GUIDE TO

PRESSURE VESSEL CODES

BHARAT HEAVY ELECTRICALS LIMITED

CORPORATE QIALITY ASSURANCE

BHARAT HEAVY ELECTRICALS LIMITED

CORPORATE QIALITY ASSURANCE

INTRODUCTION
There is an increasing use of national and international codes on unfired
pressure vessels in BHELs Plants as well as in the works of BHELs Vendors.
While interpretation of the Codes is possible by going through the actual
codes, it is felt necessary that salient features of some of the regularly used
national and international codes will be useful in concise form and in the form
of a comparative statement.
Some work in this regard was already done by Bhopal and Hyderabad Plants.
This Publication is an attempt to assist the Specialists, Executives and
Supervisors at Shop Floor level as a reference document. The efforts put in
by the Quality Services Group of Bhopal and Ramachandrapuram in
compiling this useful booklet is acknowledged.

Secunderabad
May 5, 1984.

(P.S.THILAK)
Dy. General Manger
Corporate Quality Assurance

B.S.5500 : 1976
A. SCOPE OF THE COSES
Covers design, constructions,
inspection,
testing
and
certification of unfired fusion
welded pressure vessels.
Sections include:
1. General (Definitions and
responsibility of purchaser,
manufacturer,
inspectors
etc.)
2. DESIGN

3. MANUFACTURE
WORKMANSHIP

&

4. INSPECTION & TESTING

5. APPENDICES
mandatory)

(all

non-

ASME SEC VIII : 1980 (Div .1)

Covers
minimum
construction
requirements for design, fabrication
inspection and certification of unfired
pressure vessels.
Sections Included:
Subsection
A
(Covering
general
requirements applicable to all types of
vessels)
SUB-SECTION
B
(Covering
requirements separately for welded
riveted forged or brazed methods)
SUB-SECTION
C
(Covering
requirements applicable to different
classes or materials i.e., cast iron, clad
and lined material and nodular iron etc.,)
MANDATORY APPENDICES (including
design
formulas,
porosity
charts,
methods,
for
Magnetic
particle
inspection, Q.C. systems etc.,)
NON-MANDATORY
APPENDICES
(Some suggested good practices e.g. in
ultrasonic examinations for bolted flange
connection).
This standard does not cover the
following:
i) Vessels with design pressures
exceeding 3000 Psi (20, 670K Pa).
ii) Vessels with I. Dia width, height or
cross section diagonal less than 152
mm.
iii) Vessels for internal/external pressure
operation not exceeding 15 Psi (103
K Pa)

This standard does not cover

the following:
1.
Storage tanks designed
for the storage of liquids
near
atmospheric
pressure (i.e. 140m-bar
above
and
6m-bar
below
atmospheric
pressure). Low pressure
storage tanks with one
vertical
axis
of
revolution with pressure
less than I bar.
2.
Vessels where stresses iv) Vessels subjected to federal control
calculated are 10% of
the
design
stress
permitted by section 3.
3.
Scrip wound compound
or other special designs
of vessels for very high
pressures.
3

B.S. 5500 : 1976

4. Transportable vessels
5.
Vessels
for
specific
applications which are covered
by BSI year book

ASME SEC VIII : 1980 (Div.1)

5. Unfired steam boilers excluding
evaporators heat exchangers and
vessels in chemical. Petroleum industries
where steam is generated incidental to
operation of a processing system
containing a number of pressure vessels.
6. Vessels used for hot water supply
storage tank heated by steam within the
following limitations:
a. Heat input of 20,000 Bt.U/hr. (58.6
Kw).
b. Water temp. of 210 o F (99o C).
c. Nominal Water capacity of 120
gallons (454 liters)
7. Pressure containers which are integral
parts of rotating or reciprocating
mechanical devices e.g. pumps, turbine
generators, hydraulic or pneumatic
cylinders
where
primary
design
consideration and / or stresses are
derived from functional requirements of
the device.
8. Vessels with a nominal water
containing capacity of 120 gal (454 liters)
or less containing water under pressure
including those containing air the
compression of which service only as a
cushion.
9.Piping components such as pipes &
valves,

IS 2525 : 1969
Covers
minimum
construction
requirements for design, fabrication,
inspector, testing, and certification of
fusion welded unfired pressure
vessels, in ferrous and non-ferrous
materials.
1)
2)
3)
4)

I.B.R
Covers design, construction, testing and
certification of boilers mainly. However
chapter XV Heat exchangers etc., and
similar vessels recommended that heat
exchangers and similar vessels be
constructed following the applicable
regulations, covered under different
General, material & design.
chapters.
Usually Chapter XII shell type boilers of
Fabrication and welding
Inspection test, marking and welded construction is being followed.
Also regulation 523A stipulates that
records.
Appendices (both mandatory and feed water heaters may be constructed
as per chapter XII.
non-mandatory)
Hence reference is mostly made to
chapter XII shell type boilers of welded
constructions is being followed.
Also regulation- 523 A stipulates that
feed water heaters may be constructed
as per chapter XII.
Hence reference as per chapter XII
ONLY.
For
workmanship
various
chapters covered are:

Chapter I
General requirement
II
Material for construction
XII Shell type boilers of
welded construction.
Equipments governed by I.B.R. are as
noted below:
1) All boilers.
2) Steam pipes with pressure 3.5
Kg/ SQ. Cm. Or with dia
exceeding 254 mm in I.D and
with out limitations of pressure.
3) Equipments like feed water
heaters etc connected after
boilers etc connected after boiler
feed pump in which steam is the
medium.
This standard does not included the
following:
1.Vessels which design pressure
exceeding 210 KG/Cm2
2.Vessels with O.D/I.D > 1.5
3.Vessels operating under internal
pressure below 1 Kg/Cm2
4.Vessels with I.D. > 150 mm

IS 2525: 1969

I.B.R

5. Equipments under I.B.R. per view

6. Vessels where internal pressure is
only due to static head of liquid
7. Vessels with a nominal capacity of
500 liters or less for containing water
under pressure including those
containing air, the compression of
which services only as a cusion.

B.S. 5500: 1976

B. CLASSIFICATION OF VESSELS
Vessels are classified into three construction
categories, on the bases of material, NDT
temperatures etc., These are as follows:

Construction
category.

NDT
permitted
material

100%
all

Spot
M0 & M1,M2
M 3, M4
Austenitic
steels.

Visual
only M0,
Austenitic
steels

Max,
thickness
(mm)

None
except

M0, M1-40
M2-30
M3-20
M4-15
Austenitic
none

M0-25
Austenitic
steels
none.

Upper
Temperature
limits

Values
to be
based
on
design
life
time
etc., as
per
table
2.3
Note
Note

Same
as 350o C
category

Lower
temperature
limit

For M0
M1, M2,
M3, M4
Less
than
10oC above

For M0
M1, M2,
M3, M4
Less
than
20oC
above

ASME SEC VIII: 1980

(Div.1)
Welded
joints
are
categorized into A, B, C, D
according to their location
and special requirements
are specified at different
places in the code. No
classification of vessels in
line with the other codes.
It may be recalled that the
entire code has been
classified as per the
materials, methods of
manufacture of the vessels,
quality control etc.,
A. Category A Long welded
joints in main shell, nozzles
et. Any welded joint within a
sphere, with in a formed or
flat head, side plates of flat
sided vessel, circumferential
welded joints connecting
hemispherical heads to main
sheets, to transition in
diameters, to nozzles etc.
Category B Circumferential
welded joints within the main
shell, nozzles or transitions
in diameter, circumferential
joints in connecting formed
heads other than
hemispherical to main
shells, nozzles etc.
Category C Joints
connecting flanges, tube
sheets or flat heads to main
shell, to formed heads, to
transitions in diameter, to
nozzle etc., to transition in
diameter, to nozzle etc.

Category D joints
connecting communicating
chambers of nozzles to main
sheels, to heads, to
transitions in diameters

IS 28 25 : 1969
B.
CLASSIFICATION
VESSELS

I.B.R
OF Classification: Class I
Application: No limits
thickness: inch

limits of
Minimum

Classification: Class II
Limits of Application: When the
following limits are not exceeded:
a. Working pressure 105 psi
b. Working
pressure
in
psi
multiplied by ID in inches - 5250
Minimum thickness: Boilers upto 36
inches I D 5/16 inch.
Classification: Class III
Limits of Application: when the
following limits are not exceeded:
Vessels are classified in three
groups on the bases of use,
thickness. Joint design and
efficiency materials of construction
and Quality Control requirements.

a. Working pressure 30 psi

b. Working pressure multiplied by I
D in inches 3000.

