CHAPTER : I

Reg.1 Reg.2 Reg.3 Reg.3A Reg.4 Reg.4A Reg.4B Reg.4C Reg.4D Reg.4E Reg.4F Reg.4G Reg.4H Reg.5 Reg.5A Reg.6 Reg.7 Reg.8 Reg.9 Reg.10 Reg.11 Reg.12 Reg.13 Reg.13A Reg.14 Reg.15 Reg.16

Short Title, Extent, Application and Commencement Definitions General Requirements, Applications of Standard Conditions and Expectations thereto Inspection of Boiler to comply into any foreign code Standard Requirements-Material, Construction, Inspecting Authority's Certificates and Maker's Stamp 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 Appeal Function of Evaluation committee Modification of Formulae Material not fully identified Standard Specifications for Materials Boiler Shells not in Accordance with Standard Conditions Use of Welding Process of manufacture Chemical Analysis Freedom from defects, etc Rolling Margin Testing and Inspecting. Designate steel Selection of test pieces Tensile Test pieces Tensile tests

Reg.17 Reg.18 Reg.19 Reg.20 Reg.21 Reg.22 Reg.23 Reg.24 Reg.25 Reg.26 Reg.27 Reg.28 Reg.29 Reg.30 Reg.31 Reg.32 Reg.33 Reg.34 Reg.35-1 Reg.35-2 Reg.35-3 Reg.36 Reg.37 Reg.38 Reg.39 Reg.40 Reg.41 Reg.42 Reg.43 Reg.44

Number of Tensile Tests Dump Tests Bend Tests Number of Bend Tests Manufactured Rivets Additional tests before rejection Branding Defacing of rejected material Facilities for inspection Steel not produced where rolled Makers Certificate Rivet Bars Manufactured Rivets Tests Stay Bars Stay Bars - Bend Tests Special Iron for Screw Stays for Fire-boxes and Combustion Chambers Plates Stay and Rivet bars Copper Tubes Brass Tubes Carbon steel tubes Material process Selection of Tubes for Test Tensile and Hardness Tests Flattening Test Expanding or flaring test Additional test before rejection Hydraulic Test Material Tensile, Bend and Flattening tests

Reg.45 Reg.46 Reg.47 Reg.48 Reg.49A Reg.49B Reg.49C Reg.50 Reg.51 Reg.52 Reg.53A Reg.53B Reg.53C Reg.53D Reg.54A Reg.54B Reg.54C Reg.55 Reg.56 Reg.57 Reg.58 Reg.59 Reg.60 Reg.61 Reg.62 Reg.63 Reg.63A Reg.73 Reg.74 Reg.75

Additional tests before rejection Hydraulic Test General Material Tensile and Hardness Tests Flattening Test Expanding or flaring test Additional tests before rejection Hydraulic test. General Material Heat treatment Workmanship and tolerance Selection of Tubes for testing Tensile Test Bend Test Flattening Test Additional tests before rejection Hydraulic Test General Material Flattening & Flaring test Tensile Test Hydraulic test Test specimens Number of tests Material Scope Process of manufacture Freedom from all rectification of defects

Reg.76 Reg.77 Reg.78 Reg.79 Reg.80 Reg.81 Reg.82 Reg.83 Reg.84 Reg.85 Reg.86 Reg.87 Reg.88 Reg.89 Reg.90 Reg.91 Reg.92 Reg.93 Reg.94 Reg.95 Reg.96 Reg.97 Reg.98 Reg.98A Reg.99 Reg.100 Reg.101 Reg.102 Reg.103 Reg.104

Number of tests Tensile Test Bend tests Additional tests before rejection Procedure for Welding Forged or rolled pressure parts Selection of test pieces Tensile strength Bend Tests Additional tests before rejection General grey iron casting (Grade A) Provision of test bars Dimension of test bars Mechanical test Transverse test Tensile test Number of transverse and tensile tests Additional Tests General requirements Requirements for Normal Penetration Electrodes Requirements for Deep Penetration Butt-Welding Electrodes Requirements for Deep Penetration Fillet Welding Electrodes Periodic Check Test Filler rods for gas welding of steel Preparation of Plates Normalizing of certain steel plates Minimum thickness of Plates Cylindrical Shells Position of Longitudinal Seams Circumferential and End Seams

Reg.105 Reg.106 Reg.107 Reg.108 Reg.109 Reg.110 Reg.111 Reg.112 Reg.113 Reg.114 Reg.115 Reg.116 Reg.117 Reg.118 Reg.119 Reg.120 Reg.121 Reg.122 Reg.123 Reg.124 Reg.125 Reg.126 Reg.127 Reg.128 Reg.129 Reg.129A Reg.130 Reg.131 Reg.132 Reg.133

Angle Rings Thickness of Shell Angle Rings Welded Shell Plates Longitudinal Seams Butt Straps Thinning of Butt Straps Alternative Construction Local Welding of Butt Seams 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 Flanging of End Plates 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 in Copper Fire Boxes Bar Stays Longitudinal Stays Nuts and Washers for Stays Jointed Stays

Reg.134 Reg.135 Reg.136 Reg.137 Reg.138 Reg.139 Reg.140 Reg.141 Reg.142 Reg.143 Reg.144 Reg.145 Reg.146 Reg.147 Reg.148 Reg.149 Reg.150 Reg.151 Reg.152 Reg.153 Reg.154 Reg.155 Reg.156 Reg.157 Reg.158 Reg.159 Reg.160 Reg.161 Reg.162 Reg.163

Diagonal Bar or Rod Stays Screwed Stays Axial drilling Stay Nuts Spacing of End Stays Allowance for curves, etc. Girder Stays for Firebox and Combustion Chamber Crowns Gusset Stays Breathing Space Gussets Angles Load on Gusset Stay Gusset Riveting Steel and Wrought Iron Tubes Fitting of Plain Tubes Screw Threads of Stay Tubes Stay Tubes Thickened ends of Stay Tubes Load on Stay Tubes Steel Tubes Attachment of Steel Tubes Copper Tubes Headers, Mud Boxes, etc., of Water Tube Boilers Stand Pipes and Pads Design of stand pipes Pressed Plate Saddles Seating for Mountings Attachment of Mountings Insufficient thickness of End Plates Attachment of Water and Pressure Gauges Mountings on Flat Plates Bolts and Nuts

Reg.164 Reg.165 Reg.166 Reg.167 Reg.168 Reg.169 Reg.170 Reg.171 Reg.172A Reg.172B Reg.172C Reg.173 Reg.174 Reg.175 Reg.176 Reg.177 Reg.178 Reg.179 Reg.180 Reg.181 Reg.182 Reg.183 Reg.184 Reg.185 Reg.186 Reg.187 Reg.188 Reg.189 Reg.190

Access Compensating Rings and Frames for Openings in Shells Doors and Cross Bars Raised Manhole Frames and Cover Plates Position of Manhole in Shell Compensation Rings to Manholes Compensation for cutting large holes in Shell Type Boilers Rivets securing compensating rings and Stand Pipes Rivet Heads Tolerances on shanks Rivet Holes Riveting Fullering and Caulking Maximum pressure 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 of rivets Circumferential and End Seams of Water Tube Boilers Compensation for Manholes and other openings Uncompensated holes in Water Tube Boilers Complete hemisphere without stays or other support made of one or more plates and subject to internal pressure Dished ends subject to internal pressure Dished ends subject to external pressure

Reg.191 Reg.192 Reg.193 Reg.194 Reg.195 Reg.196 Reg.197 Reg.198 Reg.199 Reg.200 Reg.201 Reg.202 Reg.203 Reg.204 Reg.205 Reg.206 Reg.207 Reg.208 Reg.209 Reg.210 Reg.211 Reg.212 Reg.213 Reg.214 Reg.215 Reg.216 Reg.217 Reg.218

Dished ends of Lancashire and Cornish Type Boilers Dished shell and firebox crowns Flat plates supported by solid screwed stays, marginal seams or flanges 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, etc., supported only at edges Bar or bulb stiffened end plates and smoke-box tube plates of Loco-type boilers Flat plate margins Manholes and Mudholes in Flat Plates Solid screwed stays Stresses in steel jointed stays Stay Tubes Stays in tension and compression Measurements of stayed areas in the end plates of Locotype and Vertical Boilers Gusset Stays Bolts and Studs Compression of tube plates Parts to be stayed Minimum thickness and cross-section Holding power of plain tubes Tubes plates, other than ends of vertical boilers forming parts of outer shell Curved tube plates of water-tube boilers Efficiency of Ligament Boiler and Superheater Tubes Subject to Internal Pressure Headers and Section Boxes of Water Tube Boilers Boiler Tubes (Smoke) Subject to External Pressure

Reg.219 Reg.220 Reg.221 Reg.222 Reg.223 Reg.224 Reg.225 Reg.226 Reg.227 Reg.228 Reg.229 Reg.230 Reg.231 Reg.232 Reg.233 Reg.234 Reg.235 Reg.236 Reg.237 Reg.238 Reg.239 Reg.240 A Reg.240 B Reg.240 C Reg.240 D Reg.240 E Reg.241 Reg.242 Reg.243

Brass and Copper Tubes 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 Foundations of Vertical Boiler Furnaces Foundations of Loco-type Boiler Fireboxes Cross Tubes Uptakes of Vertical Boilers Girder stay for firebox crowns Marshall Type Garrett Type Fowler Type Fusion Welded and Seamless Forged Drums for Water Tube Boilers and Super Heaters Materials of Construction Seamless Forged Drums Chemical Analysis Freedom from defects Heat Treatment Mechanical Tests Selection of Test Pieces Tensile test pieces Tensile test Bend test pieces Bend Tests Additional tests before rejection Discard Forging

Reg.243 A Reg.244 A Reg.244 B Reg.245 Reg.246 Reg.247 Reg.248 Reg.249 Reg.250 Reg.251 Reg.252 Reg.253 Reg.254 Reg.255 Reg.256 Reg.257 Reg.258 Reg.259 Reg.260 A Reg.260 B Reg.261 Reg.262 Reg.263 Reg.264 Reg.265 A Reg.265 B Reg.265 C Reg.265 D Reg.266 A Reg.266 B

Tolerance Tubes, Pipes in Boilers, Headers and Steel Castings Pipes Headers Steel Castings Fusion Welded Drums Equipment of Workshop Constructional details and preparation for welding Preparation of plates Cylindrical shells of drums Method of making welded joints Type of welded joints Number of joints Position of the Tube holes Circularity of drums Mechanical test and test plates for fusion welded seams Selection of Test Pieces* Tensile Test Pieces Tensile Tests All-weld Metal Bend Test Pieces Bend Tests Notched-Bar Impact Tests Additional tests before rejection Non-Destructive Tests Radiographical Examination Magnetic particle flaw detection Dye-Penetrant flaw detection General Longitudinal Seams

Reg.266 C Reg.266 D Reg.266 E Reg.266 F Reg.266 G Reg.266 H Reg.266 I Reg.267 A Reg.267 B Reg.267 C Reg.267 D Reg.267 E Reg.267 F Reg.267 G Reg.268 Reg.269 Reg.270 Reg.271 Reg.271 A Reg.271 B Reg.272 Reg.273 Reg.274 Reg.275 Reg.276 Reg.277 Reg.278

Circumferential Seams Removal of Defects Examination before Re-welding Process used for Repairs Radiographical Examination after Repairs Specimen Representing Repairs Diagram of Welded Repairs Heat Treatment Heat Treatment Heat Treatment Heat Treatment Heat Treatment Heat Treatment Heat Treatment Hydraulic test at makers works Inspection and Testing Shells Permissible working stresses for shells of Boiler and Integral Super-heater Drums and Headers Permissible working stresses for shells of Boiler and Integral Super-heater Drums and Headers Permissible working stresses for shells of Boiler and Integral Super-heater Drums and Headers Fusion Welded and Seamless Forged Drums for Water Tube Boilers and Super Heaters Longitudinal Stress Intermediate Boiler Drum Supports Shape of Dished End Plate General Dished End with Opening End Plate subject to pressure on the concave side

Reg.279 A Reg.279 B Reg.279 C Reg.280 Reg.281 Reg.281 A Reg.282 A Reg.282 B Reg.282 C Reg.283 Reg.284 Reg.285 Reg.286 Reg.287 Reg.288 Reg.289 Reg.290 Reg.291 Reg.292 Reg.293 Reg.294 Reg.295 Reg.296 Reg.297 Reg.298 Reg.299 Reg.300 Reg.301 Reg.302 Reg.303

Standpipes and Nozzles Standpipe and nozzles welded to dished end plates Minimum thickness of Flanges Attachment of Stand blocks and Branch Pipes by Welding Requisite Mountings, Fittings and Auxiliaries Additional requirements for automatic boilers only General Requirements Limits of cast Iron Limits of copper alloy Method Of Construction Packing of Cocks Covers and Spindles Direction of Operation Moving Parts Flanges Valve Seatings Chests etc., in General Special Requrements Definition Minimum Aggregate Area Over pressure of Safety Valves Pressure Drop Attachment to Boiler Opening in Shell Discharge Passage Drainage Moving Parts Bearings for Levers Attachments of weights and Springs Easing Gear

Reg.304 Reg.305 Reg.306 Reg.306 A Reg.307 A Reg.307 B Reg.308 Reg.309 Reg.310 Reg.311 Reg.312 Reg.313 Reg.314 Reg.315 Reg.316 Reg.317 Reg.318 Reg.319 Reg.320 Reg.321 Reg.322 Reg.323 Reg.324 Reg.325 Reg.326 Reg.327 Reg.328 Reg.329 Reg.330 Reg.331

Lift High and Low water Alarms Final Settings Adjustment of safety valve set pressure Springs And Torsion Bars Torsion Bars Dimensions Determination of Working Pressure Test Extension Springs Number of Effective Coils Spacing of Coils Finishing of Ends Lever Valves Steam Stop Valve Blow-Down Cock Or Valve And Pipes Blow-down Mountings Blow-down Valve or Cock Water Gauges Drains Protectors Glass size Safety Devices Gauge columns Isolating Cocks Pressure Gauges Connections Gauge Cocks Test Connections-Inspectors Pressure Gauge Attachment Fusible Plugs

Reg.332 Reg.333 Reg.334 Reg.335 Reg.336 Reg.336 A Reg.337 Reg.338 Reg.339 Reg.340 Reg.341 Reg.342 (a) Reg.342 (b) Reg.343 Reg.344 Reg.345 Reg.346 Reg.347 (a) Reg.347 (b) Reg.347 (c) Reg.347 (d) Reg.347 (e) Reg.347 (f) Reg.348 Reg.349 Reg.350 Reg.351 Reg.352 Reg.353 A Reg.353 B

Type Material Attachment to Boiler Feed Valves Operating position Requirements as to feed apparatus in certain cases Material and Construction Boiler and Super Heater Tubes, Headers and other Pressure Parts Tubes Materials and Construction Rectangular Headers Symmetrical in Form Headers Irregular in Form Cylindrical Headers End Attachments Pipes Material Condition of Pipes Mechanical Tests Flattening test (for pipes up to and including 102 mm. (4 in.) Nominal bore) Cold bend test (for pipes over 102 mm. (4in.) Nominal bore) Bend test on the weld Additional test Tensile test Steam-Pipes and Fittings Method of manufacture, Heat treatment and Marking Steam-Pipes and Fittings Steel Pipes Cast Steel Pipes Copper Pipes Flanges Flanges of Alloy Steel Pipes

Reg.353 C Reg.354 Reg.355 Reg.356 Reg.357 Reg.357 C Reg.358 Reg.359 Reg.360 Reg.361 Reg.361 A Reg.362 A Reg.362 B Reg.362 C Reg.363 Reg.364 Reg.365 A Reg.365 B Reg.365 C Reg.365 D Reg.365 E Reg.365 F Reg.366 Reg.366 B Reg.366 C Reg.366 D Reg.367 Reg.368 Reg.369

Non-Ferrous Flanges Screwed on Flanges Loose Flanges Riveted on Flanges Welded on flanges Heat treatment after welding Flanges of copper pipes Standard Flanges Joints Wrought Bends Butt-welding fittings Branches, Bosses and Drain pockets External reinforcement Thickness where no external reinforcement is provided Blowdown pipes Valves Chests Steam Receivers, Separators, Catch Waters, Accumulators and Similar Vessels Construction and Workmanship Access to shells Compensating Rings to Opening and Doors Branches and other Connections Shell Joints Determination of Working Pressure End Plates Branches Inspection during construction Steel Screwed and Socketed Joints and Mountings of Steel Bronze Screwed and Socketed joints and mountings and fittings of bronze Reducing Valve

Reg.370 Reg.371 Reg.372 Reg.373 Reg.374 Reg.375 Reg.376 Reg.377 Reg.378 Reg.379 Reg.380 Reg.381 Reg.382 Reg.383 Reg.384 Reg.385 Reg.386 Reg.387 Reg.387 A Reg.388 Reg.389 Reg.390 Reg.390 B Reg.390 C Reg.390 D Reg.390 E Reg.390 F Reg.390 G Reg.390 H

Flexibility Pipe work supports Drainage Freedom from rust and other foreign matter Steam-Pipes and Fittings Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Preparation for Inspection Hydraulic test of boilers for registration Preparation for hydraulic tests Procedure of hydraulic tests Steam tests Procedure for registration Engraving of registry number Measurement of heating surface Boiler rating Registration fee Memorandum of Inspection Book Registration Book Maintenance of Records Transfer of Memorandum of Inspection Book and Registration Book Grant of certificate Procedure for inspection of installed boilers Scale Oils, etc Corrosion, Grooving Stays Manholes and other Openings Fire Surfaces.-Bulging, Blistering, Leaks Lap Joints, Fire Cracks Testing Staybolts

