.3 - Process Piping
• 4.          ASME B31.4 - Pipeline Transportation Systems for Liquid
• Hydrocarbons and other Liquids.
• 5.          ASME B31.5 - Refrigeration Piping
• 6.          ASME B31.8 - Gas Transmission and Distribution Piping
• Systems
• 7.          ASME B31.9 - Building Services Piping
• 8.          ASME B31.11 - Slurry Transportation Piping Systems.
• Through the use of codes and standards, safety and uniform economy are
obtained. The codes and standards primarily cover the following aspects:
• 1.      Factors safety
• 2.      Material property
• 3.      Thickness calculation
• 4.      Loads
• 5.      Load combinations
• 6.      Stress limits
• 7.      Stress intensification factors
• 8.      Flexibility factors
• 9.      Supports
• 10.   Flexibility analysis.
• Even though the use of codes and standards is not a legal requirement
the same becomes a legal requirement in a contractual situation.
Certain regulations are legally binding. The Indian Boiler
Regulations, 1950 (IBR) is binding on the Indian Boiler-makers and
Boiler-users, of certain kind of boilers. The codes and standards do
not cover all aspects of the piping. The codes and standards are not
textbooks. They do not cover the theory. They provide answers to the
following aspects:
•  
• 1.      Know what
• 2.      Know how
• The “Know why” is not covered by the codes and standards. The
“Know why” is learned by study, experimentation, application and
experience. In most of the situations, a knowledge of “Know what”
and “Know how” is sufficient to solve the problems. A knowledge of
“Know why” will help in handling the following situations:
•  
• 1.      Material selection
• 2.      Applicable code and standards
• 3.      Evaluation of the deviations
• 4.      Use of new fabrication and inspection methods.
• Codes and Standards:
•  
• The following codes and standards are referred:
•  
• 1.ASME-I : Rules for Construction of Power Boilers
• 2.ASME B31.1-1998 : Power Piping
• 3.ASME B16.5-1996 :Pipe Flanges and Flanged Fittings – NPS ½ through 24.
• 4.IS 1239 (Part-I)-1990 :Mild Steel Tubes, Tubular and other
• Wrought Steel Fittings - Mild Steel Tubes
• 5.IS 1239 (Part-II)-1992 :Mild Steel Tubes, Tubular and other
• Wrought Steel Fittings – Steel Pipe Fittings
• Nominal Pipe Size (NPS):
•  
• The Nominal Pipe Size (NPS) in an ASME method of indicating the
approximate outside diameter of the connected pipe in inches. Note
that the unit (inch) is not followed after the designation.
•  
• Class of Fittings:
•  
• The class of fittings is an ASME method of indicating the pressure
carrying capacity of the fittings.
• Schedule of Pipes:
• The schedule of pipes is an ASME method of indicating the pressure
carrying capacity of the fittings.
• Types of Flanges:
• The following types of flanges are used:
•  
• 1.                   Threaded
• 2.                   Socket welding
• 3.                   Blind
• 4.                   Slip-on welding
• 5.                   Lapped
• 6.                   Welding neck.
•  
• Pressure – Temperature Rating:
•  
• Ratings are maximum allowable working gauge pressure at
a given temperature. These values are given in ASME
B16.5.

• Selection of Flanges:
•  
• The flanges are selected based on the application, pressure,
temperature and size.
 REFERENCES

 ASME Section-I PG 9 – Materials Specifications List.

 
ASME Section-II Part-A – Material Specifications.
- SA106, 192, 299, 210, 213, 234, 515.
 
ASME Section-II Part-D – Table IA – Maximum Allowable Stress
- Table Y, U
 
ASME Section-II Part-A
 
Tubes - SA450 - Specification for General Requirements for tubes.
 
Pipes - SA530 - Specification for General Requirements for Pipes.
 
Fittings - SA234 - Specification for Piping Fittings.
 
Drum combined bending Stress – BS 1113, ANNEX-B. 
 COMPARISON OF BOILER CODES 

Boiler Codes have been written by various nations in the past

century to ensure safety of personnel and to avoid loss of property. Boiler
codes cover the whole gamut of activities including Design, Fabrication,
Testing, Construction and Operation. Although these codes are framed on a
common intent, there are variations on the degree of conservation on
different aspects. One such area where variations do exist between Boiler
Codes is the criteria stipulated for calculating the allowable stresses. In the
present day context of evolving competitive design without sacrificing the
safety needs laid down in the boiler codes, an attempt has been made by
comparing the various aspects in the design like allowable stress, Design
temperature criteria, the various formulae used to determine the thicknesses
for drums / shells, headers, tubes, dished / flat ends, etc, other aspects like
minimum design requirements for drums/headers & tubes and presented in
annexures. The various aspects of IBR Regulations are called out and
consolidated against major items like drum, headers, lines & links, etc. The
following codes have been considered for the study:-
 
1.IBR 1950
2.ASME Section-I
3.BS 1113
4.DIN TRD 300. 
 The observations made between various boiler codes in respect
of design are given below:-
 
1) Yield strength at room temperature is not considered in BS1113
and IBR whereas factor of safety at room temperature in ASME
Section-I is 1.5 and the same in TRD is 2.4.
 
For tensile strength at room temperature, both IBR and BS1113
considers a factor of safety of 2.7 whereas in ASME Section-I
indicates 3.5 and not considered in TRD. In the case of rupture
strength, all codes consider factor of safety as 1.5 except
BS1113 which shows 1.3.

