IBR Book - File

INDIAN BOILERS REGULATIONS 1950
Regulation No. 2
(a) after clause (C), the following clause shall be inserted, namely: (cc) "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;
(b)
For clause (dd), the following shall be substituted, namely:(dd) "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;
(c) after clause (dd), the following clause shall be inserted, namely:(ddd)
"Design pressure" means:(i) in relation to a natural or assisted circulation boiler, the 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;
(d) After clause (e), the following shall be inserted, namely:(ee) "Evaluation Committee" means a committee constituted by the Central Government consisting of,(a) Technical Adviser (Boilers) - Chairman
(b) Chief Inspector (Boilers) of the State where the unit is located - Member
(c) A representative of the manufacturers of boilers/ancillaries in public sector Member
(e) For clause (g), the following shall be substituted, namely:"(g) "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, IIA or IIB;
(f) In clause (h) after sub clause (ii), the following sub-clause shall be inserted, namely:(iii) in respect of:(a)
(b)
(c)
(a) approval of drawings of boilers of parts thereto with minor changes, where necessary, except for the drawings of the
first set of boilers or parts there to;
(b) inspection at stages of manufacture including examination of repairs;
(c) signing and issue of certificates in the relevant forms except for the certificates of the first set of boilers or parts
there to; an officer acting on behalf of an Inspecting Authority;
(g) After clause (h), the following shall be inserted, namely:(hh) "Liaison Sub-Committee" means a committee constituted by the Central Boilers Board under bye-law 3(i) (e) of the Bye-laws
of the Central Boilers Board;
(h) After clause (m), the following shall be inserted, namely:(n) "Technical Adviser (Boilers)" means Technical Adviser (Boilers) to the Government of India in the Ministry of Industry
(Department of Industrial Development).
Regulation No.3
(a) In regulation 3, in sub-regulation (2), in paragraph (i), the following shall be added, at the end, namely:and that the methods of manufacture, fabrication and heat treatment conform to the specified Codes or Standards;
(b) After clause (3) of regulation 3, the following shall be inserted, namely:(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 B.S., ASME Boiler and pressure vessel 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.
(5) Notwithstanding anything contained in these regulations, the Inspecting Authority may approve, inspect and issue certificates when the
material used in the construction of the boiler, steam-pipe, economiser, superheater or other pressure parts is not in conformity with these
regulations, but is in conformity with I.S.O. Boiler code, ISO/R-831.
(6) Notwithstanding anything contained in these regulations, the Inspecting Authority may accept, the design or constructional features of
boiler, steam-pipe, economiser, superheater or other pressure parts which is not in conformity with these regulations, but is in conformity
with I.S.O. Boiler code, I.S.O./ R-831.
(7) Notwithstanding anything contained in sub-regulation (1), and subject to the provision of Regulation 7 and 8, the chief inspector of
boilers may register a boiler, and order the issue of a certificate authorizing the use thereof, under any of the following circumstances,
namely:(i) When the material intended to be used in the construction of a boiler, steam-pipe, economiser, superheater or other pressure
parts is not in conformity with these regulations, but is in conformity with I.S.O. Boiler code, I.S.O./ R-831.
(ii) When the design and constructional features of a boiler steam-pipe, economiser, superheater or other pressure parts is not in
conformity with these regulations, but is in conformity with I.S.O. Boiler code, I.S.O./ R-831.
After Regulation 3, the following regulation shall be added, namely: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 IIA.
Regulation No.4
(i) In sub-clause (i) of clause (c), the following shall be inserted at the end, namely:In case of Waste Heat Boilers, a certificate in Form II may be issued by the Inspecting Authority of the State, where the boiler is
installed, after completion of construction at site on the strength of the certificates supplied to him in prescribed forms by the owner for the
individual components which are required to be furnished for registration of a boiler under Regulation 4(c), shall be submitted to the
Inspecting Authority of the State, where the boiler is installed, before the commencement of construction of such boiler at the site.
(ii) After sub-clause (i) of clause (c), the following note shall be added at the end, namely: 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 he Inspection Authority
under sub-regulation (5) or sub regulation (6) of regulation, 3.
(iii) For paragraph 3 of sub-clause of (iv) of clause (c), the following shall be substituted, namely: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 IVA 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 IIID or
IIIE, as the case may be, shall be accepted in lieu of a certificate from an Inspecting Authority;
(iv) For paragraph 4 of sub-clause (iv) of clause (c), the following shall be substituted, namely:-
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 he
Inspecting Authority, shall be acceptable in lieu of the certificate in Form IV. Original steel maker's certificate or manufacture and results of tests
shall be produced to the Chief Inspector on demand.
(v) After sub-clause (vi) of clause (c), the following note shall be inserted, namely:Note:- Until 33,000 hours tests are carried out by National Metallurgical Laboratory or Corporate Research & Development
Laboratory of Bharat Heavy Electricals Limited for Collecting elevated temperature data of alloy steel produced indigenously against ASME or
BS Grades, these grades of steel may be accepted and long time elevated temperature properties / maximum allowable stress values given in
ASME code or BS, as the case may be, may be used for the purpose of design provided:
(a) 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 ASME Code or BS to assure that the creep rupture requirements are complied with.
(b) The Steel maker, furnished the necessary certificate that the steel conforms to the chemical analysis, room and elevated
temperature mechanical properties given in ASME Code or BS as the case may be.
(c) The short-term stress rupture tests for 10,000 hours as described below are carried out by National Metallurgical Laboratory,
Corporate Research and Development Laboratory of Bharat Heavy Electricals Ltd. 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 Code or BS as the case may and a certificate is given by National Metallurgical Laboratory / Corporate Research and Development
Laboratory of Bharat Heavy Electricals Ltd. to this effect.
(d) A minimum of three casts are tested from each steel manufacturer for each grade of steel.
(e) Each grade of steel is tested at three temperatures, namely 500C, 550C and 600C for T22 grade of steel and 460C, 500C and
550C for T12 grade of steel and at three stress level to give rupture lives of 1000, 3000, 10000 hours at each temperature and taking two
specimens under each test condition in conformity with the code/Specification to which the steel is made.
(f) Concurrently the stress rupture tests for 33,000 hours duration are taken up on the same three casts from each steel manufacturer
for each grade of steel at three tests temperatures and taking two specimens at each temperature.
(vi) After clause (f), the following shall be inserted, namely: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.
(vi) in clause (g), the existing Note shall be renumbered as Note 1 and after Note 1 as so renumbered, the following Notes shall be inserted at the
end, namely:Note 2 - For the purpose of clause (c), (e), (f) and (g) of this regulation, certificate issued by an authority empowered in this behalf by
or under the law in force or national code of standard of any foreign country in respect of plates, bars, tubes, pipes, forgings and casting,
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.
After clause (g), the following clauses shall be inserted, namely:(h) Certificates of inspection during construction of pipes for which variation from standard conditions have been permitted. - A
certificate of manufacture and test in Form III-A (i), signed by the maker and the Inspecting Authority shall be furnished.
(i) Certificate of inspection during construction of tubes for which variation from standard condition 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.
After regulation 4, the following regulation shall be inserted namely:- (Regulation 4A to 4H)
PROCEDURE FOR RECOGNITION OF COMPETENT AUTHORITY, INSPECTING AUTHORITY, WELL-KNOWN MATERIAL

TESTING LABORATORY, WELL-KNOWN STEEL MAKER, WELL-KNOWN FOUNDRY/FORGE, WELL-KNOWN TUBE/PIPE
MAKER .4A. Application for Recognition:(1) An application for recognition as Competent Authority, Inspecting Authority, Well-known Material Testing Laboratory, Wellknown Steel Maker, Well-known Foundry/Forge and Well-known Tube/Pipe Maker 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.
(2) On receipt of application under sub-regulations (1), the Secretary, Central Boilers Board shall send a questionnaire in any of the
Forms (Form XV-A to XV-F) applicable to the area of activity to the applicant who shall send the same after duly completed, to the Secretary,
Central Boilers Board.
(3) 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.
(4) 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) only shall be deposited along with the completed
Questionnaire form.The Evaluation Committee shall carry out the evaluation of the manufacturing works of the firm with in 120 days of receipt
of the fees.
4B. Scrutiny of Applications by the Evaluation Committee(1) The Secretary, Central Boilers Board shall send all the applications received under sub-regulation (1) of Regulation 4A, along with
replies to the questionnaire under sub-regulation (2) of Regulation 4A, to the Evaluation Committee.
(2) 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 for 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 and Well Known Tube/Pipe Maker, the Evaluation Committee shall inspect the laboratory of such Material Testing Laboratory
or the factories of such steel makers, foundry or forge and tube or pipe makers, where the testing and manufacturing activities are being carried
out in order to evaluate the performance quality of the tests conducted and products manufactured.
(3) The Evaluation Committee after satisfying itself that the requirements specified in sub-regulations (1) and (2) are fulfilled, shall
submit a report along with its recommendations to the Liaison Sub-Committee.
4C. 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 subregulation (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.
(2) 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-H) 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.
4D. Validity of Certificate of RecognitionA certificate of recognition issued under Regulation 4C, shall be valid for a period of three years.
4E. 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 three 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.
4F. 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, 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
recognised 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.
4G. 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.
(2) 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.
4H. Function of Evaluation CommitteeThe 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 nonconforming material;
(xiii)
Indication of inspection status;
(xiv)
Protection and preservation of product quality(a) material handling;
(b) storage;
(c) delivery;
(xv) Training. "
Regulation No.5.
Clause (iv) shall be omitted.
After Regulation 5, the following new regulation shall be inserted, namely:5A. Material not fully identifiedWhere 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 by the Inspecting
Authority; the registering authority 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)
(ii)
(iii)
(i) The plates shall have a steel maker's 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 tubes-Shipping documents shall be made available to establish the specifications for manufacture for inspection
and testing.
Regulation No.7
The following shall be substituted, namely:7. Registration of second-hand boilers not in accordance with the standard conditionsIf 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 the 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 secondhand 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 (Click here to view the Table) given
Regulation No. 8
In clause (b) the Note shall be deleted.
CHAPTER II For the heading, the following heading shall be substituted:STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL..
Regulation No. 9
(i) The following regulation shall be substituted, namely: 9. 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 De-oxidation practice shall be appropriate to the type of steel used, particularly where the de-oxidation practice influence
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 up to 20 mm.
(d) Plates of Carbon Steel shall conform to one of the following four grades of tensile strength namely:(i) 37 to 45 kgf/mm2
(ii) 42 to 50 kgf/mm2
(iii) 47 to 56 kgf/mm2
(iv) 52 to 62 kgf/mm2
(ii) After clause (d), the following clause shall be inserted, namely:(e) Semi-skilled 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 50 mm under service temperature condition 0-450C.
Regulation No. 10
(i) For clause (a) the following shall be substituted, namely:(a) The Steel shall not contain more than 0.05 per cent of sulphur or phosphorus.
(ii) After clause (c) the following clause shall be inserted, namely:(d) Plates not intended for hot forming shall be supplied in the normalized conditions unless otherwise agreed upon between the boiler
manufacturer and the Inspecting Authority. Normalizing may be omitted if it is demonstrated that equivalent properties can be produced by the
rolling subsequent cooling.
NOTE:- The boiler manufacturer may, if he so wishes order a check analysis.
Regulation No. 11
The following shall be substituted, namely:11. Freedom form defects, etc. Minor surface defects of the plates may be removed by mechanical means to achieve the smooth level surface
provided that the minimum specified thickness as maintained surface defects may be repaired by welding only with the approval of the Inspecting
Authority provided that the plate is stress relieved after welding where necessary.
Regulation No. 13
After regulation 13, the following new regulation shall be inserted namely :13A. 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 those 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 Authorities/Chief Inspector of Boilers of
the State.
Regulation No.15
The following regulation shall be substituted, namely :(a) The tensile strength and percentage elongation shall be determined from test pieces of gauge length preferably equal to Lo=5.65 Ao (See
Regulation 16). Alternatively, other gauge lengths may be used, provided the elongation value on a gauge length of 5.65 Ao.
(b) In arbitration cases a test piece of gauge length equal to 5.65 Ao for rectangular test pieces of 5do for round test pieces shall used. For plate
thickness exceeding 60 mm 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.
Regulation No.16
The following regulation shall be substituted, namely :16. 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 not be less than 50% of the specified minimum tensile strength at room
temperature.
(c) - The breaking elongation in percentage shall be not less than
Where,
Where
Notes-
Rm
N
=
=
tensile strength at room temperature in Kgf/ mm2