Joints have been categorized as

in ASME Sec. VIII in to A, B, C, D.

Minimum thickness: Boiler 36 inches

I d 3/8 inch

Class 1 vessels are those

intended for lethal substances or
for operation below 20o C or when
mutually
agreed
upon
by
purchaser
&
manufacturer.
Category A & B joints in such
vessels to meet requirements of
Table 1.1, class 2.
Class 2 Vessels are medium, =
duty vessels and shall meet the
requirements of table 1.1, class2.
Class 3 Vessels are light duty
vessels here plates are less than
16 mm thick & working pressure
less than 3.5 Kgf/Cm2 hydrostatic
design pressure at temperature
less than 250o C and unfired.
Class 3 Vessels: are
recommended below 0oC.

not

B.S. 5500: 1976

1

ASME SEC VIII: 1980 (Div. 1)

Minimum
specified
in
a
Appendix
D None
austenitic
steels

Minimum
specified,
None
austenitic
steels.

Other classifications are made on the

bass of joints efficiency & extent of
radiography. A short summary of the
classification is as follows:
A. Efficiencies: Double welded butt joints
0.7, 0.85, 1.00 (depending) on no
radiography, spot or full joint with back
strip (0.65, 0.8, 0.9) and without back
strip 0.6 double full fillet lap joint 0.55.
B. Radiography: A list of joints where full
radiography (e.g. all butt welds in
vessels containing lethal substances),
spot radiography (e.g. double welded
butt joints not required to be fully radio
graphed) and no radiography is required
is given.

I.S. 2825 : 1969

I.B.R.

10

B.S. 5500: 1926

ASME SEC. VIII DIV. 1: 1980

C. MATERIAL REQUIREMENTS
Materials should take into account the
fabrication and operating conditions.
Special consideration should be given
for use below 0o C. Any special limits
e.g. w.r.t. Composition, heat treatment
should be agreed upon at the time of
enquiry or order.

Materials subjected to stress due to

pressure shall conform to one of the
specifications given in ASME Sec. II and
shall be limited to those that are permitted
in the applicable part of subsection cexpect as permitted UG-10 (procedure for
material not fully identified) and UG-II (misc
preformed or prefabricated pressure parts
like pipe fittings, valve flanges etc.,)

All material normally to conform to BS

unless otherwise mentioned Welding
material
shall
conform
to
the
requirements of section 4 & 5.

Material not conforming to the above will

require special approval of boiler and
pressure vessel committee.

For casting, a quality specification is to

be draw for acceptance standards
between manufacturer and material
supplier. As a minimum, fillets and
changes of section to be Dye
penetration or magnetic crack detection
tested.

Carbon or low alloy steels having a carbon

content or more than 0.35% by ladle
analysis shall not be used in welded
construction or oxygen cut List of approval
specs, given in UGS-23 along with stress
values at various temperatures. For service
temperatures above 850o F (454 o C) it is
recommended that killed residual silicon be
used. The stress values in table are to be
multiplied by a casting quality factors
given in UG-24.

Bolts and nuts to conform to BS 4882.

Lugs, baffles and non-pressure parts to
be of established.

High alloy steels are listed in Table UHA23 and appendix HA given suggestions on
the selection and treatment of austenitic
chromium Nickel steels. High alloys steel
casting are mentioned in Table 23. The
stress values are to be multiplied by
casting quality factor of UG-24.

Materials used should be covered

under Table 2.3 (specs for C, c. Mn
Low alloy, high alloys steels. In case
some other material is used it should
comply with the general requirements
mentioned and should be covered by a
written specification, at least as
comprehensive
as
the
nearest
equivalent materials).

In recognition of controversial opinion

relative to the effects of post-weld heat
treatment on austenitic stainless steels,
mandatory requirement have been omitted.
However,
for
maximum
corrosion
resistance, a suggested heat treatment
1850-20 50 o F (1010-1121o C) and

Nominal design strengths and methods

of calculations are given in Table 2.3 &
Appendix K. Details to be agreed upon
by manufacturer and purchaser and
recorded.
Non-destructive
testing
requirements for plates, forgings, pipes
and castings are given in Art 5.6.2.
General requirements for materials not
covered under Table 2.3.

11

IS 2525 : 1969

I.B.R

For class 1 & 2 vessels this standard

prohibits for pressure parts the use of
structural steels standard, high
tensile, fusion welding or ship
building verity (IS 226, 961, 2062 &
339). The materials used for the
above classes should conform to
table given in Appendix A.

R-537- Platters elt used in the

construction of these Boilers shall
comply in all respects with the
requirements of chapter II and V, where,
however, the tensile strength exceeds 32
Tons per SQ. in, the full details of
welding and post heading, and the plate
preparing to be used, shall be submitted
to the inspecting Authority for approval
before manufacture commences.

Class 3 vessels may use the above Electrodes (R: 538) They shall comply
mentioned prohibited materials and with the regulations of 94 to 98.
also IS 2041 (steel plates for
pressure vessels), IS 1570 (wrought
steels general engineering purposes),
IS 2002 (Steel plates for boilers).
Nothing in the foregoing precluded
the use of otherwise suitable material
agreed upon. Special care to be
taken for weld ability and ductility. No
such material shall have an
elongating (on 5.65 50) of less than
100-Rm
where Rm is the tensile
2.2
strength in kgf/mm2 subjected to a
minimum of 16% fore carbon
manganese steels. 14 % for alloy
steels other than austenitic and 25%
for austenitic steels. Material for lugs,
baffles, etc. to be weldable quality All
materials shall be supplied in
accordance with IS 1387 1967, and
threaded fasteners in accordance
with IS 1369-1967.

Tubes: They shall comply with the

regulations of 36 to 63. The tubes shall
be seamless and made by an open
hearth or Electric Process, acid or basis,
and shall be certified as such by the
makers of the steel by the tubes. The
material of the tubes shall shoe on
analysis not more than 0.05 percent of
sulphur and 0.05 percent phosphorus
and the manufacturer shall supply a
certificate of the analysis when required
to do so.

Stress safety factors to calculate

allowable values are given in Table
2.1 (varying from 1 to 3) and values
calculated on these criteria given in
Appendix A. Shear and bearing
stress to be 50% of Appendix A
values. Compressive stresses to be
calculated as per appendix C, . For
castings, the factor of Table 2.1 shall
be divided by 0.75, except when the
casting has been radio graphed, dye
or magnaflux tested.

Note: Where the materials used for

designed
temperature
for
design
temperature above 750o F (399 O C) the
steel shall be of non-segregated or fully
killed type.

12

B.S. 5500: 1976

ASME SEC VIII DIV. 1: 1980

Material spec. Should at least

specify
making
process.
Compositional limits deoxidation
practice. Heat treatment and
appropriate
mechanical
properties.

One hour per inch of soaking time

and rapid cooling from 700 o F to
1000 o F (371 538 o C ) has been
given.

For forritic steels for welding C >

0.25%. For C> 0.25 % special
agreement between manufacturer
and purchaser. Phosphorus &
sulphur < 0.05%.
Deoxidation practice should be
appropriated to the type of steel
ordered, particularly when high or
low temp. Properties are affected.
Following are permissible.
Semiskilled steel-plates, seamless
& welded tubes in C.C. Mn steels
for U.T.S. < 640 N/mm2 and
thickness < 100 mm
Rimming steel- only for welded
tubes in C, C-Mn, steels with
U.T.S. < 490 N/mm2 temperature
0-1380 o C. 2
Mechanical properties (BS 18)
UTS, Lower stress or 0.2 % proof
stress
(1%
for
austenitic),
minimum elongation at fracture
(L= 5.65 so, Charpy V-Notch (B.S.
131 Pt.2).
Permitted % elongation is 16% for
plates, > 15% for casting > 14%
for tubes and forgings.
For materials used over 20o C , a
certifiable lower Y.P. or proof,
stress (ref. BS 3688) to be
specified.
Stress reputed properties
materials in creep range.

for

Plates fro hot forming to be

supplied condition as agreed
between suppliers & manufacturer

13

I.S. 2525 : 1969

I.B.R

14

B.S. 550 : 1976

ASME SEC VIII DIV .1 : 1980

B. C, C-Mn plates for cold forming

to be normalized for thickness >
25 mm unless post weld heat
treatment is sufficient

15

I.S. 2525 : 1969

I.B.R

16

B.S 5500: 1976

ASME SEC VIII (DIV.1) 1980

D. MANUFACTURE AND
WORKMANSHIP
GENERAL

GENERAL

1.

Fully dimensional drawings 1.

giving
material
specn,
welding procedures, NDT
and test plate requirements,
pressures
corrosion
allowance
etc.,
to
be
submitted
by
the
manufacturer.

