CODES & STANDARDS

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

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

 ASME Section-I PG 9 – Materials Specifications List.

ASME Section-II Part-A – Material Specifications.

- SA106, 192, 299, 210, 213, 234, 515.

ASME Section-II Part-D – Table IA – Maximum Allowable Stress

- Table Y, U

ASME Section-II Part-A

Tubes - SA450 - Specification for General Requirements for tubes.

Pipes - SA530 - Specification for General Requirements for Pipes.

Fittings - SA234 - Specification for Piping Fittings.

Drum combined bending Stress – BS 1113, ANNEX-B.

 COMPARISON OF BOILER CODES

Boiler Codes have been written by various nations in the past

century to ensure safety of personnel and to avoid loss of property. Boiler
codes cover the whole gamut of activities including Design, Fabrication,
Testing, Construction and Operation. Although these codes are framed on a
common intent, there are variations on the degree of conservation on
different aspects. One such area where variations do exist between Boiler
Codes is the criteria stipulated for calculating the allowable stresses. In the
present day context of evolving competitive design without sacrificing the
safety needs laid down in the boiler codes, an attempt has been made by
comparing the various aspects in the design like allowable stress, Design
temperature criteria, the various formulae used to determine the thicknesses
for drums / shells, headers, tubes, dished / flat ends, etc, other aspects like
minimum design requirements for drums/headers & tubes and presented in
annexures. The various aspects of IBR Regulations are called out and
consolidated against major items like drum, headers, lines & links, etc. The
following codes have been considered for the study:-

1.IBR 1950
2.ASME Section-I
3.BS 1113
4.DIN TRD 300.
 The observations made between various boiler codes in respect
of design are given below:-

1) Yield strength at room temperature is not considered in BS1113

and IBR whereas factor of safety at room temperature in ASME
Section-I is 1.5 and the same in TRD is 2.4.

For tensile strength at room temperature, both IBR and BS1113

considers a factor of safety of 2.7 whereas in ASME Section-I
indicates 3.5 and not considered in TRD. In the case of rupture
strength, all codes consider factor of safety as 1.5 except
BS1113 which shows 1.3.

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

pressure drop for various components inline with erstwhile ISO
R831 whereas the rest of the codes indicate the boiler to be
designed for drum design pressure.

3) In respect of Design Temperatures, all codes apply some fixed

temperature allowances over the medium temperature except
ASME Section-I which states that parts to be designed for actual
metal temperatures.
4) Comparison material grades among various codes indicate
specification as common for most of the material
compositions. DIN (GERMAN) indicates a specification 12
Cr, 1 Mo, ¼ V composition (X20) which is not finding a
place in both ASME & BS1113. Also, when there is a
specification indication for austenitic steels like 18 Cr 8 Ni,
18 Cr 10 Ni Cb in both ASME & BS1113, there is no such
grade under TRD 300.

It is concluded that ASME Section-I gives the most

stringent criteria on design for deciding the allowable
stresses (Tensile / 3.5) compared to other international
codes below creep region. BS1113 & IBR are same in
respect of design criteria for allowable stresses (Tensile /
2.7). TRD 300 is in between ASME & IBR / BS1113 since
the allowable stress values of DIN falls in between them.
Above creep region, BS1113 gives more liberal criteria
(Creep rupture / 1.3) compared to other international codes.
Weight savings arising out of adopting BS1113 compared
to ASME Section-I is also illustrated in an annexure.
 COMPARISON OF BOILER CODES
Sl.No. Item Description

01. Applicability of Code Regulations

02. Maximum Allowable Working Pressure

03. Design Pressures & Design Temperatures

04. Comparison of Codes

05. Design Stresses - Factors of Safety

06. Comparison of Material Grades

07. Temperature Limits for various Steel Grades

08. Design - Calculation of Thickness Required

09. Openings in Shell

10. Ligament Efficiency

11. Drum / Headers comparison - 2 sheets

12. Tubes comparison

13. Relationship between Allowable Stress, Weight Savings

14. IBR Regulations - Clauses - 2 sheets

15. IBR Regulation Numbers - Ascending Order - 8 sheets

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

17. Salient Clauses of BS1113 - 3 sheets

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

   
ASME It is the maximum pressure to which any part
Sec. I of the boiler is subjected to except when SV
or SRV or Valves are discharging at which
time the MAWP shall not be exceeded by
more than 6%.
   
