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INDIAN BOILER REGULATIONS
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INDIAN BOILERS REGULATIONS, 1950 .
and

. INDIAN BOILERS ACT, 1923
NARENDAR KUMAR JAIN AKALANK KUMAR JAIN

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BOOKSEllERS AND AUTHORISED DEALER: GOVfRNMENT OF INDIA
124.125, Municipal Market. super Bazar Compound, Connaughl Plat,), P.O. Box No 708 New Delhi ·110 001 Phone: 23413899123411919 . Fax: 91·11·2341382 8 • Hltp:llwww.sbtioodiLhI • Email: Sales@sbcin~ir

akalank publicatilons
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..Published by :
Akalank Kumar Jain for Akalank Publications

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No part of this publication may be reproduced or transmitted in any form or by any means, electronically or mechanically, including photocopying, recording or any information storage or retrieval system, without prior permission in writing from the publisher or in accordance with the provisions of .the Copyright Act, 1956 (as amended). Any person who does any unauthorised act in relation to this publication may be liable to criminal prosecution and civil claims for damages. This book is intended to be used only for general guidance and should not be quoted as an authority. In case of any doubt, relevant act, rules, regulations, orders, etc. on the subject from Government Department Concerned or Gazette notifications should be referred to. This Publication is sold with the understanding that the Publishers, Authors or Book sellers are not responsible for the result of any action taken on the basis of this book nor for any error or omission to any person whether a purchaser of this publication or not. Every effort has been made to avoid errors or omissions in this book.lnspite of this, errors may creep in. Any mistake, error or discrepancy noted, may be brought to the publisher's which shall be taken care of in the next edition. The book is subject to replacement only if there is any binding mistake, misprint or for missing pages within 30 days from the date of purchase of the book with the same edition or the next available edition if so published, All expenses in this .connection are to be born by the purchaser. . . All disputes are SUbject to District Courts, Tis Hazari, Delhi Jurisdiction only. 002009113000 *****

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A WORD FROM PUBLISHERS
Patrons of our Publications have encouraged us to bring out the eleventh edition (revised and updated)' of Akalank's Indian Boiler Regulations. Our 1st single volume edition (5th Edition) 1998) was much appreciated by our readers. This edition of book is revised by all . Gazette Notifications issued by Central Boilers Board) New Delhi published in'Gazette of India till date. The Boilers Act, 1923 as amended by the Boilers (Amendment) Act 2007 (Act 49 of 2007) is given after the Indian Boilers Regulations. All out, efforts have been made to make the book upto date and fool proof in all respects. All the Diagrams, Drawings and Graphs have been incorporated after the relevant Chapter(s), Regulati.on(s), Para(s) or Appendix for the purpose of quick reference of our valued readers. However, suggestions pertaining to improvement of the book are always welcome and shall be duly considered. Moreover, we have incorporated the suggestions received from our readers in this edition. We trust that the book will be of immense practical utility to' all Boiler users, manufacturers, engineers, inspecting authorities and all those concerned with the subject matter. The book is widely referred and appreciated by readers in India and in other Countries. To serve the people is our objective. We have already published the book on Delhi Master Plan (MPD-1962, MPD-2001, MPD-2021), Master Plan for NCR Delhi, Delhi Municipal Corporation ACt, Specifications, New Delhi Municipal Council Act, Drugs and Cosmetics Act & Rules,' Mandai Commission Report, Environment & Pollution Control Laws, Water Supply & Treatment, Civil Accounts Manual, Statutes of India and Delhi Local Laws, Central Civil Services Rules) etc. We had also published books under special arrangements with International Code Council, USA. If our patrons have any suggestion or any compilation worth publishing, we shall, feel it our pleasure to discuss it with them for its publication ..

The Publishers

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Dedicated to My Mother
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.Late Mrs. Raj Rani Jain
(14-11-1947 - 6-2-2007)
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Akalank Kumar Jain

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'INDIAN BOILER REGULATIONS
CONTENTS REGULATIONS PRELIMINARY
1. Short Title, Extent, Application and Commencement 2. Definitions

1
1

CHAPTER I GENERAL REQUIREMENTS, APPLICATION OF STANDARD CONDITIONS AND EXCEPTIONS THERETO
3. General requirements, application of standard conditions and exception thereto 3A. Inspection of Boiler to comply intQany Foreign Code

STANDARD REQUIREMENTS
4. Standard Requirements-Material, Construction Certificates, etc. 5

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4 4

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PROCEDURE FOR RECOGNITION OF COMPETENT AUTHORITY, INSPECTING AUTHORITY, WELL-KNOWN MATERIAL TESTING LABORATORY, WELL-KNOWN STEEL MAKER, WELL-KNOWN FOUNDRY/FORGE, WELL-KNOWN TUBE/PIPE MAKER AND WELL-KNOWN REMANENT LIFE ASSESSMENT ORGANISATION
4A. 4B. 4C. 40. 4E. 4F. 4G. 4H. Application for Recognition Scrutiny of Applications by the Evaluation Committee Recognition of a Firm as Competent Authority, Inspecting Authorities etc. Validity of Certificate of Recognition Renewal of Certificate of Recognition Application for Registration of Existing Competent Authority etc. Appeal Function of Evaluation Committee 5. Modification of Formulae SA. Material not fully identified 6. Standard specifications for materials 7. Registration of second-hand boilers not in accordance with the standard conditions 8. 'Welding
9 10 10 11 11 11 11

11
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13 13 13 14

CHAPTER II MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL
9. Process of manufacture 10. Chemical analysis 11. Freedom from defects, etc. 12. Rolling margin 13. Testing and inspecting 13A. DeSignate steel , 138. Testing and certification of semi-skilled steel for which all tests not carried out in a steel plant 14. Selection of test pieces 15. Tensile test pieces 16. Tensile test 17. Number of tensile tests 18. Dump tests
15

15 16 16 16 16 17 17 17 18
19 19

(viii) 19. Bend tests-Cold bends 20. Number of bend tests 21. Manufactured rivets 22. Additional test before rejection 23. Branding 24. Defacing of rejected material 25. Facilities for Inspection 26. Steel not produced where rolled 27. 'Maker's certificate

Indian Boiler Regulations
19 20 20 20 20 21 21 21 21

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WROUGHT IRON STAY AND RIVET BARS
28. 29. 30. 31. 32. Rivet bars Manufactured rivet tests Stay bars Stay bars-bend tests Special iron for screw stays for fire-boxes and combustion chambers

21 22 22 22 22 22
23

COPPER PLATES, STAY AND RIVET BARS
33. Plates 34. Stay and Rivet Bars

COPPER, BRASS AND STEEL TUBES
35. (1) Copper tubes 35. (2)Brass Tubes 35. (3) Carbon Steel Tubes

24 25 27
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COLD DRAWN SEAMLESS CARBON STEEL BOILER, SUPERHEATER AND HEAT EX-CHANGER TUBES FOR DESIGN METAL TEMPERATURES NOT EXCEEDING 454DC (850DF)
36. 37. 38. 39. 40. 41.. 42. Material process Selection ofTubes for Test Tensile and Hardness tests Flattening test Expanding or Flaring test Add itional test before rejection Hydraulic test 29 30 '30 31 31 31

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SEAMLESS CARBON STeEL PIPES FOR HIGH TEMPERATURE SERVICE FOR DESIGN METAL TEMPERATURES NOT EXCEEDING 454DC (850DF)
43. Material 44. Tensile, Bend and Flattening tests 45. Additional tests before rejection 46. Hydraulic test .

32 34 35

35

SEAMLESS FERRITIC AND AUSTENITIC ALLOY STEEL BOILER, SUPERHEATER AND HEAT EXCHANGER TUBES
47. 48. 49. 50. 51. 52. 53A. 538. 53C. 53D. 'General Material Tests Additional tests before rejection Hydraulic test 36 42
43

35

43
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SEAMLESS FERRITIC PIPES FOR HIGH TEMPERATURE SERVICE
General Material Heat treatment Workmanship and tolerance Test Specimen

44
44 45 46

47

Indian Boiler Regulations
53E. 54. 55. 56. 56A. Numberof Tests Test Additionaltests beforerejection Hydraulictest Seamless Ghromium·MolybdenumSteel Boiler and Superheater Tubes for design metal temperatures not exceeding 577°G (1070°F)

(ix)
47 47 48 48 49

ELECTRIC-RESISTANCE-WELDED STEEL BOILER AND SUPERHEATER TUBES FOR DESIGN METAL TEMPERATURES NOT EXCEEDING 454°C (850°F)
57. General 5S. Material 59. Flattening & Flaringtest 60. Tensiletest 61. Hydraulictest 62. Test specimens 63. Numberof tests 52 52 53 54 54 55 55

COLD DRAWN-RESISTANCE-WELDED STEEL BOILERAND SUPER-HEATER TUBES FOR DESIGN METAL TEMPERATURE NOT EXC.EEDING 454°C (850°F)
63A Material 56

STEEL CASTING
73. 74. 75. 76. 77. 78. 79. Scope Processof manufacture Freedomfrom and rectification of defects Numberof test provisionof test samples Tensiletest Bendtests Additional tests before rejection, hardness test after heat treatment and non-destructive ~~ SO. Procedurefor welding 56 57 57 57 58 59 ~ 60

FORGED OR ROLLED PRESSURE PARTS OTHER THAN SEAMLESS DRUMS OR CARBON STEEL
81. 82. 83. 84. 85. 86. 87. 8S. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. Forgedor rolled pressure parts Selectionof test pieces Tensilestrength Bendtests Additionaltests beforerejection 61 61 62 62 63 63 63 63 64 64 65 66 66 66 68 69 70 71 71 77

GENERAL GREY IRON CASTINGS (GRADE A)
Generalgrey iron casting (Grade A) Provisionof test bars Dimensionof test bars Mechanicaltest Transversetest Tensiletest Numberof transverse and tensile tests Additionaltests

COVERED ELECTRODES FOR METAL ARC WELDING OR MILD STEEL
Centralrequirements ' 'Requirementsfor normal penetration electrodes-Initial tests Requirementsfor deep penetration butt-welding/electrodes Requirementsfor deep penetration fillet welding electrodes initial test Periodiccheck test APPENDIX H-1 APPENDIX H-2

Minimum Thickness of Plates 85 85 85 85 . 104. 109. 98A. 87. 110. ANGLE RINGS. 103. Thinning of Butt Straps Alternative Construction Local Welding of Butt Seams END PLATES Flat End Plates Strengthening of Flat End Plate at Manhole End Plates in Steam Spaces Hemispherical Crowns Dished End and Crown Plates Tube Plates Parts of Flat Tube Plates within the Tube Nests Flangingot"End Plates 87 87 88 88 88 89 89 89 C) ( . 116. etc. 118. ' FILLER ROADS FOR GAS WELDING OF STEEL I . 138. 122. 133. 129..() (x) Indian Boiler Regulations \ . ETC. 85 85 86 86 I. 136. Preparation of plates 100. 114. 131. 119. 128. 105._j ~.. 125. 113. 126. 120. 108. 127. 124. BUTT STRAPS.. 135. 115.Filler rods for gas welding of steel 83 CHAPTER III CONSTRUCTION AND WORKMANSHIP GENERAL 99. Normalising of certain Steel Plates 101. 106.1Q ( SHELLS. 117. 132. \. 111. 130. 86 86 86 86 87 . Cylindrical SheHs Position of Longitudinal Seams Circumferential and End Seams Angle Rings Thickness of Shell Angle Rings Welded SheH Plates Longitudinal Seams Butt Straps . 92 93 93 I STAYS Bar Stays longitudinal Stays Nuts and Washers for Stays Jointed Stays Diagonal Bar or Rod Stays 96 96 96 96 96 SCREWED STAYS Screwed Stays Axial Drilling Stay Nuts SpaCingof End Stays-Alowance for Curves. 102.. 121. 123. 134.. 112. 97 97 97 97 . 107. 129A. FURNACES Furnaces in General Furnaces of Horizontal Boilers Furnaces of Vertical Boilers Longitudinal Seams 'Fusion Welded Longitudinal Seams Furnace Crown Cross Tubes Uptakes Loco Type Fireboxes Welded Joints to Copper Fire Boxes 89 89 90 91 91 92 92 . 137.

( l 172A. 167. Copper Tubes HEADERS. Gusset Riveting 100 100 100 100 100 BOILER TUBES SUBJECT TO EXTERNAL PRESSURE 145. Gusset Angles 143. . 171. Steel and Wrought Iron Tubes 146. / 155. Gusset Stays 141. 160. Headers. 168. . 162. Breathing Space 142. FuUeringand Caulking RIVETING APPENDIX H-4 . PADS ETC. ETC. 1728.(xi) 98 99 99 GUSSET STAYS 140. 150. MUDHOLES. 169. Mud Boxes. 163. 148. -. 158. 157. Load on Gusset Stay 144. etc. Steel Tubes 152. MUD BOXES. 170. 161. Stand Pipes and Pads Design of Stand-Pipes Pressed Plate Saddles Seatings for Mountings Attachment of Mountings Insufficient Thickness of End Plates Attachment of Water and Pressure Gauges Mountings on Flat Places Bolts and Nuts MANHOLES. Girder Stays for Firebox and Combustion Chamber Crowns . Rivet Holes 173. 165. Screw Threads of Stay Tubes Stay Tubes Thickened Ends of Stay Tubes Load on Stay Tubes 100 101 102 102 102 105 105 106 106 107 107 t07 108 108 108 109 109 109 110 110 111 112 112 112 114 114 115 115 116 116 117 BOILER AND SUPERHEATER TUBES SUBJECT TO INTERNAL PRESSURE 151. Indian Boiler Regulations GIRDER STAYS 139. Access Compensating Rings and Frames for Openings in Shells tnternal Doors Raised Manhole Frames and Cover Plates Positions of Manhole in Shell Compensation Rings to Manholes Compensation for Cutting Large Holes in Shell Type Boilers Rivets Securing Compensating Rings and Stand Pipes \_. Tolerances on Shanks l72C. 156. 149. Fitting of Plain Tubes STAY TUBES ( 147. 166. 164. OF WATER TUBE BOILERS 154. Attachment of Steel Tubes 153.l) (. Riveting 174. Rivet Heads . ETC. 159. of Water Tube Boilers STAND PIPES.

186. 207. 210. ) SHELLS 176.. 200. Dished Ends Subject to External Pressure 191. 198. 187. 183. (_) i ) REGULATIONS FOR DETERMINING THE WORKING PRESSURE TO BE ALLOWED ON VARIOUS PARTS OF BOILERS OTHER THAN FUSION WELDED AND SEAMLESS FORGED DRUMS 175. 213. 178. 177. 179. supported only at Edges Bar or Bulb Stiffened End Plates and Smokebox Tubes Plates of Locotype Boilers Plate Margins Manholes and Mudholes in Flat Plates STAYS Solid Screwed Stays Stresses in Steel Jointed Stays Stay Tubes Stays in Tension and Compression . 204. Formula for Working Pressure of Shell Methods of Calculating the Strength of Riveted Joints When Pitch Exceeds Maximum Allowed Butt Straps and Spacing of Rivets Below Requirements Percentage of Welded and Strapped Seams Percentage to be Allowed for Solid Rolled Shells Thickness of Butt Straps Maximum Pitch of Rivets in Longitudinal Joints Spacing of Rows o_f ivets R Circumferential and End Seams of Water Tube Boilers Compensation for Manholes and Other Openings Uncompensated Holes in Water Tube Boilers 118 119 120 120 120 120 120 121 122 123 123 124 (! I ) I. 206.. 197. Complete Hemisphere Without Stays or Other Support Made of One or More Plates and Subject to Internal Pressure 189. 208. 202. Dished Ends of lancashire and Cornish Type Boilers 192. 211. 201.. Flat Plates supported by Solid Screwed Stays. 184. 180. Dished Shell and Firebox Crowns 125 126 126 126 127 () C) () FLAT PLATES 193. Dished Ends Subject to Internal Pressure 190. 199. 182. 212. 181. 209. 205. 203.(xii) CHAPTER IV Indian Boiler Regulations ~ ') . Maximum Pressure 118 ( . ) ( DISHED END PLATES 188. 215. 194. otherthan Ends of Vertical Boilers Forming Parts of Outer Shell Curved Tube Plates of Water-Tube Boilers Efficiency of ligament . Flat Plates supported by Stays and Nuts and large Washers or Strips or Doublings Flat Tube Plates Plates supported by Gusset Stays Flat Crown Plates of Vertical Boilers Circular Flat Ends of Drums. 195. 185. etc. 214. Measurement of Stayed Areas in the End Plates of locotype and Vertical Boilers Gusset Stays Bolts and Studs TUBE PLATES Compression of the Tube Plates Parts to be Stayed ·Minimum Thickness and Cross-Section Holding Power of Plain Tubes Tube Plates. Marginal Seams or Flanges . 196.

Foundations of Vertical Boilers Furnaces Foundations of Locotype Boiler Fireboxes Cross Tubes Uptakes of Vertical Boilers 145 145 146 146 146 146 . 241. 236. General ReqUirements 151 MATERIALS OF CONSTRUCTION 234. Garret Type 232. 242. Fowler Type 149 149 150 . HEADERS AND STEEL CASTINGS 244. 227. 239. Steel and Wrought Iron Tubes 219. Equipment of Workshop 157 158 . Brass and Copper Tubes FURNACES 220. Headers 246. 222. 238. Marshall Type 231. Boiler and Super heater Tubes Subject to Internal Pressure (xiii) . 223. 237. Manufacture 'Chemical Analysis Freedom from Defects Heat Treatment Mechanical Tests Selection of Test Pieces Additional Tests before Rejection Discard Forging 155 155 TUBES. Definition of Term 'Fusion Weld' 248. 221. Steel Castings 155 155 157 FUSION WELDED DRUMS 247. 144 144 144 144 HEADERS AND SECTION BOXES OF WATER TUBE BOILERS 217. 243. 240. CHAPTER V FUSION WELDED AND SEAMLESS FORGED DRUMS FOR WATER TUBE BOILERS AND SUPERHEATERS 233. 228.Indian Baller Regulations BOILER AND SUPERHEATER TUBES SUBJECT TO INTERNAL PRESSURE 216. 147 147 148 148 SUPPORTS FOR COMBUSTION CHAMBER AND FIREBOX CROWN 229: Girder Stays for Firebox Crowns PATENT FIREBOX ROOFS OF LOCOTYPE BOILERS 230. Plain Furnaces of Horizontal Boilers Corrugated Furnaces of Horizontal Boilers Plain Furnaces of Vertical Boilers Hemispherical Furnaces of Vertical Boilers Corrugated Fireboxes of Vertical Boilers. 225. Headers and Section Boxes of Water Tube Boilers BOILER TUBES (SMOKE) SUBJECT TO EXTERNAL PRESSURE 218. 224.. 226. Tubes 245. PIPES IN BOILERS. Materials for Fusion Welded Boiler Drums 151 153 153 153 153 153 153 154 SEAMLESS FORGED DRUMS 235.

GAUGES AND AUXILIARIES 281A Additional Requirements for Automatic Boilers only GENERAL REQUIREMENTS 282. 255.0' () (") .. Packing of Cocks /) \:. ) (xiv) 249. CHAPTER VI VALVES. Headers 272. Longitudinal Stress 274. 278A. RequiSite Mountings. Inspection during Construction o C) REGULATION FOR DETERMINING THE WORKING PRESSURE OF WATER TUBE BOILERS WITH FUSION WELDED AND SEAMLESS FORGED DRUMS SHELLS 270. 256. 253. Materials. 258. \. 254. 262. Castings 284. The ligament Efficiency of Drum Shells shall Comply with Reg. Shell of Steam and Water Drums 271. 266.. 257.\. 273. 251. Temperature and Pressure Limits 281. 268. 277. 264. 261. 250. 278. 263. / . Shape of Dished End Plate General Dished End with Opening End Plate subject to Pressure on the Concave Side Internal Doors 178 179 183 183 179 STANDPIPES AND NOZZLES Standpipes and Nozzles Welded to Shell 'Standpipe and Nozzles Welded to Dished End Plates Minimum Thickness of Flanges Attachment of Stand Blocks and Branch Pipes by Welding 184 186 186 186 . 215. 279B. 252. 161 164 165 166 167 168 170 163 162 167 171 173 174 INSPECTION AND TESTING 269. 265. 260. 276. 259. 267. Intermediate Boiler Drum Supports 174 175 () 176 176 178 END PLATES 275. 280. 279A. Constructional Details and Preparation forWelding Preparation of Plates Cylindrical Shell of Drums Method of Making Welded Joints Types of Welded Joints Number of Joints Position of the Tube Holes Circularity of Drums and Tolerance Mechanical Test and Test Plates for Fusion Welded Seams Selection ofTest Pieces Tensile Test Pieces Tensile Tests Bend Test Pieces Bend Tests Notched-Bar-lmpact Test Additional Tests before Rejection Non-Destructive Test General Heat Treatment Hydraulic Test at Makers' Works Indian Boiler Regulations 158 158 159 159 159 159 160 160 l. 279C.. Permissible Working Stresses for Shells of Boiler and Integral Super-Heater Drums and. Fittings and Auxiliaries 191 192 194 195 195 i J METHOD OF CONSTRUCTION 283.

Bearings for Levers 302. Finishing of Ends 199 199 200 201 201 201 201 201 202 202 202 202 202 203 203 203 203 203 204 204 206 206 206 207 207 207 207 STOP VALVES 315. Test 311. 287. Lift 305. Drainage 300. 294 . Over-Pressure of Safety Valves 295. Blow-Down Mountings 319. General 292. in General (xv) 196 196 196 196 196 196 SPECIAL REQUIREMENTS SAFETY VALVES 291. Definition 293. Materials 308. 327. 322. 326. 328. 288. Blow-Down Valve or Cock 208 208 209 WATER GAUGES 320. Openings in Shell 298. Adjustment of Safety Valve Set Pressure 307.() ( (. Water Gauges Drains Protectors Glass Size Safety Devices ·GaugeColumns Isolating Cocks 209 209 209 209 210 210 210 PRESSURE GAUGES Dials Connections Gauge Cocks Test Connections-Inspector's 210 210 210 211 Pressure Gauge Attachment . Determination of Working Pressure 310. 329. 289. Spacing of Coils 314. 'Number of Effective Coils 313. Minimum Aggregate Area. Final Settings 306A. Steam Stop Valve BLOW·DOWN COCK OR VALVE AND PIPES 317. Pressure Drop 296. 286. Indian Boiler Regulations 285. Attachments of Weights and Springs 303. High and Low Water Alarms 306. Easing Gear 304. 325. 324. Moving Parts 301. 316. Mountings of Safety Valves 297. 321. Dimensions 309. General 318. Discharge Passage 299. 323. 290. 330. Covers and Spindles Direction of Operation Moving Parts Flanges Valve Seatings Chests etc. Lever Valves.. Extension Springs 312.

357. 333. 358. Headers and other Pressure Parts Tubes 213 214 217 217 220 220 220 ! ) HEADERS AND SIMILAR PRESSURE PARTS 339. 354. Material and Construction 338. 351. 340. ) FLANGES Flanges Screwed on Flanges Loose Flanges Riveted on Flanges Welded on Flanges Flanges of Copper Pipes Standard Flanges Joints . Boiler and Super Heater Tubes. 347. Operating Position 336A. Butt-Welding Fittings (S) (J C) . General 336.'j STEAM~PIPE FITTINGS AND CONNECTIONS 361. 360. Pipes 221 c) MATERIAL 344. Number of Sets of Tests Tests Method of Manufacture. HEADERS & OTHER PARTS TUBES 337. ) FUSIBLE PLUGS 331. 359. 348. 332. Requirements as to Feed Apparatus in Certain Cases 212 212 212 i ) CHAPTER VII BOILER AND SUPERHEATER TUBES. 350. Condition of Pipes 222 222 () MECHANICAL·TEST 346.353. . 342A. 355. General Type Material Attachment to Boilef 211 211 211 211 FEED VALVES 335. 334. Heat Treatment and Marking Steam-Pipes and Fittings Steel Pipes Cast Steel Pipes Copper Pipes 223 223 225 226 226 227 228 229 229 230 230 231 233 234 234 239 241 () I. 356. 341. 352. Steel Pipes 345.r" """ (xvi) Indian Boiler Regulations (.Wrought Bends 361A. 342B.. 349. . Material and Construction Rectangular Headers Symmetrical in Form Headers Irregular in Form Cylindrical Headers End Attachments CHAPTER VIII STEAM·PIPES AND FITTINGS 343.