a quality index of 100 for plate thickness up to 50 mm or 95 for plate thickness
over 50 mm.
2.2 for only gauge lengths of Lo= 5do or L= 5.65 Ao
Lo
=
gauge length
do
=
Original diameter of the round test piece.
Ao
=
Original cross-section of the rectangular test piece.
C=1.9 for gauge lengths of 4Ao or for test piece in 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 Table (Click here to view the Table) given.
Regulation No.17
(i) For sub-regulation (a), the following sub-regulation shall be substituted, namely: (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.
(ii) sub-regulation (b) shall be omitted;
(iii) sub-regulation (c) shall be renumbered as sub-regulation (b).
Regulation No.20
For sub-regulation (a), the following sub-regulation shall be substituted namely:(a) Plates- A bend test shall be taken from each plate as rolled. The bend tests 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 tests.
Regulation No.22
The following paragraph shall be added at the end, namely:
If the unsatisfactory result of a test is obviously due to technical conditions of the testing method or to a closely limited defect of a test piece,
then the failure can be left out of consideration in the decision on the fulfillment of the requirement and another test piece may be substituted. If
the unsatisfactory result of test is due to an unfavorable heat treatment the plate and the test strip may be heat treated again. Following this, the
entire test shall be repeated.
Regulation No.23
Regulation 23 shall be re-numbered as sub-regulation (i) thereof and after sub-regulation (i) as so re-numbered, the following subregulation shall be inserted, namely :(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.
Regulation No.35
After sub-regulation (2), the following sub-regulation shall be inserted, namely:(3) Carbon Steel Tubes-Tubes of Carbon Steel for boilers and super heaters subject to internal pressure shall comply with the requirements of
Regulations 36 to 42, Regulations 43 to 46 or Regulations 57 to 63, as the case may be.
Regulation No.36
For clause (a), the following shall be substituted, namely:(a) Material process:The tubes shall be seamless and made of steel produced by an Open Hearth or Electric process or any of the oxygen processes. The steel shall not
contain more than 0.05 percent of sulphur or phosphorus. The manufacturers shall supply a certificate of analysis when required to do so.
Regulation No.38
The following regulation shall be substituted, namely :38. Tensile strength (a) The tensile strength of a material cut from finished tubes shall conform to one of the following five grades namely:(i) 31 to 41 kgf/mm2
(v) 50 to 62 kgf/mm2
(b) The upper yield point at room temperature shall be not less than 50 percent of the specified minimum tensile strength at room temperature.
(c) The minimum values of the stress at proof limit 0.2 percent at elevated temperature (Et) of the material may be calculated by multiplying the
specified minimum tensile strength at room temperature (R20) by the ratio (Et/R20) given in the table below:Table: Minimum values for the ratio of the stress at proof limit 0.2 percent at elevated temperature (Et) to the minimum specified tensile strength
at room temperature (R20) of carbon steel tubes.
Temperature
250C
*275C
300C
325C
350C
375C
Et/R20
0.40
0.38
0.36
0.34
0.33
0.32
Temperature
375C
400C
425C
Et/R20
0.32
0.31
0.30
*For temperature lower than 300C any test required for acceptance purposes (in the absence of record of previous tests at the temperatures) shall
be made at 300C in which case he proof stress shall be not less than the value obtained by calculation from the specified minimum tensile
strength at room temperature and the above ratio of 0.36 for 300C.
(d) The breaking elongation in % shall be not less than
where
C=2.2 for only gauge length or L=5 do or 5.65A0

d=original diameter of the round test piece.
A=original cross section of the rectangular test piece.
NOTE: C=1.9 for gauge lengths of 4 A of test piece, in Appendix-A.
Regulation No.39
The following regulation shall be substituted, namely :39. Flattening Test A ring not less than 50mm in length cut form one end of each selected tube shall be flattened between two parallel flat
surfaces to a distance between the plates (H) as calculated by the formula given below without showing any sign of a crack of flaw.
where,
a
D
C
C
=
=
=
=
thickness of tube (9 mm).

Outside diameter of the tube (mm).
a constant as given below.
0.09 for steel having a specified minimum tensile strength from 31 kgf/mm2 upto and
including 35 kgf/mrn2.
0.07 for steel having a specified minimum tensile strength over 35 kgf/mm2 upto and
including 42 kgf/mm2.
Regulation No.40
The following regulation shall be substituted, namely :40. Flanging and drift expanding tests (a) The tube shall withstand either the flanging test or the drift expanding test, at the option of the
manufacturer.
(b) Flanging tests- A test piece cut from the end of the tube in a plane perpendicular to the axis of the tube shall show no crack or flaw
after flanging to the specified outside diameter as given in the table below(c) Drifting expanding test- A test piece cut from the end of a tube in a plane perpendicular to the axis of the tube shall show no crack
after expanding by a mandrel having an included angle of 30 or 60 at the option of the manufacturer to increase the outside diameter as given in
the table below:Table: Minimum increase of outside diameter of tubes in Flanging and drift expanding test.
Type of test
Minimum specified
strength(s)
Kgg/mm2
Flanging test
S<42
tensile
Outside diameter (D) of the

tube
Increase of outside diameter of

the tube
A=D<63.5,
B=63.5<D<150mm
A
%
17
S>42
11
14
18
Drift expanding test
17
11
Regulation No.42
The following regulation shall be substituted, namely :42. Hydraulic Test- (i) Each tube shall be tested at the Maker's Works on completion of manufacture and shall withstand a hydraulic pressure, to
one and half times the design pressure subject to a minimum of 0.70 kgf/mm2 but not greater than pressure calculated by the following formula
Where,
P
D
t
s
=
=
=
=
test pressure.
Outside diameter of the tube.
Nominal wall thickness of the tube.
Stress which shall be taken as 40% of the minimum tensile strength at room
temperature.
(ii) Notwithstanding anything contained in clause (i), the hydraulic test for tubes in Makers' premises may be dispensed with by the
Inspecting Authority provided that the tubes are subject to non-destructive testing by an appropriate method like ultrasonic or/and Eddy current
testing.
Regulation No.43
(i) In clause (a) the words and figures and the steel produced by the Oxygen process shall in addition not contain more than 0.006
percent of nitrogen shall be omitted.
(ii) In clause (a) the following shall be added at the end, namely:When the ladle analysis is not available, the analysis of the sample tubes selected at random may be used.
(iii) In clause (a) for he words, manganese..0.35% maximum, the following shall be substituted, namely:Manganese.0.35% minimum.
(iv) In clause (d), for sub-clause (i), the following shall be substituted, namely:(i) Diameter: The external diameter of the tubes measured at any point shall be within the following tolerances of diameter specified:Outside diameter of tubes
Tolerances
Upto and including 63.5mm
+ 0.4 mm
- 0.8 mm
Over 63.5 mm
1 %
Regulation No.44
For clauses (a), (b) and (c), the following clauses shall be substituted, namely:(a) Tensile strength. (1) The tensile strength of the material cut from finished tubes shall conform to one of the following five grades namely:(i) 31 to 41 kgf/mm2
(v) 50 to 62 kgf/mm2
The upper yield point at room temperature shall be not less than 50 % of the specified minimum tensile strength at room temperature.
(2) The minimum values of the stress at proof limit 0.2 % at elevated temperature (Et) of the material may be calculated by
multiplying the specified minimum tensile strength at room temperature (R20) by 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 tubes.
Temperature
250C
*275C
300C
325C
350C
375C
375C
400C
425C
Et/R20
0.40
0.38
0.36
0.34
0.33
0.32
0.32
0.31
0.30
(3) The breaking elongation in % shall be not less than
where
C=2.2 for only gauge length or L=5 do or 5.65 A0

d0=original diameter of the round test piece.
A0=original cross section of the rectangular test piece.
NOTE: C=1.9 for gauge lengths or 4A0 for test piece in Appendix-B
(b) Flattening test- A ring not less than 50 mm in length cut from one end of each of selected tube shall be flattened between two
parallel flat surfaces to a distance between the plates (H) as calculated by the formula given below without showing any sign of a crack or flaw.
where,
a
D
C
C
=
=
=
=
thickness of tube (mm).