BS 1113 It is the highest set pressure on any SV
mounted on the steam drum.

   
TRD 300 For steam generators, the design pressure
  shall be the allowable pressure.
 DESIGN PRESSURES & DESIGN
TEMPERATURES - ALLOWANCES USED IN
VARIOUS CODES
         
AREA IBR ASME BS DIN
SEC.I 1113 TRD
Drum Drum Drum
300
Drum
DESIGN PRESSURE design design design design
pressure
with
pressure pressure pressure
pressure
   
drop    
RADIATION 50°C 50°C 50°C

ACTUAL METAL TEMPERATURE

       

371°C (MIN) FOR GAS

TOUCHED PORTION
CONVECTION 39°C 35°C 35°C

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

           
DESIGN DESIGN DRUM DESIGN DRUM DESIGN DRUM DESIGN
PRESSURE PRESSURE PRESSURE PERSSURE PRESSURE
WITH
DESIGN PRESSURE
         
TEMPERATUE DROP
50°C   50°C 50°C
ALLOWANCE  
RADIATION  
           
CONVECTION 39°C ACTUAL 35°C 35°C
METAL
TEMPERATURE
    371°C (MIN)      
ECONOMISER 11°C   25°C (15 + 2 Se) °C Se - ACTUAL WALL
  Max. 50°C THICKNESS
  in mm.
       
WATER WALL 28°C 50°C 50°C

           P=DESIGN PR.
TUBE PD PD PD PD D=OUTSIDE DIA
THICKNESS ---------
+ *C --------- + --------- ---------
f=ALLOWABLE
FORMULA tmin 2f + P 0.005D 2f + P 2f + PSTRESS
2f + P CORR. TO
DESIGN
METAL TEMP.
  Et R Et R Et R Et R  Et = YIELD
FACTOR OF 1.5 , 2.7 1.5 , 3.5 1.5 , 2.7 1.5 , 2.4 STRENGTH
SAFETY  SR SC  SR SC  SR  SR R = TENSILE
1.5 1.5 1.3 1.0 STRENGTH
SR = RUPTURE
STRENGTH
  SC = CREEP
FOR ASME MATERIALS ALLOWABLE STRESS CAN BE TAKEN DIRECTLY FROM ASME SEC.II PART-D
STRENGTH

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

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

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

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

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

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

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

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

For Austenitic steels, FS = 1.35

To be used at temperature below 1500°F
For components without an acceptance test certificate to DIN 50049, FS shall be increase
 COMPARISON OF MATERIALS GRADES
Max. 475°C 500°C 550° 560° 575°C 600°C 625°
Service 885°F 930°F C C 1065°F 1110°F C
Temperat 102 104 115
 ure            0°F   0°F       5°F
ASME                  
SA 106 Gr. Gr. Gr.            
SA 192 A B C            
SA 209 - SA 210 A19     T1          
SA 213 - SA 335 2 Gr. Gr. P1 T2 / T12/ T11/ T22/ T9/P
A1 C P2 P 12 P11 P22 9

                     
BS                    
3059- 360 410 440 490 243 620 621 622 660 629
3602- - Nb
3604 460
                           