370. 271 271 . Submission of Manufacturing Drawings and the Particulars of Boilers in Advance 394. Fees for Inspection of Pipes _ 395C_ Fees for Inspection of Valves 3950. Preparation for Hydraulic Tests 379. 367. 372. 368. CATCH WATERS. Transfer of Memorandum of Inspection Book and Registration Book 389. Submission of Plans of Steam Pipes 395A. Procedure for Inspection of Installed Boilers 391. 365F. Thickness where no External Reinforcement is provided Blow-Down Pipes Valves Chests (xvli) 241 252 252 242 242 STEAM RECEIVERS. Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes 376. 363. Registration Book 387A. Hydraulic Test of Boilers for Registration 378. 3650. 369. 365e. 365B. CHAPTER IX REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES 375. Preparations of Inspection 377. Grant of Certificate 390. 362B. Maintenance of Records 388. Inspection Fees for Boilers and Part Thereof Constructed in India 3958. Boiler Rating 385. Calculation of Wasted Shell 391A. 393. Registration Fee 386. Memorandum of Inspection Book 387. Procedure for Repairs. Bosses and Drain Pockets External Reinforcement . Fees for Inspection of Components of Valves 272 273 273 275 276 277 280 281 282 272 274 279 280 282 282 282 287 290 292 295 288 283 '296 297 297 298 298 299 . 365E. Materials Construction and Workmanship Access to Shells Compensating Rings to Openings and Doors Branches and Other Connections Shell Joints Determination of Working Pressure Steel Screwed and Socketed Joints and Mountings of Steel Bronze Screwed and Socketed Joints and Mountings and Fittings of Bronze Reducing Valve Flexibility Pipe Work Supports Drainage Freedom from Rust and other Foreign Matter Test Pressures . SEPARATORS. Measurement of Heating Surface 384. 374. Branches. 364. Ageing of Boilers 392. ACCUMULATORS AND SIMILAR VESSELS '365A. 362C. 253 253 255 255 255 263 262 266 268 268 268 270 270 . Inspections of Steam Pipes 395. Steam Tests 381. 371. Welding etc. Engraving of Registry Number 383. 366. 373.Indian Boiler Regulations STEEL BUTT WELDING FITTING 362A. Procedure for Registration 382. Repairs to Boilers and Steam Pipes 392A. Procedure of Hydraulic Tests 380.

_'::. 421. Construction and Workmanship TESTS FOR CLASS I FUSION WELDED SEAMS 417. 419.:.._. 432. Application . 433. _-_ .--..construction and Workmanship Working Pressure of Shells Strength of Riveted Joints Thickness of Butt-Snaps. 399. 414. 415. Unstayed Flat-End Plates ...! 1 C) -_ ." . 403. 407.' ') \l ._--_.. Selection of Test Pieces Tensile Test Bend Test Nick Break Test Re-tests Specimens after Tests Heat Treatment Hydraulic and Hammer Test Determination for Working Pressure Welds and Compensation for Manholes and Branches Manholes and Other Openings in Shells Dlsbed End Plates with Pressure on Concave Side Unstayed Flat End Plates Thickness of Angle Rings Hydraulic Test .. Markings 395G..--_---- () " _ :. 428..._. . _. Safety of Persons Working Inside Boilers 301 CHAPTER X ELECTRODE BOILERS GENERAL REQUIREMENTS 397. 422. 413 . Fees for Inspection of Feed Water Heaters and other Fittings 395F.". Fee for Inspection of Spares and Scantlings Indian Boiler Regulations 299 300 300 ."--:-. 427.. ...._--_. 411. 423. __ . . 404. 426. _-. 418. 429. 398. . 402. 406. 410. Material Specifications for Structural Parts of Electrode Boilers 302 302 302 302 302 302 303 303 303 303 303 303 305 308 308 308 308 308 308 308 310 310 311 311 311 311 311 312 312 312 312 313 313 313 313 313 313 'J RIVETED SrEEL BOILERS 400 ._-. _--_. 425._ . 420.. 408. 430.. 409.... Nuts and Studs Hydraulic Test C) () C) () () FUSION WELDED BOILERS 416.. ._.. " . 431. 405.... Maximum Pitch of Rivets in Longitudinal Joints Spacing of Rows of Rivets End and Circumferential Seams ¥anholes and Other Openings in Shells Dished End Plates with Pressure on Concave Side Seatings for Mounting Flanges Thickness and Drilling Pads. 412. 424._.c ( j ) (xviii) 395E.I CHAPTERIXA SAFETY OF PERSONS INSIDE BOILERS 396. "' ._-_..-._--_. General Terms Relating to Certificates from Makers etc... .._..:.Thickness of Angle Rings Bolts. 401.".. ...

Procedure for Regulation 325 325 TUBES 526. 505. 503. FEED HEATERS AND OTHER SIMILAR VESSELS ECONOMISERS 500. Studs and Flanges 321 VALVES AND MOUNTINGS 519. 523A. 'Procedure for Hydraulic Test 328 326' . Economiser Water Outlet Temperature 319 319 320 320 320 320 320 320 STEEL ECONOMISERS WITH OR WITHOUT CAST IRON SLEEVES ON THE TUBES 513. 523. 508. TUBES AND HEADERS Process of Manufacture Test Bars Number of Tensile Tests Standard Test Piece CONSTRUCTION REQUIREMENTS CAST IRON ECONOMISERS 510. 521. Application of Standard Conditions and Exceptions Thereto General Requirements Modification of Formula Maker's Certificates for Steel Economisers Hydraulic Test for New Economisers Workmanship and Manufacture 315 315 316 316 316 316 317 318 318 319 CAST IRON. 509. Cast Iron Economisers 511. 517. Preparation for Inspection 525. 507. Fittings and Connections (for All Types of Electrode Boilers) CHAPTER XI STANDARD CONDITION FOR THE DESIGN AND CONSTRUCTION OF ECONOMISERS. Determination of Working Pressure End Plates Manholes and Other Opening in the Shells " Mountings. FEED PIPES. 514. 522. Valves and Mountings 322 FEED PIPES 520. General Steel Feed Pipes Cast Iron Feed Pipes Copper Feed Pipes Feed Heaters and Similar Vessels Fitted to FeedPipes 323 323 324 324 324 REGULATION FOR REGISTRATION AND INSPECTION OF ECONOMISERS AND FEED PIPES 524. Tubes: Construction Tubes: Working Pressure Headers: Construction Headers: Working Pressure Attachment of Tubes to Headers JOINT BOLTS AND STUDS 518. "Joint Bolts. 437. Joint Bolts and Studs for Cast Iron Economisers 512. 501. 436. 506.\ ) \ -' Indian Boiler Regulations I . (xix) SEAMLESS SHELL BOILERS 313 314 314 314 434. 515. Procedure at Subsequent Inspection 527. 516. 502. 435. 504.

Repairs to Welded Seams 561. Horizontal Shelves of Tube Plates Forming Part of the Shell 566. Tests on Welded Seams 562 . Submission of Plans of Feed Pipes Indian Boiler Regulations 328 328 328 329 329 329 329 r . Circularity 545. 559. Dished End Plates for Lancashire and Cornish Boilers 567. Seatings for Mountings 556. Shells 565. Dished Ends Subject to External Pressure 569. Manhole Frames. Cover Plates and Joint Bolts 573.. Methods ofWeJding . 529B. General Requirements 536A Equipment of Workshop 537. Mouthpieces and Doors 554A Internal Doors 555. Construction and Workmanship 541. End Plates. Crown Plates and TubePlates 546. Raised Manhole Frames. 553. Transfer of Memorandum of Inspection Book and Registration Books 530. Fireboxes and Combustion Chambers 548.1 330 330 330 CHAPTER XII SHELL TYPE BOILERS OF WELDED CONSTRUCTION 535. 574. Cylindrical Shells 544.. Registration Fee 534. Gusset Stays . Economiser Rating 533. Use of Dished Ends 568. ) 360 ·361 361 363 363 364 365 C) . Memorandum of Inspection Book 529A Regjstratlon Books . Preparation of Plates 542. Application 536. 570.: Heat Treatment 563 . Uptakes 549. Classification of Fusion-Welded Boilers 564. ) (xx) 528. Cross-Tubes 550. Casual Visits 532. Manholes and other Openings in Shells 571. Compensation for Openings in Shells 572. ) 357 360 360 356 358 359 -. ) 345 345 346 346 353 355 346 I. Grant of Certificate 531. Materials of Construction 538. Stress-Relieving 543. Definition of the Term 'Fusion Weld' 558. Bar Stays and Firebox Stays 551. Engraving of Registry Number 534A "Inspection of Feed Pipes 534B. Types of Welded Shell Seams 560. Stayed Flat Surfaces (other than Crowns of Vertical Boilers) 575.) .I. Dished EndsSubject to Internal Pressure 567 A. Covered Electrodes 539. Flat Crown Plates for Vertical Boilers 331 331 331 331 332 332 332 331 co) 332 332 333 8 C) C) C) 333 334 336 338· 338 339 339 337 . Compensating Plates 557. 'Internal Flues 547. Girder Stays for Firebox and Combustion Chamber Crowns 552. 339 340 343 344 341 -. Standpipes and Branches . Access 554. Hemispherical Crowns . Plain and Stay Tubes 540.

Gusset Link. Scope 603. 579. Award of Certificate . Issue of Duplicate Certificate 606. . 582.ERECTION AND FABRICATION AT . Loads on Stay Tubes and Bar Stays ~.Furnaces. Definition 604. SITE IN INDIA AND IN REPAIRING BOILERS AND STEAM·PIPES BY WELDING 602. Stays for Fireboxes and Circular Furnaces 586. Validity of Certificate. Revalidation of Certificate etc. BreathingSpace 591. Hydraulic and Hammer Tests ill 373 376 378 382 382 382 383 383 384 384 385 385 CHAPTER XIII QUALIFICATION TESTS FOR WELDERS ENGAGED IN WELDING OF BOILERS AND STEAM-PIPES UNDER CONSTRUCTION. Longitudinal Bar Stays 588. (xxi) 365 365 366 366 367 368 369 369 370 370 371 371 372 Wide Water Spaces Between and Around Tube Nests Flat Tube Plates and Tubes Nests Manhole Openings in Flat Plates Plain Tubes Pitch of Tubes Stay Tubes Compression of Tube Plates 583. Brace and Similar Stays 592 -". 577. Examination of Test Specimens for Requalification Tests 613. Tests for Requalification 611. Wet-back Reversal Chambers and Fireboxes of Cylindricalform subject to External Pressure 593: Plain Furnaces of Vertical Boilers 594. 608. Maintenance of Records 616. 581. Foundations of Vertical Boiler Furnaces 597. Awarding of Marks 614. Furnace Components. Engagingof Certified Welders 605. Foundations of Locotype Boiler Fireboxes 598. Cross Tubes 600. Fees for Examination of Welders 617.I ' Indian Boiler Regulations 576. 615. Definition 418 418 . Tests for Initial Qualification of a Welder 610. Examination of Test Specimens for Initial Qualification Tests 612. Firebox Crown Stays for Locotype Boilers 587. Initial Qualification Test and Issue of Certificate 605A.580. Corrugated Fireboxes of Vertical Boilers 595.~~~~ 590. Uptakes of Vertical Boilers 599. Age and Experience 609. Pads Welded to Shell or the Attachment of Flanged Mountings 601. Penalty 408 408 408 408 408 408 408 409 409 412 412 414 415 415 415 417 417 CHAPTER XIV SMALL INDUSTRIAL BOILERS GENERAL 618. Productionof Certificate 607. Hemispherical Furnaces of Vertical Boilers 596. ·578. Girder Sling Stays 585. Girders for Firebox and Combustion Chamber Crowns 584. Scope 619.

1950 Questionnaire to be Answered by Tube/Pipe Maker Seeking Recognition by Central Boilers Board as "Well-known Tube/Pipe Maker'" under Indian Boiler Regulations. 624. . 1950 . 1950) : Qualified Boiler Weider's Certificate Issued under the Indian Boiler Regulations. Fittings and Feed Supply 622. 626. Scope Requirements Sampling Test Methods 423 423 423 423 FORMS Form I Form II Form II-A Form 11-8 Form III' Form III-A Form 111-8 Form III-C Form III-D Form III-E Form III-F Form III-G Form IV Form IV-A Form V Form VI Form VII Form VIII Form IX Form X ForrnXI 'Form XII Form XIII Form XIV Form XV-A ' : Memorandum of Inspection or Registration Book : Inspecting Authorities Certificate of Inspection during Construction : Inspecting Authorities Certificate of Inspection during Construction in respect of a Boiler made to Foreign Code for Export : Inspecting Authority Certificate of Inspection during Construction of Boilers for which variations from Standard Condltions have been permitted : Constructor's Certificate of Manufacturer and Test : Certificate of Manufacture and Test : Certificate of Manufacture and Test : Certificate of Manufacture and Test of Boiler Mountings and Fittings : Certificate of Manufacture and Test : Certificate of manufacture and Test : Certificate of Manufacture and Test of Castings and Forgings : Certificate of Manufacture and Test of Forgings/Castings(SEMIS) : Steel Maker's Certificate of Manufacture and Results of Tests : Certificate of Manufacture and Results of Tests in Lieu of Form IV : Provisional order under section 9 of the Indian Boilers Act of 1923 : Certificate for Use of a Boiler : Inspecting Authority's Certificate of Inspection under Construction DeSignation of Inspection Authority : Contractor's Certificate of Manufacture and Test : Memorandum of Inspection or Registration Book-Economisers : Provisional Order under Indian Boilers Act.Steam Pipes and Connected Fittings : Questionnaire to be Answered by Firms Seeking Recognition by the Central Boilers Board to become an Inspecting Authority Under the Indian Boiler Regulations. Registration.. 1950 : Memorandum of Inspection Book . 1923 : Certificate for Use of an Economiser : Record of Welder's Qualifications/Requalifications Tests (Indian Boiler Regulations.(. : Questionnaire for Eliciting Information Regarding the Competency of a Firm to be Recognised as "Competent Authority" under Regulation 4A(2) of the Indian Boiler Regulations.Gauges. Valves..I (xxii) Indian BoilerRegulations 418 420 422 .) 483 484 . Operation and Maintenance CHAPTER XV FEED WATER FOR BOILER 623. (J 620. . 1950 : Questionnaire to be Answered by Steel Makers seeking Recognition by Central Boilers Board to be Notified as "Well-known Steel Makers" under Regulation 4A(2) of the Indian Boiler Regulations. 1950 : Questionnaire to be Answered by Foundry/Forge Seeking Recognition by Central Boilers Board to be Notified as "Well-known Foundry/Forge" under Regulation 4A(2) of the Indian Boiler Regulations. 1950 425 441 442 \ 442 443 453 455 457 458 460 461 461 463 463 464 464 466 467 468 471 471 473 475 476 480 481 482 (J () FormXV-D FormXV-E \ . 625. Extent to which Variation from the Standard Conditionstao down in the Preceding Chapters is Permissible 621.

Application of Act to economisers 3.11 : Diagrams of Riveted Joints with Formulae : Forms of Standard Tensile Test Pieces : Proof Test for Creep Quality of Carbon Steel Plate of Boiler Plate QualitySpeCification : Flanges for Pipes. Alterations and renewals of boilers . 28. Twelve Months of the Certification under Appendix 'JA' and Appendix 'JB' 485 485 486 487 487 488 488 489 489 490 490 491 492 493 496 APPENDICES Appendix -A Appendix . Conditions precedent for repairing boiler and boiler component 5. Use of boiler pending grant of certificate 11.Inspection and Testing of Boilers during Construction : Power Utility Boilers : Waste Heat Boilers : Safety Valve Discharge Efficiency Testing : Converslon Table 505 510 519 521 527 529 531 508 525 INDIAN BOILERS ACT.F Appendix -J Appendix . Registration 8.JB Appendix .L Annexure . Renewal of certificate 9. under the .JA Appendix . extent and commencement 2. Provisional orders 10. Conditions precedent for manufacture of boiler and boiler component 4D.D Appendix . Valves and Fittings : Transverse Rupture Stress (Modulus·of Rupture) : . 1923 1. 1950 : Certificate of Approval for Inspecting Authority : Certificate of Approval for Competent Authority : Certificate of Approval for Well-known Steel Maker : Certificate of Approval for Well-known Foundry : Certificate of Approval for Well-known Forge : Certificate Of Approval for Well-known Tube maker : Certificate of Approval for Well-known Pipe maker : Certificate of Approval for Wen-known Material Testing Laboratory : Certificate of Approval for Well-known Remanent Life Assessment Organisation : Certificate of Manufacture and Test for Small Industrial Boilers (Manufactured Under Chapter XIV) : Questionnaire Form for Repairer of BOilers/EconomiserlSteam Line/Feed Water Lines etc. Chief Inspector.''''1' 532 534 532 534 535 535 536 537 534 535 535 536 537 538 539 538 541 541 541 542 . 1950 : Questionnaire to be answered by Firm seeking recognition by Central Boilers Board as Remanent Life Assessment Organisation under Regulation 391A of the IndianBoiler Regulations. Deputy Chief Inspectors and Inspectors 6. -Welders certificate 4C.VIII Form XIX : Questionnaire to be Answered by a Laboratory seeking recognition by Central Boilers Board as a "Well-known Material Testing Laboratory" under Subregulation (2) of Regulation 4A of the Indian Boiler Regulations.B Appendix. Short title. Definitions 2A Application of Act to feed pipes .E Appendix . Power to limit extent 4A.Indian Bailer Regulations. 1950 : Details to be Furnished alongwith Application for Inspection of Boiler after . Prohibition of use of unregistered or uncertificated boiler 7. Revocation of certificate or provisional order 12.Indian Boiler Regulations I " (xxiii) Form XVI-A FormXVI-B FormXVI-C FormXVI-D FormXVI-E FormXVI-F FormXVI-G Form XVI-H Form XVI-I Form XVII Form X. Inspection during manufacture 4E. Limitation of application 4. Inspection during erection 4F. Technical Adviser 48.

Exemptions 35: Repeal of enactments Indian Boiler Regulations 542 542 543 543 543 543 543 544 545 .. etc. Penalties for illegal use of boiler 24.. Finality of orders 22. Power to make rules 30: Penalty for breach of rules 31. Applicability to the Government 34... Penalty for tampering with register mark .. T ransfer of certificates. Power to make regulations. . 33. 28A: Power of Central Government to make rules 2g. Appeals to Chief Inspector 20.26.(xxiv) 13.. Powers of entry 18. 17.25. ."J () C) THE SCHEDULE Enactments repealed 552 ( C) _ _ __ -_.__ .. Recovery of fees etc.. Production of certificates. Trial of offences 27A.. 548 550 551 551 551 551 551 551 552 C. Central Boilers Board 28.. Power of Central Government to give directions 32. Publication of regulations and rules 31A. I I ....' 544 545 545 546 546 547 549 545 546 ._ --. Power of Central Government to revise order of appellate authority 21." '\. Other penalties . .· Report of accidents 19.. 16. .. Appeals to appellate authority 20A.. etc.... Alteration or renewal of boiler component 14.. Minor penalties 23. Duty of owner at examination 15. Limitation and previous sanction for prosecutions 27..

(d) "Chief Inspector" and "lnspector' means. unless the context otherwise requirea-> (a) The "Act" means the Indian Boilers Act. I. 1 . dated Simla. (2) They extend to the whole of India.Extent. 2. 15th September. 1950 . the 15th September. respectively.dated the 15th September. Section 3. (3) 2Theyshall come into force at once. the same having been previously published as required by sub-seotion (1) of section 31 of the said Act. 1936. pp. a person appointed to be a Chief Inspector and an Inspector under the Act. Jammu . except lrrhe State of. Part tI. (cc) "Calculatlon Pressure". 1950. Short Title. See Gazette of India. 607 to 825 . Application and Commencement S.No.75 litres (five gallons) in capacity which is used expressly for generating steam under pressure and includes· any mounting or other fitting attached to such vessel.O. for the words and letter "except Part B States" the words "except the State of Jammu and Kashmir" shall be substituted. (2a) These Regulations shall apply to all boilers including those working on the principles of natural circulation. Definitions In these Regulations. which is wholly or partly under pressure when steam is shut off. the Central Boilers Board is pleased to make the following Regulations. 1.INDIAN BOILER REGULATIONS 1950)-ln exercise of the powers conferred by section 28 of the Indian Boilers Act. in clause (2) of Regulation 1. . means the design pressure of any part adjusted to take into account the pressure drops corresponding to the most severe conditions of pressure drop and hydraulic head. forced circulation and forced flow with no fixed steam and water line. (1) These Regulations may be called the Indian Boiler Regulations. Extraordinary. and in supersession of the Government of India Notification . 1950. 600 (New Delhi. All Diagrams/Drawings in this book are not to scale. (b) "Accident" means an explosion of a boiler or steam-pipe or any damage of a boiler or steampipe which is calculated to weaken the strength thereof so as to render it liable to explode. 470.R. 1923 N of 1923). 2. and Kashmir] . namely: REGULATIONS PRELIMINARY . A.. 1923. the 27th October. In the said Regulations. in relation to a boiler. (c) "Boiler" means any closed vessel exceeding 22.

manner as laid down in regulations 4A to 4H. as competent to grant a certificate in Form II. (iii) in respect of. where necessary.. ' acting on behalf of the Inspecting Authority. except for the drawings of the first set of boilers or parts thereof.(a) approval of drawings of boilers of parts thereto with minor changes. water passes directly to a boiler. ) (b) Chief Inspector (Boilers) of the State where the unit is located (c) a representative of the manutacturers of boilers/ancillaries in public sector --Member (f) "feed-pipe"- C) (1 (i) means any pipe or connected fitting wholly or partly under pressure through which feed.~. Oi) in respect of material manufactured or boilers constructed outside the State an officer -. CD Oi) every reference to a steam-pipe or steam-pipes shall be 'deemed to include also a 0 reference to feed-pipe or feed-pipes respectively. (h) "Inspecting Officer" means(i) in respect of material manufactured or boilers constructed in any State an officer appointed by the Inspecting Authority in that State. I . CD . .(dd) "Competent Authority" means an authority recognised by the Central Boilers Board iii the.. (ii) in relation to a once through forced-circulation boiler. (e) "Economiser" means any part of a feed-pipe that is wholly or partly exposed to the action of flue .. gases for the purpose of recovery of waste heat.. (b) inspection at stages of manufacture including examination of repairs. IIA or liB. the maximum allowable working pressure in the steam drum of t~e boiler.. (ddd) "design pressure" means . (ee) "Evaluation Committee" means a commi~ee constituted by the Central Government consisting ·of(a) Technical Adviser (Boilers) -Chairman -Member l -.2 Indian Boiler Regulations . () (g) "Inspe~ing Authority" means an authority recognised by the Central Boilers Board in the manner as laid down in regulations 4A to 4H.. the maximum allowable working ( \ i pressure at the final superheater steam outlet. (i) in relation to a natural or assisted circulation boiler. as competent to issue certificates to welders for l the purposes of regulation 4(b)(ii) and regulation 605.