outside diameter of the tube (mm)
a constant as given below.
0.09 for steel having a specified minimum tensile strength from 31 Kgf/mm2 upto and
including 35 KgfIrnm2.
C
=
0.07 for steel having a specified minimum tensile strength over 35 Kgf/mm2 upto and
including 42 Kgf/mm2.
C
=
C
=
(c) Flanging and drift expanding test- The tube, shall withstand either the flanging test or the drift expanding test, at the option of the
manufacturer:(i)Flanging test- A test piece cut from the end of the tube in a plane perpendicular to the axis of the tube shall show no crack or flaw
after flanging to the specified outside diameter as given in the table below
(ii)Drift expanding test- A test piece cut from the end of a tube in a plane perpendicular to the axis of the tube shall show no crack
after expanding by a mandrel having an included angle of 30, 45or 60, the option of the manufacturer to increase the outside diameter as given
in the table below
Table- Minimum increase of outside diameter of tubes in flanging and drift expanding test
Type of test
Minimum specified
strength(s)
Kgf/mm2
Flanging test
Drift expanding test
tensile
Outside diameter (D) of the

tube
S<42
A=D<63.5,
B=63.5<D<150mm
A
S>42
B
B
A
B
Increase of outside diameter of

the tube
%
17
11
14
8
17
11
Regulation No.46
The following regulations shall be substituted, namely: 46. (i) Hydraulic test - Each tube shall be tested at the Makers Works on completion of manufacture and shall withstand a hydraulic pressure, to
one and a half times the design pressure subject to a minimum of 0.70 kgf/mm2 but not greater than the pressure calculated by the following
formula:
Where,
P
D
T
S
=
=
=
=
test pressure.
outside diameter of the tube.
nominal wall thickness of the tube.
stress, which shall be taken as 40% of the minimum tensile strength at room
temperature.
(ii) Notwithstanding anything contained in clause (i), the hydraulic test for tubes in Makers' premises may be dispensed with by the Inspecting
Authority provided that the tubes are subject to non-destructive testing by an appropriate method like ultrasonic or/and Eddy current testing.
Regulation No.48
(i) In clause (a) for the words The tubes shall be manufactured from steel produced by the open hearth or Electric process, the following words
shall be substituted, namely:The tube shall be manufactured from steel produced by the Open Hearth or Electric process or any of the oxygen processes.
(ii) For sub clause (i) of clause (c), the following shall be substituted namely:(i) Diameter.- The external diameter of the tubes measured at any point shall be within the following tolerances of the diameter
specified:Types of tubes
Outside Diameter of Tubes
Tolerances
Hot finished C+
Cold drawn
Upto and including 63.5 mm
+ 0.4 mm
- 0.8 mm
Over 63.5 mm
1 %
All sizes
+0%
-1%
Regulation No.51
The following regulation shall be substituted, namely:51 (i) Hydraulic test Each tube shall be tested at the Makers works on completion of manufacture and shall withstand a hydraulic pressure, to
one and a half times the design pressure subject to a minimum of 0.70 kgf/mm2 but not greater than the pressure calculated by the formula.
Where,
P = test pressure
D = outside diameter of the tube
t = nominal wall thickness of the tube
S = stress, which shall be taken as 40% of the minimum tensile strength at room temperature.
(ii) Notwithstanding anything contained in clause (i), the hydraulic test for tubes in Makers premises may be dispensed with by the Inspecting
Authority provided that the tubes are subject to non-destructive testing by an appropriate method like ultrasonic or / and Eddy current testing.
Regulation No.53
In clause (a) for the words The tubes shall be manufactured from steel produced by the open hearth or Electric Process the following
shall be substituted namely:The tubes shall be manufactured from steel produced by the Open Hearth or Electric process or any of the Oxygen processes.
Regulation No.56
The following regulation shall be substituted, namely:(i) Hydraulic test - Each tube shall be tested at the Maker's works on completion of manufacture and shall withstand a hydraulic
pressure, to one and a half times the design pressure subject to a minimum of 0.70 kgf/ mm2 but not greater than pressure calculated by the
following formula.
Where,
P = test pressure.
D = outside diameter of the tube.
t = nominal wall thickness of the tube.
S = stress which shall be taken as 40% of the minimum tensile strength at room temperature.
(ii) Notwithstanding anything contained in clause (i), the hydraulic test for tubes in Makers' premises may be dispensed with by the Inspecting
Authority provided that the tubes are subject to non-destructive testing by an appropriate method like ultrasonic or/and Eddy current testing.
Regulation No.56A
In Regulation 56A (i) for the opening paragraph of clause (ii), the following shall be substituted, namely:(ii) Material- The tubes shall be manufactured from steel produced by the Open Hearth or Electric Process or any of the Oxygen
Process and shall conform to the following limits of chemical composition:
(ii) after sub-regulation (x), the following sub-regulation shall be added, namely:(xi) Notwithstanding anything contained in sub-regulation (x), the hydraulic test for tubes in maker's premises shall be dispensed
with by the Inspecting Authority provided that the tubes are subject to non-destructive testing by an appropriate method like ultrasonic or/and
Eddy current testing.
Regulation No.58
(i) For clause (a), the following shall be substituted, namely:(a) Material process:The steel shall be produced by an open Hearth or Electric process or any of the Oxygen processes. The steel shall not contain more
than 0.05 percent of sulphur or phosphorus.
(ii) For clause (c), the following clause shall be substituted, namely:(c) Chemical composition. (1) The ladle analysis shall conform to the following requirements:Carbon
0.25% maximum
Silicon
0.40% maximum
Manganese
1.40% maximum
Phosphorous
0.05% maximum
Sulphur
0.05% maximum
When the ladle analysis is not available, the analysis of sample tubes selected at random may be used.
Where the temperature is below 400C either rimming or killed steel may be used. If rimming steel is used in the manufacture of
electric resistance welded tubes, the strip shall be rolled in single widths and shall not be slit longitudinally except to trim the edges. The steel
used for design temperature above 400C but not exceeding 454C shall be of the fully killed type. The question of high temperature creep
strength of the material shall be the subject of agreement between the manufacturer and Inspecting Authority.
Regulation No.59
For Clause (b), the following shall be substituted, namely:(b) (i) Flanging and drift expanding text:- The tube shall withstand either the flanging test or the drift expanding test at the option of the
manufacturer.
(ii) Flanging test:- A test piece cut from the end of a tube in a plane perpendicular to the axis of the tube shall show no crack or flaw after
flanging to the specified outside diameter as given in the table below:
(iii) Drift expanding test:- A test piece cut from the end of a tube in a plane perpendicular to the axis of the tube shall show no crack after
expanding by a mandrel having an included angle of 30, 45 or 60 at the option of the manufacturer to increase the outside diameter as given in
the table below:
Type of
Minimum
Outside diameter
Increase of
Test
Specified tensile
(D) of the tube
Outside
Strength (s)
Diameter of the tube
Kgf/mm2
A=D<63.5mm
%
B=63.5<D<150mm
S<42
A
17
B
11
Flanging
S>42
A
14
Test
B
8
Drift
A
17
Expanding
B
11
Test
Regulation No.60
The following regulation shall be substituted, namely:60. Tensile strength (a) The tensile strength of the material cut from the finished tubes shall conform to one of the following four grades:(i) 31 to 41 kgf/mm2
(b) The upper yield point at room temperature shall not be less than 50% of the specified minimum tensile strength at room temperature.
(c) The minimum values of the stress at proof limit 0.2 % at elevated temperature (Et) of the material may be calculated by multiplying the
specified minimum tensile strength at room temperature (R20) by 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 tubes.
Temperature
250C
*275C
300C
325C
350C
375C
375C
400C
425C
Et/R20
0.40
0.38
0.36
0.34
0.33
0.32
0.32
0.31
0.30
(3) The breaking elongation in % shall be not less than
where
C=2.2 for only gauge length or L=5 do or 5.65 A0

d0=original diameter of the round test piece.
A0=original cross section of the rectangular test piece.
NOTE: C=1.9 for gauge lengths or 4A0 for test piece in Appendix-B
Regulation No.61
The following regulation shall be substituted, namely:61. Hydraulic test - Each tube shall be tested at the Maker's works on completion of manufacture and shall withstand a hydraulic pressure, to one
and a half times the design pressure subject to a minimum of 0.70 kgf/ mm2 but not greater than pressure calculated by the following formula
where,
P = test pressure.
D = outside diameter of the tube.
t = nominal wall thickness of the tube.
S = stress which shall be taken as 40% of the minimum tensile strength at room temperature.
Provided that the test may be dispensed with by the Inspecting Authority if the tube is subjected to non-destructive testing by an appropriate
method like ultrasonic or / and Eddy Current testing.
Regulation No.63
For clause (a), the following shall be substituted, namely:(a) Tests specified in Regulation 59 and 60 shall be made from each lot of 250 tubes or 610 meters or fraction thereof.
Regulation No. 63 under the heading COLD DRAWN ELECTRIC RESISTANCE WELDED STEEL BOILER AND SUPERHEATER TUBES
FOR DESIGN METAL TEMPARATURES NOT EXCEEDING 454C (850F) shall be renumbered as 63A.
Regulation No.73
The following regulation shall be substituted, namely:73 scope (a) This regulation shall cover carbon steel castings used in the construction of boiler and steam pipes including their fittings.
(b) For all types of steel castings conforming to these regulation only the maximum values for tensile strength are fixed. The minimum values
shall be between 40 and 50 kgf/mm2.
Regulation No.74
For clauses (a) and (b), the following shall be substituted namely:(a) Process of manufacture- The steel used for castings shall be made by the Open Hearth or Electric Furnace or any other process which gives
steel having equivalent properties.
(b) Chemical analysis- The ladle analysis shall conform to the following requirements, namely:
*Carbon
0.25% Maximum
Silicon
0.60% Maximum
Manganese
1.40% Maximum
Phosphorus
0.05% Maximum
Sulphur
0.05% Maximum
A carbon content not exceeding 0.30% may be accepted subject to the agreement between the boiler maker and the Inspecting Authority.
Regulation No.75
The following regulation shall be substituted, namely:75. Freedom from and rectification of defects- The steel castings shall have clean surfaces and shall be free from injurious defects. The specified
permissible variations in size or thickness shall not be exceeded. Defects may be repaired by welding only, with the approval of the Inspecting
Authority provided that the castings are stress-relieved after welding wherever necessary.
Regulation No.77
The following regulation shall be substituted, namely:77. Tensile test- (a) The upper yield point at room temperature shall be not less than 50% of the specified minimum tensile strength at room
temperature.
(b) A proportional test piece with Lo-5do shall be used as test specimens.
(c) The minimum values of stress at proof limit of 0.2% at elevated temperature (Et) of the material may be calculated by multiplying the
minimum specified tensile strength at room temperature (R20) by the value of ratio Et/R20 given in table under regulation 16.
(d) The breaking elongation % shall be not less than
Where,
Rm = measured tensile strength at room temperature in Kgf/mm2