Reg.390 I Reg.390 J Reg.390 K Reg.390 L Reg.390 M Reg.390 N Reg.390 O Reg.390 P Reg.390 Q Reg.390 R Reg.391 Reg.391 A Reg.392 Reg.392 A Reg.392 B Reg.392 C Reg.392 D Reg.392 E Reg.392 F Reg.392 G Reg.392 H Reg.392 I Reg.392 J Reg.392 K

Tubes -Their defects, etc Ligaments between tube holes Steam Pockets Pipe Connections and Fittings Water column Baffling-Water tube boilers Localization of heat Suspended boilers-Freedom of expansion Safety Valves Steam Gauges Calculation of Wasted Shell Aging of boilers Repairs to boilers and steam pipes Repairs to boilers and steam pipes Welding Riveting and Other Repairs Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes

Reg.392 L Reg.392 M Reg.392 N Reg.392 O Reg.392 P Reg.393 Reg.394 Reg.395 Reg.395 A Reg.395 B Reg.395 C Reg.395 D Reg.395 E Reg.395 F Reg.395 G Reg.397 Reg.398 Reg.399 Reg.400 Reg.401 Reg.402 Reg.403 Reg.404 Reg.405 Reg.406 Reg.407

Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Regulations for the Registration of Boilers and Inspection of Boilers and Steam-Pipes Inspections of Steam Pipe Submission of plans of steam-pipes Inspection fee for boilers and parts thereof constructed in India Fees for inspection of Pipes Fee for inspection of valves Fees for inspection of components of valves Fees for inspection of feed water heaters and other fittings Marking Fee for inspection of spares and scantlings Electrode Boilers Electrode Boilers Electrode Boilers Riveted Steel Boilers Working Pressure of Shells Strength of Riveted Joints Thickness of Butt-Straps Maximum pitch of rivets in Longitudinal Joints Spacing of rows of rivets End and Circumferential Seams Manholes and other openings in Shells

Reg.408 Reg.409 Reg.410 Reg.411 Reg.412 Reg.413 Reg.414 Reg.415 Reg.416 Reg.417 Reg.418 Reg.419 Reg.420 Reg.421 Reg.422 Reg.423 Reg.424 Reg.425 Reg.426 Reg.427 Reg.428 Reg.429 Reg.430 Reg.431 Reg.432 Reg.433 Reg.434 Reg.435 Reg.436

Dished End Plates with pressure on concave side Seating for Mounting Flange-Thickness and Drilling Pads Unstayed Flat-End Plates Thickness of Angle Rings Bolts, Nuts and Studs Hydraulic Test Construction and Workmanship Selection of Test pieces Tensile test Bend Test Nick Break Test Retests 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 Dished End Plates with pressure on Concave side Unstayed Flat End Plates Thickness of Angle Rings Tests for Class II Fusion Welded Seams Tests for Class II Fusion Welded Seams Hydraulic Test Determination of Working Pressure End Plates Manholes and other opening in the Shells

Reg.437 Reg.500 Reg.501 Reg.502 Reg.503 Reg.504 Reg.505 Reg.506 Reg.507 Reg.508 Reg.509 Reg.510 Reg.511 Reg.512 Reg.513 Reg.514 Reg.515 Reg.516 A Reg.516 B Reg.517 Reg.518 Reg.519 A Reg.519 B Reg.519 C Reg.519 D Reg.519 E Reg.519 F Reg.519 G Reg.519 H Reg.519 I

Mountings, Fittings and Connections (For all types of Electrode Boilers) Application of standard conditions and exceptions thereto General requirements Modification of formula Makers Certificates for Steel Economisers Hydraulic test for new economisers Workmanship and manufacture Process of manufacture Test bars Number of tensile tests Standard test piece Cast Iron Economisers Joint bolts and studs for Cast Iron Economisers Economiser water outlet temperature Tubes: Construction Tubes: Working Pressure Headers: Construction Working Pressure Cylindrical headers Attachment of tubes to headers Joint bolts, studs and flanges Valves and Mountings Relief valves Pressure Gauge Air Release valves Below off drain valves Non-return valves in return feed line Reserve Flues Explosion Doors Hydraulic Test

Reg.519 J Reg.519 K Reg.520 Reg.521 Reg.522 Reg.523 Reg.523 A Reg.523 B Reg.523 C Reg.524 Reg.525 Reg.526 Reg.527 Reg.528 Reg.529 A Reg.529 B Reg.530 Reg.531 Reg.532 Reg.533 Reg.534 Reg.534 A Reg.534 B Reg.535 Reg.536 Reg.536 A Reg.537 Reg.538 Reg.539 A Reg.539 B

Feed Line Non-return valve Feed Pipes Steel feed pipes Cast Iron feed pipes Copper feed pipes Feed Heaters and similar vessels fitted to feed pipes Working Pressure Safety valve requirement in Feed Heaters and similar vessels Regulations for Registration and Inspection of Economisers and Feed Pipes Procedure for Registration Procedure at subsequent inspection Procedure for Hydraulic test Memorandum of Inspection Book Registration Books Transfer of Memorandum of Inspection Book and Registration Books Grant of certificate Casual visits Economiser rating Registration fee Engraving of registry number Inspection of Feed Pipes Submission of plans of Feed Pipes Shell type Boilers of Welded Construction General Requirements Equipment of Workshop Materials of Construction Covered Electrodes Plain and Stay Tubes Seamless Steel Crosstubes and uptake Tubes

Reg.540 Reg.541 Reg.542 Reg.543 Reg.544 Reg.545 Reg.546 Reg.547 A Reg.547 B Reg.547 C Reg.547 D Reg.548 Reg.549 Reg.550 Reg.551 Reg.552 Reg.553 Reg.554 Reg.555 Reg.555 A Reg.555 B Reg.555 C Reg.555 D Reg.555 E Reg.555 F Reg.555 G Reg.556 Reg.557 Reg.558 Reg.559

Construction and Workmanship Preparation of Plates Stress Relieving Cylindrical Shells Circularity End Plates, Crown Plates and Tube Plates Internal Flues Fireboxes and Combustion Chambers Hemispherical fireboxes Loco-type fireboxes Water-cooled combustion chambers Uptakes Cross Tubes Bar stays and Firebox stays Girder stays for Firebox and Combustion Chamber Crowns Gusset stays Access Manhole frames, mouthpieces and doors Seatings for mountings Standpipes Saddles Pads Attachment of Standpipes Tensile Tests Attachment of water and pressure gauges Bolts and Nuts Compensating plates Definition of the terms Fusion Weld Method of Welding Types of welded shell seams

Reg.560 Reg.561 A Reg.561 B Reg.561 C Reg. 561 D Reg.562 Reg.563 Reg.564 Reg.565 Reg.566 Reg.567 Reg.567 A Reg.568 Reg.569 Reg.570 Reg.571 Reg.571 A Reg.571 B Reg571 C Reg571 D Reg.572 Reg.573 Reg.574 Reg.575 Reg.576 Reg.577 A Reg.577 B Reg.578 Reg.579 A Reg.579 B

Repairs to welded seams Tests on welded seams Test for Class I boilers Test for Class II Boilers Test for Class III boiler Shell type Boilers of Welded Construction Classification of Fusion-Welded Boilers Shells Horizontal shelves of tube plates forming part of the shell Dished end plates for Lancashire and Cornish boilers Dished ends subject to internal pressure Dished ends subject to internal pressure Dished ends subject to external pressure Hemispherical crowns Manholes and other openings in shells Compensation for openings in shells Area to be compensated Compensating area Compensating plates Compensation for openings in shells Raised manhole frames, cover plates and joint bolts Shell type Boilers of Welded Construction Stayed Flat surfaces (other than Crowns of Vertical Boilers). Flat crown plates for vertical boilers Wide water spaces between and around tube nests Flat tube plates and tube nests Parts of flat plates within tube nests Manhole openings in flat plates Plain tubes Plain tubes

Reg.579 C Reg.579 D Reg.580 Reg.581 Reg.582 Reg.583 Reg.584 Reg.585 A Reg.585 B Reg.586 Reg.587 Reg.588 Reg.589 Reg.590 Reg.591 Reg.591 A Reg.591 B Reg.591 C Reg.591 D Reg.591 E Reg.592 Reg.593 Reg.594 Reg.595 Reg.596 Reg.597 Reg.598 Reg.599 Reg.600 Reg.601

Plain tubes Plain tubes Pitch of tubes Stay tubes Compression of tube plates Girders for fire-box and combustion chamber crowns Girder sling stays Stays for fire-boxes and circular furnaces Circumferential stays for circular furnaces and fire-bo Fire-box Crown stays for Loco-type Boilers Longitudinal Bar Stays Loads on Stay Tubes and Bar Stays Flat Plate Margins Breathing space Gusset Link, Brace and Similar Stays Load on each stay Gusset plates Link stays Anchor plates angles, link pins and the line members Weld attachment Shell type Boilers of Welded Construction Plain Furnaces of Vertical Boilers Corrugated Fireboxes of Vertical Boilers Hemispherical Furnaces of Vertical Boilers Foundations of Vertical Boilers Furnaces Foundations of Loco-type Boiler Fireboxes Uptakes of Vertical Boilers Cross Tubes Pads Welded to shell or the attachment of Flanged Mountings Shell type Boilers of Welded Construction

Reg.602

Qualification Tests for Welders Engaged in Welding of Boilers and SteamPipes under Construction, Erection and Fabrication at Site in India and in Repairing Boilers and Steam-Pipes by Weldingt Definition Engaging of Certified Welders Initial Issue of duplicate certificate Production of certificate Validity of certificate Re-validation of certificate Validity of certificate Age and experience Tests for initial qualification of a welder Tests for Requalification Examination of test specimens for initial qualification tests Fillet welded plate specimens Groove and fillet welded pipe and tube specimens Welded Tube Joints Additional tests before rejection Examination of Test Specimens for Requalification Tests Awarding of Marks Award of Certificate Maintenance of records Fees for examination of welders Penalty Small Inductrial Boilers General Definition Extent to which variation from the standard conditions laid down in the preceding Chapters is permissible Valves, Gauges, Fittings and Feed Supply Registration, Operation and Maintenance

Reg.603 Reg.604 Reg.605 Reg.605 A Reg.606 Reg.607 A Reg.607 B Reg.607 C Reg.608 Reg.609 Reg.610 Reg.611 A Reg.611 B Reg.611 C Reg.611 D Reg.611 E Reg.612 Reg.613 Reg.614 Reg.615 Reg.616 Reg.617 Reg.618 Reg.619 Reg.620 Reg.621 Reg.622

Reg.623 Reg.624 Reg.625 Reg.626 Reg.627 Reg.628 Reg.629 Reg.630 A Reg.630 B Reg.630 C Reg.630 D Reg.631 Reg.632 Reg.633 Reg.634 Reg.635

Feed Water for Boiler Requirements Sampling Test Methods Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted

Reg. 1 Short Title, Extent, Application and Commencement:

1) 2)

These Regulations may be called the Indian Boiler Regulations, 1950. They extend to the whole of India, except the State of Jammu and Kashmir.

2a) These Regulations generally apply to:(i) all boilers, including those working on the principles of natural circulation, forced circulation and forced flow with no fixed steam water line, and (ii) to steam pipes. 3) They shall come into force at once

Reg. 2 Definitions In these Regulations, unless the context otherwise requires a) b) the Act means the Indian Boilers Act, 1923: Accident means an explosion of a boiler or steam-pipe or any damage of a boiler or steam-pipe, which is calculated to weaken the strength thereof so as to render it liable to explode: Boiler means any closed vessel exceeding 22.75 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, which is wholly or partly under pressure when steam is shut off: Calculation Pressure, in relation to a boiler, 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; Chief Inspector and Inspector means, respectively, a person appointed to be a Chief Inspector and an Inspector under the Act: Competent Authority means an authority recognised by the Central Boilers Board in the manner as laid down in regulation 4A to 4H, as competent to issue certificates to welders for the purposes of regulation 4(b)(ii) and regulation 605; "Design Pressure" means:(i) in relation to a natural or assisted circulation boiler, the

c)

cc)

d)

dd)

ddd)

maximum allowable working pressure in the steam drum of the boiler; (ii) in relation to a once through forced-circulation boiler, the maximum allowable working pressure at the final superheater steam outlet; 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: Evaluation Committee means a committee constituted by the Central Government consisting of :(a) Technical Adviser (Boilers) (b) Chief Inspector (Boilers) of the State where the unit is located : Chairman : Member

ee)

c) A representative of the manufacturers of boilers/ancillaries in public sector. : Member f) feed-pipe (i) means any pipe or connected fitting wholly or partly under pressure through which feed-water passes directly to a boiler. (ii) every reference to a steam-pipe or steam-pipes shall be deemed to include also a reference to feed-pipe or feed-pipes respectively. Inspecting Authority means an authority recognised by the Central Boilers Board in the manner as laid down in regulation 4A to 4H, as competent to grant a certificate in Form-II, II-A or II-B. 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; in respect of material manufactured or boilers constructed outside the States an officer acting on behalf of the Inspecting Authority: in respect of : (a) Approval of drawings of boilers or parts thereto with minor changes, where necessary, except for the drawings of the first set of boilers or parts thereto;

g)

h)

(ii)

(iii)

(b) hh)

Inspection at stages of manufacture including examination of repairs;

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. 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 : prescribed means prescribed by regulations or rules made under the Act: Steam-pipe means any pipe through which steam passes from a boiler to a prime-mover or other user or both if :(i) the pressure at which steam passes through such pipe exceeds 3.5 Kilograms per square centimetre above atmospheric pressure; or such pipe exceeds 254 millimetres in internal diameter; and includes in either case any connected fitting of a steam-pipe.

i)

j) k)

(ii)

l) m)

State or States means a State or the States to which these regulations extend. Structural alteration, addition or renewal shall not be deemed to include any renewal or replacement, of a petty nature when the part or fitting used for replacement is not inferior in strength, efficiency or otherwise to the replaced part or fitting Technical Adviser (Boilers) means Technical Adviser (Boilers) to the Government of India in the Ministry of Industry (Department of Industrial Development).

n)

Reg. 3 GENERAL REQUIREMENTS, APPLICATION OF STANDARD CONDITIONS AND EXCEPTIONS THERETO: 3(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, design and construction, which are specified in the subsequent Chapters of these Regulations, are satisfied in respect of such a boiler. (2) Notwithstanding anything contained in sub-regulation (1), the Chief Inspector may, subject to the provisions of regulation 7 and 8, register a boiler and order the issue of a certificate

authorising the use thereof, under any of the following circumstances, namely (i) when the material used in the construction of a boiler, steam-pipe, economiser or superheater is not in conformity with the Indian Boiler Regulations but is known to be commonly used in other countries as being suitable for use in the construction of boilers and steam-pipes, provided that such material is not specifically prohibited by the Regulation and that the methods of manufacture, fabrication and heat treatment conform to the specified Codes or Standards; when the constructional features of a boiler, steam-pipe, economiser or superheater are not in conformity 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 manufacturing practice of boilers and steam-pipes in other countries;

(ii)

(iii) when a boiler, steam-pipe, economiser or superheater has obviously been built in conformity with the regulations but no certificate as required under the regulations is forthcoming. (3) No structural part of a boiler, which is subject to pressure, shall be made of Bessemer process steel or of Cast or Malleable Cast Iron. (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, manufacture, stage inspections and certification of such pressure parts including the valves, mountings and fittings conforming to the Codes or Standards like BS, ASME Boiler and pressure vessels code, TEMA, TRD, GOST and JIS which are known to be commonly used in industrially advanced countries. The decision of Inspecting Authorities shall be binding on all Registering authorities. (4A) The tubes of boilers and heat exchangers made of Titanium and other exotic metals may be approved as per international codes, including ASME, BS, DIN, TEMA with the minimum thickness specified in those codes of manufacture. Reg. 3A Inspection of boiler to comply into any foreign code: Notwithstanding anything contained in these regulations, 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-II-A. Reg. 4 STANDARD REQUIREMENTS (a) Material.-All plates, rivets and bars used in the construction of boilers shall be tested and found to conform with the Regulations hereinafter contained.

(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. Tubes and steampipes shall also be inspected at the makers works at the stages prescribed in Appendix J, and the tests conducted by the makers shall also be witnessed by the Inspecting Officer.