Manufacturer must have ASME

Certificate of Authorization and
must have in force a valid
inspection contracts. Inspector
must be qualified by state.
Manufacturer
must
supply
drawings and a host of other
documents listed in UG 90 (e.g.
design calculations written QC
System etc). to the inspector.

2.

A
position
identification 2.
system for pressure parts is
necessary so that they can
be traced back to their origin.

Material must in general conform

to action II of ASME Boiler and
pressure
vessel
code
unidentified material may be
used for non-pressure parts e.g.
skirts, baffles, and lugs. For all
such parts 3/8 thick doublewelded butt joint shall be made
from each lot and guide bend
tested.

3.

For vessels made in two or

more courses longitudinal
seams to be completed
before
starting
adjoining
circumferential seams and
longitudinal seams to be
staggered wherever possible.

Partially identified, material may

be used as per a procedure
given. A table or sketch showing
location on vessel of items and
their identifications. Marking to
be steel die stamped as specified
in ASME sec. II.

Where more than two seams 3.

meet at a point, intermediate
stress relief is desirable.

Except when radio graphed 4

(120 mm) on each welded
intersection, vessels made up of
two or more courses, shall have
centers of longitudinal joints
staggered on separated by a
distance of five (5) times the
thickers plate.

17

I S 2525 : 1969
GENERAL

I.B.R
GENERAL

1.

Manufacturer shall normally 1.

submit drawings material
specn. Welding processes
weld
designs
design
parameters, amount and
location of allowances etc., to
purchaser

Manufacturer shall be submit the

detailed drawings including weld
details,
calculations
and
materials to the inspecting
Authority for approval prior to the
construction.

2.

Procedure for identification 2.

and its transfer on cut items
for pressure parts is given.

MATERIALS
(Procedure
for
identification):
All plates, rivets and bars used in
the construction of boilers shall
be tested and found to conform
with the regulations to conform
with the regulations. A certificate
in form II, III, III-A and IV.

3.

Concentration
of
joints 3.
should be avoided such that
no two main seams come
together under an acre angle
or cross each other. Where
unavoidable,
the
intersections should be radio
graphed 100 mm on each
side of inter section be
staggered by five (5) times
the thickness of thicker plate.
Welding of attachments near
main seams to be avoided. If
unavoidable welds should
cross rather than stop
abruptly near seams.

Shall Courses assly etc (R 543)

The longitudinal seam or seams
may be placed in any suitable
position but the seams in
successive rings shall not fall in
line.

18

B S 5500: 1976

ASME SECI VIII: 1980 (Div.1)

CUTTING FORMING &

TOLERANCE
1. Cold shearing may be used for
plates < 25 mm but edges to be
ground at least 1.5 mm. Grinding not
required for sheared plates < 10mm.

1. All cutting methods may be used in

general Exposed inside edges to be
rounded off to a radius at least 1/8
(4mm) flat.

Thermal cutting on machining are

preferable. For materials requiring
preheat during welding, thermal
cutting should be done with preheat.

For plates over (12.5 mm) thick

used for corner joints (joints at
approx, 90o), edges to be tested by
D.P. or M.C.D

Thermal cut ferritic alloy steel shall be All materials to be impact tested shall
dresses by grinding or machining.
be inspected for surface cracks.
Visual examination for laminations, Adjoining edges of longitudinal joints
crackers, slag inclusions may be to be preliminary formed to avoid flat
supplemented by N.D.T.
spots after rolling.
2. Prior to forming, visual examination
of plates, followed by thickness
measurement, to be done.
3. Austenitic steels for hot working
shall be heated uniformly in neutral or
oxidizing temp. Deformation below
900o C and local heating is
prohibited.
After
hot
working,
softening to be carried out by heating,
at a recommended temp, hot less tan
30 minutes. Descalling to done.

3. For P.W.H.T (post weld heat

treatment) of austenitic stainless
steels mandatory requirements have
been omitted. However for maximum
corrosion resistances, a suggested
heat treatment (1850o 2000o F)
(1010O-1104o C) and one hour per
inch of thickness as soaking time with
rapid cooling from time (1000o F) has
been given.

Austenitic steels after cold working

shall be subsequently softened &
descabed unless thickness is less
than 10 mm or the purchaser waives
this requirements.
4. All plates after being formed shall
be check visually and checked for
thickness. Places where attachments
are to come may be non-destructive
tested if specially called for in design.

19

IS 2825: 1969
1. Where thickness < 25 mm, cold
shearing may be used provided
edges are chipped or machined
one quarter of plate thickness or
minimum. 3 mm.
Caron steels may be mained,
chipped ground or flame cut but
alloy steels and non-ferrous
materials shall not be flame cut
unless agreed upon.
Preheating may be required and
visual examination for flaws
laminations, inclusions shall be
made special inspection may be
required for cracks on cut surfaces
and HAZ in high carbon and alloy
steels
Hand flame cut edges shall be
chipped or machined 3 mm
minimum or one quarter plate
thickness
2. Seams may be welded prior to
forming but must be radio graphed
fully after wards. In carbon steels
< 25 mm and alloy steels DP or
MCD to be done.

I.B.R
1. Chapter XII. Regulation 541
plates which are to flame- cut by
machine without subsequent heattreatment, grinding or machining,
shall not have or machining, shall
not have a carbon content higher
than 0.26 percent. Where the
carbon content exceeds 0.26
percent. Heart-treatment grinding
or machining shall be carried out.

2. Examination of Tubes before

forming: (R 338):
a. Where tubes are bent, the
deviation from circularity at any
cross section shall not exceed
20D/R.
where,
D nominal out side diameter and
R: radius of bend on the center
line of the bend.
b. Where the tubes are bent
resulting thickness of the tubes at
the thinnest part shall not be less
than that required for plain tubes.
Tolerance on thickness shall be
5, + 10% of the specified
thickness.
c. All pipes shall be commercially
straight, free from longitudinal
seaming, grooving blistering or
other injurious surface marks (R
35).
3. Ref I S D R-831
4. Ref I S D R-831
20

BS 5500: 1976

ASME SEC VIII: 1980 (Div.1)

5. TOLERANCES
I) Assembly Tolerance:
I) Alignment tolerance
a. Longitudinal joints and spherical joints Thickness Longitufor plate thickness e.
dinal
Middle line
Upto in t
e
alignment
(12.5 mm)

Circumferential
t

<10 mm
>10 and 50 mm

1 mm
Over
1/8 in (3 t
10% of e or 3 mm into mm mm)
(whichever smaller) (125-19
mm)

>50 and 220 mm

e/16 or 10 mm Over to 1/8 in (3 3/16 in (5

(whichever smaller 1 in (19- mm)
mm)
)
38 mm)

> 200 mm

As agreed upon

Over 1 1/8 in (3 1/8 t

to 2 in (38- mm)
50 mm)
Over 2 in Lesser of
(50 mm)
1/16 t or
3/8 in (9.5
mm)

Lesser of
1/8 t or
in
(19
mm)

b) Circumferential joints:
Middle line
alignment

e
10 mm
> 10 and
60 mm

The above are the alignment at the

edges to be but welded. Surface
alignments are not given

1 mm

Any off set within the allowable

10% of e of the range shall be faired at a 3.1 taper
thinner plate + over the width of the finished weld.
1mm or 6 mm Build up may be done.
(whichever
smaller).

>60 and 200 mm

10% of e or the
thinner part.

> 200 mm

As agree upon.

Permissible surface alignments are as

shown below: If these are exceeded a taper
of 1:4 to be given which should include the
weld. The lower surface may be build up to
given the 1:4 taper.
a. Longitudinal joints
e 12 mm
13 < 0 50 mm
e> 50 mm

E/4 mm
3mm
Lesser of e/16 or
10mm.

21

I.S. 2525 : 1969

I.B.R.

I) Alignment tolerance

5. TOLERANCES:

Defects in alignment at surface (R-250) and (5-544)

shall be less than the followings:
For plated less than 5 mm thick t/6 5.1.a) Before welding of the joint
for long seams and t/4 for
is commenced it shall be
circumferential seams, subject to
ascertained that the edges
a maximum of 1 mm.
are in alignment and the
defects in alignment shall
not exceed the following
limits:
For plates more than 3 mm thick
10% of nominal thickness wit a
maximum of 3 mm for long. Joints.
But for plates upto 10 m / for
circumferential joints, the values
are 10% of max. nominal plate
thickness plus 1 mm subject to a
maximum of 4 mm.

1. 10 % of the nominal plate

thickness with a maximum
of 3 mm for long seams.
2. 10% of nominal plate
thickness plus 1 mm with a
maximum of 4 mm for C/
seam joints.