2) In the case of Design Pressure of the boiler IBR alone considers

pressure drop for various components inline with erstwhile ISO
R831 whereas the rest of the codes indicate the boiler to be
designed for drum design pressure.
 
3) In respect of Design Temperatures, all codes apply some fixed
temperature allowances over the medium temperature except
ASME Section-I which states that parts to be designed for actual
metal temperatures.
4) Comparison material grades among various codes indicate
specification as common for most of the material
compositions. DIN (GERMAN) indicates a specification 12
Cr, 1 Mo, ¼ V composition (X20) which is not finding a
place in both ASME & BS1113. Also, when there is a
specification indication for austenitic steels like 18 Cr 8 Ni,
18 Cr 10 Ni Cb in both ASME & BS1113, there is no such
grade under TRD 300.
 
It is concluded that ASME Section-I gives the most
stringent criteria on design for deciding the allowable
stresses (Tensile / 3.5) compared to other international
codes below creep region. BS1113 & IBR are same in
respect of design criteria for allowable stresses (Tensile /
2.7). TRD 300 is in between ASME & IBR / BS1113 since
the allowable stress values of DIN falls in between them.
Above creep region, BS1113 gives more liberal criteria
(Creep rupture / 1.3) compared to other international codes.
Weight savings arising out of adopting BS1113 compared
to ASME Section-I is also illustrated in an annexure.
 COMPARISON OF BOILER CODES
Sl.No. Item Description

01. Applicability of Code Regulations

02. Maximum Allowable Working Pressure

03. Design Pressures & Design Temperatures

04. Comparison of Codes

05. Design Stresses - Factors of Safety

06. Comparison of Material Grades

07. Temperature Limits for various Steel Grades

08. Design - Calculation of Thickness Required

09. Openings in Shell

10. Ligament Efficiency

11. Drum / Headers comparison - 2 sheets

12. Tubes comparison

13. Relationship between Allowable Stress, Weight Savings

14. IBR Regulations - Clauses - 2 sheets

15. IBR Regulation Numbers - Ascending Order - 8 sheets

16. Requirements as per ASME Section-I - 3 sheets

17. Salient Clauses of BS1113 - 3 sheets

 APPLICABILITY OF CODE REGULATIONS
   
IBR Applicable to boiler that is a closed vessel exceeding
22.75 litres in capacity which is used to generate
steam under pressure.
   
ASME Sec. Applicable to boilers in which the steam or any other
I vapour is generated at a pressure more than 15 PSI
(g).
   
BS 1113 The rules specify the requirements for the water
tube steam generating plant subject to internal
pressure.
   
TRD 300 The rules apply to steam boilers and to feed water
preheaters, SH with shut off devices, RH, DESH,
  steam and hot water lines and fittings which are
 
  regarded as part of the steam boiler installation.
 MAXIMUM ALLOWABLE WORKING PRESSURE
   
IBR It is the working pressure of any component of the
boiler.

   
ASME Sec. It is the maximum pressure to which any part of
I the boiler is subjected to except when SV or SRV or
Valves are discharging at which time the MAWP
shall not be exceeded by more than 6%.

   
BS 1113 It is the highest set pressure on any SV mounted on
the steam drum.

   
TRD 300 For steam generators, the design pressure shall be
  the allowable pressure.
 DESIGN PRESSURES & DESIGN TEMPERATURES -
ALLOWANCES USED IN VARIOUS CODES
         
AREA IBR ASME BS DIN TRD
SEC.I 1113 300
 
DESIGN PRESSURE Drum design
pressure with
Drum design
pressure
Drum design
pressure
Drum design
pressure
pressure drop

       
RADIATION 50C 50C 50C
 

ACTUAL METAL TEMPERATURE

       

371C (MIN) FOR GAS

CONVECTION 39C 35C 35C

TOUCHED PORTION
 
       
ECONOMISER 11C 25C 15+2xAct.
wall thick)
  C
Max. 50C
       
WATER WALLS / SH WALLS 28C 50C 50C
 
       
GAS TOUCHED DRUMS/HEADERS 28C 25C 20C
 
 COMPARISON OF CODES
  IBR 1950 ASME SEC.I BS 1113 DIN TRD 300 REMARKS

           
DESIGN PRESSURE DESIGN PRESSURE DRUM DESIGN DRUM DESIGN DRUM DESIGN  
WITH PRESSURE PRESSURE PERSSURE PRESSURE
DROP
DESIGN          
TEMPERATUE 50C   50C 50C  
ALLOWANCE  
RADIATION  
           
CONVECTION 39C ACTUAL METAL 35C 35C  
TEMPERATURE
371C (MIN)
           
ECONOMISER 11C   25C (15 + 2 Se) C Se - ACTUAL WALL
  Max. 50C THICKNESS in mm.

         
WATER WALL 28C 50C 50C

           P=DESIGN PR.
TUBE THICKNESS PD PD PD PD D=OUTSIDE DIA
FORMULA tmin --------- + *C --------- + 0.005D --------- --------- f=ALLOWABLE STRESS
2f + P 2f + P 2f + P 2f + P CORR. TO DESIGN
        METAL TEMP.