(ii) Welders engaged in site welding of boilers, steam-pipes, economisers and superheaters shall possess and produce to the satisfaction of the Chief Inspector the Welders Performance Qualification Certificate issued by a Competent Authority. (c) Certificates, etc. under section 14(1)(c) of the Act.-In advance of or along with an application for registration of a boiler the following certificates and drawings or specifications shall be furnished to the Chief Inspector, 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. 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. In case of a boiler which is to be assembled only at site, requirement of the hydraulic test on a completely assembled boiler by the Inspecting 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. NOTE.-In lieu of Form-II, a certificate in Form-II-B may be granted by the Inspecting Authority for boilers for which variations from the standard conditions in respect of material, design and construction features have been permitted by the Board or the Inspection Authority under sub-regulation (5) or sub-regulation (6) of regulation 3. (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, its principle dimensions, particulars of the kind of material used in its construction, the thickness of all plates, the diameter of and method of forming the rivet holes in the shell plates, particulars of any departure from ordinary practice in making the shell such as solid rolling or welding, the hydraulic test to which the boiler was subjected, the intended working pressure, the area of heating surface, the maximum continuous evaporative capacity, the year and place of make, and the works number of the boiler. NOTE.-The Chief Inspector may, however, approve a modified form of certificate wherein items which do not pertain to a particular boiler may be omitted. (iii) A drawing or print to a scale, in the case of large boilers of not less than inch to the foot and, in the case of small boilers of not less than 1 inches to the foot, showing the principal dimensions and a longitudinal section and end view of the boiler, and bearing

the works number of the boiler and Makers office stamp. The drawing shall show details of riveting of longitudinal and circumferential seams with pitch of rivets, cross spacing of dished end plates, fillets and flanges and corners of bent plates, and where gusset stays are fitted the number and diameter of rivet holes in each gusset stay. In the case of water tube boilers, the foregoing scales shall apply to the main boiler drums only, but in addition a general arrangement drawing of the boiler to a scale of not less than inch to the foot shall be provided. (iv) A certificate in Form-IV from the steel maker and a certificate from the maker of the plates, rivets or bars, shall show the charge numbers, the plate or bar numbers and the number and dimensions of the various plates etc. tested, their chemical analysis, their ultimate tensile breaking strength in tons per square inch of section, the percentage of elongation and the length on which measured, the number, kind and result of bend or other tests made and the date of tests: Provided that where an Inspecting 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 for registration of the boiler. 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 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, a certificate of Well-known Steel Maker in Form-IV-A shall be accepted in lieu of a certificate from 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, a certificate of manufacture and test of Well-known tube/pipe maker in Form-III-D or III-E, as the case may be, shall be accepted in lieu of a certificate from an Inspecting Authority. In case where certificate in Form-IV is not producible owing to such certificate containing details of plates used for other purpose, also, all the relevant information in respect of the boiler furnished in Form IV-A duly signed by the Makers of the boiler and countersigned by the Inspecting Authority, shall be acceptable in lieu of the certificate in Form-IV. Original steel makers certificate or manufacture and results of tests shall be produced to the Chief Inspector on demand. In the case of fusion welded drums the diagram of welded repairs and temperature charts of heattreatment shall also be furnished. In addition, certificates in respect of yield point at service temperature (0.2 per cent proof stress), the average stress to produce elongation of 1 per cent (creep) in 100,000 hours and the average

and the lowest stresses to produce rupture in 100,000 hours in the material, wherever is applicable, are to be furnished. (vi) For tubes and pipes subjected to internal pressure, a certificate giving results of tests regarding chemical analysis, warm yield point (0.2 per cent proof stress), the average stress to produce an elongation of 1 per cent (creep) in 100,000 hours and the average and the lowest stresses to produce rupture in 100,000 hours in the material wherever applicable, shall be furnished. NOTE:- Until 33,000 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 BS or EN Code, these grades of steel may be accepted and long time elevated temperature properties/maximum allowable stress values given in ASME or BS or EN Code, as the case may be, may be used for the purpose of design. 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 BS or EN Code to assure that the creep rupture requirements are complied with. (II) the Steel maker furnishes the necessary certificate that the steel conforms to the chemical analysis, room and elevated temperature mechanical properties given in ASME or BS or EN Code as the case may be. (III) the short-term stress-rupture tests for 1000 hours as described below are carried out by NML/Steel 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 BS or EN Code, as the case may be, and a certificate is given by NML/Steel plant to this effect. (IV) two numbers of 1000 hour creep rupture tests shall be carried out at a temperature 50C above the service temperature for each grade of steel for tubing or piping or castings or plates grades; when in furnace and/or in superheater zone. However, the forging to be used in valves should be tested at 550C for 1000 hours. The stress to cause rupture in 1000 hours at above temperatures may be taken from the master curve corresponding to 20% line. At this stress, a minimum rupture life of 1000 hours is expected. Both the samples should pass 1000 hour tests at the above stress and temperature. These samples may be selected at random by the Chief Inspector of Boilers of the respective State. The samples could be in the form of semi-finished products, say, forged bars of about 25mm2 which will undergo heat treatment as prescribed by the relevant specifications.

(d) Makers Stamp.- The boiler shall have stamped upon its front plate in a conspicuous position the following particulars:MAKERS NAME Works Number_____________________________________ Year of make__________________ Tested to __________________________ Lbs.________________________ on _______________ W.P.________________________________________________ Lbs._____________ Inspecting Officers or Inspecting Authoritys Official Stamp ___________________________________ (e) Certificates for steam-pipes A certificate of manufacture and test in Form III-A, signed by the maker and the Inspecting Authority shall be furnished. (f) Certificates for tubes A certificate of manufacture and test in Form III-B, signed by the maker and the Inspecting Authority shall be furnished. 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, 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 Form III-B. In case, certificate from the Well-known Tube Makers as aforesaid, is produced, such certificate may be accepted in lieu of the certificate from the Inspecting Authority in so far as it relates to testing of material including mechanical tests specified in this form. (g) Certificates for mountings and fittings:- A certificate of Manufacture and Test in Form IIIC signed by the Maker and the Inspecting Authority in respect of boiler mountings and steampipe fittings during manufacture, shall be furnished. Note-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, in respect of mountings and fittings in that country and containing the particulars required to be specified in this certificate, may be accepted. Where, however, the material used, is in conformity with the code of the country of manufacture and is covered by those Regulations, the permissible stress figures specified in the Code at different temperatures may be accepted in lieu of figures computed from the data required to be furnished under Regulation 271 in any of the following cases, 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. (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. Note-2: For the purpose of clause (c), (e), (f) and (g) of this regulation, certificates issued by an authority empowered in this behalf by or under the law in force or national Code or Standard of any foreign country in respect of plates, bars, tubes, pipes, forgings and castings 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. Note-3: Photostat copy of the certificate in Form III-C shall be accepted provided it is endorsed by the manufacturer or the Inspecting Authority. (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 IIIA(I), signed by the maker and the Inspecting Authority shall be furnished. (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), signed by the maker and the Inspecting Authority shall be furnished. Reg. 4 A PROCEDURE FOR RECOGNITION OF COMPETENT AUTHORITY, INSPECTING AUTHORITY, WELL-KNOWN MATERIAL TESTING LABORATORY, WELLKNOWN STEEL MAKER, WELL-KNOWN FOUNDRY/FORGE AND WELL-KNOWN TUBE/PIPE MAKER AND WELL-KNOWN REMNANT LIFE ASSESSMENT ORGANISATION:-

Application for recognition:(1) An application for recognition as Competent Authority, Inspecting Authority, Well-known Material Testing Laboratory, Well-known Steel maker, Well-known Foundry/Forge and Well-known tube and pipe Maker and Well-known Remnant Life Assessment Organisation shall be made by a firm to the Secretary, Central Boilers Board, Ministry of Industry (Department of Industrial Development), New Delhi, for recognition as one of the aforementioned areas of activity in which that firm is engaged. On receipt of applications under sub-regulation (1), the Secretary, Central Boilers Board

(2)

shall send a questionnaire in any of the Form (Form XV-A to XV-G) applicable to the area of activity to the applicant who shall send the same after duly completed, to the Secretary, Central Boilers Board. (3) (4) Any firm applying for recognition under sub-regulation (1) shall have a minimum experience of two years in the area of activity for which recognition is applied for. In case of firms in foreign countries seeking recognition as Well known Steel Maker, Well known Pipe/Tube maker, Well known Foundry or Well known Forge, a fee of US$ 10,000/- (Ten Thousand US Dollars) to meet the expenses of the visit of the Evaluation Committee shall be deposited along with 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/- (Two Thousand US Dollars) per additional unit shall be deposited. The Evaluation Committee shall carry out the evaluation of the manufacturing works of the firm within 120 days of receipt of the fees. Reg. 4 B Scrutiny of applications by the Evaluation:(1) The Secretary, Central Boilers Board shall send all the applications received under subregulation (1) of regulation 4A, along-with replies to the questionnaire under subregulation (2) of regulation 4A, to the Evaluation Committee. The Evaluation Committee shall examine all the applications and replies to the Questionnaire under sub-regulation (1) and (i) where the application is for recognition as Competent Authority or Inspecting Authority, the Evaluation Committee may, (a) call any of the applicants if it considers necessary, to appear before it to give clarification or additional information that may be required by the said Committee; (b) visit any of the applicant firms on a specific request in writing from such firm to evaluate the performance of the said firm: (ii) where the applicants are for recognition as Well-known Material Testing Laboratory, Well-known Steel Maker, Well-known Foundry or Forge, Well-known tube / pipe maker and Well-known Remnant Life Assessment Organisation, the Evaluation Committee shall inspect the laboratories of such Material Testing Laboratory and Remnant Life Assessment Organisation or the factories of such steel makers, foundry or forge and tube or pipe makers, where the testing or manufacturing activities are being carried out in order to evaluate the performance quality of the tests conducted and product manufactured. (3) The Evaluation Committee after satisfying itself that the requirements specified in subregulations (1) and (2) are fulfilled, shall submit a report along with its recommendations to the Liaison Sub-Committee.

(2)

Reg. 4 C Recognition of a firm as Competent Authority, Inspecting Authorities etc.: (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 aspects of such report, shall either accord recognition to a firm or refuse recognition to such firm. In case the Liaison Sub-Committee decides to accord recognition to a firm a certificate of recognition in one of the Forms (Form XVI-A to XVI -I) applicable to the area of activity shall be issued by the Secretary, Central Boilers Board and in case the Liaison SubCommittee decides to refuse recognition, it shall inform the applicant in writing giving reasons therefore.

(2)

Reg. 4 D Validity of certificate of recognition: A certificate of recognition issued under regulation 4C, shall be valid for a period of three years. Reg. 4 E 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, 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: (b) Notwithstanding anything contained in sub-regulation (a), the period of validity shall be deemed to have been extended till such time the decision on the renewal is communicated to the firm. Reg. 4 F Application for registration of existing Competent Authority etc.: All the existing firms recognised as Competent Authority, Inspecting Authority, Well-known Steel maker, Well-known Foundry/Forge and Well-known Tube and Pipe Maker and Wellknown Remnant Life Assessment Organisation, shall make an application to the Secretary, Central Boilers Board, within one year from the commencement of the Indian Boiler (4th amendment) Regulations, 1988, 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 continue to be so recognized as such till the expiry of the period of three years:

Provided further that if an application is not made in time, the same may be entertained by the said authority if the applicant satisfies the authority that there was sufficient cause for not making application in time. In regulation 4F, in the opening sentence, after the words Inspecting Authority, the words Well-known Material Testing Laboratory shall be inserted. Reg. 4 G 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, Central Boilers Board, for reconsidering its application. All applications received by Chairman, Central Boilers Board, under sub-regulation (1), shall be decided in the meeting of the Central Boilers Board and the decision of the Board thereon shall be final.

(2)

Reg. 4 H 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, in particular, in the following areas, namely:(i) Quality System; (ii) Organisation; (iii) Review of quality system; (iv) Documentation(a) Inspection and test procedures; (b) Records; (c) Technical data; (v) Inspection equipment; (vi) Inspection of purchased material or services (a) purchasing; (b) purchasing data; (c) receiving inspection; (d) verification of purchased material;

(vii) In-process inspection; (viii) Workmanship; (ix) Corrective action; (x) Inspection and test of completed items; (xi) Sampling procedure; (xii) Control of non-conforming material; (xiii) Indication of inspection status; (xiv) Protection and preservation of product quality; (a) Material handling; (b) Storage; (c) Delivery; (xv) Training. Reg. 5 Modification of Formulae (i) Under the Regulations for determining the working pressure to be allowed on various parts of boilers, 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.

(ii) Where no test certificate for plates and rivets are produced, the material may be treated as iron, if the Chief Inspector is satisfied that the material is of suitable boiler quality. If in such cases the Chief Inspector is clearly satisfied that the material is of good quality, a higher strength than that allowed for iron may be permitted but the strength of the plates shall not, save for special reasons, be assumed to be more than 26 tons per square inch. In such cases the values of tensile and shear strength shall not be more than 26 and 21 tons per square inch for steel, and 21 and 18 tons per square inch for iron. For iron across the grain the tensile strength may be 18 tons per square inch. (iii) For flat plates of copper, the working pressure as found from the formulae, reduced by 50 per cent shall be the working pressure permitted. Reg. 5 A Material not fully identified: Where the material as for example plate, bar, billet, 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 shall have a steel makers stamp. (ii) Use of such uncertified plates, however, will not be allowed for manufacture of Shell or Drum of the boilers.

(iii) Shipping documents/order documents shall be made available to establish the specifications of the manufacture for inspection and testing of plates. (b) For Billets, bars, pipes and tubesShipping documents shall be made available to establish the specifications for manufacture for inspection and testing. Reg. 6 Standard specifications for materials. The standard specifications for steel wrought iron and copper plates and bar, and for cast steel shall be those prescribed in Chapter II. Reg. 7 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, then the same shall not be registered except in the following cases, 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, 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, being not more than the working pressure allowed by the code of manufacture, may be allowed on the recommendation of the Board made by it on the basis of life assessment tests carried out on the boiler. (ii) Shell Type Boilers - Where the documents required under its code of manufacture, for its registration are furnished, 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 of first use) in years. 25 35 45 50 60 70 80 90 100

Reduction in working pressure (percent) 5 10 15 20 30 40 50 60 70 Reg. 8 Welding:(a) The use of welding in the construction of boilers shall be permitted only where specifically provided for in the standard conditions.

Reg. 9 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Process of manufacture (a) Steel for plates shall be made by the open hearth, electric furnace or basic oxygen process or any other process which gives steel having equivalent specified properties. (b) General deoxidation practice shall be appropriate to the type of steel used, particularly where the deoxidation practice influences the level of the elevated temperature properties of steel. (c) Rimmed steels may be permitted only for riveted drums or shells made of plates having a nominal thickness upto 20 mm. (d) Plates of carbon steel shall conform to one of the following four grades of tensile strength:(i) (ii) 37 to 45 kgf/mm2 42 to 50 kgf/mm2

(iii) 47 to 56 kgf/mm2 (iv) 52 to 62 kgf/mm2 (e) Semi-killed steel may be used for plates in C and C-Mn steel with an upper limit of the tensile strength not exceeding 56 kg /mm2 and with thickness not exceeding 50mm under service temperature condition 0-450C.

Reg. 10 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Chemical Analysis (a) The steel shall not contain more than 0.05 per cent of sulphur or phosphorus. (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. The stage in manufacture at which this test is made shall be at the option of the Steel-Maker. (c) When the material is required for flame cutting and/or welding, the carbon content shall not exceed 0.30% and special precautions shall be taken when the carbon content exceeds 0.26%. When steels are intended for service temperatures over 700F the silicon content shall be not less than 0.10% or alternatively, the material shall pass the proof test for creep quality of carbon steel plates of boiler quality. (d) Plates having thickness of 12 mm and less than that, not intended for hot forming, can be supplied in unnormalized or as rolled condition subject to the condition that the code of manufacture provides for the same. For plates having thickness more than 12mm, not intended for hot forming, shall be supplied in the normalized conditions: 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. NOTE:- The boiler manufacturer may, if he so wishes order a check analysis. Reg. 11 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Freedom from defects, etc. 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. Surface defects may be repaired by welding, only with approval of the Inspecting Authority provided that the plate is stress relieved after welding where necessary.

Reg. 12 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Rolling Margin No plate or rolled section shall be under the specified thickness at any part, nor more than 5 per cent over the calculated weight, 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 Thickness Width in inches 132 and over

Under 48 to 60 to 72 to 84 to 96 to 108 to 120 48 under under under under under under120 to 60 72 84 96 108 under 132 In to under 5/16 5/16 to under 3/8 3/8 to under 7/16 7/16 to under to under 5/8 5/8 to under to under 1 % 5 % 5 % 5 % 7 % 9 % 12 % % -

% -

7.5

10

11

12

11

15

7.5

12

7.5

10

1 to under 2

All the above margins will be taken over nett theoretical weight. Reg. 13 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Testing and Inspecting The following tests and inspections shall be made at the place of manufacture prior to despatch; but in the event of any of the material proving unsatisfactory in the course of being worked into boilers, such material shall be rejected, notwithstanding any previous certificate of satisfactory testing, and such further tests of the material from the same charge shall be made as the Inspecting Officer in attendance may consider desirable. Reg. 13A MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Where a 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, the steel plant may supply steel with a certificate in respect of such of these tests as it has been possible, for them to carry out indicating the tests which it has not been possible for them to conduct in order to get the steel certified as IS: 2002. It is open to the manufacturer to take such steel which has the required potentialities of IS: 2002, provided he can arrange the remaining tests to be conducted at any of the independent testing laboratories, namely, the National Metallurgical Laboratory, Jamshedpur; The Central Mechanical Engineering Research Institute, Durgapur; and the National Test House, Alipur or Sewri, provided that samples be drawn in the presence of the Inspecting Authority. Such remaining tests may also be conducted at the Bharat Heavy Electricals Limited, Tiruchirapalli in the presence of the Inspecting Authority in respect of plates intended for their use. If the certificate of tests from steel makers and the National Metallurgical Laboratory, Jamshedpur, or the Central Mechanical Engineering Research Institute, Durgapur or the National Test House, Alipur or Sewri or Bharat Heavy Electricals Limited, Tiruchirapalli be furnished in the manner mentioned above, the boiler quality plates shall be accepted by the Inspecting Authority/Chief Inspector of Boilers of the State.

Reg. 14 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Selection of test pieces All test pieces shall be selected by the Inspecting Officer and tested in his presence, and he shall satisfy himself that the conditions herein described are fulfilled. Reg. 15 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Tensile Test pieces (a) The tensile strength and percentage elongation shall be determined from test pieces of gauge lengths preferably equal to Lo=5.6(Ao)1/2 (see regulation 16). Alternatively, other gauge lengths may be used, provided the elongation is expressed as the equivalent value on a gauge length of 5.65(Ao)1/2.