Indian Boiler Regulations 3 (c) signing and issue of certificates in the relevant forms except for the certificates of the first set of boilers or parts thereof. or (ii) such pipe exceeds 254 millimetres in internal diameter. efficiency or otherwise to the replaced part or fitting. square centimetre above atmospheric pressure. if- a boiler to a prime-mover or (i) the pressure at which steam passes through such pipe exceeds 3. 0) "prescribed" means prescribed by regulations or rules made under the Act. (I) "State" or "States" means a State or the States to which these regulations extend. an officer acting on behalf of an Inspecting Authority. (m) . and includes in either case any connected fitting of a steam-pipe. of a petty nature when the part of fitting used for replacement is not inferior in strength. (i) "owner" includes any person using a boiler as agent of the owner thereof and any person using a boiler which he has hired or obtained on loan from the owner thereof. addition or renewal" shall not be deemed to include any renewal or replacement. . (hh) "Liaison Sub-Committee" means a committee constituted by the Central Boilers Board under bye-law 3(i)(e) of the Bye-laws of the Central Boilers Board.5 Kilograms per . (k) "Steam-pipe" means any pipe through which steam passes from other user or both."Structural alteration. and (n) "Technical Adviser (Boilers)" means Technical Adviser (Boilers) to the Government of India in the Ministry of Industry (Department of Industrial Development).

mountings and fittings conforming to the Codes or Standards like BS. under any ofthe following circumstances. Inspection of Boiler to comply into any Foreign Code Notwithstanding anything contained in these regulations. design and construction. register boiler. steam-pipe. the Chief Inspector may. The decision of Inspecting Authorities shall be binding on all Registering Authorities. provided that such material is not specifically prohibited by the Regulations and that the methods of manufacture. General requirements. which are known to be commonty used in industrially advanced countries. including ASME. steel or of Cast or Malleable Cast Iron. which is subject to pressure.and order the issue of a certificate authorising the use thereof. BS. 3A. ecdnomiser or superheater are not in jn ccmformity with the Regulations but are not considered by the Chief Inspector to be inferior in strength to those prescribed in the Regulations and form part of the usual manufa·cturing practice of boilers and steam-pipes in other countries. (ii) when the constructional features of a boiler. (4) Where no specific provision is made in these regulations for design or manufacture of any pressure part. the Inspecting Authority may permit the design. the Inspecting Authority may inspect any boiler meant for export during the various stages of its construction so as to comply with the requirements of any foreign code and may grant a certificate in Form IIA. 4 . application of standard conditions and exception thereto (1) A boiler shall not be registered under sub-section (4) of Section 7 of the Act and a certificate shall not be issued under sub-section (5) of that section with reference to a boiler.. unless the standard conditions in respect of material. economiser or superheater is a not in conformity with the Indian Boiler Regulations but is known to be commonly used other countries as being suitable for use in the construction of boilers and steam-pipes. steam-pipe. manufacture. are satisfied in respect of such a boiler. TRD. (3) No structural part of a boiler. economiser or superheater has obviously been built in conformity () (_) ( with the regulations but no certificate as required under the regulations is forthcoming. (4A) The tubes of boilers and heat exchangers made of Titanium and other exotic metals may be approved as per international codes. fabrication and heat treatment conform to the specified Codes or Standards. stage inspections and certification of such pressure parts including the valves. shall be made of Bessemer process /") . TEMA with the minimum thickness specified in those codes of manufacture. DIN. ASME Boiler and pressure vessel code.CHAPTER I GENERAL REQUIREMENTS. (2) Notwithstanding anything contained in sub-regulation (1). TEMA. (iii) when a boiler. namely(I) when the material used in the construction of a boiler. GOST and JIS. APPLICATION OF STANDARD CONDITIONS· AND EXCEPTIONS THERETO 3. steam-pipe. subject to the provisions of regulations 7 and 8. which are specified in the subsequent Chapters of these Regulations.

a certificate in Form II may be issued by the Inspecting Authority of the State. after completion of construction at site on the strength of the certificate supplied to him in prescribed forms by the owner for the individual components which are required to be furnished for registration of a boiler under Regulation 4(c). the thickness of all plates. . namely:(i) A certificate in Form II-From an Inspecting Authority certifying that the material was tested and the boiler was built under their supervision. the hydraulic test to which the boiler was subjected. the year and place of make. Together with such certificate the Inspecting Authority may furnish a Memorandum of Inspection Book in Form I prepared in the manner prescribed by Regulation 386 in respect of the Inspection of the boiler during construction and the hydraulic test applied on completion. the maximum continuous evaporative capacity. such as. the intended working pressure. 14(1)(c) of the Act-In advance of or alongwith an application . (a) Material-All plates. steam-pipes. solid rolling or welding. its principal dimensions. however. . particulars of the kind of material used in its construction. rivets and bars used in the constru. economisersand super-heaters shall possess and produce to the sansfacncn of the Chief Inspector the Welders Performance Qualification Certificate issued by a Competent. In case of a boiler which is to be assembled only at site. etc. under Sec.departure from ordinary practice' in making the shell. Note: The Chief Inspector may.Indian Boiler Regulations STANDARD REQUIREMENTS 5 4.Authority. and the works number of the boiler. (ii) Welders engaged in site welding of boilers.heating surface.ction of boilers ~hall be tested and found to conform with the Regulations hereinafter contained. particulars of any . (c) Certificates. where the boiler is installed.efInspector. for registration of a boiler the following certificates and drawings or specifications shall be furnished to the Chl. before the commencement of construction of such boiler at the site. requirement of the hydraulic test on a completely assembled boiler by the Inspecting . the area of . . (b) Construction-(i) All boilers during construction shall be. under the supervision of an Inspecting Officer and shall be inspected at all stages of construction prescribed in Appendix J. the diametre of and method of forming the rivet holes in the shell plates. Tubes and steam-pees shall also be inspected at the makers' works at the stages prescribed in Appendix J. where the boiler is installed. (ii) A certificate in Form III of manufacture and test signed by the maker or by a responsible representative of the maker of the boiler containing a description of the boiler. In case of Waste Heat Boilers.submltted to the Inspecting Authority of the State.shall be . approve a modified form of certificate wherein items which do not pertain to a particular may be omitted. and the tests conducted by the makers shall also be witnessed by the Inspecting Officer. Authority shall not apply provided that the individual parts of such boiler have been hydraulically tested and certified by the Inspecting Authority separately' as required under these Regulations.

6 Indian Boiler Regulations :. shall be accepted in lieu of a certificate from an Inspecting Authority. fillets and flanges and corners of bent plates. the owner shall if requested by the Chief Inspector obtain and furnish the original documents specified in the said clauses: Provided further that in respect of the steel made and tested by Well-known Steel Makers ' recognised by the Central Boilers Board in the manner laid down in regulations 4A to 4H. the plate or bar numbers 0 and the number and dimensions of the various plates etc. Note: For pressure parts. ultimate tensile breaking strength in tons per square inch of. and where gusset stays are fitted the number and diameter of rivet holes in each gusset stay. owing to such certificate containing details of plates used for other purposes also. cross spacing of rivets rows and diameters of rivet-holes. an Inspecting Authority: \ () Provided also that in respect of the tubes/pipes made and tested by well-known tube/pipe maker ( recognised by the Central Boilers Board in the manner as laid down in regulations 4A to 4H.' (iii) ·A drawing or print to a scale. the percentage af \. section. the number. showing the principal dimensions and a longitudinal section and even view of the boiler of bearing the works number of the boiler and Maker's office stamp.'. the radii of curvature of dished end plates. rivets or bars. their r=.) _elongation and the length on which measured. in the case of large boilers of not less than 3/4 inch to the foot and in the case of small boilers of not less than 1% inches to the foot. an extract from the original certificate duly signed by the makers of the boiler and countersigned (. certificate of Well-known Steel Maker in Form IVA shall be accepted in lieu of a certificate from . as the case may be. the scale tobe used is 1:50 for drum and 1: 100 for General Assembly drawing. a . of the riature referred to in Regulations 26 and 27 respectively. a certificate of manufacture and test of well-known tube/pipe maker in Form IIID or IIIE. kind and result of bend or other C) tests made and the date of tests: Provided that where an rnspecting Authority furnished a certificate in Form II together with a Memorandum of Inspection Book in Form I in accordance with sub-regulation (c)(i) the certificates prescribed under clauses (ii) and (iv) need not be furnished to the Chief Inspector when application is made forregistration of the boiler. In the case of water tube boilers. assembly drawings of boiler capacity 200 rvMI and above. their chemical analysis. But should any question arise in respect! of the fitness of the boilers for the working pressure approved by the Inspecting Authority within a period of three years from the date of their registration. the foregoing scales shall apply to the main boiler drums only. The drawing shall show details of riveting of longitudinal \-. In case where the original certificate from well-known steel makers in Form IV is not produceable. rivets or bars. The certificate from the C) maker of the plates. but in addition a general arrangement drawing of the boiler to a scale of not less than % inch to the foot shall be provided. and circumferential seams with pitch of rivets. tested. l (iv) A certificate in Form IV from the steel maker and a certflcate from the maker of the plates.{i . shall show the charge numbers.

Provided that: (I) a certificate is furnished by the producer of the steel to the effect that the steel has been manufactured strictly in accordance with the technical requirements of the ASME or as or EN Code to assure that the creep rupture requirements are complied with. In addition. the average stress to produce an elongation of 1 per centtcreep) in 100. as the case may be. forged bars of about 25 mm2 which will undergo heat treatment as prescribed by the relevant specifications. these grades of steel may be accepted and long time elevated temperature properties/maximum ellowable stress values given in ASME or BS or EN Code. the forging to be used in valves should be tested at 550°C for 1000 hours. However.000 hours in the material wherever applicable. At this stress. (IV) two numbers of 1000 hour creep rupture tests shall be carried out at a temperature 50°C above the service temperature for each grade of steel for tubing or piping or castings or plates grades. warm yield point (0.000 hours and the average and the lowest stresses to produce rupture in 100. (vi) For tubes and pipes subject to internal pressure.000 hours in the material. are to be furnished. a minimum rupture life of 1000 hours is expected. may be used for the purpose of design. shall be furnished: Note: Until 33. . a certificate giving results of tests regarding chemical analysis. and a certificate is given by .2 per cent proof stress). provided all information required in Form IV and furnished in the extract. These samples may be selected at random by the Chief Inspector of Boilers of the respective State. (II) the Steel maker furnishes the necessary certificate that the steel conforms to the chemical analysis.. wherever is applicable.2 per cent proof stress). certificates in respect of yield point at service temperature (0.000 hours tests are carried out by National Metallurgical Laboratory or Corporate Research and Development Laboratory of Bharat Heavy Electricals Limited for collecting elevated temperature data of alloy steel produced indigenously against ASME or as or EN Code. (Ill) the short-term stress-rupture tests for 1000 hours as described below are carried out by NMUSteel Plants for the purpose of checking whether the steel is up to the specification and also to ensure that the Steel is capable of meeting the long-term rupture stress values/maximum allowable stress values given in ASME or as or EN Code. Both the samples should pass 1000 hour tests at the above stress and temperature. as the case may be. (v) In the case of fusion welded drums of diagram of welded repairs and temperature charts of heat-treatment shall also be furnished. The samples could be in the form of semi-finished products. room and elevated temperature mechanical properties given in ASME or BS or EN Code as the case may be. the average stress to produce an elongation of 1 per cent (creep) in 100. The stress to cause rupture in 1000 hours at above temperatures may be taken from the master curve corresponding to-20% line. say. . Indian Boiler Regulations 7 by the Inspecting Authority shall be acceptable in lieu of the certificate in Form IV. when in fumace and/or in superheater zone. NMUSteel plant to this effect.000 hours and the average and the lowest stresses to produce rupture in 100.

(vii) For such boilers having a capacity of 20 Tons per hour and above which are required to be assembled at site. 8 Indian Boiler Regulations .P Tested to Lbs . the permissible stress figures specified in the Code at different temperatures may be accepted in lieu of figures computed from the data '. is in conformity with the code of the country of manufacture and is covered by those Regulations. . (ii) Where the basis upon which these stresses have been arrived at is made available and such basis is not found to be such as to give rise to stresses higher than those permissible under the Regulations. MAKER'S NAME Work's Number. Inspecting Officer's or Inspecting AuthoritY's Official Stamp (e) Certificates for steam-pipes-A certificate of manufacture and test in Form III-A. shall be furnished.. the mountings may' be supplied separately.. All boilers of capacity less than .. issued at the time of manufacture of boilers. Notes: (1) For the purpose of this clause certificates issued by an authority empowered in this behalf by or under the law in force or the national code in a foreign country. certificate of manufacture and test in Form III-B. the material used. in respect of mountings and fittings ln that. '.. . country and containing the particulars required to be specified in this certificate. In case. -"'. signed by the maker and the Inspecting Authority shall be furnished. Form III-B. Where. signed by the Maker and the Inspecting Authority in respect of boiler mountings and steam-pipe fittings during manufacture. namely:(i) Where a certificate is furnished from an Inspecting Authority to the effect that the steel complies with the requirements of the grade steel (to be specified) and the permissible stress for the working conditions as allowed for in the Code of the country of manufacture falls within the limit permissible under this Regulation.· (d) Maker's Stamp-The the following particulars: boiler shall have stamped upon its front plate in a conspicuous position. certificate from the 'Well~known Tube Makers' as aforesaid is produced. may be accepted. . such certificate may be accepted in lieu of the certificate from the Inspecting Authority insofar as it relates to testing of material including mechanical tests specified in this form. 20 Tons per hour shaH carry all the mountings or fittings certificates in respective forms with' details mentioned in Form III. Lbs on Year of Make . CD . W. (g) Certificates for mountings and fittings-A certificate of manufacture and test in Formlll-C. (f) Certificates for tubes-A ( . signed by the maker and the Inspecting Authority shall be furnished.-~ \. however. Note: In case of tubes made by Well-known Tube Makers {recognised by the Central Boilers Board in the manner as laid () down in regulations 4A to 4H] in India or other countries listed in Appendix 'M' material testing including mechanical tests may be carried out by them and the particulars regarding testing of material including mechanical tests as certified by them shall be noted in the appropriate column or paragraphs in the certificate in. required to be furnished under Regulation 271 in any of the following cases.

Central Boilers Board. a fee of US $ 10. Well-known Foundry/Forge. forgings and castings.a minimum experience of two years in the area of activity for which recognition is applied for. (3) Any firm applying for recognition under sub-regulation (1) shall have. Well-known Material Testing Laboratory. for recognition as one of the aforementioned areas of activity in which that firm is engaged. Well-known Tube/Pipe Maker and Well-known Remanent Life Assessment Organisation shall be made by a firm to the Secretary. Central Boilers Board.(Two Thousand US Dollars) per additional unit shall ~e deposited. WELL-KNOWN STEEL MAKER. (4) In case of firms in foreign countries seeking recognition as "Well-known Steel Maker". PROCEDURE FOR RECOGNITION OF COMPETENT AUTHORITY. the Secretary. pipes. foreign country in respect of plates. (f) and (g) of this regulation. certificate issued by an authority empowered in this behalf by or under the law in force or national Code or Standard of any. Central Boilers Board shall send a questionnaire in any of the Forms (Forms XV-A to XV-G) applicable to the area of activity to the applicant who shall send the same after duly completed. Ministry of Industry (Department of Industrial Development). New Delhi. signe~ by the maker and the Inspecting Authority shall be furnished. WELL-KNOWN TUBE/PIPE MAKER AND WELL-KNOWN REMANENT LIFE ASSESSMENT ORGANISATION 4A. Application for Recognition (1) An application for recognition as Competent Authority. (i) Certificate of inspection during construction of tubes for which variation from standard conditions have been permitted-A certificate of manufacture and test in Form III-B(i). WElLKNOWN FOUNDRY/FORGE. (e).Indian Boiler Regulations 9 (2) For the purpose of clauses (c). (h) Certificates of inspection during construction of pipes for which variation from standard conditions have been permitted-A certificate of manufacture and test in Form III-A(i). Well-known Steel Maker.000 (Ten Thousand US Dollars) to meet the expenses of the visit of the Evaluation Committee shall be deposited alongwith the completed Questionnaire form: Provided that where the firm has more than one manufacturing unit in the same country an additional fee at the rate of US $ 2000/. (2) On receipt of application under sub-regulation (1). "Wellknown PipelTube Maker". . bars. to the Secretary. Inspecting Authority. signed by the maker and the Inspecting Authority shall be furnished. (3) Photostat copy of the certificate in Form IIJ-Cshall be accepted provided it is endorsed by the manufacturer or the Inspecting Authority. WELL·KNOWN MATERIAL TESTING LABORATORY. "Well-known Foundry or Well-known Forge". tubes. INSPECTING AUTHORITY. manufactured in that country and containing the particulars required to be specified in the steel makers certificates referred to in the above mentioned clauses of regulation 4 may be accepted provided such certificates contain a statement duly signed by the Inspecting Authority to the effect that these materials comply with the requirements of the law or the Code or Standard of the foreign country.

Scrutiny of Applications by the Evaluation Committee (1) The Secretary. to appear before it to give clarification for additional information that. (b) visit any of the applicant firms on a specific request in writing from such firm to evaluate the performance of the said firm. may be required by the said Committee. In the case of renewal of the recognition. (3) The Evaluation Committee after satisfying itself that the requirements specified in sub- regulations (1) and (2) are fulfilled. . Well-known () (J Steel Maker. .recognised after following the procedure laid down in the regulations and the certificate shall be issued for a further period of five years. Recognition of a Firm as Competent Authority. Evaluation Committee may. it shall inform the applicant in writing giving reasons therefor. the firm may be . foundry or forge and tube or pipe makers. Central Boilers Board shall send all the applications received under sub-- regulation (1) of regulation 4A. -. ( '~ C_) C) . Central Boilers Board and in case the Liaison Sub-Committee decides to refuse . 4C. under sub-regulation (1) and- 0) where the application is for recognition as Competent Authority or Inspecting Authority.es are being carried out in order to evaluate the performance quality of the tests conducted and products manufactured. (1) The Liaison Sub-Committee shall consider the reports and the recommendations of the Evaluation Committee submitted under sub-regulation (3) of regulation 4B and after examining all the . Inspecting Authorities etc. Well-known Foundry or Forge. to the Evaluation Committee.' the . aspects of such report shall either accord recognition to a firm or refuse recognition to such firm. (a) call any of the applicants if it considers necessary. if the application is received for renewal alongwith the required fee as per the regulations. 48. (ii) where the applicants are for recognition as Well-known Material Testing Laboratory. the Evaluation Committee shall inspect the laboratories of such Material Testing Laboratory and Remanent Life Assessment Organization or the factories of such steel makers. recoqnitlon. a certificate of recognition in one of the Forms (Forms XVI-A to XVH) applicable to the area of activity shall be issued by the Secretary.10 Indian Boiler Regulations The Evaluation Committee shall carry out the evaluation of the manufacturing works of the firm within 120 days of receipt of the fees. (2) The Evaluation Committee shall examine all the applications -and replies to the Questionnaire . where the testing and manufacturing activiti. . The certificate of recognition shall be from the date of the visit of th~ plant by the Evaluation Committee and shall be for a period of five years. (2) In case the Liaison Sub-Committee decides to accord recognition to a firm. Well-known Tube/Pipe Maker or Well-known Remanent Life Assessment Organisation. shall submit a report along with its recommendations to the Liaison Sub-Committee.' along with replies to the questionnaire under sub-regulation (2) of regulation 4A.

the same may be entertained by the said authority that there was sufficient cause for not making application in time. Central Boilers Board. in particular in the following areas. AI! the existing firms recognised as Competent Authority. Function of Evaluation Committee The Evaluation Committee shall evaluate the performance of a firm applying for recognition in accordance with the provisions of these regulations. 1988. within one year from the commencement of the Indian Boiler (4th Amendment) Regulations. Central Boilers Board who after following the procedure laid down in these regulations may renew the certificate of recognition and such renewal shall be valid for a further period of five years. Application for Registration of Existing Competent Authority etc. Central Boilers Board. .r) r ) I ! Indian Boiler Regulations 40. the period of validity shall be deemed to have been extended till such time the decision on the renewal is communicated to the firm. Inspecting Authority. \ 11 ( 4E. 4H. 4G. Well-known Steel Maker.. 4F.known Material Testing Laboratory. (iii) Review of quality system. Appeal (1) Any firm not satisfied with the reasons given by the Liaison Sub-committee for refusing to accord recognition may file an appeal in writing to the Chairman. (b) Notwithstanding anything contained in sub-regulation (a). shall be valid for a period of five years. shall be decided in the meeting of the Central Boilers Board and the decision of the Board thereon shall be final. (2) All applications received by Chairman. Central Boilers Board. Well-known Foundry/Forge. shall continue to be so recognised as such till the expiry of the period of three years: Provided further that if an application is not made in time. Validity of. Certificate of Recognition A certificate of recognition issued under regulation 4C. (ii) Organisation. . under sub-regulation (1). Well . and in case no application is made within the time specified the recognition of such firm shall be deemed to have been withdrawn: Provided that the firm which has been granted recognition and has not completed a period of three years. shall make an application to the Secretary. Renewal of Certificate of Recognition (a) A firm desiring renewal of the certificate of recognition shall apply for such renewal at least three months before the expiry of the validity of the certificate to the Secretary. Well-known Tube/Pipe Maker and Well-known Remanent Life Assessment Organisation. for reconsidering its application. namely:(i) Quality System.

(x) Inspection and. (Ix) Corrective action. (vii) In-process inspection. (d) verification of purchased material. . For iron across the grain the tensile strength' may be 18 tons per square inch. (xii) Control of non~conforming material. (viii) Workmanship. if the Chief Inspector is satisfied that the material is of suitable boiler quality. Modification of Formulae Indian Boiler Regulations ('I ( ) ( ) I " o (~ '--) G o () (i) Under the Regulations for determining the working pressure to be allowed on various parts of boil~rs. (v) Inspection equipment. (xiii) Indication of inspection status. the material to which the formulae apply shall in the absence of express provision to the contrary be steel complying with the requirements of Chapter II.Sampling procedure. the material may be treated as iron. (xv) Training.12 (iv) Documentation(a) Inspection and test procedures. (b) storage. (ll) Where no test certificates for plates and rivets are produced. (b) Records. (vi) Inspection of purchased material or services(a) purchasing. (xi) . (c) Technical data. In such cases the values of tensile and shear strength shall not be more than 26 and 21 tons per square inch for steel. If in such cases the Chief Inspector is clearly satisfied that the material is of good quality. be assumed to be more than 26 tons per square inch. 5. a higher strength than that allowed for iron may be permitted but the strength of the plates shall not. (c) delivery. (xiv) Protection and preservation of product quality(a) material handling. and 21 and 18 tons per square inch for iron. save for special reasons. . (c) receiving inspection.} Ij o () .test of completed items. (b) purchasing data. .

the' second-hand Water Tube Boiler may be registered by reducing the working pressure of the parts of the boiler as calculated from these regulations by ten percent: Provided that a higher working pressure. bars. and the cast steel shall be those prescribed in Chapter II. billet. will not be allowed for manufacture of Shell or Drum of the boilers.Indian Boiler Regulations cent shall be the working pressure permitted. (iii) Shipping documents/order documents shall be made available to establish the specifications of the manufacture for inspection and testing of plates. . pipes and tubes are not covered by mill test certificate either due to misplacement or late receipt of the same but otherwise there are reasons to believe that the materials are genuine and of standard specifications registering authority or Chief Inspector of Boilers may permit the use of such materials as a special case after thorough verification test in a Test House to his satisfaction at the rate not less than 25% subject to the following conditions: (a) In respect of Plates(i) The plates ~hall have a steel maker's stamp. namely:(i) Water Tube Boilers-Where the documents required under its code of manufacture for its registration are furnished and its workmanship is not in any way doubtful. 13 (iii) For flat plates of copper. 5A. then the same shall not be registered except in the following cases. Material not fully identified Where the material as for example plate. !. Registration of second-hand boilers not in accordance with the standard conditions If a second-hand boiler is not conforming to the requirements of these regulations for its registration. being not more than the working pressure allowed by the code of manufacture. however. 7. the working pressure as found from the formulae. reduced by 50 per (iv) When the quality of material and the make of steel pipe have not been supported by certificates from the manufacturers in Form III-A. may be allowed on the recommendation of the Board made by it on the basis of life assessment tests carried out on the boiler. the pipes shall be tested in a test house and the maximum permissible working stress shall be such as the Chief Inspector of Boilers may in his discretion determine. (ii) Use of such uncertified plates. bar. Standard specifications for materials The standard specifications for steel wrought iron and copper plates and bars. pipes and tubesShipping documents shall be made available to establish the specifications for manufacture for inspection and testing. (b) For Billets. 6.