DIN             15            
(GERMAN St.3 St.4 17 19 15   Ni 13Cr 10Cr (14 (X12
Y) 5.8 5.8 Mn Mn5 Mo 16 Cu Mo4 Mo Mo Cr
17175     4   3 Mo Mo 4 9 10 V63 MO
VdTUV.B1 1.0 1.0   1.04   5 Nb 1.73 1.73 ) 91)
(Werkstof 305 405 1.0 82 1.5 1.5 5 35 80 1.7 1.73
 f-Nr.)     481 415 423 1.6     715   86
GOST     36      
(RUSSIAN 20 8 15 1 (1
) XM 2 5X
TY 14-3- X IMI
460-75 1 F)
              M      
JIS             F      
(JAPAN) STP STP STP STP STP STP STP STP STP
G3456 T38 T T A12 A20 A22 A23 A24 A26
G3458 STB 42 49 STB STB STB STB STB STB
G3461 35 STB A12 A20 A22 A23 A24 A26
G3462
    42
                 
NF A 49- TU3 TU4 TU4 TU5 TU1 TU1 TU1 TU1 TU1 TU
213 7-C 2-C 8-C 2-C 5 5CD 3CD 0CD 0 Z10
(FRENCH) D3 2.05 4.04 5.05 CD CD9
9.10

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

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

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

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

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

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

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

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

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

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

         
AREA IBR ASME SEC.I BS 1113 DIN TRD 300

         
Tube PD PD PD PD
thickness + C +0.005D
2f + P 2f + P 2f + P 2f + P

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

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

  t branch
  For dia of Opg. ≤ 50 mm, ≤ 2
  t shell
TRD 300
  opg dia t branch
  if ≤ 0.2, then
For dia of Opg > 50 mm, ≤ 2.
shell ID
opg dia tt shell
branch
if > 0.2, then
≠ 2.
shell ID t shell
 LIGAMENT EFFICIENCY
       
EFFICIENCY ASME IBR BS 1113

  P −d   P −d   P −d
Longitudional
P P P

    PC − d   PC − d   PC − d
Circumferential
PC PC PC

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

RD 300 gives lengthy equations for calculating the ligament efficiency factors. For a single opening,
σ ’all
di Aσ + A’ σ
σ all
VA = and for multiple openings,
σ ’all
SV 2 AP+ A’σ − A’ σ
σ all

σ ’all σ ”all
di Aσ 0 + Aσ 1 + Aσ 2
σ all
σ all
VL =
σ ’
all
σ ”all
DRUM / HEADERS - COMPARISON WITH VARIOUS CODES
         
DESCRIPTION IBR ASME SEC.I BS 1113 DIN TRD 300

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

         
Type of weld joint Single or double ‘U’ Double welded butt Double ‘V’ Type or Double ‘V’ type.
or ‘V’ type. type. The shape ‘U’ type.
shall be such as to
permit complete
fusion and
     complete joint    
Position of tube Allowed through penetration.
Any type of opening Machining of holes -----
holes welded seams, if that meets the through the centre
they are requirements for of main seam welds
radiographed and compensation may is permitted
stress relieved. be located in a provided the seam
The ligament welded joint. welds have been
   efficiency shall be    subjected to NDE.  
Circularity of Drum Difference
multiplied between
by a The drum shall be Maximum internal The average bore
internal diameter of
factor 0.95. circular within a diameter of drum shall not deviate by
drum shall not limit of 1% of mean shall not exceed the more than 1% from
exceed 1%. diameter based on nominal internal the nominal
the differences diameter by more diameter.
between maximum than 2%.
     and minimum mean    
Percentage 2 (d max. − d min.) D max. − D min.
diameters. D max. − D min. 2 (d max. − d min.)
deviation from X 100 X 100 X 100 X 100
circularity d max. + d min. d max. + d min.

    DS  DS    
Hand hole size in 89 x 63.5 89 x 70 ----- ------
Headers
          
DESCRIPTION IBR ASME SEC.I BS 1113 DIN TRD 300

         
Hydraulic test Drums & Headers ----- Drums & Headers -----
point - Shop & test greater than 1000 greater than 600
pressure. mm shall be mm shall be
hydraulic tested at hydraulic tested at
shop to 1.5 times shop to 1.5 times
the Design the max.
Pressure. permissible
       
working pressure.  
Wall thickness + 15% − 12.5% + 10% + 12.5%
tolerance for pipes − 5% − 10% − 10.0%
/ headers.  