(b) In arbitration cases, a test piece of gauge length equal to 5.65(Ao)1/2 for rectangular test piece or 5 do for round test pieces shall be used. For plate thickness exceeding 60mm, test pieces shall be taken from the exterior third of the plate cross section. Wherever practicable, the rolled surface shall be retained on two opposite sides of the test piece. Reg. 16 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Tensile tests

(a) The tensile strength of different grades of material shall be within the limits specified in regulation 9 (d). (b) The upper yield point at room temperature shall be not less than 50% of the specified minimum tensile strength at room temperature. (c) The breaking elongation in percentage shall be not less than ( N-Rm)/C Where Rm = Tensile strength at room temperature in kgf/mm2 N = a quality index of 100 for plate thickness upto 50 mm or 95 for plate thickness over 50mm. C = 2.2 for only gauge lengths of L=5 do or L=5.65/ A Where L = gauge length A = original cross section of the rectangular test piece.

d = original diameter of the round test piece. NOTE: C= 1.9 for gauge lengths of 4 A for test piece of Appendix-B. (d) The minimum values of the stress at proof limit 0.2% at elevated temperature (Et) may be calculated by multiplying the minimum specified tensile strength at room temperature (R20) by the value of the ratio (Et/R20) given in the table below: TABLE Minimum values for the ratio of the stress at proof limit 0.2% at elevated temperature (Et) to the minimum specified tensile strength at room temperature (R20) of carbon steel boiler plates. Temperature Et/R20 Temperature Et/R20 250C 0.40 400C 0.31 *275C 0.38 425C 0.30 300C 0.36 325C 0.34 350C 0.33 375C 0.32

*For temperatures lower than 300C any test required for acceptance purposes (in the absence of records of previous tests at these temperatures) shall be made at 300C, 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 0.36 for 300C. Reg. 17 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Number of Tensile Tests (a) Plates For shell plates, butt straps and plates, gusset plates, end plates, furnace plates and flanging plates one tensile test piece shall be cut from each plate as rolled. (b) Angle, tee, 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, 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, in which case one tensile test shall suffice. For round bars of 1 inches diameter and under, the numbers 50 and 20 shall be substituted for 15 and 8 respectively for determining the number of tests required. Reg. 18 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Dump Tests Short lengths equal to twice their diameter cut from the rivet bars shall, when cold, withstand without fracture being compressed to half their length. A dump test shall be made for each Tensile Test. Reg. 19 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Bend Tests Cold Bends.-(a) Test pieces shall be sheared lengthwise or crosswise from plates or bars, and shall not be less than 1 inches wide, but for small bars the whole section

may be used. For rivet bars bend tests are not required. b) In all cold bend tests, on samples 0.5 inch in thickness and above, the rough edge or arris caused by shearing may be removed by filing or grinding, and samples 1 inch in thickness and above may have the edges machined, but the test pieces shall receive no other preparation. 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. (c) (i) For bend test of plates of all grades of steel, the test piece shall withstands, without fracture, being bent cold through 180o around a mandrel, the radius of which shall have a relationship to the plate thickness as given below: Tensile strength 36 - 49 kg./mm2 41 - 57 kg./mm2 45 - 64 kg./mm2 where T = Plate thickness (ii) For cold bend test of sections and bars, the test piece shall withstand, without fracture, being doubled over until the internal radius is equal to that shown in Table under regulation 16 and the limbs are parallel. Mandrel Radius 1T 1T 1.5 T

(d) For small sectional material these bend tests may be made from the flattened bar. (e) Bend tests may be made either by pressure or by blows. Reg. 20 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Number of Bend Tests (a) Plates.- A bend test shall be taken from each plate as rolled. The bend test from shell plates, butt straps and other plates which have not to be flanged or worked in the fire or which when in use are not to be exposed to flame shall be cold bend test.

(b) Angle Bars.- A cold bend test shall be made from each angle bar rolled, provided that the cold bend test need not be carried out if basic material specification does not call for it. (c) Stay Bars.- A cold bend test shall be made from every 15 stay bars as rolled from each charge. Reg. 21 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Manufactured Rivets (a) Quality of Material.- Rivets shall be manufactured from steel complying with the aforementioned requirements of this Chapter in respect of rivet bars. (b) Tests.(i) (ii) The rivet shanks shall be bent cold, and hammered until two parts of the sank touch, without fracture on the outside of the bend. The rivet heads shall be flattened while hot, without cracking at the edges until their diameter is 2 times the diameter of the shank.

(c) Number of Tests.- Upto half per cent of rivets of each size shall be selected by the Inspector or Inspecting Officer from bulk for the above tests. Reg. 22 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Additional tests before rejection Should the test pieces first selected by the Inspector or Inspecting Officer not fulfil the test requirements, two further tests of the same kind may be made, but should either of these fail, the plates or bars from which test pieces were cut shall be rejected. In all such cases further tests shall be made before any material from the same charge can be accepted. If the unsatisfactory result of a test is obviously due to technical conditions of the testing method or to a closely limited defects of a test piece, 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. If the unsatisfactory result of test is due to an unfavourable heat treatment the plate and the test strip may be heat treated again. Following this, the entire test shall be repeated. Reg. 23 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Branding

(i) Every plate, section and bar shall be clearly and distinctly marked by the maker in two places with the number of identification mark by which they can be traced to the charge from which the material was made. 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. (ii) Every plate shall also be stamped by the steel maker as provided in IS: 2002. The following information shall necessarily be provided:1. Name of the manufacturer; 2. Specification: 3. Heat No.; 4. Plate No.; and 5. Stamp. Reg. 24 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Defacing of rejected material In the event of the material failing in any case to withstand the prescribed tests, the identification mark of the Inspecting officer which has been stamped on the material, shall be defaced by punch marks extending beyond the identification mark, in the form of a cross, thus denoting that the material has failed. Reg. 25 MATERIALS OF CONSTRUCTION

STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Facilities for inspection The maker shall adopt a system of making the ingots, billets, slabs, plates, bars, etc. which will enable all finished material to be traced to the original charge, and the Inspector or Inspecting Officer shall be given every facility for tracing all plates and bars to their respective charges, and for witnessing the required tests. When he is satisfied with the material and with the results of the tests, he shall be furnished with two copies of the advice notes of the material for his signature. Reg. 26 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Steel not produced where rolled Where steel is not produced in the works at which it is rolled, a certificate in Form IV or Form III-B, 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, the name of the Steel-Maker who supplied it, also the numbers of the charges for reference to the books of the Steel-Maker. The number of the charge shall be marked on each plate or bar for the purpose of identification. Reg. 27 MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL Makers Certificate Before the mill sheets are signed, the maker shall furnish the Inspecting Officer with a certificate in Form IV or Form III-B, as the case may be, guaranteeing that the material has been made by the Open Hearth or an Electric Process, acid or basic, and that it has been subjected to, and has withstood satisfactorily the test above described in the presence of the Inspecting Officer. Reg. 28 MATERIALS OF CONSTRUCTION

WROUGHT IRON STAY AND RIVET BARS Rivet Bars The tensile breaking strength shall be between 21 and 25 tons with an elongation of not less than 25 per cent measured on the standard Test Piece B (as rolled) or 30 per cent measured on the Standard Test Piece B1 (as rolled). Reg. 29 MATERIALS OF CONSTRUCTION WROUGHT IRON STAY AND RIVET BARS Manufactured Rivets Tests To comply with Regulation 21. Reg. 30 MATERIALS OF CONSTRUCTION WROUGHT IRON STAY AND RIVET BARS 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 B or 27 per cent measured on the Standard Test Piece B1. Reg. 31 MATERIALS OF CONSTRUCTION WROUGHT IRON STAY AND RIVET BARS Stay Bars - Bend Tests To comply with Regulation 19. CHAPTER : II Reg.9 Process of manufacture

Reg.10 Reg.11 Reg.12 Reg.13

Chemical Analysis Freedom from defects, etc Rolling Margin Testing and Inspecting.

Reg.13A Designate steel Reg.14 Reg.15 Reg.16 Reg.17 Reg.18 Reg.19 Reg.20 Reg.21 Reg.22 Reg.23 Reg.24 Reg.25 Reg.26 Reg.27 Reg.28 Reg.29 Reg.30 Reg.31 Reg.32 Reg.33 Reg.34 Reg.351 Reg.352 Selection of test pieces Tensile Test pieces Tensile tests Number of Tensile Tests Dump Tests Bend Tests Number of Bend Tests Manufactured Rivets Additional tests before rejection Branding Defacing of rejected material Facilities for inspection Steel not produced where rolled Makers Certificate Rivet Bars Manufactured Rivets Tests Stay Bars Stay Bars - Bend Tests Special Iron for Screw Stays for Fire-boxes and Combustion Chambers Plates Stay and Rivet bars Copper Tubes Brass Tubes

Reg.353 Reg.36 Reg.37 Reg.38 Reg.39 Reg.40 Reg.41 Reg.42 Reg.43 Reg.44 Reg.45 Reg.46 Reg.47 Reg.48 Reg.49

Carbon steel tubes Material process Selection of Tubes for Test Tensile strength Flattening Test Flanging and drift expanding test Additional test before rejection Hydraulic Test Material Tensile strength Additional tests before rejection Hydraulic Test General Material Tensile Test

Reg.49B Flattering Test Reg.49C Expanding Test Reg.50 Reg.51 Reg.52 Additional tests before rejection Hydraulic test. General

Reg.53 a Material Reg.53 b Heat treatment

Reg.53 c Workmanship and tolerance Reg.53 d Selection of Tubes for testing

Reg.54 a Tensile Test Reg.54 b Flattening Test

Reg.54 c Expanding Tests Reg.55 Reg.56 Additional tests before rejection Hydraulic Test

Reg.56A Seamless Chromium Reg.57 Reg.58 Reg.59 Reg.60 Reg.61 Reg.62 Reg.63 General Material Flattening test Tensile Test Hydraulic test Test specimens Number of tests

Reg.63A Cold Drawon Electric Reg.73 Reg.74 Reg.75 Reg.76 Reg.77 Reg.78 Reg.79 Reg.80 Reg.81 Reg.82 Reg.83 Reg.84 Reg.85 Reg.86 Reg.87 Reg.88 Reg.89 Scope Process of manufacture Freedom from all rectification of defects Number of tests Tensile Test Bend tests Additional tests before rejection Procedure for Welding Forged or rolled pressure parts Selection of test pieces Tensile strength Bend Tests Additional tests before rejection General grey iron casting (Grade A) Provision of test bars Dimension of test bars Mechanical test

Reg.90 Reg.91 Reg.92 Reg.93 Reg.94 Reg.95 Reg.96 Reg.97 Reg.98

Transverse test Tensile test Number of transverse and tensile tests Additional Tests General requirements Requirements for Normal Penetration Electrodes Requirements for Deep Penetration Butt-Welding Electrodes Requirements for Deep Penetration Fillet Welding Electrodes Periodic Check Test

Reg.98A Filler rods for gas welding of steel

CHAPTER : III Reg.99 Reg.100 Reg.101 Reg.102 Reg.103 Reg.104 Reg.105 Reg.106 Reg.107 Reg.108 Preparation of Plates Normalizing of certain steel plates Minimum thickness of Plates Cylindrical Shells Position of Longitudinal Seams Circumferential and End Seams Angle Rings Thickness of Shell Angle Rings Welded Shell Plates Longitudinal Seams

Reg.109 Reg.110 Reg.111 Reg.112 Reg.113 Reg.114 Reg.115 Reg.116 Reg.117 Reg.118 Reg.119 Reg.120 Reg.121 Reg.122 Reg.123 Reg.124 Reg.125 Reg.126 Reg.127 Reg.128 Reg.129

Butt Straps Thinning of Butt Straps Alternative Construction Local Welding of Butt Seams 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 Flanging of End Plates 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

Reg.129A Welded Joints in Copper Fire Boxes Reg.130 Reg.131 Reg.132 Reg.133 Reg.134 Reg.135 Reg.136 Bar Stays Longitudinal Stays Nuts and Washers for Stays Jointed Stays Diagonal Bar or Rod Stays Screwed Stays Axial drilling

Reg.137 Reg.138 Reg.139 Reg.140 Reg.141 Reg.142 Reg.143 Reg.144 Reg.145 Reg.146 Reg.147 Reg.148 Reg.149 Reg.150 Reg.151 Reg.152 Reg.153 Reg.154 Reg.155 Reg.156 Reg.157 Reg.158 Reg.159 Reg.160 Reg.161 Reg.162 Reg.163 Reg.164 Reg.165

Stay Nuts Spacing of End Stays Allowance for curves, etc. Girder Stays for Firebox and Combustion Chamber Crowns Gusset Stays Breathing Space Gussets Angles Load on Gusset Stay Gusset Riveting Steel and Wrought Iron Tubes Fitting of Plain Tubes Screw Threads of Stay Tubes Stay Tubes Thickened ends of Stay Tubes Load on Stay Tubes Steel Tubes Attachment of Steel Tubes Copper Tubes HEADERS, MUD BOXES, ETC., OF WATER TUBE BOILERS Stand Pipes and Pads Design of stand pipes Pressed Plate Saddles Seating for Mountings Attachment of Mountings Insufficient thickness of End Plates Attachment of Water and Pressure Gauges Mountings on Flat Plates Bolts and Nuts Access Compensating Rings and Frames for Openings in Shells

Reg.166 Reg.167 Reg.168 Reg.169 Reg.170 Reg.171

Doors and Cross Bars Raised Manhole Frames and Cover Plates Position of Manhole in Shell Compensation Rings to Manholes Compensation for cutting large holes in Shell Type Boilers Rivets securing compensating rings and Stand Pipes

Reg.172A Rivet Heads Reg.172B Tolerances on shanks Reg.172C Rivet Holes Reg.173 Reg.174 Riveting Fullering and Caulking

Reg. 99, Reg. 100, Reg. 101 CONSTRUCTION AND WORKMANSHIP GENERAL Preparation of Plates The edges of all plates and butt straps shall be machined or flame-cut by machine and the caulking edges shall be beveled to an angle not sharper than 70 degrees to the plane of the plate and between 70 and 80 degrees wherever practicable. Plates which are to be flame-cut by machine without heat treatment or subsequent grinding or machining shall not have a carbon content higher than 0.26 per cent. Where the carbon content exceeds 0.26 per cent heat treatment, grinding or machining shall be carried out. The edges of all plates shall have a smooth finish.

Reg. 100 CONSTRUCTION AND WORKMANSHIP GENERAL Normalizing of certain steel plates

All steel plates which are dished, flanged or locally heated shall be afterwards normalized unless they have been heated during the operation within the normalizing range. Reg. 101 CONSTRUCTION AND WORKMANSHIP GENERAL Minimum thickness of Plates No boiler plate shall be less than inch in thickness. Reg. 99, Reg. 100, Reg. 101 CONSTRUCTION AND WORKMANSHIP GENERAL Preparation of Plates The edges of all plates and butt straps shall be machined or flame-cut by machine and the caulking edges shall be beveled to an angle not sharper than 70 degrees to the plane of the plate and between 70 and 80 degrees wherever practicable. Plates which are to be flame-cut by machine without heat treatment or subsequent grinding or machining shall not have a carbon content higher than 0.26 per cent. Where the carbon content exceeds 0.26 per cent heat treatment, grinding or machining shall be carried out. The edges of all plates shall have a smooth finish.

Reg. 100 CONSTRUCTION AND WORKMANSHIP GENERAL Normalizing of certain steel plates All steel plates which are dished, flanged or locally heated shall be afterwards normalized unless they have been heated during the operation within the normalizing range.

Reg. 101 CONSTRUCTION AND WORKMANSHIP GENERAL Minimum thickness of Plates No boiler plate shall be less than inch in thickness. Reg. 99, Reg. 100, Reg. 101 CONSTRUCTION AND WORKMANSHIP GENERAL Preparation of Plates The edges of all plates and butt straps shall be machined or flame-cut by machine and the caulking edges shall be beveled to an angle not sharper than 70 degrees to the plane of the plate and between 70 and 80 degrees wherever practicable. Plates which are to be flame-cut by machine without heat treatment or subsequent grinding or machining shall not have a carbon content higher than 0.26 per cent. Where the carbon content exceeds 0.26 per cent heat treatment, grinding or machining shall be carried out. The edges of all plates shall have a smooth finish.

Reg. 100 CONSTRUCTION AND WORKMANSHIP GENERAL Normalizing of certain steel plates All steel plates which are dished, flanged or locally heated shall be afterwards normalized unless they have been heated during the operation within the normalizing range. Reg. 101 CONSTRUCTION AND WORKMANSHIP

GENERAL Minimum thickness of Plates No boiler plate shall be less than inch in thickness. Reg. 102, Reg. 103, Reg. 104 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Cylindrical Shells Each ring shall be bent while cold to cylindrical form to the extreme ends of the plate. The bending shall be done entirely by machine and heating or hammering is prohibited.

Reg. 103 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Position of Longitudinal Seams Each ring of plate forming the shell, barrel or drum shell, where practicable, be in one piece and have its longitudinal seam well out of line with those of the adjoining rings. In Lancashire, Cornish, and other types of boilers, where parts of the shell are exposed to flame, the longitudinal seams shall, where practicable, be in the steam space, arranged alternately on each side of the crown and clear of the brick work.

Reg. 104 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Circumferential and End Seams The calculated efficiencies of circumferential joints based on the thickness of plate determined by Equation1, shall be not less than 38 per cent for joints connecting end plates with cylindrical shells or 42 per cent for intermediate joints. In no case, however, shall the efficiency of an intermediate joint be less than 50 per cent of that of the longitudinal joints. Where the shell plate thickness exceeds 11/16 inch the intermediate circumferential joints shall be double riveted.

Reg. 102, Reg. 103, Reg. 104 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Cylindrical Shells Each ring shall be bent while cold to cylindrical form to the extreme ends of the plate. The bending shall be done entirely by machine and heating or hammering is prohibited.

Reg. 103 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Position of Longitudinal Seams Each ring of plate forming the shell, barrel or drum shell, where practicable, be in one piece and have its longitudinal seam well out of line with those of the adjoining rings. In Lancashire, Cornish, and other types of boilers, where parts of the shell are exposed to flame, the longitudinal seams shall, where practicable, be in the steam space, arranged alternately on each side of the crown and clear of the brick work.