  Et R Et R Et R Et R  Et = YIELD STRENGTH

FACTOR OF SAFETY 1.5 , 2.7 1.5 , 3.5 1.5 , 2.7 1.5 , 2.4 R = TENSILE STRENGTH
 SR SC  SR SC  SR  SR SR = RUPTURE
1.5 1.5 1.3 1.0 STRENGTH
SC = CREEP STRENGTH

 
FOR ASME MATERIALS ALLOWABLE STRESS CAN BE TAKEN DIRECTLY FROM ASME SEC.II PART-D

*C = CORROSION ALLOWANCE = 0.75mm FOR P ≤ 70 bar; 0 mm FOR P > 70 bar

DESIGN STRESSES – FACTORS OF SAFETY IN VARIOUS CODES
         
PROPERTIES IBR ASME BS 1113 DIN TRD
SEC.I 300
 

         
Min. yield strength at Room Temperature --- 1.5 --- ---
 

         
Min. yield strength at Design Temperature --- --- 1.5 1.5
 

         
Average yield strength at Design 1.5 1.5 --- ---
Temperature  

         
Min. ultimate tensile strength at Room 2.7 3.5 2.7 2.4
Temperature  

         
Average creep rupture strength for 100,000 1.5 1.49 1.3 1.0
hours life at Design Temperature  

         
Average creep strength for 1% creep in 1.0 1.0 --- ---
100,000 hours at Design Temperature

 For Austenitic steels, FS = 1.35

 To be used at temperature below 1500F
 For components without an acceptance test certificate to DIN 50049, FS shall be increased by 20%.
 COMPARISON OF MATERIALS GRADES
Max. Service 475C 500C 550C 560C 575C 600C 625C
Temperature  885F 930F 1020 1040 1065F 1110F 1155
F F F
                   
     
     
     
     
     
ASME
SA 106 Gr.A Gr.B Gr.C            
SA 192 A192                
SA 209 - SA 210 Gr.A1 Gr.C T1          
SA 213 - SA 335 P1 T2 / P2 T12/P T11/P1 T22/P2 T9/P9
12 1 2

                     
BS          
       
       
   
3059-3602- 360 410 440- 490Nb 243 620 621 622 660 629
3604 460

                           
DIN             15Ni    
       
   
(GERMANY) St.35. St.45. 17 19 15   CuM 13Cr 10Cr (14M (X12Cr
17175 8 8 Mn4 Mn5 Mo3 16 oNb
  Mo44
  Mo o MO
VdTUV.B1           Mo5 5 1.7335 9 10 V63) 91)
(Werkstoff-Nr.) 1.030 1.040 1.048 1.0482 1.541 1.542 1.63 1.7380 1.771 1.7386
5 5 1 5 3 68 5
           
GOST    
               
       
 
(RUSSIAN)   20 15 XM 12 (15X
TY 14-3-460-75 X1 IMI
MF F)

                   
JIS (JAPAN)      
     
     
     
     
G3456 G3458 STPT STPT STPT STPA STPA2 STPA2 STPA2 STPA2 STPA2
G3461 G3462 38 42 49 12 0 2 3 4 6
STB STB STBA STBA2 STBA2 STBA2 STBA2 STBA2
35 42 12 0 2 3 4 6
                               
NF A 49-213 TU37 TU42 TU48 TU52- TU15 TU15C TU13C TU10C TU10 TU
(FRENCH) -C -C -C C D3 D D D CD Z10
2.05 4.04 5.05 9.10 CD9

 This is indicative only. However, the actual maximum service temperature for various steels shall be limited as prescribed in the relevant codes.
TEMPERATURE LIMITS FOR VARIOUS STEEL GRADES OF TUBES / PIPES
Sl. Nominal MATERIAL SPECIFICATION Temp.

No. Composition ASME Section-I DIN – TRD 300 BS 1113 Limit C

           
01. Carbon Steel SA178 Gr.C, Gr.D, St 35.8 BS3059 P2 S2 360, 440 427
SA192, SA210 Gr.A1 St 45.8 BS3602 P1 360, 430, 500  
& Gr.C Nb
SA106 Gr.B, Gr.C
           
02. ½ Mo SA209 T1 15 Mo3 ---- 482

           
03. 1 Cr ½ Mo SA335 P12 13 Cr Mo 44 BS3059 P2 S2 620 535
SA213 T12 BS3604 P1 620 – 440

           
04. 1¼ Cr ½ Mo SA213 T11 ---- BS3604 P1, 621 552
SA335 P11

           
05. 2¼ Cr 1 Mo SA213 T22 10 Cr Mo 910 BS3059 P2 S2 622-490 577
SA335 P22 BS3604 P1, 622

           
06. 9 Cr 1 Mo ¼ V SA213 T91 X 10 Cr Mo V ----- 635
SA335 P91 Nb91

           
07. 12 Cr 1 Mo ¼ V ----- X 20 Cr Mo V 121 BS3059 P2 S2 762 700
BS3604 P1 762

           
08. 18 Cr 8 Ni SA213 TP304 H ----- BS3059 P2 304 S51 704
BS3605 – 304 S59 E

           
09. 18 Cr 10 Ni Cb SA213 TP347 H ----- BS3059 P2 347 S51 704
BS3605 347 S59 E
DESIGN - CALCULATION OF THICKNESS REQUIRED IN VARIOUS CODES

         
AREA IBR ASME SEC.I BS 1113 DIN TRD 300
 

         
Tube PD PD PD PD
thickness + C +0.005D
2f + P 2f + P 2f + P 2f + P
 
    PR   PR   PR   PR
Shell + 0.75
thickness fE  0.5 P fE  (1 Y) P fE  0.5 P fE  0.5 PE
   