         
Hydraulic test 1.5 times the Drum 1.5 times the 1.5 times the 1.3 times the
pressure at site. Design Pressure. maximum maximum maximum
allowable Working permissible allowable Working
Pressure. Working Pressure. Pressure.
         
Requirement of Two safety valves - Two or more safety Two safety valves. Two or more safety
Safety Valves. the bore not less valves. Minimum bore 20 valves.
than 19mm. mm.

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

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

         
Minimum Up to D32 - Up to D32 - Up to D38 - Min. - 3 mm
thickness 2.03 2.41 1.7 Max. - 6.3 mm
allowed for Up to D51 - Up to D51 - D38 to D51 - for Water wall
2.67
various tube 2.34 2.2 tubes
D51 to D76 -
Diameters - D51 to D76 - D51 to D70 -
3.05
Seamless. 2.64 D76 to D102 - 2.4
D76 to D89 - 3.43 D70 to D76 -
3.25 D102 to D127 - 2.6
  D89
 D to D114
Max. -
− D Min.  D − D Min.
3.81  D76 to D95 -  
Ovality 3.66 x x 3.0
2(DMax.−DMin.) Provides
(Deviation from 100 100 D95 to D102 - calculation for
circularity) D D 3.3
x100 wall thickness for
shall not exceed  shall not be DMax
D102 to+D127
DMin - inside & outside
more than  3.5 of bend as per
20D 50D TRD301 Annex-2.
%
R
         
Wall thickness + 10% R + 22% + 10% + 15%
tolerance − 5% − 0% − 10% − 10%
RELATIONSHIP BETWEEN ALLOWABLE STRESS, WEIGHT
AND SAVINGS IN WEIGHT
(TYPICAL 250 MW)
      Allowable Stress % Correspond
increase -ing
Sl. Item Materia Design Kg/mm2 in
in
No l Temp. allowable allowable
Specn. °C Stress Stress
ASME BS 1113

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

             
02. Downcomer SA106 357 11.993 13.570 13.0 9.8
s Gr.C

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

             
04. Economiser SA210 311 10.546 12.896 22.3 16.0
A1

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

IV) LINES & LINKS (BOILER INTEGRAL PIPING)

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

a) Discharge capacity 293

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

B. WATER GUAGES

a) Requirements 320 a, b.

VI) GENERAL

1) Procedure of Hydro test of boiler 379

2) Registration Fee 385
3) Submission of plans of boilers 393
4) Submission of plans of steam pipes 395
 IBR
BOILER & SH TUBES

Regn. 151: Tubes Cold drawn or hot finished

a) Seamless or ERW tubes

b) Tubes < 5” dia - can be used inside the boiler

> 5” dia - can be used outside the boiler

c) Flash welding allowed.

HEADERS MUD BOXES, ETC. OF WATER TUBE BOILERS

Regn. 154:

a) Headers Seamless or Welded steel or cast steel.

i) Where welded, the welding shall be stress relieved, radiographed or

UT.

ii) Headers may be closed by forging, bolting, screening or welding.

 MAIN HOLES

Regn. 164 (a): Hole size not less than 3½ x 2½ in.

PD
Regn. 187: Uncompensated hole - Maximum 203 mm =
1.82 fe
FUSION WELDED DRUMS

Regn. 244 (a): Tubes

Regn.244 (b): Pipes of boiler shall comply with Chapter VIII.

Regn.243 (a): Circularity of drum 1%.

2 (d max. − d min.)
Regn. 243 (b): Percentage deviation = x 100
from circularity (d max. + d min.)

d = internal dia

Regn. 249: Fully dimensioned sectional drawing showing in full

detail the construction of drum - Fully dimensioned
drawings of the proposed weld preparation of the main
seams to a scale - attachment, seatings, etc. to be
furnished.
Regn. 253: Drum - type of welded joint - Single or double ‘U’ or
‘V’ type.

Regn. 254: Longitudinal seams in successive rigs shall not fall

in line except where the rigs of drum are in two
halves of unequal thickness.