(Welds with backing strip require

better alignment).

b) If the edges of unequal

plate thickness are abutted
and the difference between
the two exceeds the above
limits 1 in 4 tapper shall be
provided on the thicker
plate.

The increase or decrease in root

gap at any point in seam after
tacking shall not exceed 1 mm.
L a misalignment
permitted.

of

mm

22

B.S. 5500: 1976

ASME SEC VIII: 1980 (Div. 1)

b) Circumferential joints
e 20 mm

e/4 mm

20 < e 40 mm

5 mm

E > 40 mm

Lesser of e/8
or 20 mm

ii) All pads, reinforcing plates manhole frames lugs, brackets,

supports or other attachments.
Shall have a gap at exposed
edges to be welded < 2 mm or
1/20th of the thickness of
attachment, whichever is greater.

ii) All lugs, brackets, saddle type

nozzle, manhole frames etc, shall
conform reasonably to surface to
which they are attached.

Except where shown otherwise on

drawing maximum gap between
outside of branch & in side of
edge of hole in shell, flange
reinforcing ring or backing ring
shall be < 1.5 mm for opening up
to 300mm and 3mm for openings
above 300mm. To achieve this the
branch may be machined, but the
machined surface should not
extend beyond the toe of weld and
shall not reduce the thickness of
branch below design thickness
plus corrosion allowance.
iii) Tolerance for ends
a) Circumference as calculated a) Circumference not mentioned
from Nominal I.D + Actual anywhere.
thickness
and
the
actual
circumference should agree as
follows:
O.D.
Circumference
(nominal
Tolerance
Dia + actual
thickness)
550 mm 5 mm
> 650 mm
0.25%
of circumference.

23

I.S. 2525: 1969

I.B.R

ii) All lugs, brackets, saddle type

nozzles, manhole frames etc. shall
conform
reasonably
to
the
curvature of the shell or surface to
which they are attached.

5.2 (R-544)
a) The difference between the
internal diameter of the drum
measured at any cross section
shall not exceed 1 % nominal I.D.
The departure shall not exceed:
i) Upto and including 36 I.D.
0.375%
ii) Over 36 upto and including 45
I.D. 0.35%
iii) Over 45 I.D.

a) Circumference same as for 5.3 there shall be no flats at the

shells.
welded seams and any local
departure from circularity shall be
graded.

24

B.S 5500: 1976

ASME SEC. VIII: 1980 (Div.1)

b) Circularity shall be same as that b) Circularity (out of roundness

for shall.
shall be the same as that for shell
i.e. 1% of nominal I.D.)
c) Thickness is that after the c)
manufacture of and shall be
uniform over the whole area
knuckle. From this point, a gradual
thinning
of
upto
10%
is
permissible.
*Nor inside of 5/8% of I.D.
d) Profile: the depth of dishing d
should never be less than
theoretical or more than that given
below:
Knuckle radius shall not be less
than theoretical and shall have
common tangents with straight
flange and dishes profile.

d) The inner surface of head shall

not deviate out side of the
specified shape by more than 1
% of I.D. *charge shall be
gradual and decimations shall be
measured perpendicular to the
specified shape.

Dia of end

When the skirt of an un-stayed

head is machined to make a close
fit in to or over a shell, the
thickness shall not be reduced to
less than 90%. The transition shall
be tapered to at least 3 times the
thickness difference.

permissible
increase in the
depth of dishing
< 3000 mm
1.25% of dia
3000-7600mm 3.8 mm
< 7600 mm
0.5% of dia

iv) Tolerance for shells

a) No mention of circumference.
a) Circumference: as for e
ends.

b) Straightness: Max deviation

from straight line 0.3%
either of total

25

I.S 2525: 1969

I.B.R

b) Circularity same as that for

shall.
c)

d) The inner surface shall not

deviate from the specified shape
by more than 1.25% of the I.D. of
head skirt, such deviations shall
not be abrupt, shall be outside of
the
theoretical
shape
and
measured perpendicular to the
specified shape.
When the skirt of an unstayed
head is machined to make a close
fir into or over shell the thickness
shall not be reduced to less than
90% of original. Transition shall be
trapped to at least 4 times
difference.
a) The external circumference
based on nominal I.D. and actual
thickness should be within the foll.
tolerances:
O.D.
300-600 mm
over 600 mm

Tolerance

5 mm
0.25%

Notwithstanding
these,
the
governing factor shall be the
misalignment tolerances.
Max. deviation from straightness
is to be 0.3% of total length or 5
meters length, for shells over 2
meters long.

26

B.S. 5500: 1976

ASME SEC. VIII. 1980 (Div. 1)

cylindrical length or any individual

5 meters.
c) Circularity - Max and Min. dia c) out or roundness (circularity) to
difference at any cross section be less than 1% of the nominal dia
shall be less than specified below. of cross sec
When the cross section passes
<1900mm
1% of I.D.
through
an
opening,
the
1900- 4750mm
19 mm
permissible difference in I.D. given
> 4750 mm
0.4% of I.D.
above may be increased by 2% of
D=shell O.D.
< .05e +
the opening.
.002 D
For vessels under external
(Max.25mm) pressure out of roundness shall be
= Irregulari- as above, but the plus or minus
deviation from the true circular
ties in profile
checked with form measured radially inside or
out side shall be within values of
20 o gauge.
e obtained from graph UG-80.1.
e= thickness pf plate.
A segmental circular template with
This maximum value may be specified dimensions to be used.
increased by 25% if the length of Templates are to be made by
irregularities does not exceed of manufacturer.
length of shell between two
circumferential seams with a max.
of 1 meter.

At nozzle positions, greater ovality Sharp bends, flat spots etc, are
is permitted if justified by not permitted.
calculations.
Measurement must be made to
surface of parent plate and not to
a weld, fitting or raised part.
For vessels to be vertically
installed but checked horizontally
dia, should be measured twice 90o
a part after turning the shell
through 90o. The sets should be
averaged and ovality calculated.

27

I.S. 2525: 1969

I.B.R.

b) Out of roundness is to be
less than 1% of I.D. on
D1 + 1250 ; (D1 = I.D.)
200
Whichever is smaller.
At nozzle positions greater values
may be permitted. Irregularities in
profile (checked by 20o gauge)
shall not exceed 3 mm + 5% of
min. plate thickness. The max.
value may be increased by 25% if
the length of irregularity is less
than of length of shell ring.

When out of roundness is

measured with shell lying on its
side, the measurement shall be
repeated after tuning 90 o.
No flats at welded seams are
permitted, and departures from
circularity must be gradual.

28

B.S. 5500: 1976

ASME SEC. VIII: 1980 (Div.1)

Cold rolling after forming permitted For vessels made or pipes, pipe
(for small rectification) but N.D.T. standards are applicable.
must be done. For vessels made
of pipes, pipe standards are
applicable.
6. WELDED JOINTS
Welding procedures and welders
to be qualifies. Test plates to be
used only on purchasers request.
Consumables used shall be those
used in qualification tests.

Welders, welding operators and

procedures to be qualified to
ASME Sec. IX before any
commencement of production
welding.

Tack welds if made to approved

procedured procedure may be
retained.
The areas of removal of
attachments may be made
through intermediate pieces.
Permanente backing strips not
permitted in longitudinal joints but
permitted in circumferential joints.
No less than two runs to be used
for attachments expect where a
agreed by purchaser.

Welding procedures restricted to

SMSSW, SAW, GMAW, Oxyhydrogen.
No
mechanical
pressure or below to be applied
except peening, pressure welding
pricesses are limited to flash,
introduction, resistance, pressure,
thermit & pressure gas.
Tack welds to be either removed
or their ends grounds. Whether
removed on retained they should
be made by a qualified welder and
procedure

29

I,S, 2525: 1969

I.B.R

Cold rolling for small rectification is

permitted but then N.D.T. is
essential.
For vessels made from pipes, pipe
standards are applicable.
6. WELDED JOINTS (R 604 and R 607)
6.1

a) No welder shall be engaged on

welding of boilers or steam
pipes unless he is qualified and
possesses a certificate.
b) The certificate shall be valid for
2 years.
c) The test specimens shall be
examined under X-ray. One
tensile test, forward bend test,
one reverse bend test two
macro examinations shall be
conducted. For fillet welds one
root bend and one face bend
test shall have to be conducted.
d) Record of all welding personnel
engaged on welding of boiler or
steam pipes particulars of each
welder qualification shall be
maintained.