() () () (J C) () . the second-hand Shell Type Boiler may be registered by reducing the working pressure of the parts of the boiler as calculated under these regulations as per the table given below: Age of boiler (from the date offirst use) in years Reduction in working pressure (percent) 25 . 35 45 50 60 70 80 90 100 (' { .use of welding in the construction of boilers shall be permitted only where specifically provided for in the standard conditions. for its registration are furnished.( . 5 10 15 20 30 40 50 60 70 8. Welding (a) The .\ . \ ( 14 Indian Boiler Regulations (H) Shell Type Boilers-Where the documents required under its code of manufacture.

(i) 37 to 45 kgf/mm2 (ii) 42-to 50 kgf/mm2 (iii) 47 to 56 kgf/mm2 (iv) 52 to 62 kgf/mm2 (e) Semi-skilled steel may be used for plates in C and C-Mn Steel with an upper limit of tlie tensile strength not exceeding 56 Kg/mm2 and with thickness not exceeding 50 mm under service temperature condition 0-450°C. (c) When the material is required for flame cutting and/or welding the carbon content shall not exceed 0. the material shall pass the proof test for creep quality of carbon steel plates of boiler quality.( CHAPTER II ( MATERIALS OF CONSTRUCTION STEEL PLATES. electric furnace or basic o~ygen process or any other process which gives steel having equivalent specified properties. (b) General de-oxidation practice shall be appropriate to the type of steel used. The stage in manufacture at which this test is made shall be at the option of the steel-Maker. particularly where the de-oxldation practice influence the level of the elevated temperature properties of steel. RIVETS. not intended for hot forming. shan be supplied in the normalized conditions: 15 .10% or alternatively. (c) Rimmed steels may be permitted only for re-riveted drums or shells made of plates having a nominal thickness upto 20 rnm. When steels are intended for service temperatures over 700 F the sillicon content shall be not less than 0.26%. (d) Plates of Carbon Steel shall conform to one of the following four grades of tensil~ strength namely:. Q (d) Plates having thickness of 12 rnm and less than that. (b) A sulphur print test shall be taken from the material of each charge used for rivet bars for the purpose of ensuring that sulphur segregates are not concentrated in the core. 9.30% and special precautions shall be taken when the carbon content exceeds 0. not intended for hot forminq. For plates having thickness more than 12 mm. Chemical Analysis (a) The Steel shall not contain more than 0. Process of Manufacture (a) Steel for plates shall be made by the open hearth. 10. SECTION AND BARS IN CARBON STEEL .05 per cent of sulphur or phosphorus. can be supplied in unnormalized or as rolled condition subject to the condition that the code of manufacture provides for the same.

. etc. such material shall be rejected. 13A._ _ .. No plate or rolled section shall be under the specified thickness at any part.•.5 6 5 5 5 11 9 8 7..5 6 6 6 5\ 5 5 108 to under 120 % 120 to under 132 % 132 and over % () in. only with the approval of the Inspecting Authority provided that the plate is stress relieved after welding where necessary. . Testing and Inspecting The following tests and inspections shall be made at the place of manufacture prior to despatch.. except that in the case of thin plates and wide plates the weight tolerances shall be as set out in the table below: Schedule of Percentage of Rolling Weight Tolerances for Boiler Plates Width in inches Thickness Under 48 48 to under 60 % 5 5 5 5 5 5 5 5 6010 ·72 to under 72 under 84 % 5 5 5 5 % i... 1/4 to under 5116 5/16 to under 3/8 3/8 to under 7/16 7/16 to under 1/2 1/2 to under 5/8 5/8 to under 3/4 3/4 to under 1 % 5 CD () 7 6 6 5 5 5 5 5 12 10 8 7. order a check analysis..._ . Note: The boiler manufacturer may..•. 12 10 9 8 7 11 9 9 5 5 5 5 8 7 9 1 to under 2 All the above margins will be taken over nett theoretical weight.. the steel plant may supply steel with a certificate in respect of such of those tests as it has been possible for them to carry out indicating the a () . Freedom from defects.. Where steel plant is not able to designate steel as IS: 2002 because of the fact that they have not been able to carry out all the tests required as per IS: 2002._._--- . Rolling Margin . notwithstanding any previous certificate of satisfactory testing. 1i. 13.5 7 6 5 12 5 5 5 5 5 5 5 15 . -. not more than 5 per cent over the calculated weight. if he so wishes. but in the event of any the material proving unsatisfactory in the course of being worked into boilers. Minor surface defects of the plates may be removed by mechanical means to achieve a smooth level surface provided that the minimum specified thickness is maintained. and such further tests of the material from the same charge shall be made as the Inspecting Officer in attendance may consider desirable. 12. Surface defects may be repaired by welding. ) CD 84 to 96 to under 108 % under 96 % 9 7.16 Indian Boiler Regulations Provided that the normalizing may be exempted if it is demonstrated by the manufacturer that equivalent properties can be produced by the rolling subsequent cooling...

If a certificate of test is furnished by the steel makers in respect of tests carried out by them and another certificate is furnished in respect of remaining tests conducted by anyone of the independent testing ·Iaboratories or the Bharat Heavy Electrical Limited. Central Mechanical Engineering Research Institute. Tensile test pieces (a) The tensile strength and percentage elongation shall be determined from test pieces of gauge length preferably equal to L.65~ (See regulation 16). Durgapur or the National Test House. tests which it has not been possible for them to conduct in order to get the steel certified as IS: 2002. ~ provided he 'can arrange the remaining tests to be conducted at any of the independent testing laboratories. . Jamshedpur. namely.. Testing and certification of semi-skilled steel for which all tests not carried out in a steel plant Where a steel plant has not been able to carry out all the tests required under the regulations for testing the semi-skilled steel. the National Metallurgical Laboratory. 138. be furnished in the manner mentioned above. Durgapur. drawn in the presence of the Inspecting Authority. Such remaining tests may also be conducted at the Sharat Heavy Electricals Limited. and he shall satisfy himself that the conditions herein described are fulfilled. provided the elongation is expressed as the equivalent value on a gauge length of 5. Selection of test pieces All test pieces shall be selected by the Inspecting Officer and tested in his presence. Tiruchirapally. other gauge lengths may be used. Alipur or Sewri for conducting the remaining test provided that samples are . the plates should be accepted by the Inspecting Authority or the Chief Inspector of Boilers of the States provided all the requirements of the regulations are covered by these certificates. and National Test House. Alipur or Sewri. Alipur or Sewri or Sharat Heavy Electricals Limited. the boiler quality plates shall be accepted by the Inspecting Authorities/Chief Inspector of Boilers of the States. Jamshedpur. Durgapur. . the steel plant may supply such steel with a certificate in respect of such tests which have not-been possible for them to conduct in order to get the steel certified under the regulations and in such a case it is open to the manufacturers to take such steel which has the potentialities of the semi-skilled steel to any of the independent testing laboratories. and the National Test House. namely. Tiruchirapally in the presence of the Inspecting Authority in respect of plates intended for their use. Jamshedpur. . the Central Mechanical E~gineering Research Institute. 15. 14. Tiruchirapally in respect of plates intended for their use. provided that samples be drawn in the presence of the Inspecting Authority. It is open to the manufacturer to take such steel which has the required potentialities of IS: 2002. Alternatively. . Such remaining tests may also be conducted at the Sharat Heavy Electricals Limited. or the Central Mechanical Engineering Research Institute.Indian Boiler Regulations 17 . Tiruchirapally. National Metallurgical Laboratory. If the certificate of tests from steel makers and the National Metallurgical Laboratory.65JA: . == 5.

Rm = tensile strength at room temperature in kgf/mm2 N = a quality index to 100 for plate thickness upto 50 mm or 95 for plate thickness over 50 mm.2 for only guage lengths of Lo = 5do or 5. tensile strength at room temperature.65 o C) fA: where Lo = gauge lenqth do = Original diameter of the round test piece. () . surface shall be retained on two opposite sides of the test piece.30 *For temperature lower than 300°C any test required for acceptance purposes (in the absence of records of previous test at these temperatures) shall be at 300°C." c= t.32 400 0.33 375 0. the rolled .2% at elevated temperature (Et) may be ( ) calculated by multiplying the minimum specified tensile strength at room temperature (R20) by the value of the ratio (EtlR20) given in table below: Table Minimum values for the ratio of the stress at proof limit 0. Note: C = 1. 'J. Wherever practicable.2% at elevated temperature (Et) to the minimum specified tensile strength at room temperature (R20) or carbon Steel boiler plates Temperature DC EtlR20 250 0040 275 0. Ao = Original cross-section of the rectangular test piece.p. for rectangular test pieces of (: 5do for round test pieces shall be used.! 16. (b) In arbitration cases a test piece of gauge length equal to 5. For plate thickness exceeding 60 mm test pieces shall i . be taken from the exterior third of the plate cross-section.:. = 2. (b) The upper yield point at room temperature shall not be less than 50% of the specified minimum.9 for gauge lengths of 4JAo or for test piece in Appendix B.38 300 0.31 425 0.. (c) The breaking elongation in percentage shall be not less than N~R m • :C Where. (d) The minimum values of the stress at proof limit 0. Tensile test (a) The tensile strength of different grades of material shall be within the limits specified in regulation 9(d). .36 325 0.36 for 300·C.6S. in which case the proof stress shall be not less than value obtained by calculation from the specified minimum tensile strength at room temperature and the above proof-ratio of 0.18 Indian Boiler Regulations ( .34 350 0.

being bent cold through 1800 around a mandrel.lmm2 45-64 kg. (b) In all cold bend tests. 18. (d) For small sectional material these bend tests may be made from the flattened bar. the numbers 50 and 20 shall be substituted for 15 ·and 8 respectively for determining the number of tests required. without fracture. in which case one tensile test shall suffice. (ii) For cold bend test of sections and bars. the test piece shall withstand.lmm 2 Mandrel Radius 1T 1T 1. gusset plates. Bend Tests-Cold bends (a) Test pieces shall be sheared lengthwise or crosswise from plates or bars. The test pieces shall not be annealed unless the material from which they are cut is similarly annealed in which case the test piece shall be similarly and simultaneously treated with the material before testing. the test piece shall withstands. on samples 0. but for small bars the whole section may be used. Dump Tests Short lengths equal to twice their diameter cut from the rivet bars shall. and above. (c) (i) For bend test of plates of all grades of steel. furnace plates and flanging plates one tensile test piece shall be cut from each plate as rolled. . with-stand without fracture being compressed to half their length.lmm2 41-57 kg. 19. but the test pieces· shall receive no other preparation. when cold. (e) Bend tests may be made either by pressure or by blows.Indian Boiler Regulations 17. and shall not be less than 1% inches wide. (b) AngleJ teeJ rivet and stay bars-One tensile test shall be made from each 15 or part of 15 bars rolled of each section or diameter from the same charge. being doubled over until the internal radius is equal to that shown in Table under regulation 16 and the limbs are parallel. without fracture. end plates. the rough edge or arris caused by shearing may be removed by filling or grinding and samples 1 inch in thickness and above may have the edges machined. A dump test shall be made for each Tensile Test. For round bars of 1% inches diameter and under. Number of Tensile Tests· 19 (a) Plates-For shell plates. but not less than two tensile tests shall be made unless the total number of bars rolled from the same charge is 8 or less than 8· and the bars of the same section or diameter. For rivets bars bend tests are not required.5 inch in thickness. the radius of which shall have a relationship to the plate thickness as given below: Tensile strength 3649 kg. butt straps and plates.5T where T = Plate thickness.

The bend tests from shell plates. . or to a closely limited defect of a test piece.' ) (j . 21.) before any material from the .uch L without fracture on the outside of the bend. I material was made. '. but should either of these fail. Number of Bend Tests Indian Boiler Regulationk . Additional test before rejection Should the test pieces first selected by the Inspector or Inspecting Officer not fulfil the test . (b) Tests) C_) (i) The rivet shanks shall be bent cold. be flattened while hot. 2) (ii) The rivet heads shall. . .(. Branding (i) Every plate. without cracking at the edges until thei. CJ (c) Number of Tests-Upto half per cent of rivets of each size shall be selected by the Inspector oC) Inspecting Officer from bulk for the above tests. \ c:) ._ . butt straps and other plates which have not to be flanged or worked in the fire or which when ir: use are not to be exposed to flame shall be cold bend tests. In all such cases further tests shall be madl. section and bar shall be clearly and distinctly marked by the maker in two placer with the number of identification mark by which they can be traced to thecharqe from which the .. 23. " ( (a) Plates-A bend test shall be taken from each plate as rolled. Manufactured Rivets (a) Quality of Material-Rivets shall be manufactured from steel complying with the {. . two further tests of the same kind may be made. the plates or bars.same charge can be accepted. If the unsatisfactory result of test is due to an unfavourable heat treatment the plate and the test strip may b() heat treated again.. then the failure can be left out of consideration in the decision on the fulfilment of the requirement and another test piece may be SUbstituted.aforementioned requirements of this Chapter in respect of rivet bars. (b) Angle Bars-A cold bend test shall be made from each angle bars rolled: Provided that the cold bend test need not be carried out if basic material specification does not \" l:rcall for it. the entire test shall be repeated. Following this. C) ) If the unsatisfactory result of a test is obviously due to technical conditions of the testing metho(. 20 20. ( requirements. 22.from which test pieces were cut shall be rejected. (c) Stay Bars-A cold bend test shall be made from every 15 stay bars as rolled from each charge. As an alternative the rivet bars may be bundle and tabbed to enable the material to be traced to the cast of steel from which they are made. and hammered until two parts of the shank to..J diameter is 2% times the diameter of the shank.

Stamp. '.Standard Jest Piece B. acid or basic. Heat No. bars. (as rolled). ( Indian Boiler Regulations information shall necessarily be provided:- 21 (ii) Every plate shall also be stamped by the steel maker as provided in IS: 2002. 24. 4. Facilities for Inspection The maker shall adopt a system of making the ingots. and has withstood satisfactorily the test above described in the presence of the Inspecting Officer. Defacing of rejected material In the event to the material failing in any case to withstand the prescribed tests. The following ( . 1. Rivet Bars The tensile breaking strength shall be between 21 and 25 tons with an el'ongation of not less than 25 per cent measured on the Standard Test Piece B (as rolled) or 30 per cent measured on the . the identification mark of the Inspecting Officer which has been stamped on the material. etc. slabs. When he is satisfied with the. c ( 3. Name of the manufacturer. shall be defa~d by punch marks extending beyond the identification mark. the name of the Steel-Maker who supplied it. also the numbers of the charges for reference to the books of the Steel-Maker. and that it has been subjected to. as the case may be shall be supplied to the Inspecting Officer deputed to witness the testing of the material stating the Open Hearth or Electric Process or any of the Oxygen Processes by which it was made. plates. he shall be furnished with two copies of the advice notes of the material for his signature. . Plate No.. the maker shall fumlsh the Inspecting Offlcer with a certificate in Form IV or Form III-B. which will enable" all finished material to be traced to the original charge./ \. material and with the results of the tests. a certificate in Form IV or Form 111-8. 25. Steel not produced where rolled (. billets. WROUGHT IRON STAY AND RIVET BARS 28. Specification. as the case may be. guaranteeing that the material has been made by the Open Hearth or an Electric Process.. The number of the charge shall be marked on each plate or bar for the purpose of identification. in the form of a cross. 2. 27. and the Inspector or Insp~cting Officer shall be given every facility for tracing all plates and bars to their respective charges. and for witnessing the required tests. and 5. Maker's Certificate Before the mill sheets are singed. thus denoting that the material has failed. 26. Where steel is not produced in the works at which it is rolled.

Plates (a) Process-The copper shall be fire-refined or electrolytic and hot-rolled from suitable cracks.The bars as rolled shall be placed in batches of twenty. two other bars shall 'be selected for test. and a similar test piece from each batch shall be lightly and evenly nicked on one side with a sharp cutting tool and bent back at this point through an angle of 180 degrees by pressure or by a succession of light blows. Stay Bars The tensile breaking strength shall be between 21 and 25 tons with an elongation of not less than 22 per cent measured on the Standard Test Piece 8 or 27 per cent measured on the Standard Test Piece 81.Number of Tensile 1ests. the iron must withstand the following tests:(a) Tensile Tests_. If either of these is unsatisfactory. with an elongation of not less than 25 per cent measured on the Standard Test Piece 8 or 30 per cent measured on fheStandardTest Piece 81• (b) Bend 1est. (d) Number of Bend Tests-One ordinary bend test shaHbe taken from each batch. two other bars shall be selected for test. COPPER PLATES~ STAY AND RIVET BARS 33. 32. 30. and one tensile test shall be taken form each batch. Special Iron for Screw Stays for Fire~boxes and Combustion Chambers In order that iron screw stays may be approved of the same size as woutd be required for mild steel. (e) In all cases the selection of the test pieces shall be made by the Inspector or the Inspecting Officer. or turned down to 1 inch diameter. Manufactured Rivet Tests To comply with Regulation 21.) 22 Indian Boiler Regulations 29. If this is unsatisfactory. 31.The tensile breaking strength shall not be 'less than 21~ tons per square inch. (c) . chemical composition of the plates shall be as follows:- (b) Chemical Composition-The . and should either of these fail the batch shall be rejected. free from slag or dirt or any coarsecrystalline structure. and should either of these fail the batch shall be rejected. Stay Bars·Bend Tests To comply with Regulation 19. The fracture must be clean. fibrous. shall stand bending' cold until the sides are parallel and the space between the two sides is not greater than the diameter of the test piece.Test pieces either of the bar as rolled.

minimum per cent in 2 inches gauge length (f) 'Bend Tests-To 32.) (rods above 1!4 inches dia.10 maximum 23 (c) Freedom from Defects-The plates shall be clean. (e) Tensile Tests-The materials shall have the tensile properties shown in the following table: Tensile Properties Untumedrod Turned rod (rods upto 134 inches dia. comply with Regulation 33(c). from Standard Test Piece A. (b) Chemical Composition-To (c) Freedom from Defects-To (d) Rolling Margin-The bars in any part shall not be more than 1% over or more than Y2%under the specified diameter. For either hot or cold bend tests.05 maximum 0. in. not more than 5% over the calculated weight. The scrap margin.30 to . (e) Tensile Tests-One tensile test shall be taken from each plateas rolled. smooth and free from defects and shall . the test piece shall withstand being doubled over without fracture until the sides are touching and parallel. Stay and Rivet Bars (a) Process-To comply with Regulation 33(a). Elongation. have a workmanlike finish. per sq. (d) Rolling Margin-No plate shall be under the specified thickness at any' part.50 0. in.05 maximum 0.) Minimum tensile strength lb. shall be not less than 3 inches at the ends and 1Y2inches at each side. comply with Regulation 33(b). They shall be thoroughly annealed.400 40 32.Indian Boiler Regulations Percent Copper Arsenic Antimony Bismuth Oxygen 99. shall not be less than 14 tons per sq. . (f) Hot and Cold Bend Test-One hot (temperature between 1200°F and 140QoF)one cold bend test shall be taken from each plate as rolled. The tensile breaking strength.2 minimum . partly sheared and left attached. with an ek)ngation of not less than 35%. 34.400 45 comply with Regulation 33(f). .

(c) Freedom from Defects-The finished tubes. tons (32. with an elongation of not less than 50 per cent of 2 inches. From each bar selected.24 Indian Boiler Regulation$ (g) Dump Tests-A piece of rod 1 in.) per sq. in. The tubes shall be finished by cold drawing~ (b) Chemical Composition-To comply with Regulation 33(b). Unless.240 Ibs. long shall be placed on end and hammered or crushed down· cold to a thickness of 3/8 in. until. one hot bend test and one dump test shall be made.clean. (h) Number of Tests-One bar. . (1) Copper Tubes(a) Process-The copper shall be fire-refined or electrolytic and shall be made into tubes either by.50 . both externally and internally shall be sound. the ultimate tensile stress shall be not less than 14. . and should a variation of more than one ton ·(2. from which the required test specimens shall be taken. If the tensile test is made on a piece of tube. If the tensile test is made on strip cut from the tube. and the ends must be clean and square. with an elongation of not less than 40 per cent on a test piece having a gauge length of four times the square root of the area. otherwise specified. shall be selected at random from each batch of 50 (or part thereof) bars of each size from each melt. (d) Tolerance-The actual weight of each tube shall not be more than 5% above the calculated weight. () () () () DIAGRAM 1 DIAGRAM 2 . be found between any number of tubes tested. one cold bend test.480 Ibs.) per sq. the batch shall be liable to rejection. the outside diameter of the bulged or drifted and measures not less than 25 per cent more than the original diameter" of tube.360 Ibs. ' (f) Bulging or Drifting Test-The test piece shall stand bulging or drifting cold (see Diagrams 1 and 2 respectively) without showing either crack or flaw. A batch shall not consist of more than 500 tubes. the hot rolling or cold drawing process. smooth. The results obtained from a batch shall be uniform. COPPER. well finished and free from surface defects and longitudinal grooving. they shall be straight cylindrical. in. (e) Tensile Tests-Tensile tests shall be made on pieces of tubes or strips cut from the tube. without showing either crack or flaw on the circumference of the resulting disc. BRASS AND STEEL TUBES 35.) per sq. in. or uniform thickness and exterhal diameter throughout. one tensile test. the ultimate tensile stress shall be not less than 14 tons (31.