Regn. 255: Position of tube holes:-

Tube holes through welded seams, if they are

radiographed and stress relieved - The efficiency
and ligament multiplied by a factor 0.95 except the
distance from edge hole to edge of weld > 13mm
(½”).

Regn. 256: Circularity of drum:-

The difference between internal diameter of drum
shall not exceed 1%.

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

working pressure after completion of welding and
heat treatment of drum (internal dia > 1000 mm).
 2 f E (T − 0.03)
Regn.270: The working pressure - WP =
D + T − 0.03
Weld factor 0.95.

Regn. 271: For temperature at or below 454°C

Et R
(or)
1.5 2.7
For temperature above 454°C
Et SR
(or) (or) SC
1.5 1.5
In case SC valves are not available, the allowable stress may be
Et SR
lower of (or)
1.5 1.5
Regn. 272: The ligament efficiency as per Regn. 215.
P −d P − nd P P1
Diagonal and Curve
P P d P
Circumferential ligament.
 PD2
Regn. 273: Longitudinal Stress = fd =
1.273A
PD2
M=
1.273
MRY
The stress due to bending f b =
Ia

Regn. 275: Shape of Dished end plate

a) Hemispherical

b) Elliptical heads -H ⊇ 0.2D

c) Partial spherical heads - H ⊇ 0.18D.

Figures 23A, B, C.
Regn. 276: Gradual thinning up to a maximum of 10% of thickness
where the corner radius joins the dishing radius.

Regn. 277: Dished end with opening (inline with ISO).

d A
d1 = d −
√DT T

Regn. 278: Dished end plate maximum working pressure

2f (T − C)
WP =
DK (Shape factor)
Minimum head thickness - 5 mm.

Regn. 279: Reinforcement calculation.

Regn. 280: Attachments of Branch Pipes by welding.

Figures 24A to D, 26A to E, 27A to D.

 VALVES, GAUGES AND AUXILIARIES

Regn. 281: Every boiler shall be provided.

Two safety valves - one of which may be a high steam

and low water type, the bore not less than 19mm.

Two means of indicating water level.

a steam pressure gauge.

a steam stop valve.

a feed check valve.

one feed apparatus.

A blow down cock valve.

A manhole - A safety valve at the end of SH outlet.

New Regn.281A: Water level and or firing control.

SAFETY VALVES

Regn. 293: Discharge capacity.

Saturated steam E = CAP

E
Superheat steam ES =

1 + 2.7 TS
1000

Regn. 294: Over pressure of safety valves:

Where discharge area < 80% - Over pressure shall not exceed
10% of set pressure.

Where discharge area > 80% - Over pressure shall not exceed
5%.
Regn. 295: Pressure drop:

Reset at a pressure at least 2.5 below but not more than

5% below safety valve set pressure. The 5% limit
increased to 10% for valves having seat bore less than 32
mm and or having a set pressure of 2 bar gauge or less.

Regn. 296: Attachment to Boiler:

The axis valve shall be vertical. Branches shall be as short

as possible.

Regn. 320: Water Gauges:

Every boiler shall have two means of indicating the water

in it of which one shall be conventional gauge glass.
Minimum length of visible portion of gauge glass 200 mm.

b) For boilers > 10,000 lb/hr., one of water gauges may be of

remote water level indicator type.
BOILER AND SH TUBES, HEADERS

Regn. 338(a): 2f (T − C) C = 0.75 for P ≤ 70 Kg/m2

WP =
(D − T + C) = 0 for P > 70 Kg/m2

The working metal temperature.

ECO = The maximum water temperature + 11°C.

Furnace & boiler tubes = Sat. temperature + 28°C.

Convection SH =Maximum steam temperature + 39°C.

Radiant SH = Maximum steam temperature + 50°C.

For temperature at or below 454°C.

TS Et
(or)
2.7 1.5

For temperature above 454°C

SR or SC
1.5

If SC not available

Et SR
(or)
1.5 1.5

b) % Ovality = D max. − D min.

x 100
D
Regn. 340 (f): Flat ends for headers -

f (t − C)2
WP =
d2 K

Regn. 342: Cylindrical headers - As per Regn. 270.