93 = a quality index
2.2 = a constant which is valid only when Lo=5do
Where, Lo = gauge length
do = original diameter of the round test piece.
(e) If, however, the tensile tests are carried out on specimen conforming to any other standards, the material will be accepted provided the tensile
strength and elongation computed on the basis of the dimensions of the test pieces under the regulation shall conform to the above requirements.
Regulation No.79
In clause (c), after the second paragraph, the following shall be inserted, namely:High class casting for which a factor greater than 80% is taken in computation of permissible working stress shall be subject to the following
inspection requirements:
(i) Each casting shall be examined by radiographic or ultrasonic methods at all critical locations and found free from harmful defects. All the
castings shall be fully machined to such an extent that all critical sections are exposed for full thickness.
(ii) All castings shall be examined at all critical locations using magnetic-particle or penetrant-fluid procedure, or by grinding or machining and
etching.
(iii) Castings found to be defective shall be rejected or repaired to the satisfaction of the Inspecting Authority. If repairs by welding are carried
out the castings shall be subsequently stress-relieved or heat treated. Castings found to be unsound may be treated in accordance with regulation
80. Repaired areas of castings shall be re-examined by the Inspecting Officer in accordance with sub-clause (i) and shall be shown to be free from
harmful defects.
(iv) Castings to which a quality factor of 0.90 is assigned shall be clearly and permanently marked with G suitable symbol after being examined
as above and found satisfactory.
Notes : The provisions of the first paragraph of clause (c) of Regulation 79 shall apply to the castings other than high class castings for which a
factor greater than 80% is used in the computation of permissible working stress for shells of Boiler and integral super-heater Drums and Headers
under Regulations 271.
In the heading above regulation No. 81, for the words STEEL FORGINGS AND SOLID DRAWN HEADERS, the words FORGED OR
ROLLED PRESSURE PARTS OTHER THAN SEAMLESS DRUMS OF CARBON STEEL shall be substituted.
Regulation No.81
For clause (a), (b) and (c), the following shall be substituted namely:(a) Process of manufacture- The steel used for the parts shall be made by the Open Hearth or Electric or basic Oxygen process or by any other
process which gives steel having equivalent properties.
(b) Chemical Analysis- The steel shall not contain more than 0.05 per cent of sulphur or of phosphorus.
(c) Freedom from and rectification of defects- Where not machined, the pieces, shall have workman like surfaces as normally obtained by rolling,
forging or drawing. Provided that the minimum required thickness is maintained, minor surface defects may be admitted and other defects
removed by mechanical means so as to achieve a smooth surface. Surface defects may also be repaired, by welding only, with the approval of the
Inspecting Authority provided that the parts are stress-relieved after welding where necessary.
Regulation No.82
The following regulation shall be substituted, namely:82. Selection of test pieces- (a) For testing, either the parts themselves shall be used or additional material or sufficient size for test picees shall
be available. In the case of headers for examples, surplus lengths for test rings may be used. In the case of flanges swaged in dies, the punchings
left may be used as test pieces, in which case the identity of the material of the punching with that of the flange shall be evidenced in an adequate
manner. The test may be performed also on the semi-finished material for example a bar or a billet, provided it is given approximately the same
reduction and heat-treatment as the finished forging. For headers with closed ends, the test rings shall be cut off before dishing or reducing and
shall be subjected to the same heat treatment as the headers themselves. In the case of headers, which are closed by special covers, the test ring
shall be cut off after heat treatment. Similar procedure shall be followed for test pieces of other forgings.
(b) For testing, piece of one and the same cast of the same heat treatment batch as well as of similar dimensions may be gathered into one group.
At least one test piece shall be made from each group.
(c) A proportional test piece with Lo=5do shall be used as a test specimen.
(d) Tangential test piece shall be used for headers where practicable.
For header with outside diameter less than 200 mm, longitudinal test pieces may be allowed.
(e) Hydraulic test- A hydraulic test shall be carried out at the Makers works in accordance with the requirements of regulation 268, if required by
the Inspecting Authority.
Regulation No.83
The following regulation shall be substituted, namely:83. Tensile strength- (a) The tensile strength of the material shall conform to one of the following four grades:(i)
37 to 45 kgf/mm2
(ii)
42 to 50 kgf/mm2
(iii)
47 to 56 kgf/mm2
(iv)
56 to 62 kgf/mm2
(b) The upper yield point at room temperature shall be not less than 50% of the specified minimum tensile strength.
(c) 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 of the material at room temperature (R20) by the value of the ratio Et/R20 given in the table under Regulation 16.
(d) The breaking elongation in % shall not be less than
Where
Where,
Rm = measured tensile strength at room temperature in Kfg/mm2

93 = quality index
2.2 = a constant which is valid only when Lo = 5do
Lo = gauge length
do = original diameter of the round test piece.
Regulation No.113
In regulation 113, after sub-regulation (b), the following sub regulation shall be inserted, namely:(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.
Regulation No.148
(a) Stay tubes are tubes having a weld depth equal to the nominal tube thickness plus 3 millimeters. These stay tubes are not required within tube
nests except when the tube nests comprise tubes which are expanded only.
(b) If tube nests comprise plain tubes that are expanded and beaded, expanded and belled or expanded and welded, welded stay tubes shall be
used in flat plate loadings outside the tube area.
(c) For plain tubes or stay tubes exposed to flame or gas temperatures exceeding 600C1 the ends of welded tubes shall be dressed flush with the
welds. If not so exposed, the ends of welded tubes shall extend a maximum of 10 millimeters beyond the weld or, in the case of expanded tubes
the tubes shall project beyond the tube plate up to a maximun of 15 millimeters.
(d) Each stay tube shall be designed to carry its due proportion of the load on the plates which it supports.
(e) The thickness of stay tubes welded into tube plates shall be such that the axial stress on the thinnest part of the tube does not exceed
70N/mm2.
(f) The thickness of stay tube at any part shall not be less than the values shown in the Table below. Minus tolerances shall be taken into account
when ordering tubes. (Click here to view the Table).
Regulation No.151
For clause (d), the following shall be substituted, namely:(d) Arc welded but joints shall be made by the metallic shielded arc process and post weld heat treated effectively except in the following cases:
for alloy steel(i)
in case of 0.5 Molybdenum Steels if thickness does not exceed 13 mm and outside diameter does not exceed 127mm.
(ii)
in case of 1 chromium Molybdenum steel if thickness does not exceed 13 mm and outside diameter does not exceed 127
mm and preheated to 125C.
(iii)
in case of 2 Chromium 1 Molybdenum steel, post weld heat treatment is not necessary under the following conditions:
(1)
(2)
(3)
(4)
(5)
a maximum specified Chromium content of 3.0%,

a maximum nominal outside diameter of 102 mm,
a maximum thickness of 8 mm,
a maximum specified carbon content of 0.15%,
a maximum preheat temperature of 150C.
For carbon steel:(i)

a maximum carbon percentage of 0.30.
(ii)
a maximum thickness of 9 mm.
Regulation No.154
For sub-clause (i) of clause (a), the following shall be substituted, namely:(i) Headers and Mud Boxes etc., of water tube Boiler may be of seamless or welded steel, or of cast steel complying with the
requirements of the provisions contained in Regulations 73 to 80. Where welded, the welding shall be stress relieved, radiographed or
ultrasonically examined and in all respects shall be to the satisfaction of the Inspecting Authority.
Regulation No.187
The following regulation shall be substituted, namely:187. Uncompensated Holes in Water Tube Boi1ers. The maximum diameter of any un reinforced opening shall not exceed 'd' as shown in
figures 9B and 9C subject to a maximum of 203 millimeters.
The notations in Figures 9B and 9C are defined as follows.
(Click here to view the Fig 9B) (Click here to view the Fig 9C)
where,
P = working pressure ;
d=
Maximum allowable diameter of opening (in the case of an opening of elliptical or of round form, the mean value of the two axes of
the opening shall be taken for d);
D = Outer diameter of the shell;
e = actual thickness of the shell;
f = allowable stress;
When K has a value of unity or greater, the maximum size of an un reinforced opening should be 51 millimeters (2 inches).
Regulation No.215
For the sub regulation the following sub regulation shall be substituted namely:
(d) (i) When bending stresses due to weight are negligible and the tube holes are arranged along a diagonal line with respect to the longitudinal
axis, the efficiency (z) of corresponding ligaments is given in Figure 14, with the ratio b/a on the abscissa and the ratio
where,
a and b are measured as shown in Figs. 13A and 13B.(Click here to view the Fig 13A)
d = diameter of the tube holes.
(Click here to view the Fig 13B)
Notes:
1. The dimension should be measured either on the flat plate before rolling or on the medium line after rolling.
2. The data given on Figure 14 are based on the following formulae :(Click here to view the Fig.14)
( = angle of center line of cylinder to center line of diagonal holes.)

(ii) The same rule as in paragraph (i) should apply for the case of drilling holes to a regular saw-tooth shown in Figure 13C.
(iii) In the case of a regular staggered spacing of tube holes (see Figure 13A, the smallest value of the efficiency z of all the ligaments,
longitudinal, circumferential and diagonal, is given in Figure 15 by the ratio Pc/PL on the abscissa, and the ratio (Click here to view the Fig 15)
Where,
d = diameter of tube holes, inches.
Pc = 2b = twice the distance between circumferential rows of holes;
PL= 2a = twice the distance between axial row of holes.
Note: The dimension Pc should be measured on the flat plate before rolling or on the medium line after rolling. The data on Figure 15 are based
on the same formulae as shown in Figure 13A.
(e) When holes spaced longitudinally along a drum are not in a straight line, the equivalent longitudinal pitch for each spacing may be used in the
application of the above rules. The equivalent pitch is obtained by multiplying the actual longitudinal pitch by the equivalent efficiency obtained
from Figure 14 for each spacing.
Regulation No.235
The following regulation shall be substituted namely: 235. Manufacture- (a) Carbon Steel for seamless Forged Drums shall be made by the Open Hearth or electrical furnace or basic oxygen
process or any other process which gives steel having equivalent properties.
(b) Forging which may have integral ends, ends closed by means of dished plates, open ends for multi-joints drums or any combination of these
shall be made from solid cast ingot which is punched, bored or trepanned, or from a hollow cast ingot and shall comply entirely with the relevant
requirements of Chapter II
Regulation No.236
The words and figures and Oxygen process steel shall in addition not contain more than 0.006
percent of nitrogen shall be omitted.
Regulation No.237
The following paragraph shall be added at the end, namely: Where not machined, the forgings shall be workman like surfaces as normally obtained by hot working.
Provided that the minimum specified thickness is maintained, minor surface defects may be admitted and
other defects removed by mechanical means so as to achieve a smooth surface. Surface defects may be
prepared, by welding only, with the approval of the Inspecting Authority provided that the drum is stressed
relieved after welding where necessary.
Regulation No.240
For clauses (b) and (c), the following shall be substituted, namely: (b)Tensile Tests Piece- The tensile strength and percentage elongation shall be determined from round test pieces and gauge lengths of 5do.
(c)Tensile Test(i)The tensile strength and percentage elongation shall be in accordance with the requirements of regulation 9 and 16.
(ii)The upper yield point at room temperature~ shall be not less than 50% of the specified minimum tensile strength at room temperature. The
minimum values of the stress at proof limit 0.2% at elevated temperature (Et) of the material may be calculated by multiplying the minimum
specified tensile strength at room temperature (R20) by the value of the ratio (Et/R20) given in the table under regulation 16.
(iii)
The breaking elongation in percent shall be not less than
where,
Rm =tensile strength at room temperature, in kgf/mm2
100=quality index
2.2=a constant which is valid only when Lo =5do
where,
d0 =original diameter of round test piece.