70 per cent of copper and not more than a total of 0. . 2/1 alloy. or by such internal hydraulic pressure as may have been specified by the Inspecting Authority and the Inspector may re-test 5 per cent or more as he may deemnecessary.Indian Boiler Regulations 25 (g) Flanging Test-The test piece shall stand flanging cold (see Diagram 3) without showing either crack or flaw until the diameter of the flange measures not less than 40 per cent more than the original diameter of the tube. and shall contain:- (b) Chemical analysis-The 70/30 alloy.75 per cent of materials other than copper and zinc. both cold and at a red heat. . per sq. The test piece shall be flattened down until the interior surfaces of the tube meet and then be double over on itself. .75 per cent of materials other than copper and zinc. DIAGRAM 3 (h) Flattening and Doubling over Test-The test piece shall stand the following test. if not already in an annealed condition. Not less than 66.that is bend through an angl~ of 1800 (see Diagram 4) the bend being at right angles to the direction of the length of the tube. The tubes shan withstand the test without showing any signs of weeping of evidence of defects. in. tubes shall consist of an alloy of copper and zinc. before the tubes are presented for inspection by an internal hydraulic pressure of 750 Ibs. Not less than 70 per cent of copper and not more than a total at 0. (2) Brass Tubes-:(a) Composition-Brass for boiler tubes maybe of either 70/30 alloy or 2/1 alloys as specified. DIAGRAM 4 (i) Hydraulic Test-Each tube shall be tested. 35. 0) Treatment of Test Specimens-All test material. without showing either crack or flaw. shall be annealed before testing and shall comply with the mechanical tests without further heat of mechanical treatment.

until the diameter of 0 the bulged or drifted end measures not less than 25 per cent more than the original diameter of the tube. The tubes shall be straight and unless otherwise ordered they shall be uniform diameter throughout. ..) specified and the! next Standard Wire Gauge thicker.005 in. both internally and externally. On le'ngth ± 1/16 in. DIAGRAM 2 (ii) Flanging Test-The test piece shall stand flanging cold (see Diagram 3) without showing either crack or flaw until the diameter of the flange measures not less than 25 per cent more than the original diameter of the tube. 'On thickness ± half the difference between the Standard Wire Gauge (S. (J DIAGRAM 1 . a copy of his analysis* of the material.) 26 indian Boiler Regulations The manufacturer shall supply when required free of charge.-') tests:\c. smooth and free from surface defects or longitudinal grooving. and the ends shall be clean and square. ' (_j (i) Bulging or Drifting Test-The test piece shall stand bu/gingor drifting cold (see Diagrams 1 and 2 respectively) without showing either crack or flaw. (c) Freedom from defects-The tubes shall be clean. .. (e) All test material shall be annealed before testing and shall comply with the following rnechanlcel ._.. ..G. (d) Tolerances-The tubes shall be solid drawn and shall be concentric within the working margins for thickness given below.. DIAGRAM 3 if< A works analysis is defined as the routine analysis taken by or for the manufacturer in order to control the quality of the material. ! ) On external diameter ± 0. " ".! The working margins shall be as follows: ._ ..W.

before the tubes are presented for inspection. COLD DRAWN SEAMLESS CARBON STEEL BOILER. bent through an angle 1800 (see Diagram 4). The steel shall be fully killed. as the case may be.. The test piece shall be flattened down until the interior surfaces of the tube meet and then be doubled over on itself. (b) Material (i) The tubes shall be seamless and manufactured from steel produced by an open hearth or electric process or any of the oxygen processes. provided such materials are not specifically prohibited by the regulations. by an internal hydraulic pressure of 750 Ibs. SUPERHEATER AND HEAT EX-CHANGER TUBES FOR DESIGN METAL TEMPERATURES NOT EXCEEDING 454°C(8500F) 3S. superheater and heat exchanger tubes. per sq. in. superheater and heat exchanger tubes can also be used with the designations of the national or international standards. as may have been specified by the Inspecting Authority and the Inspector may re-test 5 per cent or more as he may deem necessary. (3) Carbon Steel Tubes Tubes of Carbon Steel for boilers and superheaters subject to internal pressure shall comply with ·the requirements of regulations 36 to 42.Indian Boiler Regulations (iii) Flattening and Doubling over Test-The 27 test piece shall stand the following test when cold without showing either crack or flaw. 35. (ii) The seamless tubes conforming to other national or international standards which are known to be commonly used as being suitable for use as boiler. (iii) While making tubes to other national/international standards the allowable stresses of the respective standards shall be strictly followed while designing the tubes. that is. (ii) The steel shall conform to the following limits of chemical composition: . which shall conform in all respects with the requirements herein specified. the bend being at right angles to the direction of the length of the tube. .. The tubes shall withstand the test without showing any signs of weeping. or by such internal hydraulic pressure. 43 to 46 or 57 to 63. ( oc::::::: DIAGRAM 4 (f)Hydraulic Test-Each tube shall be tested. (a) General (l) These regulations cover both hot finished and cold drawn seamless boiler.

2 to 101.1 incl Over 38.25 max 0.15 0.035 max 0.14 0.8 excL 50.5 to 228. 63.25 0. and the wall thickness is not decreased to less than that permitted.5 incl. or a normalising heat treatment after the final cold finishing process: (d) Workmanship ~nd Tolerance-The tubes shall be well finished. smooth. cylindrical and subject to the following .27-0.035 max P 0. 0. cold drawn tubes shall be given a sub-critical annealing.27 max* 0.01% below the specified carbon maximum.4 25. Over 190.2 0.1 0.6 incl.10 min S 0. maintained.1 to 50. Over 190.06-0.3 0.93 max 0.5 exel.6 Permissible variation over (mm) Permissible variation under (mm) C) (_) C) .5 to 228.6 incl.8 1.035 max *For grade TB and Te for each reduction of 0.64 1.25 0.10 min 0.tolerances.8 to 63.0. (c) Heat Treatment-Hot finished tubes need not be heat treated.63 0.35 max* Mn· 0.2 0.4 to 38.3 0. cleaned free from haimful defects. an increase of 0.35%.4 0.6 and under Over 101.5 inel. 76.2 excl.15 0.38 0.6 to-190. Over-101.06 Si 0.1 0. Surface imperfections li~e any discontinuity or irregularity found in the tube may be removed by grinding.035 max 0.29-1. Finished tubes shall be reasonably straight and have smooth ends free of burrs.4 0. 0.6 incl.6% Manganese above the specified maximum will be permitted up to a maximum of 1. ' 0.5 to 76. Cold finished seamless tubes Under 25.6 to 190.38 0:38 0. a full anneal.035·max.035 max 0.28 Chemical Composition (%) Grade TA TB Te Indian Boiler Regulations c. a (i) Permissible variations in outside diameter. Outside Diameter (mm) Hot finished seamless tubes 101. They shall have workmanlike finish.2 1. .38 0.4 0.provided that smooth curved surface is . They shall be reasonably straight.18 0. The outside '() diameter at the point of grinding may be reduced by the amount so' removed.

6 Seamless Cold Finished tubes Over 40 0 NA Under Wall thickness (mm) Over 2. Over Under Over 3. They·shall be smooth' on the ends and free from burrs and flaws.8 to 4. shall be permissible. expanding or any other forming operations or being cut to length.8 50.8 and over 5 3 5 o o o Note: These permissible variations in lengths apply to cut lengths up to and including 7. 39 and 40 shall be taken from the ends of finished tubes prior to upsetting swaging.6 incl. an additional over tolerance of 3 mm for each 3 m or fraction thereof. For large size tubes. .1 (iii) Permissible variations in length 20 22 a a Cut length (mm) . (iv) All specimens shall be tested at room temperature. 37.Indian Boiler Regulations (ii) Permissible variation in Wall Thickness in percentage.6 & under Over 101. For lengths over 7.8 incl.3 m. (a) Te!StSpecimens' (i) Test specimens required for flattening and expanding/flaring test specified in regulations 38.4 and under Over Seamless Hot Finished tubes 101. 'Length tolerances on the positive side other than specified may be mutually agreed.6 Over Under 35 35 NA a a 33 33 a a Under 28 28 a a 38. Over Under Method of manufacture Outside diameter (mm) Seamless hot finished Seamless cold finished All sizes Under 50. up' to a maximum of 13 mm. tensile test may be carried out on full section of the tubes up to the capacity of the testing machine.1 and under Over 38.3 m.4 to 3. Over Under Over 4. the tensile test specimen shall consist of strip cut longitudinally from the tube and which is not straightened within the gauge length and further heat treated. 29 Outside diameter (mm) 2. (ii) If desirable and practicable. (iii) If any test specimen shows flaws or defective machining it may be discarded and another specimen substituted.

. the first step. except as provided for in 39(5) below. F(atteningTest C) () (1) A section of the tubes not less than 63 mm in length . (4) Superficial ruptures resulting from surface imperfection shall not be cause for rejection. D t = specified thickness of tube (mm) D = specified outside dia of the tube (mm) e = a constant.8 mm decrease in walJthickness under 8 mm from the minimum elongation value requirement.5% shall be made for each 0. (b) During the second step which is a test for soundness. Evidence of laminated or unsound material.18% or less. but revealed during the first step of the flattening test. the flattening shall be continued until the specimen breaks or the opposite wansof the tube meet. The hardness test may be carried out on the wall cross section or on a flat on the outside surface of the tube sample. shall occur on the inside.2) 485 (49.2) 325 (33.07 for carbon steel with max specified carbon above 0./mm2) min Mpa (kgfmm2) min· GL =50mmmin 180 (18.· .09 for carbon steel with max specified carbon 0. Tensile and Hardness Tests The test specimen shall comply with the following requirements. as given below e = 0. which is a test for ductility. without showing any sign of a crack or flaw.1) 275 (28. (3) Surface imperfections in the test specimen before flattening. 39 and 40 shall be made on minimum 2 tubes for first 100 tubes and 1 per 100 or part thereof for tubes over 100 numbers.18% e = 0.shall be flattened cold between two parallel flat surfaces to a distance between the plates (H) as calculated by the formula given below. no crack or break. shall be judged in accordance with the finished requirements. or end surfaces in seamless tubes or on the inside or outside surfaces of welded tubes. TA TB 77 79 89 TC Note: For longitudinal strip tests a deduction in percentage elongation 1.1) 415 (42.30 Indian Boiler Regulations (b) Number of tests-The test specified in regulations 38. 39.5) 255 (26.3) 35 30 30 Hardness (Max) HRB HB 137 143 179 ~. 38. (2)(a) During. outside. . Grade Yield Strength Mpa Tensile Strength %Elongation on (kg. 1 H = -'-(+_e~) t t' e+Where. or of incomplete weld that is revealed during the entire flattening test shall ue cause for rejection.

8 0. cracks at these locations shall not be cause for rejection if the O-to-t ratio is less than 10 and the carbon content of the material is more than 0. the batch of the tubes represented may be given a further heat treatment and entre set of test shall be repeated. room temperature. Additional test before rejection (i) If anyone or more tests specified in these regulations fail.3 41.4 0.25%. 42. If any of these tests fails. (ii) If the repeat tests are satisfactory the tubes shall be accepted.5 0. 40. Expanding or Flaring test A section of the tube approximately 100 mm in length shall stand being flared with a tool having a 60 degree included angle until the tube at the mouth of the flare has been expanded to the percentages given below.9 0. . without cracking: Ratio of inside diameter to outside diameter Mi'!imum expansion of inside diameter % 0. Hydraulic test (i) Each tube shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure subject to a minimum of 1. two further tests of the same kind may be made on two other tubes of the same batch.6 21 22 25 30 39 51 68 0.00 kg.lmm2. the entire batch of the tubes shall be rejected. If any failure in the tests should occur.Indian Boiler Regulations 31 (5) When low O-to-t ratio tubular products are tested because the strain imposed due to geometry is unreasonably high on the inside surface at the six and twelve 0' clock location. but not greater than pressure calculated by the following formula: p= 28t o where P = test pressure D = specified outside diameter of the tube t = specified wall thickness of the tube 8 = stress which shall be taken as 40% of the minimum tensile strength at.7 0.

06 Si S 0.270.291. a full anneal. or a normalising heat treatment after the final cold finishing process.93 0.32 Indian Boiler Regulations (ii) Notwithstanding anything contained in the above clause.\ .35%. the hydraulic test at the maker's works may be dispensed with.035 max () *For each reduction of 0.035 max 0. Pipes manufacturer shall explore a sufficient number of visual inspections to provide reasonable assurance that they have been properly evaluated.035 max P PA PB 0. ( ·1 . cylindrical· and subject to the following tolerance. (b) Materi~1 (i) The pipes shall be seamless and manufactured from steel produced by an open hearth C···) ~- () (~J Cj or electric process or any of the oxygen processes. They shall be reasonably straiqht.035 max 0. provided that the tubes are subject to non-destructive testing by an appropriate method like Ultrasonic or Eddy Current or Stray Flux testing. SEAMLESS CARBON STEEL PIPES FOR HIGH TEMPERATURE SERVICE FOR DESIGN METAL· TEMPERATURES NOT EXCEEDING 454°C (850°F) 43.10 min PC ·0. of the national/international standards.10 min 0.35* Max 0.035 max 0.10 min 0. \: (b) Heat treatment-Hot finished pipes need not be heat treated. provided such materials are not specifically prohibited by the regulations.035 max 0.06% manganese above the specified maximum will be permitted up to a maximum of 1. (a) General (0 These regulations.01% below the specified carbon maximum. Cold drawn pipes shall be given a sub-critical anneal. an increase of 0. The steel shall be fully killed. (iii) While making pipes to other national/international standards the allowable stresses of the respective nationlinternational standards shall be strictly followed while designing the tubes. -(it) The steel shall conform to the following limits of chemical composition: Grade C Chemical composition % Mn 0. (c) Workmanship and Tolerance-The pipes shall be well finished.291.known to be commonly used as being suitable for high temperature service can also be used with the designations. The pipes shall conform in all respects with the requirements herein specified. (it) The seamless pipes confirming to other national/internationals standards which are . cover both hot finished and cold drawn seamless carbon steel pipes for high temperature service.25* Max 0.30* Max 0.06 0. cleaned free from harmful :defects. smooth.

expanding or any other forming operations or being cut to length. tensile test may be carried out on full section of the pipe up "to the capacity of the testing machine.0 incl.38 3.3 incl. Indian Boiler Regulations (i) Permissible variations in outside diameter: Hot finished and cold finished seamless pipes Outside "diameter (mm) 33 : Permissible variations (mm) " Over Under 0. the tolerances for all sizes shall be +6. Over 219.0 mm/-O.0 to 660. (e) Number of tests-The tests specified in regulations 44(a)} 44(b) and 44(c) shall be made on minimum 2 pipes for first 100 pipes and 1 per 100 or part thereof for pipes over 100 numbers.0 incl.3 to 219.79 0.79 "0. For large size pipes. Over 660. (ii) Permissible variation in wall thickness: 0040 0. Over 457.3 to 48. 44(b) and 44(c) shan "be taken from ends of finished pipes prior to upsetting.0 to 1219.( . They shall be smooth on ends and free from burrs and flaws.97 4.40 0.1 incl.79 0.59 2.79 10.79 0. swaging. Over 48. (d) Test Specimens (i) Test specimen required for flattening and expanding/flaring test specified in regulations 44(a).3 to 114.0 to 864.79 1.0 incl. the tensile test specimen shall consist of strip cut longitudinally from the pipe and which is not straightened within the gauge length and further heat treated.18 3.O mm. " Over 114. . (iii)" Permissible variation in exact length: Seamless Hot finished and Cold finished pipes can be ordered in specified length or in random length.0 incl. (ii) If desirable and practicable. (iv) All specimens shall be tested at room temperature.5% under the nominal wall thickness specified. (iii) If any test specimen shows flaws or defective machining it may be discarded" and another specimen substituted.79 0.76 The minimum wall thickness at any point shall not be more than 12.3incl. If ordered in speclfledlerqth.1 to 457. Over 864.

. ) . -_. -. .1) 240 (24. equation: strip test..07 for carbon steel with maximum specified carbon 0. . (b) Bend test-For (0) pipes of outside diameter 60. . 0= specified outside diameter of the pipe (mm) a constant. () U = specified tensile strength in Mpa. _ .1) 415 (42.L. a flattening test shall be conducted.. min for full tube testing 35 30 30 Forlongitudinal ..... the minimum required elongation shall be determined by the followino. without developlnq .3 mrn.5%. . pipes may be tested on full cross section .: 'J given below.9) where e A = = minimum elongation in 50. The tensile test may be carried out on the test pieces cut out from tL~' pipe in the longitudinal direction which shall not be further heat treated nor straightened with'......18% or less. ( ") cross sectional area of the tensile test specimen outside 2 in mm based on specified 2 diameter or nominal specimen 2 . the diameter of which is 12 times the nominal diameter of the pipe..2) 485 (49.2/UO._ .09 for carbon steel with maximum specified carbon 0.. Grade PA PB PC Yield Strength MPa (kglmm2) min 205 (21. If the area thus calculated is more than mm then use area as 484 mm 2 If the calculated area is less than 484 mm then' use the actual area thus obtained..2) Tensile Strength MPa (kg/min2) min 330 (33. . mandrel. \ 34 44.45 mnr'..3 mm and under. .•.3) % Elongation on G.:.) = e= e= 0.•... (J cracks. width and specified wall thickneL) 4~A) rounded to the nearest 6..19% or more \..8 mm.7) 275 (28.. the gauge length. a bend test shall be conducte6) A sufficient length of pipe shall stand being bent cold through 90 degree around a cylindric(. (a) Tensile test-Test pieces cut from the ends of the selected Indian Boiler Regulations pipes shall comply with the following requirements. As an alternative. = 50 mm . (c) Flattening test (i) For pipes of outside diameter over 60._--_.. without showing any sign of a crack or flaw: H= (1+e)t e+tlD where t e = specified thickness of pipe (mm) .. A section of the pipe not less than 63 mm in length shall be flattened cold between tw parallel flat surfaces to a distance between the plates (H) as calculated by the tormul= '. % rounded to the nearest 0. : e = 1944 (A O. as given below: 0...

be made on two other pipes of the same batch. 45. on the outside of the bent portion. General (i) These regulations cover both hot finished and cold drawn seamless boiler.. 46. but not greater than pressure calculated by the formula .Indian Boiler Regulations 35 (ii) For pipe whose diameter equals or exceeds 254 mm. These shall conform in all respects with the requirements herein specified. P = 2 StlO where P = test pressure o= specified outside diameter of the pipe t:. Substitution of the bend test for the flattening test shall be subject to the approval of purchaser. given below. specified wall thickness of the pipe S = stress which shall be taken as 40% of the minimum tensile strength at room temperature. Additional tests before rejection If anyone or more tests specified in these regulations fail.0 or less. The bend test specimens shall be bent at room temperature through 180 degree without cracking. the bend test described in clause (b) shall be conducted instead of the flattening test. Hydraulic test (i) Each pipe shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure. The inside diameter of thebend shall be 25 mm. the batch of the pipes represented may be given a further heat treatment and entire set of tests shall be repeated. (ii) Notwithstanding anything contained in the above clause. If the repeat tests are satisfactory the pipe shall be accepted. . the hydraulic test at the maker's works may be dispensed with provided that the pipes are subject to non-destructive testing by an appropriate method like Ultrasonic or Eddy Current or Stray Flux testing. two further tests of the same kind may . a bend test may be conducted instead of the flattening test. If any failure in the tests should occur the entire batch of the pipes shall be rejected. superheater and heat exchanger tubes of ferritic and austenitic alloy steel grades. SEAMLESS FERRITIC AND AUSTENITIC ALLOY STEEL BOILER. SUPERHEATER AND HEAT EXCHANGER TUBES 47. (iii) For pipe whose diameter exceeds 635 mm and whose diameter to Wall thicKness ratio is 7. . If any of these tests fails.

. If furnished in the normalised and tempered condition. T2 T5.. TP 316H. . the minimum tempering. T1. T91... 2... TP 321 H. (iv) The design meta. (a) Material (i) The tubes shall be seamless and manufactured from steel produced by an open heaC) or electric process or any of the oxygen processes.. Oi) The steel shall conform to the limits of chemical compositions given in Tables 1 and 2...------------~(_j . except T91. (iii) Grade T91 shall be normalised at 1040 degree C minimum and tempered at 730 degree C minimum as a final heat treatment. T9 and T22 shall be 675 Degree C.l temperatures shall not exceed the following limits:SI. (b) Heat treatment (i) All tubes of grades in Table 1. TP 347.. The steel shall be fully killed._7i_e_m_p_eft_a_tu_re--. provided such materials are rt specifically prohibited by the regulations. TP 347H TP 304L.. TP 316L 48.in sub-clause (i) above.:' tempering temperature for Grades T5. Grade __ t"~ ' --------------.... may be given a firr-~ heat treatment at 650 degree C to 730 degree C. at the option of the manufacture..(iii) While making tubes to other national/internationals standards the allowable stresses of \ respective standard shall be strictlyJollowed while designing the tubes. X20CrMoV121 TP 304. TP 321. (ii) Tubing of Grades T1. (I () . 4.. TP 3105...and X20CrMoV121 shall r reheated and furnished in full annealed....~ .. temperature for Grades T1 and T11 shall be 650 degree C and the minimti. 12X1Mq. (iii) The grain size of cold worked grade TP 321 H shall be NO. TP 304H.. No. 3.. T2 and T12 either hot finished or cold drawn. isothermal annealed or normalised ar1 tempered condition.7 or coarser. T12. T9. T11. instead of heat treatments specified ~ . 12X1Mo.\ ~ (3) (1) (2) 1.. TP316. .\ 36 Indian Boiler Regulations (Ii) The seamless tubes conforming to other natlonaldntemafional standards which are known to be commonly used as being suitable for use as boiler and superheater tubes can also be used WILll the designations of the national/international standards.

Over 190. (i) Permissible variation in outside diameter: For all grades except 12 x 1M~ and x 20CrMoV121 Outside Diameter (inm) Hot finished Seamless tubes 101.10 0. and the wall thickness is not decreased to less than that permitted. Finished tubes shall be reasonably straight and have smooth ends free of burrs. Cold finished Seamless tubes Under 25. degree 37 C and tempered at 720-750 (v) Grade X20CrMoV121 shall be normalised at 1·020 to 1070 degree C and tempered at 730 to 780 degree C for a period of 1 hour minimum. The heat treatment procedure.1 inc!. Over 38.8 excl. 63.25 0.1 to 50. They shall have a workmanlike finish..30 0.2 excl.4 to 38.6 and under Over 101.20 0.5 to 76. The outside diameter at the point of grinding may be reduced by the amount so removed.20 0. the minimum solution treating temperatures for grades TP321 H and TP347H shall be 1100 degree C and for grades TP304H and TP316H shall be 1040 degree C.5 incl. 0. provided that a smooth curved surface is maintained.4 0.5 exel.8 1. 0.4 0.15 0.30 Contd . 50. Surface imperfections like any discontinuity or irregularity found in the tube may be removed by grinding. smooth.6 Permissible Variation (mm) ·Over Under . cylindrical and subject to the following tolerances.2 1.8 to 63.25 0.6 to 190.10 0.4 Over 25. the minimum solution treatment for grades TP 321H and TP 347H shall be 1050 degree C and for grades TP 304H and TP 316H shall be 1040 degree C. They shall be reasonably straight. (vii) All H grades shall be furnished in the solution treated condition. (c) Workmanship and tolerance-The tubes shall be well finished.15 0.. except for the H grades shall consist of heating the material to a minimum temperature of 10400 C and quenching in water or rapidly cooling by other means. If cold working is involved in processing. cleaned free from harmful defects.4 0. (vi) All austenitic tubes (Table 2) shall be furnished in the heat treated condition.( ! Indian Boller Regulations (iv) Grade 12x1 M~ shall be normalised at 950-980 degree C for a period of 1 to 3 hours.6 incl. If the P grade is hot rolled.5 to 228.