    PDK PR   PDK 2P
Dished end + 0.75 R 1+ 1
thickness 2f 2f  0.2 P 2f 2f  P 
 
  CP CP P   P
Flat end d + C d Cd Cd
thickness f f f f
 OPENINGS IN SHELL

  PD
IBR 8.08 [Dt (1  K)]1/3 K=
1.82 St
  PD
ASME Sec. I 8.08 [Dt (1  K)] 1/3
K=
1.82 St
  PD
BS 1113 8.08 [Dt (1  K)] 1/3
K=
1.82 St

  t branch
  For dia of Opg.  50 mm, 2
  t shell
TRD 300
  opg dia t branch
  if  0.2, then  2.
For dia of Opg > 50 mm, shell ID t shell

opg dia t branch

if > 0.2, then ≠ 2.
shell ID t shell
 LIGAMENT EFFICIENCY
       
EFFICIENCY ASME IBR BS 1113

  P d   P d   P d
Longitudional
P P P

    PC  d   PC  d   PC  d
Circumferential
  PC PC PC

     
J + 0.25  (1 0.01 Elong) 0.75 +J 2 2
Diagonal    
  A + B+ (A  B)2 + 4C2 A + B+ (A  B)2 + 4C2
0.00375 + 0.005 J

TRD 300 gives lengthy equations for calculating the ligament efficiency factors. For a single opening,
’all
d i A + A’ 
all
VA = and for multiple openings,
’all
SV 2 AP+ A’  A’ 
all
 
  ’all ”all
di A0 + A1 + A2
all all
VL =
’all ”all
 DRUM / HEADERS - COMPARISON WITH VARIOUS CODES
         
DESCRIPTION IBR ASME SEC.I BS 1113 DIN TRD 300
 

         
Min. Plate thickness for shell 6 mm 6 mm 6 mm 3 mm

         
Type of weld joint Single or double ‘U’ or ‘V’ type. Double welded butt type. The Double ‘V’ Type or ‘U’ type. Double ‘V’ type.
shape shall be such as to
permit complete fusion and
complete joint penetration.

Position of tube holes
 
Circularity of Drum
 
Allowed through welded Any type of opening that meets Machining of holes through the -----
seams, if they are the requirements for centre of main seam welds is
radiographed and stress compensation may be located permitted provided the seam
relieved. The ligament in a welded joint. welds have been subjected to
efficiency shall be multiplied by NDE.
a factor 0.95.
Difference between internal The drum shall be circular Maximum internal diameter of The average bore shall not
diameter of drum shall not within a limit of 1% of mean drum shall not exceed the deviate by more than 1% from
exceed 1%. diameter based on the nominal internal diameter by the nominal diameter.
differences between maximum more than 2%.
and minimum mean diameters.

         
Percentage deviation from 2 (d max.  d min.) D max.  D min. D max.  D min. 2 (d max.  d min.)
circularity X 100 X 100 X 100 X 100
  d max. + d min. d max. + d min.
DS DS
         
Hand hole size in Headers 89 x 63.5 89 x 70 ----- ------
 
          
DESCRIPTION IBR ASME SEC.I BS 1113 DIN TRD 300
 

Hydraulic test point - Shop &
test pressure.
Drums & Headers greater ----- Drums & Headers greater -----
than 1000 mm shall be than 600 mm shall be
hydraulic tested at shop to 1.5 hydraulic tested at shop to 1.5
times the Design Pressure. times the max. permissible
working pressure.

         
Wall thickness tolerance for + 15%  12.5% + 10% + 12.5%
pipes / headers.  5%  10%  10.0%
 

         
Hydraulic test pressure at 1.5 times the Drum Design 1.5 times the maximum 1.5 times the maximum 1.3 times the maximum
site. Pressure. allowable Working Pressure. permissible Working allowable Working Pressure.
Pressure.

         
Requirement of Safety Two safety valves - the bore Two or more safety valves. Two safety valves. Minimum Two or more safety valves.
Valves. not less than 19mm. bore 20 mm.
 

         
Water level indication. Two means of indicating Two numbers of gauge glass. Two independent means of Two means of indicating
water leve. Two independent remote water level indication. water level.
level indicators instead of one
gauge glass.
 TUBES - COMPARISON WITH VARIOUS CODES
         
DESCRIPTION IBR ASME SEC.I BS 1113 DIN TRD 300
 

         
TYPE Cold drawn or hot Cold drawn or hot Cold drawn or hot Cold drawn or hot
finished seamless or finished seamless finished seamless or finished seamless or
ERW or ERW ERW Longitudinally
welded

         
Minimum thickness Up to D32 - 2.03 Up to D32 - 2.41 Up to D38 - 1.7 Min. - 3 mm
allowed for various Up to D51 - 2.34 Up to D51 - 2.67 D38 to D51 - 2.2 Max. - 6.3 mm
tube Diameters - D51 to D76 - 2.64 D51 to D76 - 3.05 D51 to D70 - 2.4 for Water wall tubes
D76 to D102 - 3.43
Seamless. D76 to D89 - 3.25 D70 to D76 - 2.6
D102 to D127 - 3.81
D89 to D114 - 3.66 D76 to D95 - 3.0
D95 to D102 - 3.3
D102 to D127 - 3.5

   D Max.  D Min.  D  D Min.    