6.2

a) If the defects in the weld are

distributed over the whole
length of the seam the total
length of the portions which may
be cut out from any longitudinal
or circumferential seam, shall
not exceed 15% of the total
length of the seam.
b) If the defects in the weld are all
located in a single continuous
length which may be cut out,
shall not exceed 10% of the
total length of the seam.
c) (R-599) The longitudinal and
intermediate
circumferential
seams shall be made with butt
joints of the single or double U
or V type or any other type
approved by the inspecting
Authority.

30

B.S. 5500: 1976

E.1.
PREHEAT
REQUIREMENTS

AND

ASME SEC VIII 1980 (Div.1)

OTHER

Ferritic steels may require preheat.

Table of temperatures 4.4.1.1 and
B.S. 5135 may be used to calculate
preheat temperatures. Even tacking
to be done with preheat. No welding
to be done at tem. < 5 o C. Austenitic
steels require no preheat Pre-heat
temperatures to be previously
decided
by
manufacturer
and
purchaser.

Pre-heating requirements given nonmandatory appendix-R.

Hot-formed parts, if not formed in a

range and cooled in a manner to give
grain refinement, shall be normalized.

1. More than 40% from as rolled

condition.
2. More than 5% when vessel
contain lethal substance or
requires impact testing or the
quires impact testing or the
thickness of part before cold
forming exceeds 5/8 (16 mm) or
reduction in thickness is more
than 10%. Formula are given for
calculation of extreme fibre
elongation.

F.2.
POST
WELD
TREATMENT (PWHT)
Require for:

No welding below 0 O F (-18 O C)

Between 0OF and 32OF, preheat to
above 60O F required
Vessels shell sections and heads of P 1
Gr.1 & 2 materials fabricated by cold
forming shall be heat treatment when
resulting max. Fibre elongation is:

HEAT

a) Ferritic steel vessels where

wall thickness exceeds that
specified in Table 4.4.3.1. or
designed to operate below Oo
C.
b) In general for C and C-Mn
steels PWHT is mandatory
only above 35 mm thickness.
c) Special
Purchasers
requirement.
Intermediate
stress
relief
should be carried out at lower
temperatures.
No weld repairs allowed after
stress relief except on lightly
loaded or non-pressure parts.
Suitable tests and controls to
be instituted to

For carbon steels, lower thickness limit

for P.W.H.T. given in notes to Table
UCS-56,
which
also
gives
the
temperatures.
For ferritic vessels enhanced by heat
treatment, PWHT requirement given in
UHT 56.
PWHT shall be done before hydrostatic
test and after any weld repair. A
preliminary hydrostatic test to reveal
leaks before PWHT is allowed.
In general, for carbon and low alloy
steels PWHT is mandatory only for
thickness greater than 1 .

31

I.S 2825: 1969

I.B.R

(R234 b) plates over 2 in thickness

before being fabricated shall be
uniformly heat treated to produce
gain refinement. Quenching in liquid
medium id prohibited.
Cold forming over 5% deformation (R 251) where the plates are bent to
is prohibited unless heat treatment a diameter less than 40 times
is done. Deformation is calculated thickness, they shall be heat-treated.
as follows:
Deformation = t x 100
D
t= Plate thickness
D= I D bending or forming.
Hot forming out-side normalizing
range shall be followed by
normalizing.
No welding below a base metal
temperature of 0o C preheating of
200 mm area to 15o C-20o C to
be done before welding in such
cases.

PWHT- required for ferritic carbon

and
low
alloy
steels
by
normalizing or stress relieving
when:
i) It is intended for toxic on
inflammable material.
ii) Operation prone to stress
corrosion cracking.
iii) There is excessive stress
concentration.
iv) There is excessive stress
concentration.
v) There is risk of brittle fracture.
vi) Dimensional
accuracy
id
required.
vii) Plate thickness exceeds those
given in Table 6.3 (Carbon
manganese steels > 30 mm & CMn-Cr-Mo on carbon percentage
upto 0,35& > 20 mm)

(Regulation No: 562).

All boilers shall be post weld heat
treated after completion of all welding
and before hydraulic test, when the
thickness of the part/welded recess
exceeds 50 mm and the carbon
content exceeds 0.25%.
Heat Treatment: All boilers shall be
stress-relieved by heat treatment
after complication of all welding and
before hydraulic test, when,
a) Constructed to class I & II
requirements
b)

32

The shell thickness exceeds

(D/112) + C where D=I.D. of the
shell and C=5.6 mm for carbon
steel. A stress-relieving heat
treatment shall be performed by
heating
part
to
at
least
o
600 20 C. When required by
the
characteristics
of
the
material,

B.S.5500: 1976
establish that material
adversely affected.

ASME SEC. VIII: 1980

is

not

33

34

I.S. 2525: 1969

I.B.R.
Different temperatures may be
necessary to obtain proper stress
relieving. The part to be stress
relieved shall be brought slowly upto
the specific temperature and held at
that temperature for a period
proportionate on the basis of at least
2 minutes per millimeter of the
maximum thickness of the part
(approximately one hour per 25 mm of
thickness) and shall be left to cool in
the furnace to a temperature to which
for the parts with a thickness greater
than 20 mm does not exceed 400o C.
After withdraw from the furnace the
part shall be allowed to cool in a still
atmosphere.
A temperature time diagram of the
stress relieving process shall be
provided for a welded shell or drum
and a similar diagram for other
pressure parts when the Inspection
Authority requires it.
During heat treatment official test
plates shall be inside the boiler.
Where the shell is subjected to a
primary stress relieving treatment
identical to the final heat treatment to
be given to the boiler, the test shell
during
primary
treatment
and
hereafter cut up and tested without
waiting for the final treatment of the
boiler.
Where the shell is not subject to
primary stress relieving treatment or is
subjected to primary stress relieving
treatment, which is not identical with
the final heat treatment the test plates
may be placed inside any other boiler
of comparable dimensions, which is to
be heat treated in accordance with
this chapter.
Temperature
charts
shall
be
submitted to indicate that the test
plates and the boiler they represent,
have been subjected to identical
heating,
soaking
and
cooling
treatment.
35

B.S: 5500: 1976

ASME SEC. VIII 1980 (Div.1)

E.3. METHODS OF P.W.H.T

Normally full vessel to be stress
relieved but in special cases the
following method may be applied.
1. In sections, with minimum 1500
mm or 5 Re overlap, whichever
greater (R= internal radius,
e=thickness). The portion outside
shall be shielded so that
longitudinal temp. gradient is such
that the distance between peak
and half peak temperature is more
than 2.5 Re .
2) Circumferential seams may be
heat treated locally by heating a
shielded band round the entire
circumference. Width of heated
band should exceed 5 Re is
recommended.
3) Branches/attachment shall be
locally heat treated by heating a
shielded circumferential band
round the entire vessel. The
requirements in (ii) apply except
that width of circumferential band
(2.5 Re ) shall be measured from
edge of welding which connects
nozzle/attachment to the vessel.
iv) Vessel may be internally
heated fully encased with thermal
insulating material.
v) Vessels with thickness ration
not more than 2:1 may be heat
treated in the same furnace
according to the same furnace
according to the requirements of
the thickest vessels.
For MO or M1 type materials
(carbon and carbon manganese

Whenever practicable, vessels

should be PWHT as a whole, if
not, they may be heated
inspections with 5 feet overlap and
adequate shielding of portions
outside furnace.
Circumferential seams may be
heated locally, but width of band
on each side of weld shall be
more than two times shell
thickness.
Shielding to be
provided outside the heated bond.
Heating the inside with adequate
insulation on the outside and
recording and measuring of
temperature is allowed provided
the internal pressure never
exceeds 50% of working pressure.
Heating a circumferential bandcontaining
nozzle
on
other
attachment which should extent
round the entire vessel and at
least 6 times the plate thickness
beyond
attachment
welding.
Circumferential joints in a pipe
may be treated by heating a band
on each side of center line wider
than 3 times the width of weld.
Thermocouples to be attached to
top center and bottom of charge
and any other zone of possible
temp. variation. Gas temp.
measurement is not enough.
No limit specified on the ratio of
thickness of vessels that can be
heat-treated together but cycle
should conform to the thickest
vessel.

36

I.S. 2825: 1969

I.B.R

More or less same as in BS 5500

except the followings:
i) PWHT mandatory for:
a. Low strength carbon and
carbon manganese steels (yield
strength 26-38 kgf/mm2) 30 mm
and above, high strength carbon
and carbon manganese steels (YS
44Kgf/mm2 and containing Cr.V,
Mo etc. )20 mm & above.
b. Toxic or inflammable material
carrying vessels.
c. Operation below 0o C.
D. Vessels subjected to severe
local stress concentration.
e. Dimensional accuracy required

37

B.S. 5500: 1976

ASME SEC VIII 1980 (Div.1)

steels the temp. and time given in

4.4.3.1. to be followed. For other
grades, the ranges are advisory.
The temp, in general for MO & M1
are 5800 to 6200c.
Normally, the temp, of furnace
while charging shall be 4000 C.
For complex cases, e.g. thickness
> 60 mm temp. is 3000 C.