L0 = gauge length
Regulation No.243
The following regulation shall be substituted, namely: 243. Tolerance- (a) The deviation from circularity in any section shall, in the case of normalised drums, not exceed 2% and in the case of stress
relieved drums 1%. The deviation from a straight line shall not exceed 0.3% of the cylindrical length.
(b) In order to determine the deviation from circularity of the drums the maximum and minimum internal diameter at one cross-section shall be
measured. From these measured values the percentage deviation from circularity shall be circulated according td the following formula: -
Where,
C=
percentage deviation from circularity of the drums.
d = internal diameter at one cross-section.
In order to determine the deviation from a straight line, a stretched line should be placed longitudinally against the sides and its largest distance
from the length of the cylindrical shell the deviation from the straight line shall be calculated.
Regulation No.245
In Chemical Composition (Ladle analysis), under the heading Carbon Steels, for the words Manganese.0.30% Maximum, the
following shall be substituted, namely: -
Manganese0.30%minimum.
Regulation No.249
For the second and third paragraph, the following shall be substituted, namely: -
Fully dimensioned drawings of the proposed welds preparations of the main seams drawn to a scale which clearly shows all the
relevant details shall be furnished.
Sketches showing details of the welds preparations for the attachment of the standpipes, branch pipes and seating and their locations
relative to the longitudinal and circumferential seams and to other openings shall be furnished.
Regulation No.258
(i)
For sub-clause (iv) of clause (a), the following shall be substituted namely: -
(ii)
For clause (b), the following shall be substituted, namely: -
(iv) Three notched-bar impact test specimens.
(b) Surfaces of tensile, bend and impact test specimens corresponding with the outside of the drums shall be only lightly dressed so that the
rolled surface of the parent metal is not wholly removed, except that where the rolled surfaces of the abutting plates are not level with one
another, one plate may be machined at each face of the weld provided the depth of metal removed does not exceed 0.8mm.
(iii)
After figure 16, for entry against item 4, the following shall be substituted, namely: -
4, notched-bar impact test specimen.

Regulation No.259
(i)
For clauses (a) and (b), following shall be substituted, namely: -
(a) Welded Joint- the dimensions of the reduced tensile section shall be there shown in Fig. 18, the width of the reduced section shall
be at least 25 mm.
If the thickness of the plate does not exceed 30 mm, the thickness of the specimen shall be equal to the plate thickness and the plate
surface of the specimen shall be machined to take away the surface irregularities of the plate and the weld.
If the plate thickness exceeds 30 mm. the tensile test shall be carried out on several reduced section specimens, each having a
thickness of at least 30 mm and a width at the effective cross-section of at least 25mm. These specimens shall be taken out of the test piece in
such a way that the tensile test covers the whole thickness of the weld joints as shown in Fig. 18. In this case the result of the test of every test
specimen concerned shall meet the requirements specified in regulation 260(a).
All weld metal- the dimensions of the all weld metal tensile test specimens shall be those given in Fig. 19
The diameter shall be the maximum possible consistent with the cross-section of the weld but in no case more than 20 mm. The gauge
length shall be equal to five times the diameter.

Regulation No.261
For clause (a), the following shall be substituted, namely: -
(a) One for direct and one for reverse bending shall be taken transversely to the weld and where the thickness of the plate permits, one
should be above the other. The specimens shall be rectangular in section 50 as to have a width equal to one and half times the thickness of the
specimen but not less than 30 mm. The surface of the specimens shall be machined just to remove the surface irregularities of the plate and the
weld. The corners of the specimens shall be rounded to a radius not exceeding 10% of the thickness of the specimen.
Regulation No.262
The following regulation shall be substituted, namely: 262. Bend Test- The specimen shall be mounted in such a way that the axis of the former is in the middle of the weld, and on roller
supports the faces of which are separated by a distance determined by the thickness of the specimen.
The test specimen shall be pushed through the supports by a former having a diameter also determined by the thickness of the
specimen. The requirements of table below, relating to the thickness of test specimen, shall apply. (Click here to view the Table).
On completion of the test, no crack or defect on the outer surface of the specimen shall be greater than 1.5 mm measured across the
specimen, or 3 mm measured along the specimen. Premature failure at the corners of the specimen shall not be considered as a cause for
rejection.
Regulation No.263
The following regulation shall be substituted, namely: -
263. Notched-Bar-Impact Tests - The notched bar impact test specimens are to be one of the two types and dimensions shown in
figure 21A and 21B(Click here to view the Fig 21A & B ), the notch shall be contained in the weld-metal at approximately the axis of the weld
and the axis of the notch is to be perpendicular to the surface of the plate. The test shall be carried out as follows: For the U-Notch specimen at a temperature of 20 +2C
For the V notch specimen, at a temperature of 502C

In the case of V notch specimen, the machining of the bottom of the notch shall be done very carefully.
The choice between U notch and V notch specimen shall be at the discretion of the Inspecting Authority. The minimum result to be
obtained from the impact test pieces shall be:
(a) U-notch specimen
5.50 kgfm/cm2
(b) V-notch specimen
3.46 kgfm/cm2
Note Above values are equivalent to 2.76 kgfm divided by sectional area below the notch.
Regulation No.265
(i)
For the first paragraph of clause (b), the following shall be substituted, namely: -
Every portion of the longitudinal and circumferential welded joints of the drums shall be subjected to radiographical examination or
ultrasonic examination. Where ultrasonic examination is used it shall be demonstrated to the satisfaction of the Inspecting Authority that the
equipment and the technique used are satisfactory. The manufacturer shall ensure that the operator employed is competent to use the equipment,
apply the technique interpret the results of the examination.
(ii)
After clause (b), the following shall be added, namely: (c) Magnetic Particle Flaw Detection- Magnetic method of flaw detection shall be employed wherever possible for ferritic steel.
(d) Dye-Penetrant Flaw Detection- Dye-penetrants or equivalent method of flaw detection shall be employed for Austenetic or other
non-magnetic Steel.
Regulation No.266
For clause (d) the following shall be substituted, namely: (d) Removal of Defect- Defects shall be cut out by chipping or machining or by burning out by the Air Arc Weld Process.
Regulation No.267
(i)
In clause (a), the following shall be inserted at the end, namely: -
Heat treatment of alloy steel plates shall be carried out on the basis of composition of the alloy as
shown in the table below: -
(Click here to view the Table).
(ii)
After clause (a), the following clauses shall be inserted, namely: (aa) The heat treatment referred to in clause (a) shall not be necessary in case of Carbon Steel.
Provided that the thickness of the Part weld recess does not exceed 20 mm. and the Carbon content does not exceed 0.25 per cent.
(ab) Where the welded joint connects parts that are of different thickness, the thickness to be considered in applying the limiting
thickness of 20 mm for carbon steel shall be the following nominal thickness including corrosion allowance:
(i) The thinner of two adjacent butt welded component including shell to end connection;
(ii) The thickness of the shell in connections to flat ends;
(iii) The thickness of the shell or end in nozzle attachment welds;
(iv)
The thickness of the nozzle at the joint in nozzle to flange corrections;
(v)
The thickness of the pressure part at the point of attachment where a non pressure part is
welded to a pressure part, in case of butt welds;
(vi)
The thickness of the fillet weld at the point of attachment where a non-pressure part is
welded to a pressure part, in case of fillet welds.
(iii) For clause (e), the following shall be substituted, namely: (e) For the heat treatment, the drum shall be placed in a furnace sufficiently larger to accommodate the whole drum. The furnace shall
have proper means of temperature measurement and control and shall be capable of heating the whole of the drum to a uniform temperature. It
shall be so designed as to prevent direct impingement of flame on the drum. The temperature of the furnace at the time the drum is placed in it
shall not be higher than 3000C. For carbon steel a stress relieving heat treatment shall be performed by heating the part to at least 600 + 20 0C.
When required by the characteristic of the material different temperatures may be necessary to obtain proper Stress relieving. The part
to be stress-relieved shall be brought slowly up to the specified temperature and held at that temperature for a period proportioned on the basis of
at least 2 minutes per millimeter of the maximum thickness of the part (Approximately one hour per 25 mm of thickness) and shall be left to
cool in the furnace to a temperature which for parts with a thickness greater than 20 mm does not exceed 400C.
After withdrawal from the furnace the part shall be allowed to cool in a still atmosphere. A temperature time diagram of the stressrelieving process shall be provided for a welded shell or drum and a similar diagram for other welded pressure part shall be provided where
Inspecting Authority requires it.
NoteOther stress-relieving heat treatment at a temperature as low as 55 C may be adopted provided attention is given
to the holding time in order to ensure a sufficient degree of stress relieving.
Regulation No.268
The following shall be substituted, namely: 268. Hydraulic test at maker's works- (a) Boiler drum and other cylindrical component having internal diameters greater than 600
millimeters shall be hydraulically tested on completion of manufacture at the makers' works in the presence of Inspecting Officer to 1 times the
maximum permissible working pressure without indication of weakness and defects.
(b)
All components which are not reasonably accessible for inspection after assembly into the boiler or have been tested hydraulically
prior to welding at a pressure less than that specified in sub-regulation (a) shall be tested hydraulically to 1 times the maximum working
pressure before assembly into the boiler.
(c)
Tubular products that-have been hydraulically tested to the required pressure prior to welding or ultrasonically tested shall not require
further hydraulic testing as components provided they were joined during assembly by circumferential but joint which have been welded and nondestructively tested as per relevant provisions of these regulations.
(d)
Components other than tubular products shall not require hydraulic testing before assembly into the boiler if the completed boiler is
tested hydraulically to 1 times the maximum permissible working pressure at site.
(e) In case of drums, headers which are to be fitted with tubes, the test may be made before drilling of tube holes but after attachments of
nozzles and similar fittings.
(f)The test pressure shall be raised gradually under proper control at all times so that it never exceeds by more than 6% of the acquired pressure
and maintained for 30 minutes whereupon the pressure shall be reduced to maximum allowable working pressure and maintained for sufficient
time to permit close visual inspection for leakages of the pressure parts.
(g)
The temperature of water used as medium of pressure testing shall not be less than 20 0C and more than 500C.
(h) In case of drums of 'composite' construction and partly riveted and partly welded seams or seamless forged drum shell with ends attached
by fusion welding, the test pressure shall be the same as for fusion-welded drums.
(i)
Should the hydraulic test reveal any defects in the welded steam, it shall not be repaired unless the Inspecting Authority permits to do
so.
(j)
On completion of agreed repairs to a drum which has previously been stress relieved by heat-treatment, further heat-treatment, if
required by the Inspecting Authority, shall be done and the drums shall again be subjected to hydraulic test.
Regulation No.271
For sub-regulations (i) and (ii), the following shall be substituted, namely: (i)
For temperature at or below 454C(850 F), the smaller of the following two values: -
(ii) For temperatures above 454C(850 F), the least of the following three values:
(iii) In sub-regulation (ii), after the explanation of the abbreviation SR ending with the words at the temperature, the following Note shall
be inserted, namely: -
Note: In case Sc values are not available in Material Standard and such materials are known to have been used in boilers In India or
abroad, then for such materials the allowable stress may be taken as the lower of
Regulation No.275
(i)
For regulation 275, the following regulation shall be substituted, namely: 275. Shape of Dished End Plate- When the end plate is dished to semi ellipsoidal, partial-spherical or hemispherical form, it shall
comply with the following: (see Figures 23A, 23B and 23C)
(a)
Hemispherical heads without limitation;
(b)
Elliptical heads sufficiently dished so that
H 0.2D;
(c)
Partial spherical heads satisfying all the following requirements:
r 0.1D
r 3T
R D
H 0.18D
A value of R < 1.2D is permitted for ends in which the ratio HID falls between 0.18 - 0.2.
In accordance with Figures 23A, 23B and 23C
D = outside diameter of the head;
H = height of the head measured on its outside surface from the junction of the dished part with the cylindrical shell;
R =inside radius of the spherical part of partial spherical heads;
r = inside knuckle radius of partial spherical heads.
(ii) For figure 23, the following figures shall be substituted, namely: -
(click here to view the Figures)
(click here to view the Figure(F23e &23F)