End attachments - As per Regn. 340(f).

STEAM PIPES AND FITTINGS

Regn.343(1): Carbon steel, Cast steel, Alloy steel, cold or hot

finished, butt welded or ERW.

Regn. 343(2): Material used, the permissible stress figures

specified in the code may be accepted.
Regn. 343(3): The hydraulic test may be dispensed with if id ≤
600 mm.

Regn. 349: The temperature limits for pipes, Tees, branches,

etc. shall be as per Table-2.

Regn. 350: Working Pressure.

2fe (t − C)
WP = C = 0.75.
D −t + C
STEAM PIPE FITTINGS

Regn. 361(a): Pipe bends thinning 12.5%.

Regn. 361(A): Butt welding fittings.

Regn. 362(a): Branch welded to pipe Regn. 249 to 253. Angle not
less than 60°.

Regn. 362(b): External Reinforcement :

Multiple radial plates of horse shoe form or the form

of collars applied to or around the junction between
branch and main.
Regn. 374: Hydro test pressure in the piping system - 1.5 times the
design pressure.

REGULATIONS FOR THE REGISTRATION AND INSPECTION OF BOILERS

Regn. 379: Procedure of Hydro test.

Test pressure 1.5 times the maximum working pressure.

Temperature of water > 20 < 50°C.
Not exceeding 6% of the required pressure.

Regn. 385: Registration Fee:

Regn. 393: Submission of plans of boilers:

a) Drawing Approval.

b) & c) Boilers made outside India, Technical Advisor (Boilers)

and then CIB user state.
d) Scrutiny fees as per Regn. 385 subject to a
maximum of Rs. 20,000.

Alteration fee at 10% of the fee of the first

scrutiny fee.

Regn. 395: Submission of plans of steam pipes:

Rs. 30 for 30 meters minimum of Rs. 50.

Fittings like DESH, Separators, etc. Rs. 150

each.
Sl. DESCRIPTIO CLAUS REQUIREMENT AS PER ASME REMARKS
No. N E SEC.I 2001

1. Service PG-2 a)Boilers in which

Limitations steam/vapour is generated
at a pr. more than 15 PSIG

b)High temp. water boilers >

2. Plate PG-6 160 PSIG
Shall be oforpressure
250 Deg.F
vessel
material quality SA202; SA204;
SA240(Type 405 only) SA302;
387(A.S) SA285; SA299;
SA515; SA516 (C.S), SA / EN -
3. Pipes, Tubes PG-9 10028
PG 9.1 -for
2 boiler parts
materials materials
PG 9.1 & 9.2 for superheater
matrials
4. Boiler plate PG- The min. thickness of any
min.thick 16.3 boiler plate under pressure
shall be 1/4 in (6 mm)

5. Tubing PG- "Upto and including 5 inches

calculation 27.2.1 outside dia" (127mm)
t(inch)=PD/2S+P +0.005D+e

e = 0 for tubes strength

welded to headers
P = Max. allowable working
pressure(psi) D
= Outside dia(in)
Sl. DESCRIPTIO CLAU REQUIREMENT AS PER REMARK
No. N SE ASME SEC.I 2001 S

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

Drums and 27.2.2 = PR / SE - (1-y)P+ C E
headers = efficiency of liagament
calculation of weld joints
Y = temperature co-
efficient
7. Hemispheri PG- C = Min.
t = PL / 1.6S
cal head 29.11 allowance for threading L
and structural
= radius stability
to which formed(0)
head measured on concave
side R = Inside
8. 2:1 Semi- PG- t = PR / SE - (1-y)P + C
radius in
ellipsoidal 29.7
& R = Inside radius of
end cover
9. Max. Dia of PG-
PG- K Factor = PD / 1.82 St
opening in 27.2.2
32.1.2
shell & Max. dia of opening
without compensation as
10. Compensati PG - per FigofPG
Limits 32
reinforcement
PG-
on 37 &
32.1.3.2
Calulation PW - X = greater of 2d or 2(t
15 + tn) but not greater than
pitch Y = the smaller of 2
Sl.N DESCRIPTION CLAUS REQUIREMENT AS PER ASME REMARKS
o. E SEC.I 2001