Reg. 104 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Circumferential and End Seams The calculated efficiencies of circumferential joints based on the thickness of plate determined by Equation1, shall be not less than 38 per cent for joints connecting end plates with cylindrical shells or 42 per cent for intermediate joints. In no case, however, shall the efficiency of an intermediate joint be less than 50 per cent of that of the longitudinal joints. Where the shell plate thickness exceeds 11/16 inch the intermediate circumferential joints shall be double riveted. Reg. 102, Reg. 103, Reg. 104 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Cylindrical Shells Each ring shall be bent while cold to cylindrical form to the extreme ends of the plate. The bending shall be done entirely by machine and heating or hammering is prohibited.

Reg. 103 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Position of Longitudinal Seams Each ring of plate forming the shell, barrel or drum shell, where practicable, be in one piece and have its longitudinal seam well out of line with those of the adjoining rings. In Lancashire, Cornish, and other types of boilers, where parts of the shell are exposed to flame, the longitudinal seams shall, where practicable, be in the steam space, arranged alternately on each side of the crown and clear of the brick work.

Reg. 104 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Circumferential and End Seams The calculated efficiencies of circumferential joints based on the thickness of plate determined by Equation1, shall be not less than 38 per cent for joints connecting end plates with cylindrical shells or 42 per cent for intermediate joints. In no case, however, shall the efficiency of an intermediate joint be less than 50 per cent of that of the longitudinal joints. Where the shell plate thickness exceeds 11/16 inch the intermediate circumferential joints shall be double riveted. Reg. 105, Reg. 106, Reg. 107 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Angle Rings Angle rings for the attachment of end plates to shell plates and/or flue sections shall be rolled or machined so that they fit closely to the flat and cylindrical surfaces to be

connected, and shall be machined or machine gas cut on the caulking edges.

Reg. 106 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Thickness of Shell Angle Rings Where shell plates and end plate are connected by means of an external angle ring, the angle rings shall be no less in thickness than as follows :(1) For shell plates upto and including 5/8 inch in thickness. 10 per cent in excess of the thickness of the shell plate.

(2) For shell plate exceeding 5/8 inch 90 per cent of the thickness but not in thickness and upto and including 1 less than 11/16 inch. inch in thickness. (3) For shell plates over 1 inch in thickness. Made from angle bar having a section thickness of 1 inch.

Reg. 107 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Welded Shell Plates The requirements of welded shells shall be covered by the provisions made in the Regulations in Chapter V or Chapter XII, as the case may be. The working pressure of such shells shall comply with Regulation 176 where J = 100 and C = 2.75. Reg. 105, Reg. 106, Reg. 107 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Angle Rings Angle rings for the attachment of end plates to shell plates and/or flue sections shall be rolled or machined so that they fit closely to the flat and cylindrical surfaces to be

connected, and shall be machined or machine gas cut on the caulking edges.

Reg. 106 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Thickness of Shell Angle Rings Where shell plates and end plate are connected by means of an external angle ring, the angle rings shall be no less in thickness than as follows :(1) For shell plates upto and including 5/8 inch in thickness. 10 per cent in excess of the thickness of the shell plate.

(2) For shell plate exceeding 5/8 inch 90 per cent of the thickness but not in thickness and upto and including 1 less than 11/16 inch. inch in thickness. (3) For shell plates over 1 inch in thickness. Made from angle bar having a section thickness of 1 inch.

Reg. 107 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Welded Shell Plates The requirements of welded shells shall be covered by the provisions made in the Regulations in Chapter V or Chapter XII, as the case may be. The working pressure of such shells shall comply with Regulation 176 where J = 100 and C = 2.75. Reg. 105, Reg. 106, Reg. 107 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Angle Rings Angle rings for the attachment of end plates to shell plates and/or flue sections shall be rolled or machined so that they fit closely to the flat and cylindrical surfaces to be

connected, and shall be machined or machine gas cut on the caulking edges.

Reg. 106 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Thickness of Shell Angle Rings Where shell plates and end plate are connected by means of an external angle ring, the angle rings shall be no less in thickness than as follows :(1) For shell plates upto and including 5/8 inch in thickness. 10 per cent in excess of the thickness of the shell plate.

(2) For shell plate exceeding 5/8 inch 90 per cent of the thickness but not in thickness and upto and including 1 less than 11/16 inch. inch in thickness. (3) For shell plates over 1 inch in thickness. Made from angle bar having a section thickness of 1 inch.

Reg. 107 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Welded Shell Plates The requirements of welded shells shall be covered by the provisions made in the Regulations in Chapter V or Chapter XII, as the case may be. The working pressure of such shells shall comply with Regulation 176 where J = 100 and C = 2.75. Reg. 108, Reg. 109, Reg. 110 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Longitudinal Seams The longitudinal seams of shell belts shall be butt-jointed with double straps when the

diameter or Working Pressure exceeds the limits stated below :Type of Boiler When diameter exceeds When Working Pressure (feet) exceeds (lbs/sq. inch) 2 6 6 200 125 80

Loco Types Vertical Types Other Types

Reg. 109 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Butt Straps Butt straps shall be cut from the shell plates, or, alternatively, all the butt straps of each required thickness shall be cut from one plate. The lengths of the straps wherever practicable shall be transverse to the direction of rolling of the plate. Straps shall be pressed or bent in rolls to the shell curvature.

Reg. 110 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC. Thinning of Butt Straps Thinning of the ends of the butt straps which tuck under shell rings, shall be done cold by machine and not by heating or hammering. The shell plate shall be notched out to receive that thinned end of the butt strap, so that there shall be no undue thinning of the butt strap. Reg. 108, Reg. 109, Reg. 110 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Longitudinal Seams

The longitudinal seams of shell belts shall be butt-jointed with double straps when the diameter or Working Pressure exceeds the limits stated below :Type of Boiler When diameter exceeds When Working Pressure (feet) exceeds (lbs/sq. inch) 2 6 6 200 125 80

Loco Types Vertical Types Other Types

Reg. 109 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Butt Straps Butt straps shall be cut from the shell plates, or, alternatively, all the butt straps of each required thickness shall be cut from one plate. The lengths of the straps wherever practicable shall be transverse to the direction of rolling of the plate. Straps shall be pressed or bent in rolls to the shell curvature.

Reg. 110 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC. Thinning of Butt Straps Thinning of the ends of the butt straps which tuck under shell rings, shall be done cold by machine and not by heating or hammering. The shell plate shall be notched out to receive that thinned end of the butt strap, so that there shall be no undue thinning of the butt strap. Reg. 108, Reg. 109, Reg. 110 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Longitudinal Seams

The longitudinal seams of shell belts shall be butt-jointed with double straps when the diameter or Working Pressure exceeds the limits stated below :Type of Boiler When diameter exceeds When Working Pressure (feet) exceeds (lbs/sq. inch) 2 6 6 200 125 80

Loco Types Vertical Types Other Types

Reg. 109 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Butt Straps Butt straps shall be cut from the shell plates, or, alternatively, all the butt straps of each required thickness shall be cut from one plate. The lengths of the straps wherever practicable shall be transverse to the direction of rolling of the plate. Straps shall be pressed or bent in rolls to the shell curvature.

Reg. 110 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC. Thinning of Butt Straps Thinning of the ends of the butt straps which tuck under shell rings, shall be done cold by machine and not by heating or hammering. The shell plate shall be notched out to receive that thinned end of the butt strap, so that there shall be no undue thinning of the butt strap. Reg. 111, Reg. 112 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Alternative Construction As an alternative to the tucking of butt strap ends under the shell rings, the ends may be terminated at the edge of the shell rings or ends and electrically welded thereto.

Reg. 112 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Local Welding of Butt Seams (a) The ends of longitudinal butt seams of shell rings may be welded for a length not exceeding three times the overlap at the circumferential seam, provided the butt straps are run as closely as practicable to the circumferential seam. (b) Only metal arc welding of the butt seams of shell rings shall be permitted. (c) Where hemispherical shell crowns are pressed from plate they shall be pressed to form by machine in progressive stages without thinning and on completion shall be annealed. Reg. 111, Reg. 112 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Alternative Construction As an alternative to the tucking of butt strap ends under the shell rings, the ends may be terminated at the edge of the shell rings or ends and electrically welded thereto.

Reg. 112 SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

Local Welding of Butt Seams

(a) The ends of longitudinal butt seams of shell rings may be welded for a length not exceeding three times the overlap at the circumferential seam, provided the butt straps are run as closely as practicable to the circumferential seam. (b) Only metal arc welding of the butt seams of shell rings shall be permitted. (c) Where hemispherical shell crowns are pressed from plate they shall be pressed to form by machine in progressive stages without thinning and on completion shall be annealed. Reg. 113 END PLATES

Flat End Plates a) The plates of boilers shall preferably be in one piece made from one rolled plate. Alternatively, the end plates may be built up from two pieces by riveting or by fusion butt-welding. In the latter case, the line of weld shall be parallel to the horizontal axis of the boiler and the entire plate after flanging shall be subjected to stress relieving and the weld shall be radiographed. b) The peripheral flanging of end plates shall be done by machine. Such flanging shall preferably be done in one operation, but where this is impracticable sectional or creep machine flanging may be permitted, provided that the plate is worked at a suitable temperature, and the plate is heated to an adequate distance beyond the portion under immediate treatment. bb) In the construction of unfired boilers when the dished ends do not form a part of the heating surface, cold spun dished ends conforming to IS: 2825 may be used. c) Care must be taken to see that the flanges are circular and of good surface, free from local irregularities, and that they are parallel and square with the flat part of the plate. For the purpose of relieving internal stresses, all plates which have been flanged or locally heated shall afterwards be efficiently annealed unless during the last stage of manufacture they have been uniformly heated throughout. d) Flat portions of end plates, on completion of all flanging and machining operations, shall be flat and free from set or distortion. Reg. 114 END PLATES

Strengthening of Flat End Plate at Manhole a) In the End Plates of Lancashire Boiler type, the mudhole in the lower part of the front end plate shall be fitted with a flanged riveted strengthening ring, the thickness of the flat portion of which shall be not less than (1.5T + 1/8 inch) where T equals the thickness of the end plate in inches. b) In boilers 7 ft. 6 inches diameter and above, the mudhole frame shall be fitted with a peak to reinforce the portion of the end plate between and below the furnaces, and this peak shall be securely riveted thereto with rivets of similar pitch to the remainder of the frame. c) In all cases the front end plate gusset stays below the furnaces shall be placed as closely as possible to the mudhole frame. d) Where flat end plates are flanged for connection to the shell, the inside radius of flanging shall be not less than 1.75 times the plate thickness, with a minimum of 1 inches. Reg. 115, Reg. 116, Reg. 117 END PLATES

End Plates in steam spaces When the end plates of boilers situated in the steam space are liable to contact with hot gases, the end plates shall be efficiently shielded from such contact.

Reg. 116 END PLATES

Hemispherical Crowns a) All segments shall be pressed in one heat to correct curvature. The adjacent plates shall be closely at the seams and wherever possible at the junction of two seams the plates shall be machined down to provide a fair surface to the joint. If the thinning is done by heating and hammering the plate shall be subsequently annealed. b) The cylindrical portion of the crown shall be tangential to the hemispherical portion and fit truly to the shell.

Reg. 117

END PLATES

Dished End and Crown Plates a) The dished end plates of boilers shall preferably be in one piece made from onerolled plate. If this is impracticable owing to the large diameter, the dished end plate may be made from two plates fusion butt welded together and in such cases the requirements of stress relieving and radiographic examination as provided for in Regulation 113 shall apply and the line of weld shall be parallel to the horizontal axis of the boiler. The inside radius to which a plate is dished shall not be greater than the external diameter of the shell to which it is attached, except in the case of Lancashire and Cornish boilers when the radius shall not exceed 1 times the diameter of the shell. b) The inside radius of curvature of the flanges to the shell or firebox shall not be less than four times the thickness of the crown or end plate and in no case less than 2 inches. c) The inside radius of curvature to uptakes shall be not less than twice the thickness of the crown plate and in no case less than 1 inch. d) Bunged mouth-pieces may be welded on to end plates in place of the orthodox flanging for the attachment of furnace tubes. Such welding shall comply with provisions of Regulation 125. e) Manhole frames may be similarly welded on the front end plates, and will be subject to provisions of Regulation 125. Reg. 115, Reg. 116, Reg. 117 END PLATES

End Plates in steam spaces When the end plates of boilers situated in the steam space are liable to contact with hot gases, the end plates shall be efficiently shielded from such contact.

Reg. 116 END PLATES

Hemispherical Crowns

a) All segments shall be pressed in one heat to correct curvature. The adjacent plates shall be closely at the seams and wherever possible at the junction of two seams the plates shall be machined down to provide a fair surface to the joint. If the thinning is done by heating and hammering the plate shall be subsequently annealed. b) The cylindrical portion of the crown shall be tangential to the hemispherical portion and fit truly to the shell.

Reg. 117 END PLATES

Dished End and Crown Plates a) The dished end plates of boilers shall preferably be in one piece made from onerolled plate. If this is impracticable owing to the large diameter, the dished end plate may be made from two plates fusion butt welded together and in such cases the requirements of stress relieving and radiographic examination as provided for in Regulation 113 shall apply and the line of weld shall be parallel to the horizontal axis of the boiler. The inside radius to which a plate is dished shall not be greater than the external diameter of the shell to which it is attached, except in the case of Lancashire and Cornish boilers when the radius shall not exceed 1 times the diameter of the shell. b) The inside radius of curvature of the flanges to the shell or firebox shall not be less than four times the thickness of the crown or end plate and in no case less than 2 inches. c) The inside radius of curvature to uptakes shall be not less than twice the thickness of the crown plate and in no case less than 1 inch. d) Bunged mouth-pieces may be welded on to end plates in place of the orthodox flanging for the attachment of furnace tubes. Such welding shall comply with provisions of Regulation 125. e) Manhole frames may be similarly welded on the front end plates, and will be subject to provisions of Regulation 125. Reg. 115, Reg. 116, Reg. 117 END PLATES

End Plates in steam spaces

When the end plates of boilers situated in the steam space are liable to contact with hot gases, the end plates shall be efficiently shielded from such contact.

Reg. 116 END PLATES

Hemispherical Crowns a) All segments shall be pressed in one heat to correct curvature. The adjacent plates shall be closely at the seams and wherever possible at the junction of two seams the plates shall be machined down to provide a fair surface to the joint. If the thinning is done by heating and hammering the plate shall be subsequently annealed. b) The cylindrical portion of the crown shall be tangential to the hemispherical portion and fit truly to the shell.

Reg. 117 END PLATES

Dished End and Crown Plates a) The dished end plates of boilers shall preferably be in one piece made from onerolled plate. If this is impracticable owing to the large diameter, the dished end plate may be made from two plates fusion butt welded together and in such cases the requirements of stress relieving and radiographic examination as provided for in Regulation 113 shall apply and the line of weld shall be parallel to the horizontal axis of the boiler. The inside radius to which a plate is dished shall not be greater than the external diameter of the shell to which it is attached, except in the case of Lancashire and Cornish boilers when the radius shall not exceed 1 times the diameter of the shell. b) The inside radius of curvature of the flanges to the shell or firebox shall not be less than four times the thickness of the crown or end plate and in no case less than 2 inches. c) The inside radius of curvature to uptakes shall be not less than twice the thickness of the crown plate and in no case less than 1 inch. d) Bunged mouth-pieces may be welded on to end plates in place of the orthodox flanging for the attachment of furnace tubes. Such welding shall comply with

provisions of Regulation 125. e) Manhole frames may be similarly welded on the front end plates, and will be subject to provisions of Regulation 125. Reg. 118, Reg. 119, Reg. 120 END PLATES

Tube Plates Smoke-box tube plates shall be flanged for attachment to the barrel or shall be flat and connected thereto by an external riveted angle ring.

Reg. 119 END PLATES

Parts of flat tube plates within the tube nests a) where the total area of all tube nests in directly fired multi-tubular boilers exceeds 7 sq. ft., stay tubes shall be fitted. Where the total number of tubes in horizontal multitubular waste heat boilers and direct fired loco type boilers is arranged in one next, the area of which exceed 21 sq. ft., stay tubes shall be fitted. In all cases where the total number of tubes is arranged in more than one nest, stay tubes shall be fitted. b) The parts of tube plates which lie outside the nests of tubes shall be stayed or supported wherever the size of the area of plate subject to steam pressure necessitates staying or support, either by marginal stay tubes or other means.

Reg. 120 END PLATES

Flanging of End Plates All flanges shall be a good fit to the shell and flues. Flogging and/or hammering in the

fitting of these parts is prohibited. The caulking edges of all flanged plates shall be machined or machine gas cut. Reg. 118, Reg. 119, Reg. 120 END PLATES

Tube Plates Smoke-box tube plates shall be flanged for attachment to the barrel or shall be flat and connected thereto by an external riveted angle ring.

Reg. 119 END PLATES

Parts of flat tube plates within the tube nests a) where the total area of all tube nests in directly fired multi-tubular boilers exceeds 7 sq. ft., stay tubes shall be fitted. Where the total number of tubes in horizontal multitubular waste heat boilers and direct fired loco type boilers is arranged in one next, the area of which exceed 21 sq. ft., stay tubes shall be fitted. In all cases where the total number of tubes is arranged in more than one nest, stay tubes shall be fitted. b) The parts of tube plates which lie outside the nests of tubes shall be stayed or supported wherever the size of the area of plate subject to steam pressure necessitates staying or support, either by marginal stay tubes or other means.

Reg. 120 END PLATES

Flanging of End Plates All flanges shall be a good fit to the shell and flues. Flogging and/or hammering in the

fitting of these parts is prohibited. The caulking edges of all flanged plates shall be machined or machine gas cut. Reg. 118, Reg. 119, Reg. 120 END PLATES

Tube Plates Smoke-box tube plates shall be flanged for attachment to the barrel or shall be flat and connected thereto by an external riveted angle ring.