) 38.. For. 0.0 30 to 50 Over 50.6 incl..2 to 101..1 20 22 () 0 (f) () -' .5 to 228....' .. . ' -.60% (0.-.::.60% (0. .14 ) Permissible Variation (mm) \ Over Under il Hot finished and cold finished tubes Under 30.75% (0.6 incl.. -.. ' --. Outside Diameter (mm) Permissible Variation (mm) Over Under '.grade 12 x1M~ Outside Diameter (mm) Indian Boiler Regulatk ••...-. 76... Over 101..75% (0. s 0..5incl..38 0.. .5 mm min) .38 ·0..38 Contd .~--'.6to 190. Over 190.25-mm min) .-j 0. ... .75% 0."~. .5 mm min) (...1 and under Over 38.25 rnm minrJ () Over Under 0 .75% 0. 0 0..64 1.38 0. ) \ --------------------~----------------------------~o Hot finished Seamless tubes 100 and under Cold finished Seamless tubes 120 and under Over 120 (ii) Permissible variation in Wall Thickness: For all grades except 12 x 1Mcpand x 20CrMoV121 0.38 0.0 For grade x 20CrMoV121 .

and x 20CrMoV121 Method of manufacture Outside diameter (mm) All sizes Under50.c Indian Boiler Regulations For Grade 12 x 1M.3 m.S Over Cut length (mm) Over 5 3 Under 0 Seamless Hot finished Seamless Cold finished 0 0 5 Note: These permissible variations in length apply to cut length up to and including 7. an additional over tolerance of 3 mm for each 3 m or fraction thereof.3m. Outside Diameter (mm) Permissible variation % Over 100 and under Over 100 (iii) Permissible variation in length for exact length tubes.Outside Diameter (mm) Permissible variation % Over Hot Finished Seamless Tubes 10S and under Over 108 Cold Finished Seamless Tubes All sizes For Grade x 20CrMoV121 . For grade 12 x 1Mcp Outside diameter (mm) Length of tubes (m) Permissible variaUon (mm) Over 15 Under Under 108 Under 9 9to 12 35 50 10S and over All lengths o o o . up to a maximum of 12 mm. 39 Under 15 20 10 10 5 10 Under 12.5 9 10 9 For all Grades except 12 x 1M. For lengths over 7. . shall be permissible.S 50.

(J Table 1: Chemical Requirements for Ferritic Steels Grade C T1 T2 T5 T9 T11 T12 0.80 0. (i) Test specimens required for the flattening and expanding/flaring test specified in Regulations 49(a). 49(b) and 49(c) shall be made 6. the tensile test specimen shall conslst l.65 0.45 ' 0.025 0. (d) Test specimens Indian Boiler RegulatioP"') Permissible variation (mm) Over Under.025 max max 0.60 0.65 0.44 0.10 0.10 0. (ii) If desirable and practicable.65 0.0 1..finished tubes prior to upsetting.30 0. 49(b) and 49(c) shall be taken from the ends of.50 j .30 0. (iii) If any test specimen shows flaws or defective machining it may be discarded and anoth~[ U specimen substituted. ) 40 For grade x 20CrMoV121 Length of tube (m) 6 and under Over 6 to 12 incl.05 0.65 V Ni Other Elements! ) 0. swagin~.) strip 'cut longitudinally from the tube and which is not straightened within the gauge lenge) further heat-treated.20 0.80 max max 1.15 0.15 max 0.) minimum 2 tubes for first 100 and 1 per 100 or part thereoftor tubes over 100 numbers.025 ·0. '"j 10 15 o o . (iv) All specimens shall be tested at room temperature.50.025 4.00 0.25 0. LOO 0.025 0. They shall be smooth on tr-.61 0.025 max max 8.60 0.30 0.44 0. expanding or any other forming operations or being cut to length. For large size tubes.20 0.025 0..025 0.44 0.025 0.50 1.025 0.61 Si Chemical composition % S P Cr Mo 0.30 0.05 0.15 Mn 0.10 0.10 0. (_) .00 1.25 ( 1 Contd"eJ .00 10.50 max max 0.60 '0.50 max 0. QD (e) Number of tests-The tests specified in Regulations 49(a).025 0.81 0.00 max max 6. tensile test may be carried out on full section of the tubes up ·fo the capacity of the testing machine.30 0.30 0.44 0.65 0.50 max 0.90 1.30 0.025 0..15 max 0. \ . max max 0.10 0. ends and free from burrs flaws.00 0.

10 2.60 max O.17 0.90 1.OS 2.OB 0.030 to 0.17 0.030 max 0.50 0.30 O.040 max max max 0.00 max 2.. 0.0 1.00 3.30 0.0 11.60 0.00 max - 0.13 41 0.60 0~S7 1.08 max 0..50 1.00 max 0.040 17.040 max max max 0.OO 0.00 0.70 1.20 Max max .0 18.030 0.00 max max 0.0 24.030 0.00 13.00 11.75 0.0 18.0 18.0 16.00 max 9.0 22.10 0.35 0.08 max 0.030 0.20 10.00 Nb+Ta =B x C min 1.00 3..035 2.040 0.045 max max max 0.00 max 2.90 2.0.00 Nb+Ta = 10)( C min 13.SO 0.0 20.37 max max 0.50 max max 9.75 0.00 max 2.0 20.03 max 0.75 0.0 20.0 20.05 0.10 0.30 0.040 max max max 0.05 12 x 1M~ x 20CrMoV 121 0.12 0.75 0.0 16.025 0.SO Table 2: Chemi«:al Requirements of Austentic Steel .25 Cu=0..0 12.020 S.0 11.75 0. Grade Chemical composition % C TP304 TP304H TP304L TP31 OS TP316 TP316H TP316L TP321 TP321H TP347 TP347H Mn 2.030 0.0 17.10 0.75 O.025 max max max 1.030 0.00 max 13.0 8.00 max Si S P Cr 1S.0 17.15 0.5 0.030 0.040 max max max 0.0 26.04 0.25 1.040 max max max 0.0 8.25 N = 0.75 0.0 17.04 0.10 2.00 max max 0.040 max max max 0.025 0.30 O.030.75 0.0 .Indian Boiler Regulations Contd .75 0.35 .50 max 0.0 20.0.25 0.00 2.00 3. 0.035 max 0.00 max 2.15 0.010 0..18 0.00 max 2.75 0.S5 0.000 max 9.0 10.0 16.OSO 0.00 19.75 max 0.0 14.-~ .040 max max max 0..0 5)( C min 0..070 O.60 0:20 0.030 0.23 0040 0.0 Other Elements O.0 Mo V Ni S.0 9.00 2.20 0.040 max max 0.75 max 2.030 0.040 max max max 0. T22 T91 .08 max 0.0 max max max 20.OO 11.00 Ti= 13:0 9.0 1B.030 0.00 max max 0.OS 2.04 0.00 Ti= 13.0 20.15 0.0 14.0 1S.60 max 4)( C min 0.0 15.025 0.

3) 205 (21.5) 515 (52.5) 515 (52.840 (85.5) 515 (52.0) 637 (65..0) ·690 (70.1) 205 (21.5) 192 192 192 192 192 192 192 192 192 192 192 ( I (' ) .2) 274 (28.5) 515 (52.0) 205 (21.5) 515 (52.2) 585 (59:6) 441 (45.1) 220 (22.. 205 (21.1) 205 (21.1) 205 (21.1) 205 (21. 90 90 90 250 (\ . ) TP304 TP304H TP304L .1) 17 35 35 35 35 35 35 35 35 35 35 35 25HRC 90 90 90 90 90 90 90 90 .1) 205 (21. • I C) .65.0) Tensile Strength Mpa (kg/mm2) Min (3) .JSO 515 (52.1) 205 (21. 485 (49.1) 205 (21.2) 415 (42. 380 (38.5) 515 (52. The hardness test may be carried out on the wall cross section or on a flat on the outside surface of the tube sample. Indian Boiler Regulations (a) Tensile and hardness tests-The test specimen shall comply with the requirements as given in Table 3.2) 415 (42.2) 415 (42.5) 515 (52.42 49.4) .1) 170 (17..3) .7) 415 (42.1) 205 (21.) C) () C) () 490 (50. TP31OS TP316 TP316H· TP316L TP321 TP321H TP347 TP347H *Gl . Table 3: Mechanical Property Requirements Grade Yield strength Mpa (kg/mm2) .5) 205 (21.1) 170 (17.1) 415 (42.2) 415 (42. Min (2) 205 (21.5) 485 (49.2) 415 (42.7) 30 30 30 30 30 30 30 20 21 80 85 85 89 85 85 85 25HRC 85 C .1) 205 (21.1) 205 (21.::5.% Elongation on GL=50mm Min* (4) Hardness HRBmax (5) HBmax (6) 146 163 163 179 163 163 163 250 163 (1) T1 T2 T5 T9 T11 T12 T22 T91 12 x 1M$ x 20CrMoV121.5) 515 (52.5) .

8 0. .09 for austenitic steel. without cracking: Ratio of inside diameter to outside diameter 0. Additional tests before rejection (i) ·If anyone or more tests specified in these regulations fail. Hydraulic test (i) Each tube shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and a half time the design pressure subject to a minimum of 1. (ii) If the repeat tests are satisfactory the tubes shall be accepted. If any of these tests fails.9 0.3 50. as given below: e = 0. tubes represented may be given a further heat treatment and entire set of tests shall be repeated. 51.00 kgf/mm2.Indian Boiler Regulations 43 (b) Flattening test-A section of the tube not less than 63 mm in length shall be' flattened cold between two parallel flat surfaces to a distance between the plates (H) as oaculated by the formula given below. the batch of the .6 0. 0.08 for ferritic alloy steel e = 0.4 . without showing any sign of a crack of flaw.eter % 21 22 25 30 39 51 68 occur the entire batch of the tubes shall be rejected. H=(1+e)t e+where t = specified thickness of tube (mm) t D D = specified outside diameter of the tube (mm) e = a constant. (c) Expanding or flaring test-A section of the tube approximately 100mm in length shall stand being flared with a tool having a 60 degree included angle until the tube at the mouth of the flare has been expanded to the percentages given below.5 0..7 0. two further tests of the same kind may be made on two other tubes of the same batch. If any failure in the tests should Minimum expansion of inside diam. but not gr~ater than pressure calculated by the following formula:~ .

(ii) The steel shall conform to the limits of chemical composition as given in Table-4: . :. the hydraulic test at the maker's works may be dispensed with. . P2 P5. P22. P11. The steel shall be tully kilfed. SEAMLESS FERRITICPIPES 52. r 1..44 P Indian BoilerRegulations '. (iii) ·While making pipes to other national/international () standards the allowable stresses of the respective standard shall be strictly followed while designing the tubes. P91. provided that the tubes are subject to non-destructive testing by an appropriate method like Ultrasonic or Eddy Current or Stray Flux testing. (a) Material (I) The pipes shall be seamless and manufactured from steel produced by an open hearth or electric process or any of the Oxygen processes. (ii) Notwithstanding anything contained in the above clause. P9. 537 648 53. () () (iv) The design metal temperatures shall not exceed the following limits: Grade Temperature .the national/international standards.. General FOR HIGH TEMPERATURE SERVICE (i) These regulations cover both hot finished and cold drawn seamless pipes of ferritic alloy steel grades. (ii) The seamless pipes conforming to other national/international standards which are known to be Co) commonly used as being suitable for high temperature service can also be used w~h the designations of. P12.! = 2 StlO where P = test pressure o= 5 specified outside diameter of the tube t = specified wall thickness of the tube = stress which shall be taken as 40% of the minimum tensile strength at room temperature for carbon and territic steel and 80% of the minimum yield strength at room temperature for austenitic stainless steel. provided such materials are not specifically prohibited by the regulations. These shall conform in aUrespects with the requirements herein specified. x20CrMoV121 (Degree F) (1000) (1200) . (J . Degree C P1.

10 0.17 0.30 0.60 0.60 Si 0.05 0.025 4.10 0.85 0.00 0.030 .15 max 0.44 0.50 max 0.00 0. instead of heat treatment specified in sub-clause (i) above at the option of the manufacturer.15 0.65 0.44 0.25 Nb= 0.30 0.025 0.20 0.05 0.50 1.30 0. P9 and P22 shall be 675 degreeC.12 Mn 0.60 0.5 0.025 0.65 0.00 max max 6. If furnished in the normalised and tempered condition.020 8.80 0.25 0.05 0.025 max max 0.10 0.20 0.10 0.780degree C for a period of one hour minimum.30 0.15 0.25 1.00 max max 9.30 0. tempering .30 0.025 0.45 0.25 0.Indian Boiler Regulations Table 4: Chemical Requirements for Ferritic Steels Grade Chemical composition % 45 C P1 P2 P5 pg P11 P12 P22 P91 0.0.30 0.00 max max 10.025 0.025 1.30 0.35 0.50 max max 0. the minimum.90 max max 2.030 10.20 0.1070 degree C and tempered at 730 .15 max 0.65 0.50 max 0.025 0.025 0.40 max AI =0. (ii) Pipes of grades P1.20 0.61 0.temperature for grade P1.13 V Ni Other Elements 0.00 max 0.30 0.65 0.0 max max 12.80 max max 1.070 Ni = 0.50 0.025 8.03 0.025 0. P11 and P12 shall be 650 degree C and the minimum tempering temperature for grades P5. (iii) Grades P91 shall be normalised at 1040 degree C minimum and tempered at 730 degree minimum as a final heat treatment .44 0.0. P2.08 0.18 1.23 1. isothermal annealed or normalised and tempered condition.05 0.00 0.50 max 0.00 1.025 0.04 max x 20Cr 0.60 0.10 N = 0.15 0.80 0.90 1. P2 and P12 either hot finished or cold drawn may be given a final heat treatment at 650 degree C to 705 degree C.65 0.010 0.50 0.50 0.06 .10 0.44 0.60 0.87 1.80 (b) Heat treatment (i) All pipes of grades in Table 1 except P91 and x 20CrMoV121 shall be reheated and furnished in full annealed. .30 MoV121 1.025 0.0 0.50 s p o Mo 0.61 0.60 0.81 0.025 max max 1. {IV} Grades x 20CrMoV121 shall be normalised at 1020 .50 max 0.

.5% under the nominal wall thickness specified.3 inel.3 to 114.5 12. cylindrical and subject to the following tolerances.38 1% DAD 0.1 to 300 incl. Over 300 for grade X20CrMoV121 Outside diameter (mm) Permissible variations (mm) Over Under 0. For grade x 20CrMoV121 Permissible variations (mm) Over Under' 1 ) Outside diameter (mm) 100 and under Over 100 to 320 incl.0 12. smooth. For all grades except x 2QCrMoV121. If ordered in specified length.00% 1.75% 0. Over 219. Outside diameter (mm) 10.75% 0. The minimum wall thickness at any point· shall not be more than 12. Pipes manufacturer shall explore a 'sufficient number of visual inspections to provide reasonable assurance that they have been properly evaluated.90% 1. f 12. the tolerance shall be as follows: (_) . Over 320 (ii) Permissible _ variations in wall thickness: For all grades.90% Permissible variations (mm) Over Under DAD 0.3 to 219. cleaned free from harmful defects. Hot finished and Cold finished Seamless pipes .3 incl.---- 0. .58 2. They shall be reasonably straight. Over 320 (iii) Permissible variation in length: " .5 10 12. Over 48. o () 100 and under Over 100 to 320 incl. (i) Permissible variation in outside diameter.79 0.5 15. Over 114.5 Seamless Hot finished and Cold finished pipes can be ordered in specified length or in random length.79 1.79 0.00% .79 (J Q 1% 0.1 incl.46 Indian Boiler Regulations (c) Workmanshipahd tolerance-The pipes shall be well finished. except x20CrMoV121 ------.3 to 48..

7) 380(38.4) 840(85.2) 585(59.1) 205(21.2) 415(42.65m .5) 205(21.1) 205(21.0) Tensile Strength Mpa (kg/mm2) min 380(38.2) 490(50. For large size pipes the tensile test specimen shall consist of strip cut longitudinally from the pipe and which is not straightened within the gauge length and further heat treated.2) 415(42.1) 220(22. (a) Tensile test-The test specimen shall comply with the requirements given in the Table 5.Indian Boiler Regulations For Hot finished and Cold finished pipes 47 Grade All grades except x 20CrMoV121 For grade length (m) AlIlength 6 and under Over 6 to 12 mel Permissible variation in (mm) Over 6 10 15 Under x 20CrMoV121 (d) Test specimen . Table 5: Mechanical Property Requirements Grade P1 P2 P5 P9 P11 P12 P22 P91 x Yield Strength Mpa (kg/mm2) min 205(21. tensile test may be carried out on full section of the pipe upto the capacity of the testing machine. expanding or any other forming operations or being cut to length. swaging. 54(b) and 54(c) shall be made on minimum 2 pipes for first 100 pipes and 1 per 100 part thereof for pipes over 100 numbers.(ii) If desirable and practicable.2) 415(42.1) 205(21.2) 415(42.7) 415(42.6) % elongation on GL = 50mm min* 30 30 30 30 30 30 30 20 17 20CrMoV121 *Gl = 5. 54(b)· and 54(c) shall be taken from ends of finished pipes prior to upsetting. They shall be smooth on ends and free from burrs and flaws . (iii) If any test specimen shows flaws or defective machining another specimen substituted.1) 415(42.8) 690(70. (iv) All specimens shall be tested at room temperature: it may be discarded and (eY Number of tests-The tests specified in regulations 54(a). . (i) Test specimens requiredfor o o o flattening and expanding/flaring test specified in regulations 54(a).1) 205(21. 54.

If any of these tests fails. ". a bend test shall be conducted. 0. the pipes shall be accepted. \:~.(c) FlaHeningtest (i) For pipes of outside diameter over 60. (iii) For pipes whose diameter exceed 635 mm and whose diameter to wall thickness ratio is o () C) c) 7. H= (1+e)t e+:where. If any failure in the tests should occur the entire batch of the pipes shall be rejected. without developing cracks. Indian Boiler Regulations (b) ·Bend test-For pipes of outside diameter 60.. the batch of the pipes represented may be given a further heat treatment and entire set of tests shall be repeated ..48 . Substitution of the bend test for the flattening test shall be subject to the approval of the purchaser... The inside diameter of the bend shall be 25 mm. the diameter of which is 12 times the nominal diameter of the pipe. The bend test specimens shall be bent at room temperature through 180 degree C without cracking on the outside of the bent portion. 55. A sufficient length of pipe shall stand being ·bent cold through 90 around a cylindrical mandrel.3 mm a flattening test shall be conducted.0 or less. (ii) For pipe whose diameter equals or exceeds 254 mm. A section of the pipe not less than 63 mm is length shall be flattened cold between two parallel flat surfaces to a distance between the plates (H) as calculated by the formula given below.-:} . Ad~itional tests before rejection C) (i) If anyone or more tests specified in these regulations fail. the bend test described in clause (b) shall be conducted instead of the flattening test. thickness for pipe (mm) ) 'D = specified outside diameter of the pipe (mm) e = a constant. Hydraulic test (i) Each pipe shall be tested by the manufacturer and shall withstand a hydraulic pressure to one . without showing any sign of a crack or flaw: . two further tests of the same kind may be made on two other pipes of the same batch.· 56.08 for ferritic alloy steel. (ii) If the repeat tests are satisfactory.and half times the design pressure but not greater than pressure calculated by the following formula given below. t=specified t o . a bend test may be conducted instead of the flattening test.3 mm and under. P = 2 Stld 1-0.

\ Indian Boiler Regulations where.50% 0. at a temperature approved by the Inspecting Authority. (ii) Material-The tubes shall be manufactured from steel produced by the Open Hearth or Electric Process or any of the Oxygen Process and shall conform to the following limits of chemical composition: Carbon Manganese Silicon Phosphorus Sulphur Chromium Molybdenum 0.30 to 0. P = test pressure 49 o= specified outside diameter of the pipe t = specified wall thickness of the pipe S = stress which shall be taken as 40% of the minimum tensile strength at room temperature. They shall ~e reasonably straight. 56A. smooth cylindrical and subject to the following tolerances before bending:(a) Diameter-The external diameter of the tubes measured at any point shall be within the following tolerances if the diameter specified:- . clean and free from harmful defects.04% maximum 1.The provlslonaot this regulation apply to both Hot Finished and Cold Drawn Seamless Boiler and Superheated Tubes which shall conform in all respects with the requirements herein specified.70% 0.1 to 0.2% The steel maker shall prove to the satisfaction of the Inspecting Authority that the quality of the ·steelis of the required high temperature creep strength.6% 0. the hydraulic test at the maker's works may be dispensed with provided that the pipes are subject to non-destructive testing by an appropriate method like Ultrasonic or Eddy Current or Stray Flux testing.90 to 2.15% maximum 0.04% maximum 0.87 to 1. (ii) Notwithstanding anything contained in the above clause. Seamless Chromium-Molybdenum Steel Boiler and Superheater Tubes for design metal temperatures not exceeding 577~C (1070°F) (i) Gene~al. (iv) Workmanship and tolerance-The tubes shall be well finished. (iii) Heat treatment-The tubes shall be fully annealed or normalised and tempered.

5% Where the ends of the tubes are swelled or reduced.4 mm (1/64") . the tolerances relating to thickness shall also apply. but may exceed it by the amount given below: Upto and including 9 meters (30 ft. Tolerance + 0.5 % . + 1% + 1% -1% . 39 25 *Elongation on La . The manufacturer shall provide(J at his own expense extra tube at the rate of 2 per cent of each diameter and thickness of tube 0 specified and the Inspecting Officer shall select for test such of the tubes as he may think proper .. Should the number of tubes specified of any one(') nominal size exceed 400. The samples for testing shall not be heat treated alter. 5 do or La . ('-)0 '-_ . one' additional tube shall be provided. the thickness at the ends may be .S mm (1/32D) . As an. Kind of Steel Chromium-Molybdenum Steel *Note: Tensile Strength minimum kglmm2ltonslsq.1% thickness of the tubes shall be within the following tolerances:Outside Diameter of Tube Upto and including 64 mm (2%D) Over 64 mm (2%") All sizes + 17%% + 15% + 10% Tolerance -7%% _. (vi) Tensile test-Test requirements: pieces cut from the end of the selected tubes shall comply with the following The test may be carried out on test pieces cut out from the tube in the longitudinal direction which shall not be further heat-treated nor straightened within the gauge length._ to the extent of the percentage mentioned. decreased below or increased above the nominal thickness of the tubes by an amount in proportion to "the percentage of such swelling or reduction and..> alternative. do = Original diameter. the tubes shall be presented forC) mechanical testing in accordance with Regulations 56A(vi). for every 100 tubes or part thereof above that number. tubes may be tested on full cross-section. 5.56A (vii) and 56A (viii).) 3 mm.) Over 64 mm (2% in. Swelling or reduction shall be carried out before the heat-treatment specified in Regulation 56A(iii}. (c) Length-The tubes shall be not less than the nominal length.65J!\ % minimum 20 ) Lc = Original gauge length. and ~.) Over 9 meters (30 ft.. in batches of -not more than 100 of the same nominal diameter and thickness. selection.then.:. (1/SD) 6 mm. in addition to this allowance.O.:. (1/4D) o (v) Selection of tubes for testing-After heat-treatment. in. Original ar~a of cross-secnon. .) All sizes Indian Boiler Regulations.50 Type of Tube Hot finished Hot finished Cold drawn (b) Thickness-The Type of Tube· Hot finished Hot finished Cold drawn Outside Diameter of Tube Upto and including 64 mm (2% in.

the code adopted shall be specfied. the width of which shall be" not less than 1% times the diameter of the tube.(0. subject to a minimum of 70 kg.192") Thicker than 5 mm.lsq. flaring test carried out in accordance with any other standard code may be accepted in which case. (0. (x) Each tube shall be tested at the Maker's works and shall withstand a hydraulic pressure of 1% times tHe design pressure. (0. but if definite defects are again shown. the Code adopted shall be specified. If the second repeat tests are satisfactory. inch): (xi) Notwithstanding anything contained in sub-regulation (x). the interior surfaces of the test pieces (at the middle) shall remain at a distance apart of not more than three times the specified thickness of the tubes and the test piece shall then show no sign of crack or flaw.192"} Increase in Diameter % 12% 9% 6% . (0. If the repeat tests are satisfactory. the batch of tubes represented may be re-heat-treated in accordance with the clause (iii) and then re-testedin accordance with clauses (vi). cm2 (1000 Ibs. the tubes shall be accepted provided that in all other respects they fulfil the conditions of this standard. (vii) and (viii) two further tests of the same kind may be made at the option of the manufacture from "two additional selected test tubes. (vii) and (viii) but employing twice the number of test pieces.128") and thinner Thicker than 3 mm. Should either of the tubes fail in any test.Indian Boiler Regulations - 51 (vii) Flattening test-A ring not less than 51 mm (2 inches) in length cut from one end of each selected tube shall be flattened between two parallel flat surfaces. per sq. . Flattening test carried out in accordance with any other standard code may be accepted in which case. the batch of tubes which the test pieces represent shall be rejected. (viii) Expanding test-The tubes shall withstand expanding by a drift expander having a total" included angle of between 40° and 600 (20° and 30° per side) to the following increases in external diameter without showing crack or flaw: Thickness of Tube 3 mm. In lieu of expanding test as above. When the pressure is released. (ix) Additional tests before rejection-Should a tube selected for testing purposes show definite signs of failure in anyone or more of the tests specified in clauses (vi). the hydraulic test for tubes in maker's premises shall be dispensed with by the Inspecting Authority provided that the tubes are subject to non-destructive testing by an appropriate method like ultrasonic orland Eddy current testing. the tubes shall be accepted provided that in all other respects they fulfil the conditions of these Regulations.128") upto and including 5 mm.