Ovality x 100 x 100 2(DMax.DMin.) Provides calculation
(Deviation from D x100 for wall thickness
circularity) D  shall not be more DMax + DMin for inside & outside
shall not exceed than 50D   of bend as per
% TRD301 Annex-2.
20D R

    R      
Wall thickness + 10% + 22% + 10% + 15%
tolerance  5%  0%  10%  10%
 RELATIONSHIP BETWEEN ALLOWABLE STRESS, WEIGHT
AND SAVINGS IN WEIGHT
 (TYPICAL 250 MW)
        Allowable Stress % increase Correspond
in -ing
Sl. Item Material Design Kg/mm2 in allowable
allowable
No Specn. Temp. C Stress Stress

ASME BS 1113

             
01. Water Walls SA210 385 11.038 13.228 19.8 11.4
Gr.C

             
02. Downcomers SA106 357 11.993 13.570 13.0 9.8
Gr.C

             
03 Riser Pipes SA106 357 10.339 11.859 14.7 9.8
Gr.B

             
04. Economiser SA210 311 10.546 12.896 22.3 16.0
A1

             
05. Low temp. SA210 373 10.087 12.442 23.7 17.6
SH A1
 IBR REGULATIONS
I) DRUM
a) Circularity of drum 243 (a)256 (b)
b) Drawing preparation 249
c) Type of weld joint 253
d) Long seam intersection 254
E )Position of tube holes 255
f) Hydro Test 268
g) Maximum working pressure for shell 270
h) Stress factors 271
I )Ligament efficiency 272 (215)
j) Longitudinal stress 273
K Shape of Dished end plate 275
l) Dished end with openings 277
M) Dished end maximum working pressure 278
n) Reinforcement calculation 279
o) Attachment of Branch pipes 280
p) Mountings on the drum 281
q) Attachment (SV) to dru 296
r) Water gauges 320
s) Uncompensated hole 187
II) HEADERS
a) Header shapes and Process 154 (a)
b) Hand holes 164 (a)
c) Uncompensated hole 187
d) Maximum working pressure 270
e) Stress factors 271
f) Ligament efficiency 272 (215)
g) Shape of Dished end 275
h) Dished end opening 277
i) Dished end maximum working pressure 278
j) Reinforcement calculation 279
k) Attachment of Branch pipes 280
l) Flat ends maximum working pressure 340 (f)
m) Headers for boiler & SH 342
 III) TUBES
a) Process 151 (a), (b), (c)
b) Tubes 244 (a)
c) Maximum working pressure 338 (a)
d) Percentage ovality 338 (b), (c)

IV) LINES & LINKS (BOILER INTEGRAL PIPING)

a) Integral boiler piping 244 (b)
b) Process 343 (1)
c) Material, permissible stress 343 (2)
d) Hydraulic Test 343 (3)
e) Temperature limits for Pipes, Tees, Branches 349
f) Maximum working pressure 350
g) Steam pipe bending thinning 361 (a)
h) Butt welding fittings 361 (A)
i) Branch welded to pipes 249 to 253
j) External Reinforcement 362 (b)
k) Hydraulic Test 374
V) BOILER MOUNTINGS
A. SAFETY VALVES

a) Discharge capacity 293

b) Over pressure of safety valve 294
c) Pressure drop 295
d) Attachment to boiler 296

B. WATER GUAGES

a) Requirements 320 a, b.

VI) GENERAL

1) Procedure of Hydro test of boiler 379

2) Registration Fee 385
3) Submission of plans of boilers 393
4) Submission of plans of steam pipes 395
  IBR
BOILER & SH TUBES
 
Regn. 151: Tubes Cold drawn or hot finished
 
a)           Seamless or ERW tubes
 
b)            Tubes < 5” dia - can be used inside the boiler
> 5” dia - can be used outside the boiler
 
c)             Flash welding allowed.
 
 HEADERS MUD BOXES, ETC. OF WATER TUBE BOILERS

Regn. 154:
 
a) Headers Seamless or Welded steel or cast steel.
 
i)            Where welded, the welding shall be stress relieved, radiographed or
UT.
 
ii) Headers may be closed by forging, bolting, screening or welding.
 MAIN HOLES
 
Regn. 164 (a): Hole size not less than 3½ x 2½ in.
PD
Regn. 187: Uncompensated hole - Maximum 203 mm =
1.82 fe
 FUSION WELDED DRUMS
 
Regn. 244 (a): Tubes
 
Regn.244 (b): Pipes of boiler shall comply with Chapter VIII.
 
Regn.243 (a): Circularity of drum 1%.
2 (d max.  d min.)
Regn. 243 (b): Percentage deviation = x 100
from circularity (d max. + d min.)
 
d = internal dia
 
Regn. 249: Fully dimensioned sectional drawing showing in full
detail the construction of drum - Fully dimensioned
drawings of the proposed weld preparation of the main
seams to a scale - attachment, seatings, etc. to be
furnished.
Regn. 253: Drum - type of welded joint - Single or double ‘U’ or
‘V’ type.
 
Regn. 254: Longitudinal seams in successive rigs shall not fall
in line except where the rigs of drum are in two
halves of unequal thickness.
 
Regn. 255: Position of tube holes:-
 
Tube holes through welded seams, if they are
radiographed and stress relieved - The efficiency
and ligament multiplied by a factor 0.95 except the
distance from edge hole to edge of weld > 13mm
(½”).
 
Regn. 256: Circularity of drum:-
The difference between internal diameter of drum
shall not exceed 1%.