For carbon and low alloy steels the

foll. Hold:
Temp, or furnace while charging shall
be less than 8000 F (4270 C)

Heating
rates
2200c/hr
for
thickness upto 25mm.
5500/ e00 /hr on 550C /hr which
ever greater, for thickness greater
than 25 mm.
During heating, temp, variation to
be less than 1500 C with 4500 mm
length.
Cooling rates (Cooling TO 4000 C)
275
2750 C /hr for t < 25 mm.
5870 C /e0 C /hr which ever
greater for t>25 mm.
Below 4000 C, cooling in still air.
Temperature re the actual ones
determined by thermo couples.
Holding times are given in Table
4.4.5.1. but in general are 2 Heating rate- 2200 C/hr divided by the
minutes per mm thickness.
max. Metal thickness in inches. (but
not more than 2220 C/hr).
Cooling rate- 2780 C/hr divided by the
max. metal thickness in inches.
The heading and cooling rates need
not be less than 560 C/hr.
Soaking time-1 hr per inch thickness
upto 2 inches.

38

I.S. 2525: 1969

I.B.R.

Cooling rate upto 25mm metal

thickness 2750C/hr and over 25
mm, 7000/metal thickness 0C/hr or
550C/hr whichever greater

39

B.S. 5500: 1976

ASME SEC VIII, 1980 (Div .1)

-2 hrs plus 15 min for every inch of
ma. Metal thickness above 2 inches

F.1. PROCEDURE AND WELDER Below 4270C, cooling in still air.

QUALIFICATION:
A list of all welding procedure to be
supplied by manufacturer. Welding
of test plates and testing to be
witnessed by purchaser unless
previous qualification records are
produced.
For low temp, operation, impact
testing as per Appendix-D to be
done.

Qualification records to be supplied to

inspector before commencement of
work, Welds to be identified by
welders number at every 3 feet.
Welder or operator qualified for one
manufacturer shall not be used for
another manufacturer. Qualification
as per ASME Sec. IX.

List of welders to be presented to

purchaser. Welder qualified by one
inspected
authority
may
be
accepted by another. A welder who
qualifies a procedure is him-self
qualified. Qualification of welder is
valid for six months of inactivity.
Relevant specification are:

Impact test requirements given in

subsection
C,
(Requirements
pertaining to classes of materials)
UCS-65 for carbon & low alloy steels
UHA-51 for high alloy steels.

Procedure qualification BS 4870

Part I.
Welder qualification BS 4871 Part I.
F.2. PRODUCTION
TEST PLATES

CONTROL

Not normally required unless

insisted by purchaser. The length of
plates to be at least 350 mm.
Number and size have to be agreed
upon. Circumferential joint test
plates to be welded separately.

Test plates are not required for

production control, but for carbon and
low alloy steels, test piece to be made
for vessel material and subjected to
the same heat treatment as vessel
(with slight variation). P-1 Gr.1 & 2
and standard materials listed in UG11 (a) and excluded.

At the option of the manufacturer

N.D.T. to be done on test plates like
on the production weld. If defects
found somewhere, test pieces may
be out from remaining portion.

For vessels constructed of type 405

Material, which vessels constructed of
Type 405 material which are not
PWHT (post weld heat treated),
welding test plates for two face bend
specimens required.

40

I.S 2825 : 1969

I.B.R.

Records shall be made available to

inspector. Each welder shall stamp
his number.
A welder is qualified for 6 months of
in-activity. Re-qualification is not
necessary if the company proves
having made such jobs if (or better
jobs) for past 3 years.
Qualification requirements given in
art 7.1 of IS 5825 (including impact
test requirements).

(604)
a) No welder shall be engaged on
welding o boilers or steam pipes
unless he is qualified and
possesses a certificate.
(607)
b) The certificate shall be valid for 2
years.
c) The test specimens shall be
examined under x-ray. One tensile
test, forward bend test one reverse
bend test, two macro examinations
shall be conducted. For filler welds
one root bend and one face bend
test shall have to be conducted.

a) Vessels subjected to serve duty

(efficiency factor 0.9-1.0 ) to be
provided with two test plates to
represent longitudinal seam of first
six shells of vessel. No test plate
normally required for circumferential
seam- unless welded by a different
process.
Test to be conducted are:
All weld metal tensile (1), Reduced
section tensile (1)
Bend (2), Notched bar impact (3)
Macro (1).

d) Record of all welding personnel

engaged on welding of Boiler or
steam pipes particulars of each
welder
qualification
shall
be
maintained.
(561)
2.1 Class 1 Boilers: Test specimen
shall be attached to each L-seam.
a)One Tensile test specimen for the
weld seam.
b) One all weld metal tensile test.
c) Two bend test specimens.
d) Two impact specimens.
e) One specimen each for micro
and macro examinations.

41

B.S. 5500: 1976

ASME SEC VIII: 1980 (Div .1)

Tests specified on production

control test plates are, macro
examination, hardness survey,
transverse tensile, all weld tensile,
face, side and root bend and fillet
weld fracture.

F.3.DETAILS OF DESTRUCTIVE
TESTS FOR ALL APPROVAL
TESTS:
a)

b)

c)

d)

e)

f)

All weld tensile strength and

parent
metal
strength
difference to be agreed upon.
Reduction in area for weld
metal in Mo & M1 to be >
35% and at least equal to
parents metal for alloy steels.
In transverse bend (t < 10
mm) cracks upto 1.5 mm
allowed.
In transverse bend (t> 10
mm) cracks upto 3 mm
allowed.
An excess of 50 HV over that
specified for weld metal (in
the procedure) is allowed.
For tensile bend tests, two
retests allowed.

If tensile specimen breaks in base

metal outside the fusion line, then
specimen is acceptable provided
the strength is not more than 5%
below the specified minimum
tensile strength for base metal.

42

I.S. 2825: 1969

I.B.R.

b) Vessels subjected to medium

duty (efficiency factor 0.8 0.85)
shall be provided with two plates
to represent all long seams. No
welds for circumferential seam
unless welded by a different
process.

2.2 Class II Boilers: Test pieces

shall be attached to each (561) Lseam
a) One tensile test specimen for
weld seam.
b) One bend test specimen
c) One reverse bend test
Tests to be conducted are:
specimen.
i) Reduced section tensile (1)
d) One nick break test specimen.
ii) Bend test (2)
2.3 Pipes
iii) Nick break
a) Tensile test specimen
Production test plates may be b) Flattening test Specimen
radiographed
and
defective c) Bend test specimen
portions discarded in cutting 3.1 Tensile tests:
specimen.
The ultimate tensile stress shall be
not less than the lower limits
specified for the plates.
3.2 All weld metal: (561)
(a) The UTS shall not be less than
the lower limits specified for the
plate.
(b) The elongation shall be not
less than 20% of the gauge length
or four times the square root of the
cross sectional area.
(c) Reduction in area shall nor be
less than 35%.
Macro examination of fillet weld
specimen should not reveal
cracks, incomplete root fusion,
inequality in leg length more than
1.5 mm.

3.3 Bend Test: (561)

No cracks or defects on the outer
surface of the specimen shall be
greater than /16 (1.5 mm)
measured across the specimen or
1/8 (3 mm) measured along the
lengths of the specimen.
3.4 Izod Impact Test: (561):
Impact values shall not be less
than 20 FT. Ib.
3.5 Radiography (265)
a) Where defects occur in
distributed positions in a seam,
repairs to the extent of 15%
43

B.S. 5500: 1976

ASME SEC. VIII: 1980 (Div.1)

44

I.S. 2825: 1969

I.B.R.
of the total length of the seam
shall be permitted.
b) Where the defects are located
in a single continuous length the
permissible extent of repair shall
be decided by the Inspecting
Authority.
3.6 Additional
Rejection (561):

Tests

before

If the tests show a definite sign of

failure, two further tests of the
same king shall be conducted in
the same manner. The two tests
should satisfy the requirements of
the standards. If either of the two
tests fail the representative weld is
liable for rejection.
3.7 Macro and Micro:
A specimen of the full thickness of
the plate and not les tan half an
inch wised shall be provided from
each set be test plates for the
purposes of Macro examination.