C to 940 Oeg.040 max 0. superheater or heat exchanger tubes and. f) . C. the tubes are not hydraulically tested at the pressure required under this·. superheater and heat exchanger. C to 720 Oe9.35 0.16 max 0.35 max 0. . not speCifically prohibited by these regulations can also be used provided such tubes satisfy the' requirements of these regulations and are certified as per these regulations: Provided that if. the Inspecting Authority may accept such tubes after witnessing hydraulic test at the required pressure at the maker's or fabricator's works or user's premises. Note 2: For rimmed or semi-killed steel. the C max is 0. Tube Grade WC1 WC2&WC3 Heat Treatment Normalized* or sub-critically annsaledt Normalized* *Temperature range 800 Oeg. i. .20 Si 0.e. +Temperalure range 660 Oeg.035 max 0. (b) The welded tubes conforming to other national or international standard which are known to be. (b) Manufacture-The tube shall be made by electric resistance welding and heat treated as per .4010.18 Mn 0. Indian Boiler Regulations .12/0.52 .25 mm. removed completely.90/1. METAL TEMPERATURES NOT EXCEEDING 454°C (850°F) 57. or electric process or anyO of the oxygen processes. i C 0.. General (a) These regulations cover electrically welded tubes made of steel and intended for boiler. flushed with outside surface.17 max 0. '.80 0. . In case of cold finished tubes the heat treatment shall be done after thee) final cold finishing process. (c) 'Chemical Composition-Ladle requirements: Tube Grade WC1 WC2 WC3 analysls of the steel grades shall conform to the following'. ELECTRIC·RESISTANCE-WELDED STEEL BOILER AND SUPERHEATER TUBES FOR DESIGN . C.035 max 0.1010. . The internal weld upset shall be trimmed' throughout the length of the tube so that the maximum height shall not exceed 0. The tube shall be well finished and free from harmful defects. i '. ') Note 1: WC1 grade may be fully killed..035 max (') . rimmed or semi-killed. The external weld (flash) shall be. . commonly used as being suitable for use as boiler.10/0. in case of grade WC1. Material (J C·C) j (a) Tubes shall be manufactured from steel produced by an open hearth.70 0.35 P 0. regulations.040 max 0.30/0. 58. the table given below.19%.035 max S 0.

(f) Length-Unless otherwise specified tube shall be supplied as random length. C shall be of fully killed type. When Ladle analysis is not available the analysis of sample tube selected at random may be used. (a) Flattening test (i) A section of the tube not less than 40 mmlength shall be flattened cold between parallel plates.75% and minus 0.30 mm over and under. For every 3 metre increase in length above 6 metres. (d) Thickness-The thickness of each tube excluding the weld shall conform to the permissible variation given below: Permissible variation (in per cent) in wall thickness Tube Grade .Wall thickness Permissible variation Over WC1 WC1 WC2&WC3 3.5 mm with a maximum of 12 mm.5 10 The minimum thickness in the weld area shall not be less than that permitted in the body of the tubes.2 mm and under Over 3. the permissible variation shall be +6 mm-O mm for length up to and including 6 meters.(. Where the length is specified as exact length or cut length. C either rimming.2mm All 10 7. If rimming steel is used. the positive tolerance shall be increased by 1.::: (1+ e)t e+- t D Where. and not slit longitudinally. (e) Diameter-The outside diameter of each tube measured at any position shall conform to the specified diameter within the limits of plus 0. the strips shall be rolled in single width.75% with a minimum of 0. semi-killed or killed steel may be used. The steel used for design steam temperature above 400 Deg. Evidence of lamination or burnt material or incomplete penetration of the weld shall not develop during the testing. H. t = Specified thickness of tube (in mm) 0= Specified outside diameter of tube (in mm) . No cracks or breaks in the metal shall occur unit the distance between the plates is less than the given by the following formula. Indian Boiler Regulations 53 Where the temperature is below 400 Deg.5 10 Under 10 7. 59.

61. result of minor surface imperfections shall not be cause for rejection. I in which case the code adopted shall be specified. F 0. Tensile test .6 to 0.) (Min..) 25 24 21 .8 12 12 10 19 19 17 () C) (' ) ~--~----------------------------------~-------------------Tube Grade % Elongations+ Yield strength Mpa Tensile strength Mpa (kgflmm sq. (H) The weld shall be placed 90 degree from the line of direction of the applied force.6S. where A is the initial cross-sectional area of the specimen on the gauge' length.) 320/480 (32.0) 245 (25. Hydraulic test ) (a) . the design pressure.2) (Min.j () . (iv) Flattening test carried out in accordance with any other standard code may be accepted ..8 including 15 15 12 Over 0.9) 235 (24.7/51. (b) Allowable permissible stress at elevated temperature. subject to a minimum of 1.Each tube shall be hydraulically tested at the makers' works and shall withstand a hydraulic { \ pressure to one and half times.6/49. 60.5 times the outside diameter.) WC1 WC2 WC3 (kgf/mm sq. + On gauge length 5. lattening test constant as given below: .) (Min. shall stand:being flared with a tool having 60 or 45 degree included angle ·untHthe \ tube at the mouth of the flare has expanded to the percentage given below without cracking: Tube Grade % expansion in outside diameter D for a diD of 0.6 and under WC1 WC2 WC3 d = inside diameter of tube.9/59.54 e = . !) .07 for tube grades WC2 ) Indian Boiler Regulations s WC3. . Allowable permissible stress as per the respective code shall be strictly followed. (iii) Superficial rupture as a.. Over 0.jA. (b) Flaring test-A section of tube of length equal to 1.00) 440/580 (44. .0) . 0.10 for tube grades WC 1. but not less than 50 mm.0) 360/500 (36.. (a) The tensile strength of the material cut from the finished tube shall conform to the foliowingC) requirement: 195 (19./ (:.00 kg/mm sq.

. the batch of the tubes represented may be given a further heat treatment and entire set of tests shall be repeated. 62. the tensile test specimen shall consist of strip cut longitudinally from the tube and not flattened betWeen the gauge marks and further heat treated. If any of these tests fails. For large size tubes. swaging. (b) Notwithstanding anything contained in the above regulation. (b) If any test specimen shows defective machining or develops flaws.8 kg/mm sq.) D = specified outside diameter of the tube t = specified wall thickness S = stress (in kgt/mm sq. (b) If desirable and practicable.) which shall be taken as 40% of the specified minimum tensile strength at room temperature. . the test pressure shall not be greater than the pressure calculated by the following formula: p= 28t D Where P = test pressure (in kg/mm sq. Test Specimens (a) Test specimens required for the flattening and flaring test specified in regulations 59(a) and 59(b) shall be taken from the ends of finished tubes prior to up setting. (c) If anyone or more tests specified in these regulations fail. test at the maker's works may be dispensed with. 63. expanding or other forming operations or being cut to length.the hydraulic. However. If any failure in the tests should occur the entire batch of the tubes shall be rejected. (c) All specimens shall be tested at room temperature. If the repeat tests are satisfactory the tubes shall be accepted. Number of tests (a) The test specified in regulations 59 and 60 shall be made on minimum 2 tubes for first 100 and 1 per 100 or part thereat for tubes over 100 number. it may be discarded and anoiher specimen SUbstituted. provided that the tubes are subjected to non-destructive testing by an appropriate method like Ultrasonic or Eddy Current testing. may be carried out on full section of the tubes up to the capacity of the testing machine.Indian Boiler Regulations 55 and for tube 00 larger than 101 mm outside diameter minimum of 0. two further tests of the same kind may be made on two other tubes of the same batch. tensile test. They shall be smooth on the ends and free from burrs and flaws. The sides of the specimen shall be parallel between gauge marks.

C to 940 Oe9.•. .. tube grade and chemical composition accordance with the appropriate clause of Regulation 58. shall comply with the provision of Regulation 62. . for these tubes shall be in! (ii) Manufacture-Tube shall be manufactured as prescribed in Regulation 58(b) and subsequentlYi :: on thickness and outside diameter shall be as follows: Plus 7.' STEEL CASTING 73. shall comply with the provision of Regulation 59(b). \ (b) Flattening test-This (c) Flaring test-This (vi) Hydraulic test-This (vii) Test specimens-These (viii) Number of tests-These test shall comply with the 'provision of Regulation 59(a).cold drawn. Scope (a) This regulation shall cover carbon steel castlnqsused in the construction of boilers and steam() pipes including their fittings. ..5% Plus 0. (i) Material~Material. shall comply with the provisions of Regulation 63. WC3 above.5% .5% minus 7. final cold finishing the tubes shall be heat treated as follows: Heat treatment Normalized'" or sub-critically annealed# Normalized'" 0 () () C) asC) The ends which are subjected to cold working operation shall be suitably normalized or sub-critically annealed (v) Tests- (a) Tensile test-This test shall be comply with the provision of Regulation 60. shall comply with the provision of Regulation 61. C to 720 Deg. Temperature range 880 Oeg.56 Indian Boiler Regulations .5% minusO. COLD DRAWN·RESISTANCE·WELDED STEEL BOILER AND SUPER·HEATER TUBES FOR DESIGN METAL TEMPERATURE NOT EXCEEDING 454°C (850°F) 63A. Tolerance on length shall be in accordance with Regulation 58(f).. . (iv) Heat Treatment-After Tubes Grade WC1 WC2. C) . # Temperature range 660 Deg. (iii) Tolerances-Tolerance Thickness Outside diameter (With a minimum of 0. C.10 mm over and under). C.

with the approval of the Inspecting Authority provided that the castings are stress-relieved after welding wherever necessary. I . Process of manufacture The steel used for castings shall be made by the Open Hearth or Electric Furnace or any other process which g!ves steel having equivalent properties. The specified permissible variations in size or thickness shall not be exceeded. (b) Chemical analysis-The *Carbon Silicon Manganese ladle analysis shall conform to the following requirements.either at. The heat-treatment. . the decision as to the manner of providing test samples shall rest with the manufacturer. Phosphorus Sulphur Authority.05% Maximum 0.05% Maximum . The discretion of the manufacturer shall not. or hardenilig and tempering.30% may be subject to the agreement between the boiler maker and the Inspecting The steel shall comply with the chemical composition specified in the table above.· * A carbon content not exceeding 0. apply to the . . The maximum values shall be between 40 and 50 kgf/mm2• (c) Heat treatment-:-AII castings shall be supplied in the heat-treated condition. 75.Indian Boiler Regulations . Number of test provision of test samples Tensile and bend test pieces shall be preparedfrom test samples representative of each meltor heat-treatment batch as follows:(a) The test samples shall be cast attached to or separate from the castings as agreed between the manufacturer and the Inspecting Officer. however. Freedom from and rectification of defects The steel castings shall have clean surfaces and shall be free from injurious defects. . namely: 0.60% Maximum . . 1. and tempering. . 67 (b) For all types of steel castings conforming to these regulations only the minimum values for tensile strength are fixed. 74.. testing ofcastings made from more than one melt as indicated in clause (d) below. shall consist of annealing and normalising. If the Inspecting Officer does not make such an agreement with the manufacturer. Defects may be repaired by welding only. the discretion of the manufacturer or the Inspecting Officer and shall be carried out at suitable temperatures to give the mechanical properties specified in Regulation?? (d)· Fettlings and Dressing-All castings shall be properly fettled and dressed and all surfaces shall be satisfactorily cleaned for inspection purposes.40% Maximum 0. . The agreement for attached test samples shall include the precise location and method of attachment. 76.25% Maximum 0..

Test samples shall be stamped by the Inspecting Officer after that" heat-treatment process. (e) Test samples shall be heat-treated with the castings they represent. () () C) o C) . The test samples shall be cast in moulds of the same material as is used for the castings and shall be made at the same time as the castings. T. Lo = gauge length do = original diameter of the round test piece. (d) When a casting is made from more than one melt. The samples shall be stamped by the Inspecting Officer so as to identify the castings to which they relate. shall be made from test samples situated as far apart as possible on the casting.2% at elevated temperature (Et) of the material may be calculated by multiplying the minimum specified tensile strength at room temperature (R20) by the value of ratio EtlR20 given in table under regulation 16. shall be made from each melt. (c) The minimum values of stress at proof limit of 0.ensile test (a) The upper yield point at room temperature shall be not less than 50% of the specified minimum tensile strength at room temperature. the material will be accepted provided the tensile strength and elongation computed on the basis of the dimensions of the test pieces under the regulation shall conform to the above requirements. (d) The breaking elongation % shall be not less than 93-"Rm 2. except by agreement between the manufacturer and the Inspecting Officer. but in"no case shall there be less than 2 samples per melt. at least one tensile test.at least four tensile tests.2 = a constant which is valid only when Lo = 5do where. however. (b) "A proportional test piece with Lo = 5do shall be used as test specimen. !: 'I 77. Such test samples shall not be detached from the castings until heat-treatment of the castings has been completed and they have been stamped "by the Inspecting Officer. the tensile tests are carried out on specimen conforming to any other standards. (e) If.58 Indian Boiler Regulations (b) If the test samples are attached to the castings. (c) If the test samples are cast separately. Some of the test samples shall be taken from as near the top and others near from the bottom of the casting as is practicable. and when required one bend test.2 where. and where required four bends tests. -. Rm =" measured tensile strength at room temperature in kgffmm2 93 = a quality index 2. they shall be provided to the extent of 2 per cent of the number of castings from each melt. and run from the same ladle.

. The manufacturer shall have the right. (b) Hardness test after heat treatrrtent-The the heat-treated castings. two further samples w~. withstand being bent round a former having a radius of 1 inch through an angle not less than that given in the following table: .Grade of Casting A B 90° Angle of Bend minimum C 79. they shall be carried out in accordance with .ich represent the same casting or castings shall be selected and tested in the same manner. If the welding repairs are sanctioned by the Inspecting Officer. are selected. Should the two further test satisfy the requirements of this standard. Regulation 80. the castings represented shall be liable to rejection. Bend tests 59 Cold bend tests shall be made upon test pieces having rectangular section of one inch wide by 3/4 inch thick. No test "·c· (a) Additional tests before rejection-Should any of the original test pieces fail to pass the mechanical tests. All the castings shall be fully machined to such an extent that all critical sections are exposed for full thickness. if he so desires to re-heat-treat the castings before the two further samples. \ \ \ Inspecting Officer may call for hardness testing of (c) Non-destructive tests-The 'Inspechng Officermay call for radiographic examination or other . The test pieces shall be bent over the thinner section. castings represented by them shall be accepted. '.Indian Boiler Regulations 78. Bend tests may be made by pressure or by blows. non-destructive testing of the castings. Should either of the re-tests fail. High class castings for which a factor greater than 80% is taken in ccmputanon of permissible working stress shall be subject to the follOWing inspection requirements: ( }. or by grinding or machining or etching. The test pieces shall be machined and the edges rounded to a radius of 1/16 inch. If repairs by welding are carried out the castings shall be . Castings found to be unsound may be treated in accordance with Regulation 75. (iii) Castings found to be defective shall be rejected or repaired to the satisfaction of the Inspecting Authority. examined by radiographic or ultrasonic methods at all critical locations and found free from harmful defects. (i) Each casting shall be. (ii) All castings shall be examined at all critical locations using magnetic-particle or penetrant-fluid procedure. and the test pieces shall without fracture l .

. U or V the root of the U or V should be () sufficiently open to ensure complete penetration. Castings found to be unsound may be treated in accordance with regulation 80. Pre~heating-Variations in composition. () () () . Where cracks extend through the section of the casting. otherwise poor penetration and unmould weld metal may result. a further heal' treatment may be considered necessary. should not be allowed to go cold after welding. it is intended to weld should be cleaned and freed from all foreign matter. The preparation for the welding of cracks should be of the U or V types. Electrodes for Grades Band· C castings should be agreed between the manufacturer and the Inspecting Officer. i 80. or locally hardened areas which would cause difficulty in machining. Procedure for welding In order to maintain a high standard of workmanship in the practice of arc-welding to steel castings.60 . but the precise technique will of necessity vary according to the circumstances. When after consideration of each casting in the light of the above variables it is deemed necessary to pre-heat. Surface condition-The surfaces of the steel. mass design and the extent of welding required make it impossible to lay down specific rules to establish conditions under which pre~heatir:lgshould be applied. where possible. casting. When the later is used.90 is assigned shall be clearly and permanently marked with G suitable symbol after being examined as above and found satisfactory. such pre-heating should be carried out at a temperature of 150-300°C (302-572°F). (il) the location of the defect. The electrode manufacturer's recommendations for the use of the electrode should be strictly followed. Note: The provisions of the first paragraph of clause (c) of regulation 79 shall apply to the castings other than high class castings for which a factor greater· than 80% is used in the computation of permissible working stress for shells of Boiler and integraLsuperwheater Drums and Headers under regulation 271. but should be charged into a warm fumace and re"heated to a suitable tempering temperature which in general should be not less than 550°C (1022°F). Electrodes-The electrodes shall comply with Regulations 94 to 98 for Grade A castings.' ' .~ choice between single and double preparation. Repaired ~reas of castings shall be reexamined by the Inspecting Officer in accordance with sub-clause (i) and shall be shown to be free from harmful defects. (iv) Castings to which a quality factor of 0. Stress-relieving treatment-When the welding is carried out after the casting has received its normal heat treatment. Where·this further heat treatment is applied. U or V will be governed by (i) the thickness of the . In double preparation. This treatment need be applied only in cases where welding has been such as to induce either internal stresses which would be detrimental to the casting. 0 the included angle should be not less than 70°. the casting. the. Indian Boiler Regulations subsequently stress-relieved or heat treated. the follc:iwinggeneral principles should be followed.

FORGED OR ROLLED PRESSURE PARTS OTHER THAN SEAMLESS DRUMS OR CARBON STEEL 81.defects-Where . by welding only. Similar procedures shall be followed for test pieces of other forgings. the test ring shall be cut off after heat treatment. In the case of headers for example. If the treatment. For. provided it is given approximately the same reduction and heat-treatment as the finished forgings. Selection of test pieces (a) For testing. forging or drawing. the punching left may be used as test pieces in which case the identity of the material of the punching with that of the flange shall be evidenced in an adequate manner. shall have workman like surfaces as normally obtained by rolling. or the welding itself is such that the physical properties will be adversely affected. In the case of flanges swaged in dies. minor surface defects may be admitted and other defects removed by mechanical means so as to achieve a smooth surface. For headers with outside diameter less than 200 mm longitudinal test pieces may be allowed . .05 per cent of sulphur or of (c) Freedom from and rectification of . not machined. In the case of headers which are closed by special covers.Indian Boiler Regulations 61 When considering the advisability of applying this further treatment. (b) Chemical analysis-The phosphorus. The test may be performed also on the semi-finished material for example a bar or a billet. the test rings shall be cut ·off before dishing or reducing and shall be subjected to the same heat treatment as the headers themselves. Provided that the minimum required thickness is maintained.. (a) Process of manufacture-The steel used for the parts shall be made by the Open Hearth or Electric or basic Oxygen process or by any other process which gives steel having equivalent properties. piece of one and the same cast of the same heat treatment batch as well as of similar dimensions may be gathered into one group. the pipes. if required by the Inspecting Authority. the full heat treatment required to produce satisfactory qualities should be substituted. wherever necessary. At least one test piece shall be made from each group. 82. surplus lengths for test rings may be used. . (e) Hydraulic test-A hydraulic test shall be carried out at 'the Maker's works in accordance with the requirements of regulation 268. with the approval of the Inspecting Authority provided that the parts are stress-relieved after welding. (c) A proportional test piece with Lo = 5do shall be used as a test specimen. its effect on the. either the parts themselves shan be used or additional material of sufficient size for test pieces shall be available. (b) For testing. (d) Tangential test piece shall be used for headers where practicable.headers with closed ends. physical properties of the castings should be borne in mind. steel shall not contain more than 0. Surface defects may also be repaired.

in the table under Regulation 16. Internal radius of pend inch 1/4 3/8 5/8 . 93-Rm 2. = sd. in. (b) Test pieces shall be bent when cold through an angle of 180° without fracture. C) . Upto 32 Above 32 and upto 36 Above 36 and upto 38 Bend tests may-be made by pressure or by blows. (d) The breaking elongation in % shall not be less than.2 where. L. (c) The minimum values of the stress at proof limit 0.50% of the specified minimum tensile strength. = gauge length do = original diameter of the round test piece. Ultimate tensife stress Tons/sq. The test pieces shall be bent over the thinner section. -.62 83. Rm = measured tensile strength at room temperature in kfg/mm2 93 = quality index 2. Tensile strength Indian Boiler Regulations (a) The tensile strength of the material shall conform to one of the following four grades:(i) 37 to 45 kfg/nim2 (ii) 42 to 50 kfg/mm2 (iii) 47 to 56 kfgfmm2 (iv) 56 to 62 kfgfmm2 (b) The upper yield point at room temperature shall be not less than.2% at elevated temperature (Et) may be calculated by mu~iplying the minimum specified tensile/strength of the material at room temperature (R20) by the value of the ratio EtfR20 given. Bend tests (a) Bend test pieces shall be of rectangular cross-section machined to a finished size of 1 inch wide by % inch thick. where. ' 84. In the case of headers. the internal radius of the bend being not greater than that specified in table below for the l' inch wide by % inch thick test piece and not more than 1% T for the full-thickness test piece.2 = a constant which is valid only when t. bend test pieces may be cut transversely 1% T wide by T thick where T is the thickness of the headers: The edges shall be rounded to a radius of 1/16 inch.