Reg. 119 END PLATES

Parts of flat tube plates within the tube nests a) where the total area of all tube nests in directly fired multi-tubular boilers exceeds 7 sq. ft., stay tubes shall be fitted. Where the total number of tubes in horizontal multitubular waste heat boilers and direct fired loco type boilers is arranged in one next, the area of which exceed 21 sq. ft., stay tubes shall be fitted. In all cases where the total number of tubes is arranged in more than one nest, stay tubes shall be fitted. b) The parts of tube plates which lie outside the nests of tubes shall be stayed or supported wherever the size of the area of plate subject to steam pressure necessitates staying or support, either by marginal stay tubes or other means.

Reg. 120 END PLATES

Flanging of End Plates All flanges shall be a good fit to the shell and flues. Flogging and/or hammering in the

fitting of these parts is prohibited. The caulking edges of all flanged plates shall be machined or machine gas cut. Reg. 121 FURNACES

Furnaces in general a) No furnace or firebox top, whether plain or corrugated, shall exceed 7/8 inch in thickness, and all circular sectioned furnaces when new shall be as near the truly circular form as the type of joint will permit. b) The use of Z angle rings for furnace foundation seems shall be prohibited. c) As an alternative to riveting furnaces, furnace crowns, uptakes and other plates not in tension may be jointed by fusion welding provided the conditions laid down in Regulation 122 to 129 are complied with. The end connections of such plates to the shell or shell crown shall also comply with such conditions. This construction shall not apply to furnaces of Lancashire and Cornish type boilers consisting wholly of plain sections.

CHAPTER : IV Reg.175 Maximum pressure Reg.176 Formula for Working Pressure of Shell Reg.177 Methods of calculating the strength of riveted joints Reg.178 When Pitch exceeds maximum allowed Reg.179 Butt Straps and spacing of rivets below requirements Reg.180 Percentage of Welded and Strapped Seams Reg.181 Percentage to be allowed for Solid Rolled Shells Reg.182 Thickness of Butt Straps Reg.183 Maximum Pitch of Rivets in longitudinal joints Reg.184 Spacing of rows of rivets

Reg.185 Circumferential and End Seams of Water Tube Boilers Reg.186 Compensation for Manholes and other openings Reg.187 Uncompensated holes in Water Tube Boilers Reg.188 Complete hemisphere without stays or other support made of one or more plates and subject to internal pressure Reg.189 Dished ends subject to internal pressure Reg.190 Dished ends subject to external pressure Reg.191 Dished ends of Lancashire and Cornish Type Boilers Reg.192 Dished shell and firebox crowns Reg.193 Flat plates supported by solid screwed stays, marginal seams or flanges Reg.194 Flat plates supported by stays and nuts and large washers or strips or doublings Reg.195 Flat tube plates Reg.196 Plates supported by gusset stays Reg.197 Flat Crown plates of Vertical Boilers Reg.198 Circular flat ends of drums, etc., supported only at edges Reg.199 Bar or bulb stiffened end plates and smoke-box tube plates of Loco-type boilers Reg.200 Flat plate margins Reg.201 Manholes and Mudholes in Flat Plates Reg.202 Solid screwed stays Reg.203 Stresses in steel jointed stays Reg.204 Stay Tubes Reg.205 Stays in tension and compression Reg.206 Measurements of stayed areas in the end plates of Locotype and Vertical Boilers Reg.207 Gusset Stays Reg.208 Bolts and Studs Reg.209 Compression of tube plates Reg.210 Parts to be stayed Reg.211 Minimum thickness and cross-section

Reg.212 Holding power of plain tubes Reg.213 Tubes plates, other than ends of vertical boilers forming parts of outer shell Reg.214 Curved tube plates of water-tube boilers Reg.215 Efficiency of Ligament Reg.216 BOILER AND SUPERHEATER TUBES SUBJECT TO INTERNAL PRESSURE Reg.217 HEADERS AND SECTION BOXES OF WATER TUBE BOILERS Reg.218 BOILER TUBES (SMOKE ) SUBJECT TO EXTERNAL PRESSURE Reg.219 Brass and Copper Tubes Reg.220 Plain Furnaces of Horizontal Boilers Reg.221 Corrugated Furnaces of Horizontal Boilers Reg.222 Plain Furnaces of Vertical Boilers Reg.223 Hemispherical Furnaces of Vertical Boilers Reg.224 Corrugated Fireboxes of Vertical Boilers Reg.225 Foundations of Vertical Boiler Furnaces Reg.226 Foundations of Loco-type Boiler Fireboxes Reg.227 Cross Tubes Reg.228 Uptakes of Vertical Boilers Reg.229 Girder stay for firebox crowns Reg.230 Marshall Type Reg.231 Garrett Type Reg.232 Fowler Type

CHAPTER : V Reg.233 Reg.234 Reg.235 Reg.236 Reg.237 Reg.238 Reg.239 Reg.240 a Reg.240 b Reg.240 c Reg.240 d Reg.240 e Reg.241 Reg.242 Reg.243 Reg.243 A Reg.244 A Reg.244 B Reg.245 Reg.246 Reg.247 Reg.248 Reg.249 Reg.250 Reg.251 Reg.252 Reg.253 FUSION WELDED AND SEAMLESS FORGED DRUMS FOR WATER TUBE BOILERS AND SUPER HEATERS MATERIALS OF CONSTRUCTION SEAMLESS FORGED DRUMS Chemical Analysis Freedom from defects Heat Treatment Mechanical Tests Selection of Test Pieces Tensile test pieces Tensile test Bend test pieces Bend Tests Additional tests before rejection Discard Forging Tolerance TUBES, PIPES IN BOILERS, HEADERS AND STEEL CASTINGS Pipes Headers Steel Castings FUSION WELDED DRUMS Equipment of Workshop Constructional details and preparation for welding Preparation of plates Cylindrical shells of drums Method of making welded joints Type of welded joints

Reg.254 Reg.255 Reg.256 Reg.257 Reg.258 Reg.259 Reg.260 A Reg.260 B Reg.261 Reg.262 Reg.263 Reg.264 Reg.265 a Reg.265 b Reg.265 c Reg.265 d Reg.266 a Reg.266 b Reg.266 c Reg.266 d Reg.266 e Reg.266 f Reg.266 g Reg.266 h Reg.266 i Reg.267 a Reg.267 b Reg.267 c Reg.267 d

Number of joints Position of the Tube holes Circularity of drums Mechanical test and test plates for fusion welded seams Selection of Test Pieces* Tensile Test Pieces Tensile Tests All-weld Metal Bend Test Pieces Bend Tests Notched-Bar Impact Tests Additional tests before rejection Non-Destructive Tests Radiographical Examination Magnetic particle flaw detection Dye-Penetrant flaw detection General Longitudinal Seams Circumferential Seams Removal of Defects Examination before Re-welding Process used for Repairs Radiographical Examination after Repairs Specimen Representing Repairs Diagram of Welded Repairs Heat Treatment Heat Treatment Heat Treatment Heat Treatment

Reg.267 e Reg.267 f Reg.267 g Reg.268 Reg.269 Reg.270 Reg.271 Reg.271 A Reg.271 B Reg.272 Reg.273 Reg.274 Reg.275 Reg.276 Reg.277 Reg.278 Reg.279 A Reg.279 B Reg.279 C Reg.280

Heat Treatment Heat Treatment Heat Treatment Hydraulic test at makers works INSPECTION AND TESTING SHELLS Permissible working stresses for shells of Boiler and Integral Superheater Drums and Headers Permissible working stresses for shells of Boiler and Integral Superheater Drums and Headers Permissible working stresses for shells of Boiler and Integral Superheater Drums and Headers FUSION WELDED AND SEAMLESS FORGED DRUMS FOR WATER TUBE BOILERS AND SUPER HEATERS Longitudinal Stress Intermediate Boiler Drum Supports Shape of Dished End Plate General Dished End with Opening End Plate subject to pressure on the concave side STANDPIPES AND NOZZLES Standpipe and nozzles welded to dished end plates Minimum thickness of Flanges Attachment of Stand blocks and Branch Pipes by Welding

CHAPTER : VI Reg.281 Reg.281 A Reg.282 A Reg.282 B Reg.282 C Reg.283 Reg.284 Reg.285 Reg.286 Reg.287 Reg.288 Reg.289 Reg.290 Reg.291 Reg.292 Reg.293 Reg.294 Reg.295 Reg.296 Reg.297 Reg.298 Reg.299 Reg.300 Reg.301 Reg.302 Reg.303 Requisite Mountings, Fittings and Auxiliaries Additional requirements for automatic boilers only GENERAL REQUIREMENTS Limits of cast Iron Limits of copper alloy METHOD OF CONSTRUCTION Packing of Cocks Covers and Spindles Direction of Operation Moving Parts Flanges Valve Seatings Chests etc., in General SPECIAL REQUIREMENTS Definition Minimum Aggregate Area Over pressure of Safety Valves Pressure Drop Attachment to Boiler Opening in Shell Discharge Passage Drainage Moving Parts Bearings for Levers Attachments of weights and Springs Easing Gear

Reg.304 Reg.305 Reg.306 Reg.306 A Reg.307 A Reg.307 B Reg.308 Reg.309 Reg.310 Reg.311 Reg.312 Reg.313 Reg.314 Reg.315 Reg.316 Reg.317 Reg.318 Reg.319 Reg.320 Reg.321 Reg.322 Reg.323 Reg.324 Reg.325 Reg.326 Reg.327 Reg.328 Reg.329 Reg.330

Lift High and Low water Alarms Final Settings Adjustment of safety valve set pressure SPRINGS AND TORSION BARS Torsion Bars Dimensions Determination of Working Pressure Test Extension Springs Number of Effective Coils Spacing of Coils Finishing of Ends Lever Valves Steam Stop Valve BLOW-DOWN COCK OR VALVE AND PIPES Blow-down Mountings Blow-down Valve or Cock WATER GAUGES Drains Protectors Glass size Safety Devices Gauge columns Isolating Cocks PRESSURE GAUGES Connections Gauge Cocks Test Connections-Inspectors Pressure Gauge Attachment

Reg.331 Reg.332 Reg.333 Reg.334 Reg.335 Reg.336 Reg.336 A

FUSIBLE PLUGS Type Material Attachment to Boiler FEED VALVES Operating position Requirements as to feed apparatus in certain cases

CHAPTER : VII Reg.337 Reg.338 Reg.339 Reg.340 Reg.341 Reg.342 (a) Reg.342 (b) Material and Construction BOILER AND SUPER HEATER TUBES, HEADERS AND OTHER PRESSURE PARTS TUBES Materials and Construction Rectangular Headers Symmetrical in Form Headers Irregular in Form Cylindrical Headers End Attachments

CHAPTER : VIII Reg.343 Reg.344 Reg.345 Reg.346 Reg.347 (a) Reg.347 (b) Reg.347 (c) Reg.347 (d) Reg.347 (e) Reg.347 (f) Reg.348 Reg.349 Reg.350 Reg.351 Reg.352 Reg.353 A Reg.353 B Reg.353 C Reg.354 Reg.355 Reg.356 Reg.357 Reg.357 C Pipes MATERIAL Condition of Pipes MECHANICAL TESTS Flattening test (for pipes up to and including 102 mm. (4 in.) Nominal bore) Cold bend test (for pipes over 102 mm. (4in.) Nominal bore) Bend test on the weld Additional test Tensile test STEAM-PIPES AND FITTINGS Method of manufacture, Heat treatment and Marking STEAM-PIPES AND FITTINGS Steel Pipes Cast Steel Pipes Copper Pipes FLANGES Flanges of Alloy Steel Pipes Non-Ferrous Flanges Screwed on Flanges Loose Flanges Riveted on Flanges Welded on flanges Heat treatment after welding

Reg.358 Reg.359 Reg.360 Reg.361 Reg.361 A Reg.362 A Reg.362 B Reg.362 C Reg.363 Reg.364 Reg.365 Reg.365 B Reg.365 C Reg.365 D Reg.365 E Reg.365 F Reg.366 Reg.366 B Reg.366 C Reg.366 D Reg.367 Reg.368 Reg.369 Reg.370 Reg.371 Reg.372 Reg.373 Reg.374

Flanges of copper pipes Standard Flanges Joints Wrought Bends Butt-welding fittings Branches, Bosses and Drain pockets External reinforcement Thickness where no external reinforcement is provided Blowdown pipes Valves Chests STEAM RECEIVERS, SEPARATORS, CATCH WATERS, ACCUMULATORS AND SIMILAR VESSELS Construction and Workmanship Access to shells Compensating Rings to Opening and Doors Branches and other Connections Shell Joints Determination of Working Pressure End Plates Branches Inspection during construction 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 Pressure

PTER : IX Reg.375 Reg.376 Reg.377 Reg.378 Reg.379 Reg.380 Reg.381 Reg.382 Reg.383 Reg.384 Reg.385 Reg.386 Reg.387 Reg.387 A Reg.388 Reg.389 Reg.390 Reg.390 B REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES Preparation for Inspection Hydraulic test of boilers for registration Preparation for hydraulic tests Procedure of hydraulic tests *Steam tests Procedure for registration Engraving of registry number Measurement of heating surface Boiler rating Registration fee * Memorandum of Inspection Book Registration Book Maintenance of Records Transfer of Memorandum of Inspection Book and Registration Book *Grant of certificate Procedure for inspection of installed boilers Scale Oils, etc

Reg.390 C Reg.390 D Reg.390 E Reg.390 F Reg.390 G Reg.390 H Reg.390 I Reg.390 J Reg.390 K Reg.390 L Reg.390 M Reg.390 N Reg.390 O Reg.390 P Reg.390 Q Reg.390 R Reg.391 Reg.391 A Reg.392 Reg.392 A Reg.392 B Reg.392 C Reg.392 D Reg.392 E Reg.392 F Reg.392 G

Corrosion, Grooving Stays Manholes and other Openings Fire Surfaces.-Bulging, Blistering, Leaks Lap Joints, Fire Cracks Testing Staybolts Tubes -Their defects, etc Ligaments between tube holes Steam Pockets Pipe Connections and Fittings Water column Baffling-Water tube boilers Localization of heat Suspended boilers-Freedom of expansion Safety Valves Steam Gauges Calculation of Wasted Shell Aging of boilers Repairs to boilers and steam pipes Repairs to boilers and steam pipes Welding Riveting and Other Repairs REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES

Reg.392 H Reg.392 I Reg.392 J Reg.392 K Reg.392 L Reg.392 M Reg.392 N Reg.392 O Reg.392 P Reg.393 Reg.393A Reg.394 Reg.395 Reg.395 A Reg.395 B Reg.395 C Reg.395 D Reg.395 E Reg.395 F Reg.395 G

REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES REGULATIONS FOR THE REGISTRATION OF BOILERS AND INSPECTION OF BOILERS AND STEAM-PIPES Inspections of Steam Pipe Submission of plans of steam-pipes Inspection fee for boilers and parts thereof constructed in India Fees for inspection of Pipes Fee for inspection of valves Fees for inspection of components of valves Fees for inspection of feed water heaters and other fittings Marking Fee for inspection of spares and scantlings

CHAPTER : IX A Reg.396 Reg 396 SAFETY OF PERSONS INSIDE BOILERS (a) No person shall be compelled or allowed, by the owner or person in charge, to go inside a steam boiler for any purpose whatsoever unless the boiler is effectively disconnected in the manner hereinafter prescribed from any steam or hot water communication with any other boiler. Where power is used for working any equipment inside a boiler the metallic portion of the equipment shall be effectively earthed. (b) Effective disconnection shall be made either by the removal of the boiler stop valve or of a length of piping from all stream and hot water connections with any other boiler, vessel or pipe containing steam or hot water or by the insertion of substantial blank flanges between the boiler stop valves and piping. The shutting of a stop valve, stop cock or automatic isolating valve alone shall not be deemed to constitute compliance with this Regulation. In the case of welded pipe work, however, if a vent pipe of not less than 2 internal diameter (bore) is fitted between the main stop valve and the intermediate stop valve on the feed line, this Regulation shall be considered to have been complied with, provided such vent pipes are fitted with bolted-on blank flanges and the flanges are removed so as to effectively discharge any leakage steam or water to the atmosphere when the valves on either side of its have been closed. SAFETY OF PERSONS INSIDE BOILERS

(c) The owner of a boiler to which this Regulation is applicable shall obtain the approval of the Chief Inspector in writing to the method of disconnection which he proposes to use and shall be responsible for ensuring that the method of disconnection which he proposes to use and shall be responsible for ensuring that the method so approved is followed in practice. (d) When electric light is used for work inside a boiler shell or drum or any confined space within a boiler, the voltage shall not exceed 24 volts and the owner of the boiler shall provide a hand lamp with lamp-guard, keyless socket, insulated handle and extension cord of approved type. CHAPTER : X Reg.397 Reg.398 Reg.399 Reg.400 Reg.401 Reg.402 Reg.403 Reg.404 Reg.405 Reg.406 Reg.407 Reg.408 Reg.409 Reg.410 Reg.411 Reg.412 Reg.413 Reg.414 Reg.415 Reg.416 ELECTRODE BOILERS ELECTRODE BOILERS ELECTRODE BOILERS RIVETED STEEL BOILERS Working Pressure of Shells Strength of Riveted Joints Thickness of Butt-Straps Maximum pitch of rivets in Longitudinal Joints Spacing of rows of rivets End and Circumferential Seams Manholes and other openings in Shells Dished End Plates with pressure on concave side Seating for Mounting Flange-Thickness and Drilling Pads Unstayed Flat-End Plates Thickness of Angle Rings Bolts, Nuts and Studs Hydraulic Test Construction and Workmanship

Reg.417 Reg.418 Reg.419 Reg.420 Reg.421 Reg.422 Reg.423 Reg.424 Reg.425 Reg.426 Reg.427 Reg.428 Reg.429 Reg.430 Reg.431 Reg.432 Reg.433 Reg.434 Reg.435 Reg.436 Reg.437