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

allowable & fb =
stress for Sec.3. stress due to bending
drum 3.4 fd =
12. (Bending
Hydraulic and of
PGBS- Direct longitudinal
1.5 times the max. stress
allowable
Longi stress)
test pr. 1113
99.1 working pr. Calculate stress
at hydraulic test by
substituting in thick
formula.Stress at hydro to be
13. Min. weld PW - Check as per
leser than 90%Fig. PWstress
yield 16.1 at
size 16.1 100 deg. F.

14. Min. weld PG - 37 Combined strength of each

size path >min. weld strength
PW - required
15
15. Feed water PG - Boiler pr. 400 PSI or over the
connection 59.2 feed water inlet shall be
fitted with sleeves.
16. Blow - off PG - Boiler shall have a bottom
59.3.3 blow off outlet in the lowest
water space.
17. Water level PG - a) Two nos. gauge glass over a
indicator 60.1.1 boiler pr. Of 400 PSI b) Two
independent remote level
indicators instead of one gauge
glass in case of pr. above 900 PSI
c) The lowest visible part of
gauge shall be at least 2 in. above
Sl. DESCRIPTIO CLAU REQUIREMENT AS PER REMARK
No. N SE ASME SEC.I 2001 S

18. Water level PG - a) Connection to the gauge

indicator 60.1.6 glass shall not be less than
1/2" pipe size

b) Water gauge glass drain

not less than 1/4 in.
19. Pressure PG - Above 100connection
Pr. Gauge PSI pr. Drain
to
connects to safe discharge
gauges 60.6.1 the boiler shall not be less
point
than 1/2 in. Inside dia. for
steel pipe.
20. Test pr. PG- Connection to the test pr.
Gauges 60.6.3 gauge shall be at least 1/4
in. pipe size

21. Feed water PG-61 a)Boiler having more than

supply 500 sq. ft. of water
heating surface shall have
two means of feeding
water b) The feed
connection shall not be
less than 3/4" pipe size for
water heating surface
Sl. DESCRIPTIO CLAUS REQUIREMENT AS PER ASME REMARKS
No. N E SEC.I 2001

22. Boiler safety PG- Boiler with water heating

valve reqts 67.1 surface exceeding 500 sq.
ft. and steam generating
capacity exceeding 4000
lb/hr two or more safety
PG- a) one or more safety valves
valves are required.
67.3 shall be set at or below
max. allowable working pr.
B)The
highest pr. Setting shall not
PG - exceed 3% of valve
c) The safety the max.
will
67.2 allowable working pressure
discharge all the steam
generated by the boiler
without allowing the pr. to
rise more than 6% above
PG- max. allowablecapacity
The discharge workingof
68.2 pressure.
the safety valve on the
boiler is at least 75% of the
aggregate value capacity
required
23. Drain, vents PG - Piping connections for items
provisions 58.3.7 such as drains, vents for a
high temp. Boiler.
 SALIENT CLAUSES OF BS-1113-1990
  SECTION –2 MATERIALS AND DESIGN STRESSES

2..1.2 MATERIALS FOR PP.

 
BS MATERIALS OR AGREED BETWEEN MANUFACTURER
AND PURCHASER
 
 
2.2 DESIGN STRESSES
 
2.2.3 FOR C, C-Mn AND LOW ALLOY STEELS
 
FE = Re (T)/1.5 OR Rm /2.7 WHICHEVER GIVES A LOWER
VALUE.
 
2.2.4 FOR AUSTENTIC STEEL
 
FE = Re (T)/1.35 OR Rm /2.7 WHICHEVER GIVES A
LOWER VALUE.
2.2.7 DESIGN TEMPERATURE

2.2.7.1 DRUMS AND HEADERS

NOT HEATED BY GAS - EQUALS FLUID TEMP.