Regn. 268: Hydro test - 1½ times the maximum permissible

working pressure after completion of welding and
heat treatment of drum (internal dia > 1000 mm).
 2 f E (T  0.03)
Regn.270: The working pressure - WP =
D + T  0.03
Weld factor 0.95.
 
Regn. 271: For temperature at or below 454C

Et R
(or)
1.5                   2.7
  For temperature above 454C
Et SR
(or) (or) SC
1.5 1.5
In case SC valves are not available, the allowable stress may be
Et SR
lower of (or)
1.5 1.5
 Regn. 272: The ligament efficiency as per Regn. 215.
  Pd P  nd P P1
Diagonal and Curve
P P d P
  Circumferential ligament.
 PD2
Regn. 273: Longitudinal Stress = fd =
1.273A
PD2
M=
1.273
MRY
The stress due to bending f b =
Ia
 
Regn. 275: Shape of Dished end plate
 
a)            Hemispherical
 
b) Elliptical heads -H  0.2D
 
c)           Partial spherical heads - H  0.18D.
 
Figures 23A, B, C.
Regn. 276: Gradual thinning up to a maximum of 10% of thickness
where the corner radius joins the dishing radius.
 
Regn. 277: Dished end with opening (inline with ISO).
 
d A
d1 = d 
DT T
 
Regn. 278: Dished end plate maximum working pressure
2f (T  C)
WP =
DK (Shape factor)
Minimum head thickness - 5 mm.
 
Regn. 279: Reinforcement calculation.

Regn. 280: Attachments of Branch Pipes by welding.

 
Figures 24A to D, 26A to E, 27A to D.
 VALVES, GAUGES AND AUXILIARIES
 
Regn. 281: Every boiler shall be provided.
 
Two safety valves - one of which may be a high steam
and low water type, the bore not less than 19mm.
 
Two means of indicating water level.
 
a steam pressure gauge.
 
a steam stop valve.
 
a feed check valve.
 
one feed apparatus.
 
A blow down cock valve.
 
A manhole - A safety valve at the end of SH outlet.
New Regn.281A: Water level and or firing control.
 
SAFETY VALVES
 
Regn. 293: Discharge capacity.
 
Saturated steam E = CAP
 
E
Superheat steam ES =

1 + 2.7 TS
1000
  
Regn. 294: Over pressure of safety valves:
 
Where discharge area < 80% - Over pressure shall not exceed
10% of set pressure.
 
Where discharge area > 80% - Over pressure shall not exceed
5%.
Regn. 295: Pressure drop:
 
Reset at a pressure at least 2.5 below but not more than
5% below safety valve set pressure. The 5% limit
increased to 10% for valves having seat bore less than 32
mm and or having a set pressure of 2 bar gauge or less.
 
Regn. 296: Attachment to Boiler:
 
The axis valve shall be vertical. Branches shall be as short
as possible.
 
Regn. 320: Water Gauges:
 
Every boiler shall have two means of indicating the water
in it of which one shall be conventional gauge glass.
Minimum length of visible portion of gauge glass 200 mm.
 
b) For boilers > 10,000 lb/hr., one of water gauges may be of
remote water level indicator type.
BOILER AND SH TUBES, HEADERS
 
Regn. 338(a): 2f (T  C) C = 0.75 for P  70 Kg/m2
WP =
(D  T + C) = 0 for P > 70 Kg/m 2
 
The working metal temperature.
 
ECO = The maximum water temperature + 11C.
 
Furnace & boiler tubes = Sat. temperature + 28C.
 
Convection SH =Maximum steam temperature + 39C.
 
Radiant SH = Maximum steam temperature + 50C.
 
 
For temperature at or below 454C.
 
TS Et
(or)
2.7 1.5
 
For temperature above 454C
 
SR or SC
1.5

If SC not available
 
Et SR
(or)
1.5                 1.5
 
b) % Ovality = D max.  D min.
x 100
D
Regn. 340 (f): Flat ends for headers -
 
f (t  C)2
WP =
d2 K
 
Regn. 342: Cylindrical headers - As per Regn. 270.
 
End attachments - As per Regn. 340(f).
 

STEAM PIPES AND FITTINGS

 
Regn.343(1): Carbon steel, Cast steel, Alloy steel, cold or hot
finished, butt welded or ERW.
 
Regn. 343(2): Material used, the permissible stress figures
specified in the code may be accepted.
Regn. 343(3): The hydraulic test may be dispensed with if id 
600 mm.
 
Regn. 349: The temperature limits for pipes, Tees, branches,
etc. shall be as per Table-2.
 
Regn. 350: Working Pressure.
  2fe (t  C)
WP = C = 0.75.
Dt+C
STEAM PIPE FITTINGS
 
Regn. 361(a): Pipe bends thinning 12.5%.
 
Regn. 361(A): Butt welding fittings.
 
Regn. 362(a): Branch welded to pipe Regn. 249 to 253. Angle not
less than 60.
 
Regn. 362(b): External Reinforcement :
 
Multiple radial plates of horse shoe form or the form
of collars applied to or around the junction between
branch and main.
Regn. 374: Hydro test pressure in the piping system - 1.5 times the
design pressure.
 
REGULATIONS FOR THE REGISTRATION AND INSPECTION OF BOILERS

Regn. 379: Procedure of Hydro test.

 
Test pressure 1.5 times the maximum working pressure.
  Temperature of water > 20 < 50C.
  Not exceeding 6% of the required pressure.
 