Selection of Test pieces Tensile test Bend Test Nick Break Test Retests 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 Dished End Plates with pressure on Concave side Unstayed Flat End Plates Thickness of Angle Rings TESTS FOR CLASS II FUSION WELDED SEAMS TESTS FOR CLASS II FUSION WELDED SEAMS Hydraulic Test Determination of Working Pressure End Plates Manholes and other opening in the Shells Mountings, Fittings and Connections (For all types of Electrode Boilers)

CHAPTER : XI Reg.500 Reg.501 Reg.502 Reg.503 Reg.504 Reg.505 Reg.506 Reg.507 Reg.508 Reg.509 Reg.510 Reg.511 Reg.512 Reg.513 Reg.514 Reg.515 Application of standard conditions and exceptions thereto General requirements Modification of formula Makers Certificates for Steel Economisers Hydraulic test for new economisers Workmanship and manufacture Process of manufacture Test bars Number of tensile tests Standard test piece Cast Iron Economisers Joint bolts and studs for Cast Iron Economisers Economiser water outlet temperature Tubes: Construction Tubes: Working Pressure Headers: Construction

Reg.516 A Working Pressure Reg.516 B Cylindrical headers Reg.517 Reg.518 Attachment of tubes to headers Joint bolts, studs and flanges

Reg.519 A Valves and Mountings Reg.519 B Relief valves Reg.519 C Pressure Gauge Reg.519 D Air Release valves Reg.519 E Below off drain valves Reg.519 F Non-return valves in return feed line

Reg.519 G Reg.519 H

Reserve Flues Explosion Doors

Reg.519 I Hydraulic Test Reg.519 J Feed Line Reg.519 K Reg.520 Reg.521 Reg.522 Reg.523 Non-return valve FEED PIPES Steel feed pipes Cast Iron feed pipes Copper feed pipes

Reg.523 A Feed Heaters and similar vessels fitted to feed pipes Reg.523 B Working Pressure Reg.523 C Safety valve requirement in Feed Heaters and similar vessels Reg.524 Reg.525 Reg.526 Reg.527 Reg.528 REGULATIONS FOR REGISTRATION AND INSPECTION OF ECONOMISERS AND FEED PIPES Procedure for Registration Procedure at subsequent inspection Procedure for Hydraulic test Memorandum of Inspection Book

Reg.529 A Registration Books Reg.529 B Transfer of Memorandum of Inspection Book and Registration Books Reg.530 Reg.531 Reg.532 Reg.533 Reg.534 Grant of certificate Casual visits Economiser rating Registration fee Engraving of registry number

Reg.534 A Inspection of Feed Pipes Reg.534 B Submission of plans of Feed Pipes

CHAPTER : XII Reg.535 Reg.536 Reg.536 A Reg.537 Reg.538 Reg.539 a Reg.539 b Reg.540 Reg.541 Reg.542 Reg.543 Reg.544 Reg.545 Reg.546 Reg.547 a Reg.547 b Reg.547 c SHELL TYPE BOILERS OF WELDED CONSTRUCTION General Requirements Equipment of Workshop Materials of Construction Covered Electrodes Plain and Stay Tubes Seamless Steel Crosstubes and uptake Tubes Construction and Workmanship Preparation of Plates Stress Relieving Cylindrical Shells Circularity End Plates, Crown Plates and Tube Plates Internal Flues Fireboxes and Combustion Chambers Hemispherical fireboxes Loco-type fireboxes

Reg.547 d Reg.548 Reg.549 Reg.550 Reg.551 Reg.552 Reg.553 Reg.554 Reg.555 Reg.555 a Reg.555 b Reg.555 c Reg.555 d Reg.555 e Reg.555 f Reg.555 g Reg.556 Reg.557 Reg.558 Reg.559 Reg.560 Reg.561 a Reg.561 b Reg.561 c Reg. 561 d Reg.562 Reg.563 Reg.564 Reg.565

Water-cooled combustion chambers Uptakes Cross Tubes Bar stays and Firebox stays Girder stays for Firebox and Combustion Chamber Crowns Gusset stays Access Manhole frames, mouthpieces and doors Seatings for mountings Standpipes Saddles Pads Attachment of Standpipes Tensile Tests Attachment of water and pressure gauges Bolts and Nuts Compensating plates Definition of the terms Fusion Weld Method of Welding Types of welded shell seams Repairs to welded seams Tests on welded seams Test for Class I boilers Test for Class II Boilers Test for Class III boiler SHELL TYPE BOILERS OF WELDED CONSTRUCTION Classification of Fusion-Welded Boilers Shells Horizontal shelves of tube plates forming part of the shell

Reg.566 Reg.567 Reg.567 A Reg.568 Reg.569 Reg.570 Reg.571 Reg.571 a Reg.571 b Reg571 c Reg571 d Reg.572 Reg.573 Reg.574 Reg.575 Reg.576 Reg.577 a Reg.577 b Reg.578 Reg.579 a Reg.579 b Reg.579 c Reg.579 d Reg.580 Reg.581 Reg.582 Reg.583 Reg.584 Reg.585 A

Dished end plates for Lancashire and Cornish boilers Dished ends subject to internal pressure Dished ends subject to internal pressure Dished ends subject to external pressure Hemispherical crowns Manholes and other openings in shells Compensation for openings in shells Area to be compensated Compensating area Compensating plates Compensation for openings in shells Raised manhole frames, cover plates and joint bolts SHELL TYPE BOILERS OF WELDED CONSTRUCTION Stayed Flat surfaces (other than Crowns of Vertical Boilers). Flat crown plates for vertical boilers Wide water spaces between and around tube nests Flat tube plates and tube nests Parts of flat plates within tube nests Manhole openings in flat plates Plain tubes Plain tubes Plain tubes Plain tubes Pitch of tubes Stay tubes Compression of tube plates Girders for fire-box and combustion chamber crowns Girder sling stays Stays for fire-boxes and circular furnaces

Reg.585 B Reg.586 Reg.587 Reg.588 Reg.589 Reg.590 Reg.591 Reg.591 a Reg.591 b Reg.591 c Reg.591 d Reg.591 e Reg.592 Reg.593 Reg.594 Reg.595 Reg.596 Reg.597 Reg.598 Reg.599 Reg.600 Reg.601

Circumferential stays for circular furnaces and fire-bo Fire-box Crown stays for Loco-type Boilers Longitudinal Bar Stays Loads on Stay Tubes and Bar Stays Flat Plate Margins Breathing space Gusset Link, Brace and Similar Stays Load on each stay Gusset plates Link stays Anchor plates angles, link pins and the line members Weld attachment SHELL TYPE BOILERS OF WELDED CONSTRUCTION Plain Furnaces of Vertical Boilers Corrugated Fireboxes of Vertical Boilers Hemispherical Furnaces of Vertical Boilers Foundations of Vertical Boilers Furnaces Foundations of Loco-type Boiler Fireboxes Uptakes of Vertical Boilers Cross Tubes Pads Welded to shell or the attachment of Flanged Mountings SHELL TYPE BOILERS OF WELDED CONSTRUCTION

CHAPTER : XIII

QUALIFICATION TESTS FOR WELDERS ENGAGED IN WELDING OF BOILERS AND STEAM-PIPES UNDER CONSTRUCTION, ERECTION AND FABRICATION AT SITE IN INDIA AND IN REPAIRING BOILERS AND STEAM-PIPES BY WELDING Reg.602 Reg.603 Reg.604 Reg.605 Reg.605 A Reg.606 Reg.607 (a) Reg.607 (b) Reg.607 (c) Reg.608 Reg.609 Reg.610 Reg.611 (a) Reg.611 (b) Reg.611 (c) Reg.611 Scope Definition Engaging of Certified Welders Initial Issue of duplicate certificate Production of certificate Validity of certificate Re-validation of certificate Validity of certificate Age and experience Tests for initial qualification of a welder Tests for Requalification Examination of test specimens for initial qualification tests Fillet welded plate specimens Groove and fillet welded pipe and tube specimens Welded Tube Joints

(d) Reg.611 (e) Reg.612 Reg.613 Reg.614 Reg.615 Reg.616 Reg.617 Additional tests before rejection Examination of Test Specimens for Requalification Tests Awarding of Marks Award of Certificate Maintenance of records Fees for examination of welders Penalty

CHAPTER : XIV

SMALL INDUSTRIAL BOILERS GENERAL

Reg.618 Reg.619 Reg.620

Scope Definition Extent to which variation from the standard conditions laid down in the

preceding Chapters is permissible Reg.621 Reg.622 Valves, Gauges, Fittings and Feed Supply Registration, Operation and Maintenance

Reg. 618, Reg. 619, Reg. 620 (Regulations made under clause (a) and (aa) of section 28 of the Act) Small Industrial Boilers General Reg 618

Scope This Chapter shall apply to the design, construction, inspection, registration, operation and maintenance of small industrial boilers. Reg. 619 Definition In this Chapter, Small Industrial Boiler" means: a) a shell type boiler generating stream for use external to itself under pressure upto 7 kg/cm2 and having a volumetric capacity exceeding 22.75 litres, but not exceeding 500 litres including the volumetric capacity of all pressure parts being heated from the same heating source and connected to the boiler; or b) a coil type boiler or a once through boiler or a water tube boiler having the conditions specified in clause (a) above except that (i) the limitation of pressure shall be 12 kg/cm2, and (ii) the capacity shall be not exceeding 150 litres. Provided that in case of

boilers having combined features of clauses (a) and (b), the working pressure shall be restricted to 7 kg/cm2 and the volumetric capacity of particular pressure parts shall not exceed the limits specified in the respective clauses above subject to an aggregate of 500 litres.

Reg. 620 Extent to which variation from the standard conditions laid down in the preceding Chapters is permissible.-

The following variations from the standard conditions laid down in the preceding Chapters shall be permitted, subject to the conditions specified below, with due regard to the safety of the boilers and personnel. 1) Materials:(a) The materials used in the construction of Small Industrial boilers shall, except as otherwise provided hereinafter, conform to the provisions made in Chapter II

of these regulations. (b) Steel plates used in the construction of the boilers shall be of IS: 2062 grade B or C or equivalent and the plate for shell and heads shall be not less than 6 mm. in thickness and the heads as tube sheets for tubes rolled in shall be at least 8 mm. in thickness. (c) (i) Heads of parts of boilers when not exposed to direct impact of flame may be made of cast iron or malleable iron provided they comply with other requirements of these regulations. (ii) The allowable stress on cast iron or malleable iron shall be based on the tensile strength of material with a factor of safety of not less than 4.5. 2) Design, construction, workmanship and the method of computing the maximum

allowable working pressure: (a) (i) The construction except where otherwise specified shall be the same as those prescribed in the relevant provisions of the preceding Chapters of these regulations. (ii) In the case of fusion welded boiler neither stress relieving nor radiography of welded joints is required. (b) (i) In the Small Industrial boilers unflanged steel tube plate may be inserted into the shell and welded for the entire thickness as shown in Fig XIV/1 with a fillet weld having a throat not less than 11/4 times the thickness of the shell or tube sheet whichever is smaller. (ii) The minimum thickness of unflanged

welded tube sheets shall be 10 mm. t1 = 2 times required thickness of a seamless shell but never less than 1.25 ts or greater than t. (iii) The temperature of the heating element of electrically heated steam boilers shall be so controlled that it shall not exceed 650 C. (e) (i) The tubes shall be made of steel. (ii) The tube holes shall be drilled full size with shells butt straps and ends bolted up in position or may be punched at least 13 mm smaller in diameter than full size and then drilled, reamed or finished full size with a rotating cutter. The sharp-edges and chips removed, the plates and butt straps reassembled

metal to metal with pins fittings the holes and with tack bolts. (3) Inspection and testing:The Small Industrial Boilers shall be subjected to inspection during construction and after completion by an Inspecting Authority. The inspection of the boilers shall be made at the following stages: A. Shell type Boilers: (i) Material identification and inspection. (ii) Inspection of each component after completing welding and drilling. (iii) Assembly of boiler. (iv) Hydraulic test:(a) Every completed boiler of riveted construction shall be tested hydraulically at least twice

the working pressure; (b) In case of a boiler wholly or partly welded construction, the hydraulic test pressure shall be equal to two times the maximum allowable working pressure of the boiler. (v) A test coupon shall be provided by the maker for conducting root and face bend tests. B. Coil type Boilers, once through boilers and water tube boilers: (i) Identification of materials. (ii) Hydraulic test: The pressure for hydraulic test shall be two times that of the working pressure of the boiler. (4) Certificates and Makers Stamps.The certificate

(a)

and makers stamp shall be in conformity with the provisions of Chapter I of these regulations. (b) If owing to small size of the boiler all information cannot be visibly stamped on the boiler plate, makers certificate accompanying the boiler shall contain the necessary details, but in all cases name, works number and the year of the make must be stamped or exhibited on the boiler.

Reg. 618, Reg. 619, Reg. 620 (Regulations made under clause (a) and (aa) of section 28 of the Act) Small Industrial Boilers General Reg 618 Scope This Chapter shall apply to the design, construction, inspection, registration, operation and maintenance of small industrial boilers.

Reg. 619 Definition In this Chapter, Small Industrial Boiler" means: a) a shell type boiler generating stream for use external to itself under pressure upto 7 kg/cm2 and having a volumetric capacity exceeding 22.75 litres, but not exceeding 500 litres including the volumetric capacity of all pressure parts being heated from the same heating source and connected to the boiler; or b) a coil type boiler or a once through boiler or a water tube boiler having the conditions specified in clause (a) above except that (i) the limitation of pressure shall be 12 kg/cm2, and (ii) the capacity shall be not exceeding 150 litres. Provided that in case of boilers having combined features of clauses (a) and (b), the working pressure shall be restricted to 7 kg/cm2 and the volumetric capacity of particular pressure parts shall not exceed the limits specified in the respective clauses above subject to an

aggregate of 500 litres.

Reg. 620 Extent to which variation from the standard conditions laid down in the preceding Chapters is permissible.-

The following variations from the standard conditions laid down in the preceding Chapters shall be permitted, subject to the conditions specified below, with due regard to the safety of the boilers and personnel. 1) Materials:(a) The materials used in the construction of Small Industrial boilers shall, except as otherwise provided hereinafter, conform to the provisions made in Chapter II of these regulations. (b) Steel plates used in the construction of the boilers shall be of IS: 2062 grade B or C or equivalent and the plate for shell and heads shall be not less than 6 mm. in thickness and the heads as tube sheets for tubes rolled in shall be at least 8 mm. in thickness.

(c) (i) Heads of parts of boilers when not exposed to direct impact of flame may be made of cast iron or malleable iron provided they comply with other requirements of these regulations. (ii) The allowable stress on cast iron or malleable iron shall be based on the tensile strength of material with a factor of safety of not less than 4.5. 2) Design, construction, workmanship and the method of computing the maximum allowable working pressure:

(a) (i) The construction except where otherwise specified shall be the same as those prescribed in the relevant provisions of the preceding Chapters of these regulations. (ii) In the case of fusion welded boiler neither stress relieving nor radiography of welded joints is

required. (b) (i) In the Small Industrial boilers unflanged steel tube plate may be inserted into the shell and welded for the entire thickness as shown in Fig XIV/1 with a fillet weld having a throat not less than 11/4 times the thickness of the shell or tube sheet whichever is smaller. (ii) The minimum thickness of unflanged welded tube sheets shall be 10 mm. t1 = 2 times required thickness of a seamless shell but never less than 1.25 ts or greater than t. (iii) The temperature of the heating element of electrically heated steam boilers shall be so controlled that it shall not exceed 650 C. (e) (i) The tubes shall be made of steel. (ii) The tube holes shall be drilled full size with shells

butt straps and ends bolted up in position or may be punched at least 13 mm smaller in diameter than full size and then drilled, reamed or finished full size with a rotating cutter. The sharpedges and chips removed, the plates and butt straps reassembled metal to metal with pins fittings the holes and with tack bolts. (3) Inspection and testing:The Small Industrial Boilers shall be subjected to inspection during construction and after completion by an Inspecting Authority. The inspection of the boilers shall be made at the following stages: A. Shell type Boilers: (i) Material identification and inspection. (ii) Inspection of each component after completing welding and drilling.

(iii) Assembly of boiler. (iv) Hydraulic test:(a) Every completed boiler of riveted construction shall be tested hydraulically at least twice the working pressure; (b) In case of a boiler wholly or partly welded construction, the hydraulic test pressure shall be equal to two times the maximum allowable working pressure of the boiler. (v) A test coupon shall be provided by the maker for conducting root and face bend tests. B. Coil type Boilers, once through boilers and water tube boilers: (i) Identification of materials. (ii) Hydraulic test: The pressure for hydraulic test shall be two times that

of the working pressure of the boiler. (4) (a) Certificates and Makers Stamps.The certificate and makers stamp shall be in conformity with the provisions of Chapter I of these regulations. If owing to small size of the boiler all information cannot be visibly stamped on the boiler plate, makers certificate accompanying the boiler shall contain the necessary details, but in all cases name, works number and the year of the make must be stamped or exhibited on the boiler.

(b)

Reg. 618, Reg. 619, Reg. 620 (Regulations made under clause (a) and (aa) of section 28 of the Act) Small Industrial Boilers General Reg 618 Scope This Chapter shall apply to the design, construction, inspection, registration,

operation and maintenance of small industrial boilers. Reg. 619 Definition In this Chapter, Small Industrial Boiler" means: a) a shell type boiler generating stream for use external to itself under pressure upto 7 kg/cm2 and having a volumetric capacity exceeding 22.75 litres, but not exceeding 500 litres including the volumetric capacity of all pressure parts being heated from the same heating source and connected to the boiler; or b) a coil type boiler or a once through boiler or a water tube boiler having the conditions specified in clause (a) above except that (i) the limitation of pressure shall be 12 kg/cm2, and (ii) the capacity shall be not exceeding 150 litres. Provided that in case of boilers having combined features of clauses (a) and (b), the working pressure shall be restricted to 7 kg/cm2

and the volumetric capacity of particular pressure parts shall not exceed the limits specified in the respective clauses above subject to an aggregate of 500 litres.