Regulation No.277
The following regulation shall be substituted, namely: 277
End plate with Manhole-
(a)
Heads with opening(i) Holes cut in the heads (manholes or tube holes) should be round or elliptical
(ii) Small size openings complying with conditions of sub-regulation (c) do not require any additional thickness of head or reinforcement
of opening.
(iii) Large size openings require an increase in thickness of the head, according to sub-regulation (b) or a reinforcement of the opening
according to sub-regulation (d).
(b) Shape factor K for heads with large unreinforced openings-The shape factor K to be used in calculating the thickness of heads varies
depending on the height of the head H and on the dimensions of the largest opening. The value of K is indicated in Figure 23D, by means of
curves, each of which corresponds to a value of the ratio: The maximum limits for the area of reinforcement that should be taken into account are
Where,
R=
internal radius of the spherical part of the head (or for elliptical heads the internal radius of curvature of the meridian at the
center of the opening).
Tt = actual thickness of the nozzle,
L1 and L2 = dimensions given in Figure 23F
The position of the outer edges of the reinforcement shall comply with the provisions of sub-regulation (b) and Figure 23E.
In cases where the allowable stress of a part of the reinforcement is lower than that of the head, the corresponding area A should be
multiplied by the ratio:
Regulation No.278
(i)
For regulation 278, the following regulation shall be substituted, namely: 278.End plate subject to pressure on the concave side- Dished ends subjected to pressure on the concave side shall be determined
by the following formula:
Where,
T = Minimum thickness;
P = Maximum working pressure, Design pressure;

D = Outside diameter;
f = Permissible stress;
K =Shape factor as defined in sub-regulation (a) of regulation 277 and Figure 23D; and
C = an additive thickness equal to 0.75

The minimum head thickness should not, however, be less than 5 mm.
(ii)
Figure 22 shall be omitted.
Regulation No.280
(i)
In sub-regulation (a), for word, figures and letter and 27B the figures, letters and
word 27B, 27C and 27D shall be substituted.
(ii)
After figure number 27B, the following figures shall be inserted, namely: -
(click here to view the Figure(F27C)
(click here to view the Figure(F27D)
Regulation No.281
In the footnote, after the existing note, the following shall be inserted, namely: In the case of automatic or semi-automatic oil-fired or gas-fired boilers, low water alarms may be fitted in preference to fusible plugs
provided such boilers are equipped with automatic tripping device to disconnect fuel supply and to start the feed pump simultaneously in the
event of low water in the boilers.
Regulation No.281A
After Regulation 281, the following new regulation shall be inserted, namely: 28IA. Additional requirements for Automatic Boilers only(1) General: - Every boiler which is provided with the appropriate water level and/or firing control, to allow for automatic working,
shall comply with the following requirements:
(a) In the event of failure of automatic control, boiler shall be capable of being brought
under immediate manual control.
(b)
In those cases where the control and alarm devices are housed in chambers external
to the boiler, the following shall apply:
(i) The boiler shall have provision made for isolating the steam and water
connections of the chambers from the boilers. Such isolating valves shall be capable of being locked in the open position and should preferably be
of the parallel slide type but if screw down stop valves are fitted, those on the water connection shall be mounted with the spindle horizontal to
avoid the possibility of an air lock.
The steam and water connections of the chambers shall be not less than 25mm bore. In those cases where sequencing control water
valves are fitted, the steam isolating valve may be omitted:
(ii) The boiler shall have means provided to test the operation of the control or alarm and to blow through separately the water
connection and the chamber to prevent the accumulation of deposits. The means provided for flowing through shall be sequencing valves or
equivalent devices so arranged that the water connection to the boiler cannot be shut off unless the drain connections to the chamber is open;
(iii)
The boiler shall have a drain system from the chambers which provides a
visual indication of flow.
Tundishes of adequate size, placed in a prominent position shall be used
wherever practicable.
(c)
Where the boiler is provided with electrical equipment for water level and firing
control, it shall have this equipment so designed that any fault in the circuits caused both in the fuel and air supply the boiler to be automatically
shut off. Positive means requiring manual resetting shall be provided to cut off the fuel and air supplies to the boilers should there be a failure of
electricity supply to water level and/or firing control equipment. All electrical conductors and equipment in connection with water level and firing
controls shall be of adequate size and shall be properly insulated and protected against danger including adequate protection against the ingress of
moisture and the effects of high temperature.
(d)
Where the evaporating capacity of the boiler is greater than 3700 Kg/h, it shall have
automatic water level alarms and firing controls and can be tested regularly without altering the level of water in the boiler. The water level
alarms may be incorporated in the automatic control system. With a perceptible water level which are arranged for automatic working and not
intended for continuous supervision shall be provided with an entirely independent and separately operated over-riding control in addition to the
water level and firing control specified in clauses (2) and (3). The over-riding control shall comply with the following requirements: (i) Cut off fuel supply to the burners or the fuel and air supply to solid fuel stoker and operate an audible alarm when the water level in the boiler
falls to a predetermined low water level;
(ii)Be of the lock-out type and so arranged that control or its electrical circuit has
to be manually reset before the boiler can be brought back into operation;
(iii) Be provided with its own entirely independent electrical control circuit
(e) Where mounted externally to the boiler, the over-riding control shall: (i) Be provided with its own chamber;
(ii) Comply with the requirements of clause (b).
(2) Automatic Water Level Control : - Automatic water level controls shall be as follows
(a)
float or displacer operated; or
(b) operated by electrical probe or thermostat; or
(c)
operated by other approved principle subject to satisfaction of the Inspecting Authority. The control equipment shall
regulate the feed-water supply to the boiler in order to maintain effectively the level of water in the boiler between predetermined limits.
(3)Automatic Firing Controls- Automatic firing controls shall comply with the following requirements.
(a)
At all times they shall control effectively the supply of fuel and air to the combustion
equipment.
(i)
Flame failure or pilot flame failure in the cases of gas, oil or pulverised fuel fired boilers. This control shall be of the
lockout type required to be manually reset;
(ii)
Failure to ignite the fuel at the burner within a pre-determined time. The control shall be of the lockout type required to be
manually reset;
(iii)
When the water level in a boiler with a perceptible water level falls below a predetermined safe level. The control shall also
cause an audible alarm to sound.
(iv)
Failure of forced or induced draught fans or any automatic flue damper.
+ (v) Increase in furnace pressure to a predetermined valve.

Note: The above provisions do not apply to once-through forced circulation boiler.
Regulation No.282
(i)
In clause (a) for sub clause (i) , the following shall be substituted, namely:(ii)
(i) Steel castings shall comply with regulations 73 to 80
(iii)
In clause (a), the footnote with asterisk make shall be omitted.
(iv)
In clause (a), after sub-clause, (v) the following shall be inserted, namely:(vi) Alloy steel castings shall comply with the following requirements namely:-
Carbon Molybdenum castings
Chemical composition %
Carbon
0.25 max.
Silicon
0.20 to 0.50
Manganese
0.05 to 1.00
Molybdenum
0.40 to 0.60
Nickel
0.50, max.
Chromium
0.20 max.
Copper
0.30 max.
Sulphur
0.05 max.
Phosphorus
0.05 max.
*Incidental elements, Total not to exceed 0.80%. If Aluminium is used as deoxidiser, not more than 225 gm. Of aluminium per
metric ton of steel shall be used.
Mechanical properties:
Minimum Tensile strength 47 kg/mm2
Minimum yield point
25 kg/mm2
% Elongation on gauge
length = 5.65 A
Charpy Impact value
17 min
5.0 kgm/cm2 Min
Bend test
120. on D = 3t
(Where D=diameter of the mandrel and t=thickness of test piece)

Heat Treatment:
The castings shall be normally supplied in the annealed or normalized condition to obtain the desired properties. The normalized
castings may be tempered, at the discretion of the Inspecting Authority. Chromium Molybdenum steel castings: chemical composition(%)
Carbon
0.20 max.
0.18 max.
Silicon
0.60 max.
0.60 max.
Manganese
0.50 to 0.80
0.40 to 0.70
Chromium
1.00 to 1.50
2.00 to
Molybdenum
0.45 to 0.65.
0.90 to 1.20
Nickel*
0.40 max
0.40 max.
Copper*
0.40 max.
0.40 max.
Sulphur
0.05 max
0.05 max.
Phosphorous
0.05 max
0.05 max.
* Incidental elements.
Mechanical Properties:
Minimum Tensile strength kg/mm2
Minimum yield point kg/mm2
28
% Elongation on gauge length = 5.65A
17 min
Minimum Charpy Impact Values kgm/cm2
Bend test
Gr.A
Gr.B
49
49
2.75.
28
17 min.
4
120o on D=3t
90o on D=3t
(Where t= thickness of the test piece; D=diameter of the mandrel).

Heat Treatment:
The castings shall be supplied in the annealed or normalized condition to obtain the desired
properties. If normalised, the castings shall be subsequently tempered at a temperature not exceeding 650oC in the case of Gr.A and 690oC in
the case of Gr.B The tempering temperature may be varied by the Inspecting Authority to suit the steel being tempered.
NOTE: Alloy steels other than those specified above may be accepted at the discretion of the Inspecting Authority.
(vii)
Alloy steel forgings shall comply with the following requirements, namely:
Chemical composition (%)

Carbon
0.20 max.
Silicon
0.10 to 0.35
Manganese
0.45 to 0.80
Molybdenum
0.40 to 0.70
Nickel
0.40 max.*
Chromium
0.25 max.*
Copper
0.40 max.*
Sulphur
0.05 max.*
Phosphorus
0.05 max.*
* Incidental elements. Total not to exceed 0.80%. If aluminium is used as a deoxdiser not more than 225 grams per metric ton of steel
shall be used.
Mechanical Properties:
Tensile Strength kg/mm2
44 to 53
27
% Elongation on a guage
length of 5.65 A
20 min
Bend test:
Longitudinal
180 on D=2t
Transverse
180 on D=2t
(Where D= diameter of the mandrel: t=thickness of the test piece)
Heat Treatment:- The forgings shall be supplied in the normalised conditions. If tempering is done after normalizing the tempering
temperature shall not exceed 650C.
The tempering temperature may be varied by the Inspecting Authority to suit the steel being tempered.
Forged Chromium Molybdenum Steel:Chemical composition(%)
Gr.A
Gr.B
Carbon
0.20 max.
0.15 max.
Silicon
0.10 to0.35
0.10 to0.35
Manganese
0.30 to0.80
0.30 to0.80
Chromium
0.70 to 0.10
2.00 to 2.50
Molybdenum
0.45 to0.65
0.90 to1.10
Nickel
0.40 max.*
0.40 max.*
Copper
0.30 max.*
0.30 max.*
Sulphur
0.04 max.
0.04 max.
Phosphorus
0.04 max.
0.04 max.
Incidental elements. If aluminium is used as a deoxidiser not more than 225 gm.per metric ton of steel shall be used.
Mechanical properties:
Minimum tensile strength kg/mm2
42.5
55
25.5
38
% Elongation on gauge length 5.65 A
23 min
19 min
Longitudinal
23 min
Transverse
19 min
18 min
15 min
Bend test:
Longitudinal
180 on D=3t 150o on D=3t
Transverse
180 on D=6t 180o on D=6t
(Where D=diameter of mandrel; t=thickness of the test piece)
Heat Treatment:- The forging shall be supplied in the normalised and tempered condition, the
normalizing temperature for both grades being 920 and 960C and the tempering temperature being 620oC to 660oC in the case of Gr.A and
650C to 700C in the case of Gr.B. The tempering temperature may be varied by the Inspecting Authority to suit the steel being tempered.
(iv) For clause (b), the following shall be substituted , namely:(b) Limits of cast Iron:
Cast Iron shall not be used for:(a)
(b)
(c)
(d)
Temperatures above 220oC;