45

B.S. 5500: 1976

ASME SEC VIII: 1980 (Div.1)

G.NON DISTRUCTIVE TESTING

This
is
required
for
final
acceptance but may be used
before also. The N.D.T. personnel
to be qualified (with certificates).
All N.D.T. stages, standards and
procedure to be written down an
agreed upon.
Before examining welds, plate
material adjacent to welds shall
be ultrasonically tested
to
establish thickness and defect
flaws.
For category 1 vessels final N.D.T.
to be done after PWHT and before
any pressure test. 100% X-ray or
U.T. of pressure welds where
thickness part exceeds. Table
5.6.4.11. Welds other than full
penetration but shall be D.P/
M.C.D. tested.
For Category 2 vessels, 100% Xray/U.T. of full penetration butt
welds (which shall include each Tjoint). For each seam there shall
be one radiograph or U.T. for 200
mm.
At least 10% of all welds other
than
main
seams
to
be
D.P/M.C.D. tested. Also when
openings occur in or within 12 mm
of weld-welded seams, such seam
shall be additionally N.D.T. tested
on each side of opening for a
distance equal to the diameters of
opening.
When a particular representative
N.D.T. Is found unsatisfactory
(with reference to Art 5.7) the
whole seam represented by it
shall be scrapped.
For Category 3 vessels N.D.T. is
not required. However, in so far as
M.C.D and D.P. are

The manufacturer shall certify the

competence of D.P/M.C.D. testers
including their eyesight. For U.T.
personnel
and
radiography
personnel qualification to be in
accordance with SNT-TC IA.
N.D.T. procedures to be outlined
in the written QC system ahs to be
submitted to inspector.
All material should be examined
before fabrication to defect as far
as possible defects that would
affect the safety of the vessel.
Particular attention should be
given to the edges and other parts
or rolled plates for serious
laminations, shearing cracks etc.
Foll. Joints are to be 100% radio
graphed
1) All but welds in vessels
containing lethal substances.
ii) All butt welds in plates or vessel
walls where thinner plate exceeds
1 inches (38 mm) or exceed the
lesser thickness in UCS 57.
III) All butt welds in unfired steam
boilers with pressures more than
50 psi (3.5 Kg/Cm2)
iv) All category A& D butt welds
with efficiency 1.00 for double
welds joints and 0.9 for single
welds joints (Ref. UM-11).
For foll joints spot radiography is
to be done
i) Double welded but joints with
efficiency 0.85 and single welded
joints with backing strip and
efficiency 0.8.
No radiography required for the
following.
1) Double welded butt joints with
efficiency 0.70.

46

I.S. 2825: 1969

I.B.R

Stages of inspection are decided

by the class vessel. Records of
inspection and tests to be
maintained for the inspector.
All anstenitic chromium Nickel
alloy steel welds in plates over 20
mm thick shall be examined by
dye penetration test.
Radiography
i)
For
circumferential
butt
welds
in
extruded
connections, pipes, tubes,
hearers etc;
a) No radiography for t <
6mm
b) No radiography fort =
6~12mm and O.D. < 102
mm.
c) Where 12< t< 20mm and
102< random selected from
each welders work a
maximum of 5% length shall
be examined.
d)
For
constructions
exceeding Limits of (c), all
welds to be examined.
ii)
Butt welds in furnaces
combustion chambers and
other
pressure
parts
subjected
to
external
pressure to be spot radio
graphed. Butt weld in fully
supported end plated not to
be radio graphed.
iii)
Spot radiography is to be
at lest 10% of the total
length. Each radiograph to
be at lest 25 Cm.
Other N.D.T. methods may
be agreed upon and used
where radiography is not
possible i.g. fillet welds or
braches etc. or where it is
expedient.

(561)
Every portion of the longitudinal
and circumferential butt-welded
seams or the shell of the boiler
shall be subjected to radiographic
examinations.
The
methods
employed
in
obtaining the radiographs shall be
such as to show clearly difference
equal to 2% of the thickness at the
welded joints. To determine
whether this result is being
attained an indicator of approved
form which includes a portion,
equivalent to not more than 2% of
the joint thickness shall be placed
in the thickness shall be placed in
the vicinity of the weld so as to
make
a
record
on
each
radiograph.
Each section of every weld shall
be marked so that the radiographs
can be easily correlated to the
particular part of the seam
represented.
The examination shall be made
from the original films and the
acceptability of the welds shall be
decided
by
the
inspecting
Authority. The welds deemed
unsatisfactory shall be rejected or
dealt with under the condition of %
R 560 and be radio graphed
again. The films shall be retained
by the manufacturer for a
reasonable period for reference
and be available to the Inspecting
Authority, if required.

47

B.S. 5500: 1976

ASME SEC VIII: 1980 (Div .1)

aids to visual examination, they

may be used
Choice of N.D.T. for Welds
There is a guidance for selection
between radiography and U.T. for
internal flaws (e.g. the two
methods being suitable the two
methods being suitable for
Volume and Planner defects
repressively and that sensitive
U.T. techniques may be given too
conservative results.
For surface flaws, difference
between M.C.D. and D.P. has
been given.
General guidance for N.D.T.
Radiography
1. For thickness upto 50 mm X-ray
to be normally used.
2. Marking on radiography to
indicate work piece reference
no.(ORDER NO., S.No. etc.,)
joints, selection of joints, arrows or
other symbol to identify its position
radiographs of repair welds shall
be marked R1, R2 (First repair,
second repair etc.,)
3. Radiographs should have
sufficient overlap.

ii) Single welds/ butt joints (with

backing strip) with efficiency 0.65.
iii) Single welded butt joints
without
backing
strip
and
efficiency 0.6.
iv) Lap joints.
U.T. may be substituted for
radiography for the final closing
seam of a vessel if the
construction does not permit
interpretable radiographs.
In addition to radiography electron
bean welds should be 100%
ultrasonically tested.

Ultrasonic Testing
i) Before testing weld, the present
material shall be ultrasonically
tested to establish thickness and
any flaws, which might prevent
effective weld examinations.

Opening that do not meet

reinforcement requirements in
UG-37 may be located in
circumferential joints provided
radiographic requirements of UW51 for a length equal to 3 times
dis. Of hole are met.
When a pressure part i.e, head or
shall or is to be welded to a forged
or rolled plate thicker than to
form a corner joint under the
provisions of UM-13 (e), all cut
edges including by M.C.D. or D.P.
Tests.

MARKING
Permanent marking beside the
weld shall be made to correlate
with N.D.T. reports stamping shall
not be done vessels fro low
temperature service.

48

I.S. 2825: 1969

I.B.R

49

B.S. 5500: 1976

ASME SEC. VIII: 1980 (Div .1)

All material that are to be impact tested
shall be inspected for surf cracks.
Pressure vessels, which are to be
pneumatically tested, shall have full
length of the foll. Welds crack detected
by D.P. or M.C.D.
1. All welds round openings.
2. All attachment welds, including welds
attaching non-pressure arts to
pressure parts having a throat than
inch. (6.5 mm).
Heads attached with one plate off set
circumferential joints, which have a
longitudinal joint shall be M.C.D. or D.P.
tested from the edge of plate tested
from the edges of plate through the off
set as shown. (See sketch).
All austenitic Cr-Ni alloy steels in plates
our thick and all 36% nickel steel
welds shall be D.P. tested after heat
treatment (Ref. U.H.A.-34).
All electro slag welding in ferritic
materials shall be 100 ultrasonically
tested after gain refining (austenising)
heat treatment or P.W.H.T.
General Guidance for N.D.T
All radiography to be as per ASME Sec.
V article 2. A complete set or
radiographs and records (T 283(a) & (b)
Article 2 ASME SEC V) TO BE retained
by manufacturer for 5 years spot
radiographs may be discarded after the
acceptance of vessel by inspector.

ACCEPTANCE LEVERS FOR

N.D.T.
Notations
e - parent metal thickness
(thinner part for dissimilar
joints)
w - Width of defect
L - Length of defect
h - Height of defect

FULL RADIOGRAPHY
For radiography and U.T. the foll. Are
unacceptable.
1. Any crack, zone of incomplete fusion
or penetration.
2. Any elongated slag inclusion which is
longer than:

50

51

I.S. 2825: 1969

I.B.R

In butt welds concavity in root and

excessive penetration may be
permitted subject to approval of
inspector, but lack of root of side
fusion are not permitted.
Undercuts overlaps, abrupt rides
or valleys or irregular beads are
not permitted.

52

B.S. 5500: 1976

ASME SEC. VIII. 1980 (Div.1)

= Diameter of defect.

in (6.5 mm) for t upto in

(19mm).

C = Mean nozzle circumference.