Reg. 620 Extent to which variation from the standard conditions laid down in the preceding Chapters is permissible.-

The following variations from the standard conditions laid down in the preceding Chapters shall be permitted, subject to the conditions specified below, with due regard to the safety of the boilers and personnel. 1) Materials:(a) The materials used in the construction of Small Industrial boilers shall, except as otherwise provided hereinafter, conform to the provisions made in Chapter II of these regulations. (b) Steel plates used in the construction of the boilers shall be of IS: 2062 grade B or C

or equivalent and the plate for shell and heads shall be not less than 6 mm. in thickness and the heads as tube sheets for tubes rolled in shall be at least 8 mm. in thickness. (c) (i) Heads of parts of boilers when not exposed to direct impact of flame may be made of cast iron or malleable iron provided they comply with other requirements of these regulations. (ii) The allowable stress on cast iron or malleable iron shall be based on the tensile strength of material with a factor of safety of not less than 4.5. 2) Design, construction, workmanship and the method of computing the maximum allowable working pressure:

(a) (i) The construction except where

otherwise specified shall be the same as those prescribed in the relevant provisions of the preceding Chapters of these regulations. (ii) In the case of fusion welded boiler neither stress relieving nor radiography of welded joints is required. (b) (i) In the Small Industrial boilers unflanged steel tube plate may be inserted into the shell and welded for the entire thickness as shown in Fig XIV/1 with a fillet weld having a throat not less than 11/4 times the thickness of the shell or tube sheet whichever is smaller. (ii) The minimum thickness of unflanged welded tube sheets shall be 10 mm. t1 = 2 times

required thickness of a seamless shell but never less than 1.25 ts or greater than t. (iii) The temperature of the heating element of electrically heated steam boilers shall be so controlled that it shall not exceed 650 C. (e) (i) The tubes shall be made of steel. (ii) The tube holes shall be drilled full size with shells butt straps and ends bolted up in position or may be punched at least 13 mm smaller in diameter than full size and then drilled, reamed or finished full size with a rotating cutter. The sharp-edges and chips removed, the plates and butt straps reassembled metal to metal with pins fittings the holes and with tack bolts.

(3)

Inspection and testing:The Small Industrial Boilers shall be subjected to inspection during construction and after completion by an Inspecting Authority. The inspection of the boilers shall be made at the following stages:

A.

Shell type Boilers: (i) Material identification and inspection. (ii) Inspection of each component after completing welding and drilling. (iii) Assembly of boiler. (iv) Hydraulic test:(a) Every completed boiler of riveted construction shall be tested hydraulically at least twice the working pressure; (b) In case of a boiler

wholly or partly welded construction, the hydraulic test pressure shall be equal to two times the maximum allowable working pressure of the boiler. (v) A test coupon shall be provided by the maker for conducting root and face bend tests. B. Coil type Boilers, once through boilers and water tube boilers: (i) Identification of materials. (ii) Hydraulic test: The pressure for hydraulic test shall be two times that of the working pressure of the boiler. (4) Certificates and Makers Stamps.The certificate and makers stamp shall be in conformity with

(a)

the provisions of Chapter I of these regulations. (b) If owing to small size of the boiler all information cannot be visibly stamped on the boiler plate, makers certificate accompanying the boiler shall contain the necessary details, but in all cases name, works number and the year of the make must be stamped or exhibited on the boiler.

Reg. 621, Reg. 622 Small Industrial Boilers General Reg 621 Valves, Gauges, Fittings and Feed Supply (a) Washout Plugs, etc. for cleaning:(i) Every boiler shall be fitted with at least 3 brass wash plugs of not less than 25

mm. diameter which shall be screwed into the openings in the shells near the bottom. In the boilers of closed system type heated by removable internal electric heating elements, the opening for these elements when suitable for cleaning purposes may be substituted for wash out openings. (ii) Boilers not exceeding 300 mm. internal diameter may have two 25 mm. openings for cleaning one of which may be used for the attachments of the blow off valve. The openings shall be opposite to each other, wherever possible. All threaded openings in the boiler shall be provided with riveted or

welded reinforcement, if necessary, to give four full threads therein. (iii) Electric boilers of a design employing removable top cover flange for inspection and cleaning need not be fitted with washout openings and washout plug. Level gauges are not required for once through boilers. (b) Every boiler shall be provided with at least one feed pump or other feeding device except where it is connected with a water main carrying pressure to feed the boiler or where the steam generator is operated with no extraction of steam (closed system). In the latter case, in lieu of the feeding device, a suitable connection or opening shall be provided to feed the boilers. Such connection shall be not less than 13 mm.

in diameter. (c) Subject to the provisions of this sub-regulation every boiler shall be fitted with necessary mountings and fittings as provided in Chapter VI of these regulations, and they shall be of substantial construction suitable for 7 kg/cm2. All these fittings except safety valves shall be certified by manufacturers of the fittings themselves. (i) Feed pipe: The feed pipe shall be provided with a check valve and a stop valve of a size not less than that of the pipe. The feed water may be delivered to the boiler through the openings of the same size in the shell as that of the blow off connection. Each boiler shall be

(ii)

Blow Off:

equipped with a blow off connection, not less than 18 mm. in size located to drain the boiler water from the lowest water space practicable when the boiler is under pressure. Feed water shall not be introduced through the openings or connection needed for the water column, the water gauge glass or the gauge cock. (iii) Water Every Gauges: boiler other than a coil type or a once through boiler shall be fitted with two gauge glasses not less than 150 mm. long for

determining the water level. The boiler shall have the lowest visible part of the water gauge located at least 25 mm. above the lowest permissible water level. The lowest permissible water level of vertical boilers shall be at a point one-third of the height of the shell above the bottom head or tube sheet. Where the boiler is equipped with internal furnace, the water level shall not be less than one-third of the length of the tubes above top of the furnace tube sheet. (iv) Pressure The steam Gauge: pressure gauge shall have its dial graduated to not less than twice the maximum allowable working

pressure of the boiler. The diameter of the dial shall be at least 100 mm. and the pipe connecting the pressure gauge shall be minimum 10 mm. and the connection shall be through siphon. (v) Safety Each boiler Valve: shall be equipped with two safety valves for relieving the steam pressure. The diameter of the valve shall not be less than 19 mm. The minimum relieving capacity of the safety valve shall be sufficient to discharge all the steam that can be generated by the boiler without allowing the pressure

to rise more than 10% above maximum allowable working pressure. The safety valve shall be connected to the boiler independently of any other steam connections, without any unnecessary intervening pipe or fitting. Such intervening pipe or fitting if unavoidable shall be not longer than the corresponding face to face dimension of a tee fitting of the same diameter and the minimum opening there through shall be at least equal to the valve inlet. No valve of any description shall be placed between safety valve and the boiler not on the discharge pipe from the safety valve to the atmosphere. The electrically heated boilers shall be effectively earthed with a lead of substantial cross section.

Reg. 622

Registration, Operation and Maintenance

(a) (i) The fee required to accompany an application under sub-section (1) of section 7 of the Act shall be five hundred rupees per boiler. (ii) The annual inspection fee shall be five hundred rupees per boiler. (b) The certificate of manufacture and test for small industrial boilers shall be furnished in Form XVII appended to these regulations. The operator for these boilers shall be a pass in Class X or equivalent.

(c)

Reg. 621, Reg. 622 Small Industrial Boilers General Reg 621 Valves, Gauges, Fittings and Feed Supply (a) Washout Plugs, etc. for cleaning:-

(i) Every boiler shall be fitted with at least 3 brass wash plugs of not less than 25 mm. diameter which shall be screwed into the openings in the shells near the bottom. In the boilers of closed system type heated by removable internal electric heating elements, the opening for these elements when suitable for cleaning purposes may be substituted for wash out openings. (ii) Boilers not exceeding 300 mm. internal diameter may have two 25 mm. openings for cleaning one of which may be used for the attachments of the blow off valve. The openings shall be opposite to each other, wherever

possible. All threaded openings in the boiler shall be provided with riveted or welded reinforcement, if necessary, to give four full threads therein. (iii) Electric boilers of a design employing removable top cover flange for inspection and cleaning need not be fitted with washout openings and washout plug. Level gauges are not required for once through boilers. (b) Every boiler shall be provided with at least one feed pump or other feeding device except where it is connected with a water main carrying pressure to feed the boiler or where the steam generator is operated with no extraction of steam (closed system). In the latter case, in lieu of the feeding device, a suitable

connection or opening shall be provided to feed the boilers. Such connection shall be not less than 13 mm. in diameter. (c) Subject to the provisions of this sub-regulation every boiler shall be fitted with necessary mountings and fittings as provided in Chapter VI of these regulations, and they shall be of substantial construction suitable for 7 kg/cm2. All these fittings except safety valves shall be certified by manufacturers of the fittings themselves. (i) Feed pipe: The feed pipe shall be provided with a check valve and a stop valve of a size not less than that of the pipe. The feed water may be delivered to the boiler through the openings of the same size in the

shell as that of the blow off connection. (ii) Blow Off: Each boiler shall be equipped with a blow off connection, not less than 18 mm. in size located to drain the boiler water from the lowest water space practicable when the boiler is under pressure. Feed water shall not be introduced through the openings or connection needed for the water column, the water gauge glass or the gauge cock.

(iii) Water Every Gauges: boiler other than a coil type or a once through boiler shall

be fitted with two gauge glasses not less than 150 mm. long for determining the water level. The boiler shall have the lowest visible part of the water gauge located at least 25 mm. above the lowest permissible water level. The lowest permissible water level of vertical boilers shall be at a point one-third of the height of the shell above the bottom head or tube sheet. Where the boiler is equipped with internal furnace, the water level shall not be less than one-third of the length of the tubes above top of the furnace tube sheet. (iv) Pressure The steam Gauge: pressure gauge shall have its dial

graduated to not less than twice the maximum allowable working pressure of the boiler. The diameter of the dial shall be at least 100 mm. and the pipe connecting the pressure gauge shall be minimum 10 mm. and the connection shall be through siphon. (v) Safety Each boiler Valve: shall be equipped with two safety valves for relieving the steam pressure. The diameter of the valve shall not be less than 19 mm. The minimum relieving capacity of

the safety valve shall be sufficient to discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 10% above maximum allowable working pressure. The safety valve shall be connected to the boiler independently of any other steam connections, without any unnecessary intervening pipe or fitting. Such intervening pipe or fitting if unavoidable shall be not longer than the corresponding face to face dimension of a tee fitting of the same diameter and the minimum opening there through shall be at least equal to the valve inlet. No valve of any description shall be placed between safety valve and the boiler not on the discharge pipe from the safety valve to the atmosphere. The electrically heated boilers shall

be effectively earthed with a lead of substantial cross section.

Reg. 622 Registration, Operation and Maintenance

(a) (i) The fee required to accompany an application under sub-section (1) of section 7 of the Act shall be five hundred rupees per boiler. (ii) The annual inspection fee shall be five hundred rupees per boiler. (b) The certificate of manufacture and test for small industrial boilers shall be furnished in Form XVII appended to these regulations. The operator for these boilers shall be a pass in Class X or equivalent.

(c)

CHAPTER : XV FEED WATER FOR BOILER

Reg.623 Reg.624 Reg.625 Reg.626 Reg.627 Reg.628 Reg.629 Reg.630 A Reg.630 B Reg.630 C Reg.630 D Reg.631 Reg.632 Reg.633 Reg.634 Reg.635

Scope Requirements Sampling Test Methods Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted

Reg. 623, Reg. 624, Reg. 625 FEED WATER FOR BOILER Scope a) This chapter lays down specifications for feed water and boiler water for low and medium pressure boilers (boilers operating up to 60 kg/cm2). b) For boilers operating at pressures higher than 60 kg/cm2, better quality of water to IS:10496-1983 may be adopted.

Reg. 624 Requirements The water shall comply with the requirements given in Table 1 when tested by

the methods prescribed in col. 6 and 7 of the table.

Reg. 625 Sampling Sampling shall be done following general directions given in 2 of IS:3025-1964*. In particular, the following points shall be observed : a) It is necessary that a stainless steel or monel metal coil is fitted on the sampling cock so that the temperature of the water sample will be well below the boiling point at atmospheric pressure and there is no risk of aeration and concentration due to flashing into steam; and

b) Samples of feed water shall be collected from the delivery of the boiler feed pump, samples of boiler water from the top drum, and samples of condensate from the delivery of the condensate extraction pump. Reg. 623, Reg. 624, Reg. 625 FEED WATER FOR BOILER Scope a) b) This chapter lays down specifications for feed water and boiler water for low and medium pressure boilers (boilers operating up to 60 kg/cm2). For boilers operating at pressures higher than 60 kg/cm2, better quality of water to IS:10496-1983 may be adopted.

Reg. 624 Requirements The water shall comply with the requirements given in Table 1 when tested by the methods prescribed in col. 6 and 7 of the table.

Reg. 625 Sampling

Sampling shall be done following general directions given in 2 of IS:3025-1964*. In particular, the following points shall be observed :

b) Samples of feed water shall be collected from the delivery of the boiler feed pump, samples of boiler water from the top drum, and samples of condensate from the delivery of the condensate extraction pump. Reg. 623, Reg. 624, Reg. 625 FEED WATER FOR BOILER Scope a) This chapter lays down specifications for feed water and boiler water for low and medium pressure boilers (boilers operating up to 60 kg/cm2). b) For boilers operating at pressures higher than 60 kg/cm2, better quality of water to IS:10496-1983 may be adopted.

Reg. 624 Requirements The water shall comply with the requirements given in Table 1 when tested by the methods prescribed in col. 6 and 7 of the table.

Reg. 625 Sampling

Sampling shall be done following general directions given in 2 of IS:3025-1964*. In particular, the following points shall be observed : a) It is necessary that a stainless steel or monel metal coil is fitted on the sampling cock so that the temperature of the water sample will be well below the boiling point at atmospheric pressure and there is no risk of aeration and concentration due to flashing into steam; and Samples of feed water shall be collected from the delivery of the boiler feed pump, samples of boiler water from the top drum, and samples of condensate from the delivery of the condensate extraction pump.

b)

Reg. 626 FEED WATER FOR BOILER

Test Methods Tests shall be carried out as prescribed in the appropriate clauses of IS : 3025-1964* and IS : 3550-1965! as indicated against the characteristics in Table 1. TABLE 1: CHEMICAL REQUIREMENTS OF FEED WATER AND BOILER WATER FOR LOW AND MEDIUM PRESSURE BOILERS (Regulation 624 and 626) Sl.. CHARACTERISTIC REQUIREMENT METHOD OF TEST FOR (Ref. to Cl. No. of) No. BOILER PRESSURE ---------------------------------------------------------------Up to 2.0 2.1 to 3.9 4.0 to 5.9 IS : IS : 355 302 0- 5-_ 2 2 2 MN/m MN/m MN/m 196 196 5* 4! (1) (2) (3) (4) (5) (6) (7) i) Feed Water a) Total hardness 10 1.0 0.5 -- 16.1 (as CaCO2 ),mg/l, Max ---------------------------------------------------------------------------------------------------------------------(1) (2) (3) (4) (5) (6) (7) b) pH value 8.5 to 9.5 8.5 to 9.5 8.5 to 9.5 -- 8 c) Dissolved Oxygen, 0.1 0.02 0.01 25 -mg/1, Max

d) Silica (as SiO2), mg/l, Max ii) Boiler Water a) Total hardness(of filteredsample) (as CaCO3), mg/l, b Total alkalinity (as CaCO3), mg/l,Max c) Caustic alkalinity (as CaCO3), mg/lMax d) pH value e)

---------- Not detectable -----------700 350 11.0 to 12.0

0.5

16 --

-500 200 11.0 to 12.0

16.1 300 60 10.5 to 11.0 -0.05 to 0.3 20.2 and 15 48 and 13 5 to 20 1500 14 9 -12 ----26 13 15 8 21 --

Residual sodi um 30 to 50 20 to 30 sulphite (asNa2SO3) mg/l f) Residual hydrazine (as 0.1 to 1 0 .1 to 0.5 N2H4),mg/l (if added) (if added) g) Ratio Na2SO4/Caustic ------------ above 2.5 alkalinity (as NaOH) ---------------or Ratio NaNO3/ total alkalinity (as NaOH) ------------- above 0.4 ----------------h) Phosphates (asPO4), 20 to 40 15 to 30 mg/l (if added ) i) Total dissoslved solids mg/l, Max k) Silica (as SiO2), mg/l 3500 2500

Less than 0.4 of caustic 15 16 30 alkalinity ----------------------------------------------------------------------------------------------------------------------Note 1- Recovery Boilers - The boiler feed water used shall be completely demineralized and also the boiler feed water and boiler water shall be conditioned in accordance with high pressure boilers working at 60 kg/cm2 and above (see IS : 4343-1967**) Note 2 - When feed water heaters are of copper or copper alloy constructions, the pH of the feed water shall be maintained between 8.5 and 9.2 while when feed water heaters are of iron constructions, the pH of the feed may be maintained between 8.5 and 9.5. Note 3 - Silica in Boiler Water - Lower concentration of silica may be advisable for steam of turbines, which generally requires less than 0.02 mg/l silica in steam.

* Methods of test for routine control for water used in industry. ! Methods of sampling and test (physical and chemical) for water used in industry.

Total alkalinity should preferably be about 20 percent of total dissolved solids.

Shall not apply if reducing agents other than sodium sulphite are used. For riveted boilers only. For shell type boilers depending on parameters, the limits can be relaxed.

** Code of practice for treatment of water for high pressure boilers (under revision). Appendix

Appendix - A Appendix - B Appendix - D Appendix - E Appendix - F Appendix - J