HEATED BY GAS - ADD 25 ° C.

2.2.7.2 BOILER TUBES

SUBJECT TO RADIANT HEAT -- SAT TEMP. + 50 ° C.

NOT SUBJECT TO RADIANT HEAT -- SAT TEMP. + 25 °

C.

2.2.7.3 SH & RH TUBES

SUBJECT TO RADIANT HEAT -- SAT TEMP. + 50 ° C.

NOT SUBJECT TO RADIANT HEAT -- SAT TEMP. + 35 °

C.

2.2.7.4 ECONOMIZER TUBES

SECTION –3 DESIGN

3.3.4 COMBINED STRESSES IN DRUMS AND HEADERS.

TO BE BROUGHT IN PLACE OF REG.73 OF IBR

3.3.1 MINIMUM 9.5 mm THICK FOR HEADERS OF OD 300 mm AND

ABOVE.

3.3.2 MINIMUM 6 mm THICK FOR HEADERS UPTO OD 300 mm

t = PDi / 2 f n - P

3.3.3.1. MAX DIA OF UNREINFORCED OPENING 200 mm.

3.6.1 DISHED ENDS

TORI AND SEMI ELLIPSOIDAL DISHED ENDS.

3.6.1.2 t= PDOK/2f

MINIMUM THICKNESS OF DISHED ENDS TO BE 9.5 mm.

3.6.1.3.1 UNREINFORCED OPENINGS

OPENINGS NOT TO BE GIVEN IN D/10

AREA.

3.7.2 TUBES AND PIPES

3.7.2.1 t = P do/2f + P.

MINIMUM THICKNESS TO AS UNDER

UPTO 38 MM OD 1.7
38 TO 51 MM OD 2.2
51 TO 70 MM OD 2.4
70 TO 76 MM OD 2.6
76 TO 95 MM OD 3.0
95 TO 102 MM OD 3.3
102 TO 127 MM OD 3.5
 SECTION 4 MANUFACTURE AND WORKMANSHIP

4.2.2.5.1 PLATES CAN BE BUTT WELDED PRIOR TO

FORMING PROVIDED WELD IS NDT EXAMINED.

4.2.2.5.2 OUT OF ROUNDNESS NOT TO EXCEED 1 % OF

NOM INTERNAL DIA.

4.3.1.1.6 LONGITUDINAL DRUM SEAMS TO BE WELDED

BEFORE CIRCUMFERENTIAL SEAMS AND WHRE
PRACTICABLE THE LONGITUDINAL SEAMS OF
ADJACENT COURSES SHALL BE STAGGERED.

4.3.1.1.7 HOLES CAN BE MACHINED THROUGH THE SEAMS

AFTER SEAM HAS BEEN NDT EXAMINE PRIOR TO
PWHT.
 SECTION 5 INSPECTION AND TESTING

5.10.1.1 HYDROSTATIC TEST PRESSURE

5.10.2.1 HYDRO TEST PRESSURE OF BOILER 1.5 TIMES

THE MAX WORKING PRESSURE.

DRUMS AND CYLINDRICAL HEADERS GREATER

THAN 600 MM SHALL BE HYDROSTATICALLY
TESTED AT SHOP.

5.10.3.1 ALL COMPONENTS NOT REASONABLY

ACESSIBLE TO INSPECTION AFTER ASSEMBLY
TO BE HYDROTESTED AT SHOP.
 SECTION 7 VALVES, GUAGES AND FITTINGS

7.2 SAFETY VALVES

7.2.1.1 MINIMUM BORE 20 mm

7.2.1.2 FOR EVAPOTATION UPTO 3700 KG/H ONE

SAFETY VALVE FOR GREATER
EVAPORATION TWO SAFETY VALVES

7.2 WATER LEVEL GUAGE

EACH BOILER TO HAVE TWO INDEPENDENT

MEANS OF WATER LEVEL INDICATION.