Regn. 385: Registration Fee:
 
Regn. 393: Submission of plans of boilers:
 
a)           Drawing Approval.
 
b) & c) Boilers made outside India, Technical Advisor (Boilers)
and then CIB user state.
 
d) Scrutiny fees as per Regn. 385 subject to a
maximum of Rs. 20,000.
 
Alteration fee at 10% of the fee of the first
scrutiny fee.

Regn. 395: Submission of plans of steam pipes:

 
Rs. 30 for 30 meters minimum of Rs. 50.
 
Fittings like DESH, Separators, etc. Rs. 150
each.
Sl.No. DESCRIPTION CLAUSE REQUIREMENT AS PER ASME SEC.I 2001 REMARKS

1. Service Limitations PG-2 a)Boilers in which steam/vapour is generated  

at a pr. more than 15 PSIG
b)High temp. water boilers >
160 PSIG or 250 Deg.F

2. Plate material PG-6 Shall be of pressure vessel quality SA202;  

SA204; SA240(Type 405 only) SA302;
387(A.S) SA285; SA299; SA515; SA516
(C.S), SA / EN - 10028 - 2

3. Pipes, Tubes PG-9 PG 9.1 for boiler parts materials  

materials PG 9.1 & 9.2 for superheater matrials

4. Boiler plate PG-16.3 The min. thickness of any boiler plate under  
min.thick pressure shall be 1/4 in (6 mm)

5. Tubing calculation PG-27.2.1 "Upto and including 5 inches outside dia"  

(127mm) t(inch)=PD/2S+P +0.005D+e
e = 0 for tubes
strength welded to headers P=
Max. allowable working pressure(psi)
D = Outside dia(in)
S = Max. allowable stress
(psi)
Sl.No DESCRIPTION CLAUSE REQUIREMENT AS PER ASME SEC.I REMARKS
. 2001

6. Piping, Drums and PG- t =PD / 2SE+2YP + C (or) t = PR / SE - (1-  

headers 27.2.2 y)P+ C E = efficiency of liagament of
calculation weld joints Y=
temperature co-efficient
C = Min. allowance for threading
and structural stability (0)
7. Hemispherical PG-29.11 t = PL / 1.6S R = Inside  
head radius in L = radius to which formed
head measured on concave side

8. 2:1 Semi- PG-29.7 t = PR / SE - (1-y)P + C  

ellipsoidal & R = Inside radius of end
PG- cover
27.2.2
9. Max. Dia of PG- K Factor = PD / 1.82 St  
opening in shell 32.1.2 Max. dia of opening without
& compensation as per Fig PG 32
PG-
32.1.3.2
10. Compensation PG - 37 Limits of reinforcement  
Calulation & PW - X = greater of 2d or 2(t + tn)
15 but not greater than pitch Y = the smaller
of 2 1/2t or 2 1/2 tn
Sl.No. DESCRIPTION CLAUSE REQUIREMENT AS PER ASME SEC.I 2001 REMARKS

11. Max. allowable PG - 22 & Total stress = fb + fd  

stress for drum Sec.3.3.4 fb = stress due to bending
(Bending and Longi of BS- fd = Direct longitudinal
stress) 1113 stress
12. Hydraulic test pr. PG 99.1 1.5 times the max. allowable working pr.  
Calculate stress at hydraulic test by
substituting in thick formula.Stress at hydro to
be leser than 90% yield stress at 100 deg. F.

13. Min. weld size PW - 16.1 Check as per Fig. PW 16.1  

14. Min. weld size PG - 37 Combined strength of each path >min. weld  
PW - 15 strength required

15. Feed water PG - 59.2 Boiler pr. 400 PSI or over the feed water inlet  
connection shall be fitted with sleeves.

16. Blow - off PG - Boiler shall have a bottom blow off outlet in the  
59.3.3 lowest water space.

17. Water level indicator PG - a) Two nos. gauge glass over a boiler pr. Of 400 PSI  
60.1.1 b) Two independent remote level indicators instead of
one gauge glass in case of pr. above 900 PSI
c) The lowest visible part of gauge shall be at least 2
in. above lowest water level
Sl.No DESCRIPTION CLAUSE REQUIREMENT AS PER ASME SEC.I REMARKS
. 2001

18. Water level PG - a) Connection to the gauge glass shall not  

indicator 60.1.6 be less than 1/2" pipe size
b) Water gauge
glass drain not less than 1/4 in. Above
100 PSI pr. Drain connects to safe
discharge point
19. Pressure gauges PG - Pr. Gauge connection to the boiler shall  
60.6.1 not be less than 1/2 in. Inside dia. for
steel pipe.

20. Test pr. Gauges PG- Connection to the test pr. gauge shall be  
60.6.3 at least 1/4 in. pipe size

21. Feed water supply PG-61 a)Boiler having more than 500 sq. ft. of  
water heating surface shall have two
means of feeding water b) The
feed connection shall not be less than 3/4"
pipe size for water heating surface more
than 100 sq. ft.
Sl.No. DESCRIPTION CLAUSE REQUIREMENT AS PER ASME SEC.I 2001 REMARKS

22. Boiler safety valve PG-67.1 Boiler with water heating surface exceeding  
reqts 500 sq. ft. and steam generating capacity
exceeding 4000 lb/hr two or more safety
valves are required.
    PG-67.3 a) one or more safety valves shall be set at  
or below max. allowable working pr.
B)The highest pr. Setting shall
not exceed 3% of the max. allowable
working pressure
    PG - 67.2 c) The safety valve will discharge all the  
steam generated by the boiler without
allowing the pr. to rise more than 6% above
max. allowable working pressure.