Pressure exceeding 13 bar gauge;
Valves exceeding 200mm nominal bore which are connected directly to the boiler;
Wedge or double disc gate valves which are connected directly to the boiler;
(e)
Boiler blow down fittings
Explanation: The expression connected directly to the boiler Covers any valve which cannot itself be isolated from the boiler.
(v) After clause (b), the following note shall be inserted, namely:-
Note:- Spherodial iron may be used may be used for temperature not exceeding 282 oC and pressure
not exceeding 17.58 kg/cm2 provided it complies with the following requirements in respect of the physical
properties.
(a)
(b)
0.2% proof stress 250 kg/mm2

minimum elongation percent-12..
(vi) For clause (c), the following shall be substituted, namely:(c) Limits of copper alloy:
Copper alloy shall not be used for temperatures above 225C where the valves are connected directly to the boiler. In the case of
valves not connected directly to the boiler this temperature limitation may be increased to 260C.
Regulation No.290
(i) For clause (a), the following shall be substituted, namely: (a) All chests and fittings shall be smooth, sound and free from flaws, cracks or to other injurious defects. After completion, the chests
shall be tested hydraulically at the manufacturing works to at least twice the working pressure of the boiler for which they are intended.
Hydraulic test shall be made with water, which may contain a corrosion inhibiter, with kerosene or with other suitable liquid provided its
viscosity is not greater than that of water at a test temperature not above 520C.
(ii)
For clause (c) and (d), the following shall be substituted, namely: -
(c) The working pressure and the thickness of Bronze and Cast Iron Valve chests shall be determined
by the following formulae, subject to minimum thickness as specified in regulation 283(b):
Where R is the minimum specified tensile strength of the grade of the material.
D- is the external diameter of the chest.
T- is the minimum thickness of the chest, excluding tolerance, and

C- is the minimum positive tolerance as specified here under:For Bronze Chests C=1.5mm
For Cast Iron Chests C =5mm.
(d) The working pressure and the thickness of the steel valve chest of circular cross section shall be determined by the following formulae,
namely: -
f=
allowable stress in kg/mm2 for the material at the working metal temperature t to be determined on the
basis given below: -
The allowable stress f at or below 454C is the lower of the following two values.
For temperatures above 454C; the least of the following three values.
(a)
(b)
(c)
Where, Et = Minimum value of yield point (0.2 percent proof stress) at temperature t
R= Minimum specified tensile strength for the grade of steel concerned at room temperature.
Sr= the average stress for the grade of steel concerned to produce rupture in 100,000 hours.
If the width of the scatter band of results obtained when determining this value exceeds 20 percent of the average value, then Sr
shall be taken as 1.25 times the minimum stresses at temperature t to produce rupture in 100,000 hours.
Sc= The average stress to produce an elongation (creep) of 1% in 100,000 hours for the grade of steel concerned at temperature t. For
metal temperature below 240C values of f for 250C shall be used.
Note: 1 in case Sc values are not available in Material standard and such materials are known to have been used in boiler in India or abroad, then
for such material, the allowable stress may be taken as the lower
Note: 2. The allowable stress for cast steel shall be 80 per cent of that determined on the above basis.
D= the external diameter of the chest
C= the minimum thickness of the chest, excluding tolerance, and
T= the minimum positive tolerance as specified hereunder;
For cast steel chest C=5mm
For forged or stainless steel chest C=2.5mm
Note: Over and above the calculated thickness, additional thickness needed for assembly stresses, valve closing stresses, shapes other than
circular and stress concentrations, shall be provided by the manufactures to the satisfaction of the Inspecting authority
(iii) After clause (d), the following shall be inserted, namely: -
(e) The number of valves and fittings which shall be made available to the Inspecting Officer (excluding mechanical tests) shall be as follows:
Up to and including 51mm
10 percent
Over 51mm and up to and including 76mm
15% of the number of chests.
Over 76mm and up to and including 114mm
20% of the number of chests.
Over 114mm
100%
If the inspecting Authority is satisfied that the manufacturer has adequate facilities for testing and inspection of valves intended for service
pressure exceeding 10.5 kg/cm2 or temperature exceeding 204oC and actually tests each fitting at his works, the Inspecting Authority may, at his
discretion, undertake test on a sample basis.
(f) The working pressure and the minimum thickness of the steel valve chest of spherical cross section shall be determined by the following
formula namely:-
Where
T= the minimum thickness of the chest.

D= the external diameter of the chest
f= allowable stress for the material to be determined on the basis given in clause (d) above.
C= the minimum positive tolerance as specified hereunder:
For Cast Steel Chest C =5mm.
For forged or stainless steel chest C=2.5mm.
Regulation No.292
For clause (a), (b) and (c), the following shall be substituted, namely: Ordinary Lift Safety Valve- A safety valve in which the valve head lifts automatically a distance of at least D/24 with an over-pressure not
exceeding 10% of the set pressure. There shall not be any mechanical stop which would prevent the valve head from being lifted a distance of at
least D/8. D is the minimum bore of the body seat
(b) High Lift Safety Valve- A safety valve in which the valve head lifts automatically a distance of at lest D/12 with an over pressure not
exceeding 10% of the set pressure. There shall not be any mechanical stop which would prevent the valve head from being lifted a distance of at
least D/8. D is the minimum bore of the body Seat.
Full Lift Safety Valve- A safety valve in which the valve head lifts automatically a distance such that the area of discharge which limits the flow
through the value is between 100% and 80% of the minimum area at any section at or below in body seat this lift is achieved by a rapid opening
with in an over pressure not exceeding 5% of the set pressure.
Regulation No.293
(i) For clause (a) and (b) the following shall be substituted, namely: (a) Discharged Capacity of Safety Valves (a) Saturated Steam: -The rated discharge capacity of a safety valve which discharges saturated steam shall be calculated using the following
equation:
E = CAP
Eqn. (78)
Where,
E = rated discharged capacity of saturated steam (kg/h.):
F = highest pressure of any safety valve mounted on the boiler bar absolute);
A = area (mm2);
For the ordinary lift and high lift safety valve A is the area of the minimum bore of the body seat. For full lift safety valve A is the area of
discharge described in clause (c) of regulation 292 and its valve can only be obtained from the safety valve manufacturers. C is a constant taken
from the following table, appropriate to the type of the valve or as established by tests carried out in accordance with Appendix-L.
Type of Valve
Ordinary lift
Valve of the constant 'C'
High lift
Full lift
0.05
0.10
0.24
(b) Superheated Steam - The rated discharge capacity of a safety valve which discharges super heated steam shall be calculated using the
following equation
Where,
Es is the rated discharge capacity of super heated steam (kg/h.);
E is the rated discharge capacity of saturated steam calculated using equation (78) (Kg./h.);
Ts is the degree of superheat (C)
Equation 79 may be used to determine the rated discharge capacity of safety valves at upper-critical steam pressure. In these cases
the saturation temperature of the steam shall be taken as 375C.
(ii) For clause (c), the following shall be substituted, namely: (c)
The Total peak load evaporation of a boiler shall be calculated on the basis of evaporation not less than 30 kg/hr./rn 2 of heating
surface (exclusive of superheater and non-steaming econorniser). In the case of Waste Heat Boilers, however, when the evaporation per square
meter of the heating surface is certified by the manufacturers to be less than 30 kg. The rninimum number of safety valves required may be
calculated on the basis of the actual maximum evaporation of the boiler.
Regulation No.294
The following regulation shall be substituted, namely: 294.Over Pressure of Safety Valves: - The safety valves shall be so designed that they attain rated discharge capacity with the over pressure
not greater than that given in regulation 292; provided that the safety valves which have a discharge area less than 80 per cent of the flow area,
the over pressure at which the design lift is attained shall not exceed 10 per cent of the set pressure. For safety valves having discharge area 80
per cent of more of the flow area, the over pressure at which the design lift is attained shall not exceed 5 per cent of set pressure.
Regulation No.295
The following regulation shall be substituted, namely: 295. Pressure Drop: - The safety valves shall reset at a pressure at least 2.5% below, but not more than 5% below the safety valve set
pressure. The 5% limit is increased to 10% for valves having a body seat bore less than 32 mm and/or having a set pressure of 2 bar gauge or
less.
Regulation No.296
The following regulation shall be substituted, namely: 296. Attachment to boiler- (a) Safety valves shall be mounted, without any intervening valve, on pads or branches used for no other purpose.
The axis of the valve shall be vertical. The cross-sectional area of the bore of each pad or branch shall be at least to the area of the bore at the inlet
of the safety valve, or where two or more safety valves are mounted on the same pad or branch, at least equal to the sum of the areas of the inlet
bores of all the safety valves.
(b) Branches shall be as short as possible so as not to impair the proper action of the safety valves or impose any undue stress on the
branches at their point of attachment to the boiler. Nothing shall obstruct free flow to the safety valve. Branches, particularly when full lift safety
valves are mounted on them, should be radiused at the inlet. The inlet and outlet flanges shall be drilled in accordance with the approximate table
in Appendix E, for the diameters of flanges adopted.
Regulation No.302
In clause (b), after the first sentence, the following shall be inserted ,namely:Interference with load on the spring, after the safety valve has been adjusted, shall be prevented by the fitting of a ferrule under the
adjusting screw collar, or by using a lock nut on the adjusting screw which shall be further safe-guarded by means of a padlock or other suitable
device.
Regulation No.306
After regulation 306,the following new regulation shall be inserted ,namely:"306A. Adjustment of safety valve set pressure. The set pressure of a safety valve may be adjusted using air or other gas as the test
medium provided that the safety valve has been subjected previously to hydraulic test in accordance with the requirement of clause (a) of
regulation 290"
Regulation No.307
(i) In clause (a) after the last sentence the following shall be inserted namely:"All the springs above 16 mm bar diameter shall be formed hot and the springs below 16 mm bar diameter shall be formed hot or cold
.The springs shall be suitable hardened and tempered"
(ii) In clause (a) after the table relating to Silicon Manganese Steel ,the following Table heading and Table shall be inserted namely:"Alloy Steel"
Grade
Carbon %
Manganese %
Silicon %
Chromium %
Molybdenum %
Grade I
0.55 to 0.65
0.70 to 1.00
0.10 to 0.35
0.60 to 0.90
-
Grade II
0.46 to 0.54
0.70 to 0.90
0.10 to 0.35
080 to 1.10
-
Grade III
0.55 to 0.65
0.70 to 1.00
0.10 to 0.35
0.40 to 0.60
0.15 to 0.25
Grade IV
0.55 to 0.65
0.70 to 1.00
1.70 to 2.10
0.20 to 0.40
0.20 to 0.30
Vanadium %
0.15 min
Nickel %
0.40 to 0.70
Phosphorus %
Sulphur
Regulation No.310
For sub regulation (1) the following shall be substituted ,namely:"(1) The permanent set in the spring (defined as the difference between free height and height measured ten minutes after the springs has
been compressed solid three additional times, after pre-setting at room temperature) shall not exceed 0.5% of the free height."
Regulation No.316
For clause (a) the following shall be substituted ,namely:-
" (a) The stop valve connecting the boiler or super heater to the steam delivery pipe shall be located as near the out-let from the final super-
heater header as is convenient and practicable or in case of boilers without super-heaters as close as practicable to the drum. Where two or more
boilers are connected with a steam receiver or any other vessel, a steam' stop valve shall be fitted between the boiler and such receiver or Vessel".
Regulation No.320
(a) for sub-regulation (a) the following sub-regulation shall be substituted, namely :(a) Every boiler shall have two means of indicating the water in it of which one shall be conventional gauge glass.
Provided that in the case of boiler drums below 3 feet (91 cm) diameter where there is difficulty in fitting two water gauges, two test cocks and a
glass water gauge shall be fitted."
(b) sub -regulation (b) shall be omitted;