1/3/ t for t in to 2 in (19-57

mm)

UNACCEPTABLE DEFECTS

in (19 mm) for t over 2 in

(57mm)

Cracks or lamellar tears.

Where it is the thickness of weld.

For radiography, in addition to
above, any group of slag
inclusions in line that have an
aggregate length greater than t
in a length 12 t, except when the
distance between them exceed
6L where L is the longest
imperfection.
Porosity charts are given in
Appendix IV.

Planar
defects

Lack of root, Not

side
and permitted
inter-run
fusion
Lack of root
penetration

Isolated pores (for e/4 and Spot Radiography

individual pores in 3.0 mm for e up One spot radiograph shall be
group)
to 50 mm
examined in each 50 ft. of welding
in each vessel. Minimum length of
spot radiograph is 6 inches. Foll.
Are the acceptance levels:
Uniformly distributed 4.5 mm for e 1.
localized porosity
50 to 75mm

Any type of crack, zone of

incomplete
fusion
on
penetration is unacceptable.

Linear Porosity

Slag inclusion or cavities

graters than 2/3 T, where T
is the thinner or the two
plates welded.

6.0 mm for e 2.
> 75 mm

Uniformly distributed 2% by area (on

localized porosity
a radiography)
for e > 50 mm
and prorate for
higher
thickness.

3.

The sum of the longest

dimensions of imperfections
should not be more than T in
a length 6 T and the longest
imperfections
considerate
are separated by at least 3I
where L is the length of
largest imperfection

Linear Porosity

4.

Porosity is not a factor in

spot radiography.

Linear porosity
parallel to weld
axis may
indicated lack
53

of fusion or
penetration and
thus not
permitted.
Worm
(isolated)

holes 1 > 6 mm, W > LIQUID

PENETRANT
1.5 mm As EXAMINATION
linear porosity.

(D,P)

Worm holes (aligned) As worm holes 1. Linear indications, with length

crater pipes
isolated
more than 3 times the width will
be unacceptable if longer than
1/16 in (1.6 mm).
Surface cavities

Not permitted

11. Four or more rounded defects

(I,e. those with length less than 3
times the width) in a

54

I.S 2825: 1969

I.B.R

55

B.S. 5500: 1976

ASME SECI VIII 1980 (Div.1)

Line separated by 1/16 in
(1.6 mm) or less

Individual and
Parallel to
major axis

Main
butt
welds

L=e 100 mm
worm e/10 4
mm

Nozzle
&
branch
welds

Inner
half of
cross
sec

Outer
quarter
of cross
sec

Worth
= e/4
4mm
I=c/4
100mm

Worth =
e/8
4mm
I=c/8
1000mm

Individual and
randomly
oriented (not
parallel to axis
of weld)

As isolated pores

Non linear
group

As localized porosity

Magnetic particle (M.C.D)

Examination
All linear discontinuities are
defects
unless
proved
otherwise by re-examination.
Some other criteria of
acceptance according to this
code are:
Butt
joints
shall
have
complete joint penetration &
fusion shall be free from
undercuts, overlaps, abrupt
ridges or valleys.
Fillet welds shall have
adequate penetration into the
base metal.
Reinforcement not butt welds
not be exceed following:

Plate
thickness
Up to 1/2
Copper inclusions not permitted
in
(12
Under cut
Slight intermitted permitted 12.5mm)
depth < 0.5 mm
Over
Slight
intermitted
permitted
Shrinkage
(12.5 mm)
grooves & root depth < 1.5 mm
Over
1
concavity
(25.4 mm)
Excess
h 3mm
to 2 (25.4
Penetration
mm)
Reinforcement Smoot blending
Over
2
(50
mm)
Overlap
Not permitted
In U.T defects with h 1.5 mm or less should
be ignored

56

Reinforcement
1/6 in (4 mm)

3/32 in (2.4 mm)

1/8 in (3.2 mm)

5/32 in (4 mm)

I.S. 2825: 1969

Reinforcement in severe
medium duly vessels shall be:
Plate thickness

I.B.R

and

Max,
reinforcement

Up to 12

1.5

Over 12 up to 25

2.5

Over 25 up to 52

3.0

Over 4 52

4.0

For
light
duty
vessels,
reinforcement shall be < 5 mm

57

B.S 5500: 1976

ASE SEC VIII: 1980 (Div 1)

H. PRESSURE TESTING
All completed vessel must pass either All complete vessels must pass the
of the following tests?
standard hydrostatic, pneumatic or
proof test.
Standard hydraulic test: Where
required thickness of pressure parts
can be calculated.
Pneumatic test: Where thickness of
pressure parts can be calculated, but
liquid media are not practicable.
Proof
hydraulic
test:
Where
thickness of pressure parts cannot be
calculated.
Combined: Hydraulic/pneumatic test.

Hydrostatic test: Except for enameled

ones vessels designed for internal
pressure, shall be subjected to a test
pressure at least 1 time the max.
allowable working pressure (to be
marked on vessel multiplied by the
lowest ratio of stress value S for the
test temperature).
A calculated pressure may also be
used by mutual consist between user
and manufacturer which is 1 times
the basis for calculated test
pressure defined in U.S- 60 (e).

Method of testing
Pressure to be increased to 50% of
test pressure gradually and then in
stage of 10% until test pressure is
reached before going close for
inspection, the pressure is to be
lowered below that previously
attained.
The pressure is to be maintained for
at least 30 minutes expect in case of
vessel less than 500 mm dia, and 10
mm thick when the period may be
agreed upon.
(No shock loading (hammer testing)
allowed.
Test Pressure
Pt= 1.25 (P fa/ft X t/t-c)
Where, P= design pressure
fa= Nominal design stress
at least temperature
ft= Nominal design stress
at design

Any intermediate value between the

two given above may also be used.
There is no upper limit, but visible
permanent distortion may cause
rejection.
Following the application of test
pressure any inspection for leaks
shall be made at not less than to
thirds the test pressure unless
specially agreed upon (e.g. when gas
leak test is applied.
Any nonhazardous liquid at any temp. below
its boiling point may be used.)
Pneumatic
test:
except
for
enameled vessels, for which the
pneumatic test pressure shall be at
least equal to the maximum allowable
test pressure, the pneumatic test
pressure shall be 1.25 times the
maximum allowable working pressure
multiplied by the lowest ratio of the
test value at test temperature to
stress value at design temp.

58

I.S. 2825: 1969

I.B.R.
(R 601 Hydraulic and Hammer
tests).

The time of holding at the

calculated test pressure shall be a
minimum of 10 minutes.

a. Class-I-Boilers: Each class

boiler shall on completion of all
welding and/or repair and after
heat treatment be subjected to a
hydraulic test of 1 times the
working pressure and while under
this pressure the welds shall be
given a through hammer test
throughout their length. The
pressure shall be released and
then raised to 1 times the
working pressure + 50 psi and
steadily maintained for a length of
time sufficient to carryout
complete inspection but not less
than hour.

Vessels shall be well hammered

on both sides of welds seam.
Materials deleteriously affected by
hammering and which have been
radio graphed on main seems
require no hammer test.
Test pressure:

b. Class ii-Boilers: Each class II

boiler shall aster heat treatment
be subjected to the same form of
test as for class-I boilers, except
that every Boiler shall be given a
hammer test and hydraulic
pressure to be applied for the test
shall be 1 times the working
pressure. The pressure shall be
released and then raised to twice
the working pressure.

Test Pressure
Pt=

1.3 x
x f1/f2

design

pressure

fi=

allowed material stress at

test, temperature.

f2=

Allowable material stress at

design temperature.
This test pressure includes
the amount of any static
head acting at a point
under consideration.

59

B.S. 5500: 1976

ASME SEC VIII 1980 (Div.1)

temp. exceed the temp, for which

elevated temp, proof stress values
are available, then ft should be
derived from the proof stress at
the highest temp, for which values
are available.

The pressure shall be increased to

half the test pressure and then in
steps of one teeth the test
pressure. Then the shall be
reduced
to four fifths of the
pressure and held for a sufficient
time to permit the inspection of the
vessel unless waived by mutual
consent (e.g. when gas leak test
applied)

t=

Nominal thickness of
section under
consideration.

For proof test, the brittle coating

test displacement-measuring test
may be used.

c=

Corrosion allowance

For proof test, the brittle coating

test, displacement measuring test
or strain. I measuring test may be
used.

60

I.S. 2825: 1969

I.B.R

Vessels designed vacuum or

partial vacuum shall be subjected
to a pressure of 1.3 times the
difference
between
normal
atmospheric pressure and the
internal absolute pressure but no
in any case less than 1.5 Kg/Cm2
No procedure for proof test given.

61