    PG-68.2 The discharge capacity of the safety valve  

on the boiler is at least 75% of the aggregate
value capacity required

23. Drain, vents PG - Piping connections for items such as drains,  

provisions 58.3.7 vents for a high temp. Boiler.
 SALIENT CLAUSES OF BS-1113-1990
  SECTION –2 MATERIALS AND DESIGN STRESSES

2..1.2 MATERIALS FOR PP.

 
BS MATERIALS OR AGREED BETWEEN MANUFACTURER AND
PURCHASER
 
 
2.2 DESIGN STRESSES
 
2.2.3 FOR C, C-Mn AND LOW ALLOY STEELS
 
FE = Re (T)/1.5 OR Rm /2.7 WHICHEVER GIVES A LOWER
VALUE.
 
2.2.4 FOR AUSTENTIC STEEL
 
FE = Re (T)/1.35 OR Rm /2.7 WHICHEVER GIVES A LOWER
VALUE.
2.2.7 DESIGN TEMPERATURE
  
2.2.7.1 DRUMS AND HEADERS
 
NOT HEATED BY GAS - EQUALS FLUID TEMP.
HEATED BY GAS - ADD 25  C.
 
2.2.7.2 BOILER TUBES
  
SUBJECT TO RADIANT HEAT -- SAT TEMP. + 50  C.
 
NOT SUBJECT TO RADIANT HEAT -- SAT TEMP. + 25 
C.
 
 
2.2.7.3 SH & RH TUBES
 
SUBJECT TO RADIANT HEAT -- SAT TEMP. + 50  C.
 
NOT SUBJECT TO RADIANT HEAT -- SAT TEMP. + 35 
C.
  
2.2.7.4 ECONOMIZER TUBES
 
SECTION –3 DESIGN
  
3.3.4 COMBINED STRESSES IN DRUMS AND HEADERS.
 
TO BE BROUGHT IN PLACE OF REG.73 OF IBR
 
3.3.1 MINIMUM 9.5 mm THICK FOR HEADERS OF OD 300 mm AND
ABOVE.
 
3.3.2 MINIMUM 6 mm THICK FOR HEADERS UPTO OD 300 mm
t = PDi / 2 f n - P
 
3.3.3.1. MAX DIA OF UNREINFORCED OPENING 200 mm.
 
 
3.6.1 DISHED ENDS
 
TORI AND SEMI ELLIPSOIDAL DISHED ENDS.
  
3.6.1.2 t= PDOK/2f
 
MINIMUM THICKNESS OF DISHED ENDS TO BE 9.5 mm.
3.6.1.3.1 UNREINFORCED OPENINGS
 
OPENINGS NOT TO BE GIVEN IN D/10
AREA.
 
3.7.2 TUBES AND PIPES
 
3.7.2.1 t = P do/2f + P.
 
MINIMUM THICKNESS TO AS UNDER
 
UPTO 38 MM OD 1.7
38 TO 51 MM OD 2.2
51 TO 70 MM OD 2.4
70 TO 76 MM OD 2.6
76 TO 95 MM OD 3.0
95 TO 102 MM OD 3.3
102 TO 127 MM OD 3.5
 SECTION 4 MANUFACTURE AND WORKMANSHIP
 
 
4.2.2.5.1 PLATES CAN BE BUTT WELDED PRIOR TO
FORMING PROVIDED WELD IS NDT EXAMINED.
 
 
4.2.2.5.2 OUT OF ROUNDNESS NOT TO EXCEED 1 % OF
NOM INTERNAL DIA.
 
 
 
4.3.1.1.6 LONGITUDINAL DRUM SEAMS TO BE WELDED
BEFORE CIRCUMFERENTIAL SEAMS AND WHRE
PRACTICABLE THE LONGITUDINAL SEAMS OF
ADJACENT COURSES SHALL BE STAGGERED.
 
 
4.3.1.1.7 HOLES CAN BE MACHINED THROUGH THE SEAMS
AFTER SEAM HAS BEEN NDT EXAMINE PRIOR TO
PWHT.
 SECTION 5 INSPECTION AND TESTING
 
 
5.10.1.1         HYDROSTATIC TEST PRESSURE
 
 
5.10.2.1 HYDRO TEST PRESSURE OF BOILER 1.5 TIMES
THE MAX WORKING PRESSURE.
 
DRUMS AND CYLINDRICAL HEADERS GREATER
THAN 600 MM SHALL BE HYDROSTATICALLY
TESTED AT SHOP.
 
5.10.3.1 ALL COMPONENTS NOT REASONABLY
ACESSIBLE TO INSPECTION AFTER ASSEMBLY
TO BE HYDROTESTED AT SHOP.
 SECTION 7 VALVES, GUAGES AND FITTINGS
 
7.2 SAFETY VALVES
 
 
7.2.1.1 MINIMUM BORE 20 mm
 
7.2.1.2 FOR EVAPOTATION UPTO 3700 KG/H ONE
SAFETY VALVE FOR GREATER
EVAPORATION TWO SAFETY VALVES
 
 
7.2 WATER LEVEL GUAGE
 
 
EACH BOILER TO HAVE TWO INDEPENDENT
MEANS OF WATER LEVEL INDICATION.