When the test bars are cast separately they shall be poured at the same time and from the same . 88. for the use of which furnace permission in writing must be received from theJnspecting Authority. shall be accurately moulded in accordance with the pattern or working drawings supplied by thelhspecting Authority with the addition of such letters. Dimension of test bars (a) Transverse Test Bars-The transverse test bars ofthe diameter specified by the Inspecting Authority according to the main cross-sectional thickness of the casting represented. The number of test bars specified in Regulation 92 shall be applicable to all castings of each melt. or in loam or dry sand. If the results obtained from these retests are satisfactory. Provision of test bars The Inspecting Authority shall state at the time of enquiry whether he requires tensile or transverse tests. Freedom from defects-The castings shall b~sound. (a) Process of manufacture-The castings: shall. shall conform to the following dimensions: . When the bars are east-on. (b) Chemical composition-The composition of the iron as cast Shall be left to the discretion of the· manufacturer but the. In all cases where final retestsdo riot give satisfactory results. They shall be well dressed or fettled and shall be machinable by normal methods. The test bars shall not be subjected to any heat treatment after leaving the moulds. All test bars shall be cast in green sand or dry sand or in loam moulds according as to whether the casting or castings they represent are moulded in green sand. figures or marks as may be specified and the drawings shall include the tolerances specified in the Regulations. 87. and he may also specify cast-on bars where the design of the casting and method of running permit. ladle. or metal as the casting or castings they represent. be cast from metal melted or refined in any metallurgical plant other than an iron are smelting furnace. GENERACGR~Y-~RONCASTINGS (GRADE A) 86. the forging shall be accepted. -. the forgings represented by the test pieces which fail shall be rejected. or both." \ fndian Boifer Regufations 85..on test pieces out from the same forging. two further tests of the type which failed may be made . respectively. Additional tests before rejection 63 Should either a tensile or a bend test fail. provided that in other respects they fulfil the conditions laid down above for steel forgings. If these retests do not give satisfactory results the forgings represented may be re-heattreated together with the remainder of the test blocks and presented for further testings. (6) Moulding-The castings. the mould for the casting and the mould for the test piece shall be joined together in such a manner that the liquid metal fills both moulds at the same operation. maximum percentage of phosphorus or sulphur or both may be specified by the Inspecting Authority. if he so desires. clean out of twist and free from blow holes distortion and all surface and other defects.

also be machined before the transverse test is made. Mechanical test The casting must comply with the transverse and tensile tests specified in Regulation 90 and Regulation 91.1.045 +0.5 t2 .. 90..1 inches may be used by agreement between the manufacturer and the Inspecting Authority.090 +1.. +0. in. 64' Indian BoilerRegulations Limits on Diameter Overall length in. For diagram and table see under clause (b) of this Regulation.0.1 Bars cast to a size in excess of the limits given above may be machined to a diameter within the specified limits.6 :2. . . Transverse test A transverse test bar cast in accordance with Regulation 88(a) must when placed on supports set at the distance shown in column 2 of the following table sustain a load applied at the centre of not less than that shown in column 3 and must show before rupture a deflection not less than that shown in column 4. The supports and the point of application of the load shall be rounded to a radius of not le~s than 1/8 inch. Diameter test Bar .:. (c) For castings over 2 inches in thickness a test bar of larger diameter than 2.065 +0.10 +0.87. . in.l . 10 15 21 21 27 Main cross-sectional thickness of .10 in.satisfaction. providing that the finished diameter falls within these limits . casting represented .) (~:._7 ().. Bars may be tested with either plain or screwed ends. . All test pieces shall be selected by the Inspector and tested in his presence and to his . Bars cast within these limits of diameter may. Not exceeding 318 Over 318 and not exceeding % Over % and not exceeding 1% Over 1% and not exceeding 1% Over 1}t2 ·0:6 ·. (b) Tensile Test 8ars-The tensile test bars of the diameter specltied by the Inspecting Authority. '~ -. according to the main cross-sectional thickness of the casting represented shall co~form to the 'dimensions shown in the following table. . 89.

128 . in. 530 1.( ( ( ~ ( .6 2. Tensile test A tensile test bar machined to the dimensions shown in Regulation 88(b) and tested with either plain or screwed ends must show a breaking strength of not less than that shown in the following table: Diameter of test bar in.399 A in. Diameter of test bar in. 1% C in.2 1.875 1.798 1. 1..564 0. parallel length Min.5 10 .125 P in.07 0.P.875 1. %S.00 2 2 2 3% 3% 3% 3% 1. 4% 3 Not exceeding 3/8 Size Min.15 \ TABLE Diameter as cast Gauge diameter Area '\ Min.6 D in. 9/16 % 1% 1% 2 7-1/16 4-13/16 8% 9-1/32 5-7/8 7~ 7% 8% .1 2 E in. 12. 1% Screwed ends Main crossApproximate minimum overall sectional length thickness of casting Plain Screwed represented ends ends LS LP in. 11% Over 3/8 and not exceeding % Over % and not exceeding 1% Over 1% and not exceeding 1-5/8 Over 1-5/8 The test bars shall be cast as parallel bars of the diameters given in column B and then machined to the dimensions C and P in the above table. If the diameter of a transverse test bar as cast varies within the limits specified in Regulation 88(a) the equivalent. Indian Boiler Regulations . length of plain ends R in.breaking load for thefactors given in Appendix F. 0. radius . 9/16 S. 0. 0.F. %S.w.F.660 Minimum deflection Grade A in.596 0.F.875 1.12 0.15 0.10 0.950 4. 1% .1 Note: Self-aligning grips to ensure axjal loading are recommended.F.00 2. 1 0.W.6 2. 91. 3% 2S.5 12 11 10. in.25 0.6 0. 0.280 6.6 0. in. 9 12 18 18 24 Minimum breaking loadGrade A Ibs.. 7/8 ss« 1%S.. 2 1%S.F. length F B in. in.50 1.2· 0.Grade A Tons per sq.W. 1Y2S. 2% 1%S. Min. Minimum ultimate tensile stress . 0.185 1. 0. p/16S.2 1.6 2:1 65 Distance between support in.

i table. tensile strength not exceeding 33 tons per square inch and sulphur and phosphorus contents not greater than 0.0) per cent each. . Provided always that in the case of failure of both test pieces if either show obvious defects a thiiu-' test piece may be taken from a broken casting or a piece may be cut from a usable casting for furth( testing as follows: 3rd If this passes If this fails The batch or separate casting represented shall be accepted. The batch or separate casting represented may be rejected.G. The batch or separate casting represented shall be accepted. Additional tests '0 The additional tests to be carried out before a casting or batch of castings is rejected shall be C) accordance with the following table: Test piece 1st 2nd If this fails' If this passes If this fails Event Conditions The second test piece shall be tested. ) ---~----------------------------------'" COVERED ELECTRODES FOR METAL ARC WELDING OR MILD STEEL 94. whether taken from one or two test"bars as cast. .. Number of transverse and tensile tests Indian Boiler Regulatiorj ) The number of tests required for each batch of castings shall be in accordance with the followinq) . \ . . \. 4 cOver 1 ton and important castings where mutually agreed upon.. - (. One test for each 30 cwt.' . Over 28 lbs. all castings represented by one test must be poured from tf.) ary~) ' "larger in diameter for metal arc welding of carbon steels having ultimate.•.J same ladle or same heat as the bar or bars provided for the test.. ) One test for each 4 tons of castings or part thereof or f( ) each casting weighing 4 tons or more. The batch or separate casting represented may be rejected.j 'j Over 1 cwt. t In the' above groups 1 2 and 3. Central requirements (1) Application-The ) foHowing Regulations apply to electrodes of sizes 3132 inch (12 S.W. . Group 1 2 3 Weight of castings Upto 28 Ibs. One test for each 2 tons of castings or part thereof. of castings or part thereof. and upto 1 cwt. . The electrodes shall comply with the requirements of physical tests prescribed for each class. One test shall refer to one transverse and one tensile test.) ) 66 92. the various classes of castings being divided into four representative groups. Electrodes less than 3132inch in-diameter shall not be used in boilers. o () ~--------------------------~--------------------------------~. (_) 93. and upto one ton 'One test for each 4 tons of castings or part thereof.

(5) . (a) normal penetration electrodes for use in one or more welding positions. (c) no undue degree of spatter. (3) Manufactur~Electrodes may be made by any method that shall yield a product conforming to the requirements of these Regulations. Indian Boiler Regulations 67 ( Their characteristics and behaviour under ordinary working conditions shall be such that "satisfactory weld deposits can be made by a welder of average skill and experience and that the following characteristics are also obtained: (a) a relative ease in the control of the slag and weld metal during welding. without damage and shall be uniform in thickness all over " . in the flat and horizontal vertical positions. The variation in the thickness shall not exceed 3 percent.... (d) a fair rate of deposition and depth of penetration.. handling and use. Provision shall be made for end or centre gripping.('! r. the electrodes shall be kept ln their original bundles or packings in. When stored.002 inch. The tolerance on the specified diameter of the core wire of the electrodes shall be plus or minus 0. (2) "Classification.Covering. storage. • Trade name of the Electrodes. (e) easy removability of the slag. the electrodes shall for a period of atleast six months be capable of giving results similar to those which they would have given on the date of their despatch from the manufacturer.The electrodes shall be classified into: ( . (4) Size of electrodes-The nominal size Of the electrodes shall refer to the diameter of the core wire and the length shall not exceed 18 inches. . and (b) deep penetration electrodes for close unprepared butt-welding in the flat position and/or fillet welding.. (" (b) a good degree of stability of the arc and of the fusing of the covering. (g) a fair contour of the weld deposits. (f) no undue tendency to under-cut.a dry store room and under such conditions. so that it fuses evenly. and (h) a low internal porosity of the ~eld metal.. (6) (a) Packing and storage-Electrodes shall be suitably packed to guard against damage during transportation. (b) Marking-Each package shall be marked with the foHowing information: • Name of the Manufacturer.The flux covering shall be sufficiently robust to withstand the normal conditions of transport.

G. For electrodes recommended for all positions.. The electrodes shall be deemed to be satisfactory provided no hot I?racking . Greater cracks may be neglected provided they do not run into the full Section of the weld. !) . one each using the T smallest. preparation of the test pieces is specified in Appendix H·1. when called upon. produce the results of the most recent Periodic check tests carried out within the preceding 12 months. The method of . The ultimate tensile stress of each test specimen shall be not less than 26 tons .current range. (7) Tests-The electrodes shall be subjected to Initial tests.68 • Size and quantity of Electrodes....•. • Classification as per Indian Boiler Regulation. (c) Transverse tensile test-· One transverse tensile ·test shall be carried out for each welding position for which the electrode is recommended by the manufacturer except that two tests shall be required for the flat position.. Electrodes intended for use with more than one type of current or polarity shall be tested using . each type of current and polarity. largest diameter electrodes manufactured in this grade shall be prepared. (b) Fillet weld hot cracking test-One fillet weld hot cracking test shall be carried out as specified in Appendix H·1. hree all-weldmetal tensile test specimens.. C) o (I .. and the. two further test specimens shall be prepared using the electrodes from the same batch and submitted to the same test._. • Batch Number. The elongation shall be not less than 25 per cent . a test in the inclined position is not required . ·1 . Indian Boiler Regulations . • Recommended ... on electrodes representalive of the electrodes supplied.. The ultimate tensile stress shall be not less than 28 tons square inch. Periodic check tests and Production control to ensure that the requirements of these Regulations are fulfilled .i ! () o tests o CD The following initial tests on each brand of electrodes shall be carried out: . yield stress not less than 20 tons per square inch. and tested in accordance with the method described in Appendix H-1.occurs under the conditions of test. Where any test specimen fails to satisfy the requirements of any particular test. and the minimum reduction of area shall be not less than 35 per cent. 6 S. . The batch of electrodes shall be accepted as having passed the test provided that the tests of both the additional specimens are satisfactory.per square inch and. . Requirements for normal penetration electrodes-Initial .W. (a) AII·weld metal tensile tests. (8) Test Certificates-The manufacturers shall. 95.

SxWxC tons: where W is the width of the test piece and C is the average throat thickness of the welds. a test in the in·clined position is not required. For electrodes recommended for all positions. 6 S. shall be prepared and tested in accordance with the method specified in Appendix H·1. If the diameter of the largest size of electrode manufactured is less than % inch only two specimens need be prepared. The method of preparation and carrying out the test shall be in accordance with Appendix H-1. and the largest size manufactured electrodes respectively. Premature failures at corners of the test specimen shall not be considered a cause for rejection. Of each pair of specimens. Requirements for deep penetration butt-welding/electrodes Initial test-For electrodes recommended for deep penetration butt-welding. Premature failure. The electrode shall be deemed to be satisfactory provided that on completion of the test. If the diameter of the largest size of the electrode manufactured be less than % inch. one each from test pieces ·shall be prepared according to Table 3 in Appendix H-2 and tested as specified in Appendix H2.at corners shall not be considered cause for rejection. the following initial tests shall be carried out: (1) Transverse tensile test-Three transverse tensile test specimens. The method of preparation of the test pieces and of carrying out the tests shall be as specified in Appendix H-1. Ibs.W. 96. each welding position for which the electrode is recommended by the manufacturer. two each from test pieces. except that\ when the electrode is recommended for both the flat arid the horizontal-vertical position~. except that two in each shall be carried out for those intended for flat position only. (e) ·Cruciform flllet weld tensile test-One Cruciform fillet weld tensile test shall be carried out for .G.( ( Indian Boiler Regulations 69 I -. These test pieces shall be capable of withstanding an ultimate tensile load of not less than 36. a test . The electrode shall be deemed to be satisfactory if 6n completion of the test no crack or defect at the outer surface of the specimen is greater than 1/8 inch measured across it or 1/16 inch measured along its length. (f) All-weld metal impact test-Three Izod impact test specimen. only 4 specimens will be required.7 x the average leg length or as the actual mean throat thickness. prepared according to the Table 3 in Appendix H-2 shall be tested in accordance with the method specified in Appendix H-2. one shall be ·testedwith the side first welded in tension and one with the other side in tension. (2) Transverse bend test-Six bend test specimens. The ultimate tensile stress of each specimen shall be not less than 28 tons per square inch. (d) Transverse bend test-Two bend tests one with the face and the other with the root in tension shall be carried out for each welding position for which the electrode is recommended by the manufacturer.. no crack or defect at the outer surface is greater than 1/8 inch measured across the specimen or 1/16 inch measured along its length. C shall be taken as 0. in the flat position shall not be required.· . both in inches. one each using the smallest size manufactured. whichever is the greater. The average of the three impact values for each test specimen shall be not less than 30 ft.

. For the purpose of calculati. 97.. I t I I I I I ..~ :!:~ 1/16 3/64 .) on a section laid out with inscribed lines as shown. 5/64 I I I I I I I I <> ~. .SxWxC tons. If the diameter of the largest size of electrode manufactured is less than % inch then two specimens only are required. both in inches. from length of vertical leg. Note 2: Length of horizontal leg of fillet weld shall not vary more than 1.16 in.--. ...' .~ .70 Indian Boiler 'Regulations.. where W is the width of the test specimen and Cis...1' 111 "4 111 T ~ () () CONCAVE FILLET Note 1: Size of fillet weld C) = length of largest inscribed isosceles right angled triangle.'the effective size of deep penetration fillet welds shall be taken either as 0. ------- Size of weld ~~ Leg of Fillet . the effective size of the welds. () 1 3 1 5 3 '-+ -. (3) ·Butt-weld penetration test-Examination of the inner edges of the outer discards from the butt-weld test pieces prepared as .specified in Appendix H-2 shall show that complete penetration has been achieved. ..ng the test load. \.7 x (the average leg . Requirements for deep penetration fillet werding electrodes initial test The following initial tests on each brand of electrodes shall be carried out: (a) Cruciform fillet weld tensile test-Three test specimens one each from test pieces prepared according to the 'procedures laid down in Appendix H-2 shall be tested in accordance with the method specified therein. Each specimen shall withstand an ultimate tensile load of not less than 36. I Convexity 1 t I I I I I I CONVEX FILLET DIMENSIONS OF FILLET WELDS -c ~. FILLET WELD PENETRATION TEST-80th allowable limits shown in the figure given above../ ...Theoretical I Throat -g:::.length plus 3/32 inch) or as the actual mean throat thickness plus 1/17 inch whi~hever is the greater.:~ G) . Note 3: Fillet weld size. legs of each fillet weld deposited shall be of equal length with maximum (b) The outer discards from the cruciform fillet weld test pieces prepared as above shall show a minimum penetration beyond the root of not less than 3/32 as shown in the figure given below: ) .--------- Leg of Fillet -. convexity and leg lengths of fillet welds shall be determined by actual measurement (to nearest 1{64 in.

' . The temperature of the parent metal shall be between 50° and 100°F (10°-38°C) immediately before deposition the first run of weld metal. (c) For deep penetration fillet welding electrodes one cruciform fillet weld tensile test shall be taken as prescribed in Regulation 97(1) and the two outer discards from the test pieces shall show a minimum penetration beyond the root as required under Regulation 97(2). (ii) One Tee joint fillet weld hot cracking test as prescribed in clause (b) of Regulation 95. The test specimen shall not be subjected to any mechanical or thermal treatment other than that required herein. The two plates shall be 7 inches long and the dimension 8 from square edge to root edge of each side plate shall be between: .: Indian Boiler Regulations 98. All-weld test pieces shall be prepared as shown in Figure 1 by depositing weld metal between the chamfered edges of two plates. The joint shall be closed at the bottom by a backing plate 1% inch wide by % inch thick.angle of 200 and the distance between the plates at the root edges shall be % inch to 17/32 inch. each 7/8 inch thick. (b) For deep penetration butt-welding electrodes. Periodic check test The following Periodic Check Tests on each brand of electrodes shall be carried out: 71 (a) Periodic check tests consist of a selection of the tests prescribed under Regulations 95 to 97 .. one transverse tensile test specimen and two _ transverse bend test specimens .shall be prepared and tested as prescribed in Regulation 96 and the specimens shall show that a complete penetration has been achieved. The preparation of the plates shall give an included. APPENDIX H-1 (See Regulation 95) (1) Parent metal for test plates The parent metal used in preparing test pieces and test specimen shall be mild steel of welding quality in the normalised condition (this condition is optional in the case of all-weld metal tests) with an ultimate tensile stress of not less than 28 and not more than 32 tons per square inch and in elongation of not less than 20 per cent on standard test pieces A(1) (Appendix 8)_ (2) All-weld metal test Method of preparation of test pieces.and they shalf be repeated at intervals of not more than 6 months to provide evidence that the electrodes currently produced continue to possess the properties recorded in the initial tests: (i) All-weld tensile test with any two sizes of electrodes within the limits prescribed in clause (a) of Regulation 95.( .

Each run of weld metal shall not be less than 1/16 inch and not more than 1/8 inch thick.. electrodes. The assembly shall be welded together with these plates. MIN. The welding current used shall be within the appropriate range given by the manufacturer.. REINFORCEMENT r I ~ II II 1 11/ . On completion of the weld the specimen shall be. or 8 S._*c. :l \ THESE FACES MUST BE FREE FROM LOOSE RUST AND SCALE D= SlaiN. The time interval between the completion of one run and the commencement of deposition of the succeeding run shall be not less than 5 minutes... TO 1 IN.(3/32) inch electrodes. The: assembly shall not be quenched between the deposition of individual runs. TO SUIT TENSILE TESTING MACHINE GRIPS IN PRESET i1bSITJON[) -d-f- 118 in. /'f'"'\'J \ in: ./ ....424 IN. The weld metal shall be de-posited in single or multi-run layers and the direction of deposition of ') each layer shall be alternatively from each end of the specimen. . 1: METHOD OF PREPARATION OF ALL-WELD METAL.. 72 %IN MIN. 5 inches minimum and 6 inches maximum when testing % inch or 5/16 inch electrodes. .W.J 80° : ~ r\WELD " ---------------_1 C : • I 8 1 (J B LENGTH OF WELDING JOINT = 7 IN.G. FOR TENSILE TEST SPECIMEN =0.(C~~ ~ II 1 I --------------- . 3 inches minimum and 4 inches maximum when testing 10 S. TEST SPECIMEN '2 inches minimum and 3 inches maximum when testing 12 S.. The welding position for the assembly shall be flat.G.G.( '.G. in which case the position of weld shall be as recommended by the manufacturer. MAX.W. ! "\ PRE·SET POSITION -----------------(CUT)*C~ f ..450 IN.allowed to cool in still air.4 inches minimum and 5 inches maximum when testing 6 S. The portion including the' weld shall then be removed by cutting away the excess plates atthe places indicated in Figure 1. DIAMETER d=0.. pre-set so that the gap at the top between the chamfered edges of the plates is 1 inch and the plates may be approxlmatefy level when the butt-weld is completed. FOR IMPACT TEST SPECIMEN Indian Boiler Regulations) 10---:-- 11N... ---Yain 17 to-in ]------ 22 *C= THE CUT MAYBE FLAME·CUT BY GAS CUTTING MACHINE OR MAYBE CUT BY MACHINE TOOL OR SAW CD BACKING BAR WELDING ON o o () FIG.. I~) 1 If--.\\ •r .W. I 1 1 f 7 : 1__------------- 1:: 80· WELD::' . electrodes._: 1 ].W.. unless this is contrary to the recommended position for the electrode.

PARALLEL LENGTH 1. The temperature of the test specimen at the time of testing shall not be less than 50°F (10°C).(. ang Ie. using the maximum current of the range recommended by the manufacturer. -f- r. The second weld shall be started at that end where the first run was finished after time Interval of 4 to 5 seconds. The second plate shall be split and the welds broken open as shown in Figure 4. The specimen then shall be tested for tensile strength. 0. The surfaces of the weld shall be visually examined for cracks. i.25 m. The test piece shall be so positioned that the slope and the rotation ofthe weld are zero.69 IN. . max.W. Indian Boiler Regulations 73 The all-weld test piece shall be heat-treated by raising to a uniform temperature of 11120 to 1202°F (600° to 650°C) and maintained at that temperature for the one hour and then ailowed to cool slowly outside the furnace. to 1 in.2 inch) electrode. The gaps betwen parts after tack welding at the ends shall not exceed 0.424 IN. Two fillet welds 5 inches long 1/4 inch in leg length shall be deposited in the flat position with a single 6 S. RAD 0. The edge of the first plate abutting the surface of the second shall be prepared by machining or grinding. ' FIG. A tensile test specimen shall be machined from the test piece to the dimensions given in Figure 1(a) taking care that the longitudinal.37 IN. (3) Impact test specimen The Izod impact test specimens shall be machined from the weld metal test pieces to the dimensions given in Figure 2. (or 0. The slag shan be removed after the test piece is cooled in still air to the room temperature.01 inch.G.- T ) radius at bottom of note 0. [ in. 22mm FIG.~in.2 in. The weld shall not show any evidence of hot cracking as indicated by oxidation or temper colouring of the surface of the fractures. 2: IMPACT TEST SPECIMEN (4) Hot cracking test A 6 inches x 3 inches x 1/2·inch plate shall be welded to a second plate 6 inches x 6 inches x 1/2 inch in the form of a close square Tee joints as shown in Figure 3.90lIN. protected from draughts and chilling. axis of the specimen coincides with the centre line of the weld and the mid-thickness of the plate as indicated in Figure 1. MIN. care being taken that the longitudinal axis of the test piece coincides with the centre line of the weld and mid-thickness of the plate. 1(a): TENSILE TEST SPECIMEN STRIKING DISTANCE OF PENDULUM 5.m. dia to suit testing machine grip 45° incl. DIA.

The weldi~g procedure in making out the test pieces shall be according to the position of welding as in Table 1 b~low: . 3: METHOD OF MAKING HOT CRACKING TEST PIECE FIG.. 1Y2.74 (5) Transverse tensile and bend tests Indian Boiler Regulations The transverse tensile and bend test pieces shall be made as shown in Figure 5 by butt~welding toqether two % -inch plates of suitable length and not less than 6 inches in width.1n..) (~T .-1------. T S in. 1Y_2_j_ n. The plate edges shall be prepared to form a single Vee joint the details of which shall be as follows: " Fillet welds 114 in. . and pre-set to-allow for slight distortion after welding. FIG. leg length made in flat position.~-1---------DISCARD ' I I I-- TENSILE I I I VEE CHAMBER 2%i n.--FACE·BEND t----------.. 5(a): GROOVING IN PREPARATION FOR DEPOSITION OF BACKING RUN The plate edges shall be prepared as per Figure 5(a).\OO~77 -111/8" ___ t----------..~-1---------TRANSVERSE_ SINGLE I . min I f 1/4" 6 in. 5: METHOD OF MAKING TRANSVERSE TENSILE & BEND TEST SPECIMENS (See Figure 5a) Angle between fusion faces 60°-70° Root face 1/8 inch... 4: METHOD OF BREAKING HOT CRACKING TEST PIECE DISCARD t----------.1'----------" ROOT-BEND t----------.r-------:.. FIG... 1%i n. Maximum gap 1/8 inch. min - FiG.

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