(c) sub-regulation (c)and (d) shall respectively be re-lettered as sub-regulation (b) and (c),
(d) in sub-regulation (b) as so re-lettered ,(i) for the figure and word "2 inches" the figures and word "50 milimeter "shall be substiuted;
(ii) the following shall be added at the end, namely:"Minimum length of the visible portion of the gauge glasses shall be 200 mm. The length may be increased depending upon the capacity of the
boiler by the Chief Inspector/Director of Boiler of the manufacturing State".
Regulation No. 327
The following regulation shall be substitued, namely:"327.Dials(a) For pressure up to and including 35 kg/cm2, pressure gauge dials shall be graduated in kg/cm2 from Zero to twice the pressure as nearly as may
be practicable.
(b)
For pressure exceeding 35 kg/cm2 the range of the graduation shall be from Zero to one and a half times the maximum permissible
working pressure, as nearly as may be practicable, but in no case shall the maximum graduation on the gauge be less than 70 kg/cm 2.
(c)
The scale on the dial shall be clearly and permanently marked in kg/cm2.
(d)
The dial of each pressure gauge shall have to be marked upon it in red. The maximum permissible working pressure
(e)
Where the gauges is compensated for a head of water between the gauge and the boiler connection, the amount of such compensation
shall be marked on the dial. Pressure gauge shall be calibrated within an accuracy of +1 per cent. Boiler pressure gauges shall not be less than 150
mm in diameter.
(f)
The travel of the pointer of the dial gauge shall not exceed 3250 C".
Regulation No. 330

The following regulation shall be substituted, namely:"330.Test Connections-Inspector's Pressure Gauge Attachment- Every boiler shall be fitted with a valve or cock carrying in a vertical position a
receiving screw for attachment of the Inspector's pressure gauge. The receiving socket shall be tapped for M/20 x 1.5 metric threads and shall be
fitted with an easily removable cap".
Regulation No. 331
(i) regulation 331 shall be renumbered as sub-regulation (1) thereof ;
(ii) after sub-regulation (1) as on re-numbered and the 'Note' thereunder the following sub-regulation shall be inserted,namely:"(2)
On boilers having wet back reversing chamber, a minimum of two fusible plugs shall be fitted; one on the crown of the reversing
chamber and the other on one of the tube plates. On boilers not having Wet back reversing chamber, at least one fusible plug shall be provided on
the front end tube plate. The plug shall be fitted in such a way that in the event of fusion of the plug, the pressure inside the boiler shall push the
pellets out".
Regulation No. 337-For clause (d) the following shall be substituted ,namely:(d)
cases:
Arc welded butt joints shall be made by the metallic shielded arc process and post weld heat treated effectively except in the following
for alloy steel(i)
(i)in case of 0.5 Molybdenum steels if thickness does not exceed 13 mm and outside diameter does not exceed 127 mm.
( ii)
in case of 1 Chromium Molybdenum steel if thickness does not exceed 13 mm and outside diameter does not exceed 127
mm and preheated to 1250C.
(iii)
In case of 2'A Chromium 1 Molybdenum steel, post weld heat treatment is not necessary under the following conditions:
(1)
a maximum specified chromium content of 3.0%.
(2)
a maximum nominal outside diameter of 102 mm.
(3)
a maximum thickness of 8 mm.
(4)
a maximum specified Carbon content of 0.15%.

(5)
a minimum pre-heat temperature of 1500C.
" For carbon steel:

(i)
a maximum carbon percentage of 0.30.
(ii) a maximum thickness of 9 mm."

Regulation No. 338
For clause (a) the following shall be substituted ,namely:-
(a) The Working Pressure of the tubes shall be determined by the following formula :-
where,
T = minimum thickness of tubes, that is, nominal thickness less the permissible negative tolerance in mm (inch),
C = 0.75 mm for working pressure up to and including 70 kg/cm2 (1000 lbs/sq. inch) or C=0 for working pressure exceeding 70
kg/cm2 (1000 lbs/sq. Inch.),
W.P. = Working pressure of boiler in kg/cm2 (lbs / sq. inch)

D = External diameter of tube in mm (inch)
f = Permissible stress for the material at the working metal temperature in kg/cm2 (lbs/ sq. inch.) to be determined on the basis given
below:
The working metal temperature shall be taken as(a)
For integral economiser tubes, the maximum water temperature for which the part of the element is designed plus 11C (20F).
(b)
For furnace and boiler tubes, the saturation, temperature corresponding to the working pressure plus 28C (50F).
(c) For conviction superheater tubes, the examination steam temperature for which the part of the element is designed plus 39C
(70F).
(d)
For radiant superheater tubes, the design maximum steam temperature plus 50C (90F).
Permissible working stress for tubes: For temperature at or below 454C
whichever is lower
For temperature above 454C
whichever is lower
where,
T.S =
Minimum tensile strength of the material at room temperature,
Et = Yield point (0.2% proof stress) at working metal temperature 't',

Sr = the average stress to produce rupture in 100,000 hours and in no case more than 1.33 times the lowest stress to produce rupture at the
working metal temperature,
Sc = the average stress, to produce an elongation of 1% (creep) in 100,000 hours, at the working metal temperature.
Note:
In case Sc values are not available in Material Standard and such materials are known to have been used in boilers in India or abroad,
then for such materials the allowable stress may be taken as the lower of
Regulation No. 343

After sub-regulation (2) the following sub-regulation shall be inserted ,namely:"( 3) No twithstanding anything contained in Chapter VIII, the hydraulic test or pipes in maker's premises may be dispensed with by the
Inspecting Authority provided these pipes are fully tested and approved radiographic or ultrasonic techniques; but this dispensation shall not
apply to pipes having an internal diameter greater than 600 mm.
In the event of detection of any defect after conducting hydraulic test of these pipes at site, it shall be the responsibility of the manufacturer
to repair or replace the defective pipes, as may be deemed necessary by the Inspecting Authority.
(4) Electric fusion welded pipes in which the butt welds are fully radiographed or ultrasonically tested need not be hydraulically tested in the
shops provided the pipe system as a whole is hydraulically tested at site to the requisite test pressure m accordance with Regulation 374.
(5)
In the case of fusion welded pipes test plates to represent all welded seams shall be attached at each end of longitudinal seam and
tested in accordance with the requirements of Chapter XII except that one test plate may represent a lot of pipes up to 60 meters in length and of
the same grade of material and same thickness of the pipe subject to the same heat treatment".
Regulation No. 344
(i) In clause (a) the following words and figures shall be omited ,namely:"Oxygen process Steel shall not be used for working metal temparatures exceeding 427 0C (8000F)."
(ii) Clause (e) shall be omited.
Regulation No. 347
(i) In table 1 for the columns with heading "Sulphur maximum "and "phosphorus maximum " and related entries, the following shall be
substituted ,namely:-
0.50
Sulphur
Percent max
0.05.
Phosphorous
Percent max
(ii) After clause (e) ,the following shall be inseted ,namely:" (f) Test for valves and fitting :-As per requirement of (e) of regulation 290"
Regulation No. 348
For sub-regulation (b),(c)and (d) the following sub-regulations shall be substituted ,namely:"
(a) (i)The cold drawn seamless carbon steel pipes and welded carbon steel pipes shall be supplied in normalized condition.
(ii)
Hot finished seamless carbon steel pipes shall be supplied in hot finished condition or in normalized condition at the option
of the manufacturer.
(iii)
The seamless alloy steel pipe either cold finished or hot finished and welded pipes shall be supplied in normalized and
tempered condition.
(iv)
By agreement between the users and the manufacturer, the pipes may be delivered in a condition other than normalized
and tempered condition in which case they shall be suitable for subsequent manipulation and the user shall be informed of the heat-treatment
necessary to give required properties.
(b) (i)
Pipe bending and forming (viz. reducing / swaging) operation shall be done by any hot or cold method and to any radius
which shall result in a surface free from cracks, buckles or other defects as determined by the method of inspection specified in the
design. A post bending or post forming heat treatment for carbon steel material is required with a nominal wall thickness in excess of
19.0 millimeters unless the bending or forming operation are performed and completed at normalizing temperatures, where no further
heat treatment is required. The heat treatment where required shall be normalized or stress relieved, as the case may be.
(ii)
A post bending or post forming heat treatment shall be require for all ferritic alloy steel material with nominal pipe size
100.00 millimeters and larger or with a nominal thickness 13.0 millimeters or greater.
(iii) If hot bending or forming is performed the material shall received normalize and temper or tempering heat-treatment as required by
the design. For cold operation, tempering heat-treatment shall be applied.
(c)Marking- Marking shall be carried out in accordance with regulation 395-F".

Regulation No. 349
In Table 2, against the entries "earbon steel" and "cast steel" under the column "maximum permissible temperature"(a) under the sub-heading "0 C" for the entry "482" wherever it occurs the entry "850" shall be substituted .
(b) under the sub-heading "0 F" for the entry "900" wherever it occurs the entry "850" shall be substituted .
Regulation No. 350
(i) The following regulation shall be substituted namely:"350.Steel pipes :The maximum working pressure allowed on steel pipes shall be determined by the following formula:
(a) Where the outside diameter is the basis for calculation.
(b) Where the inside diameter is the basis for calculation
Where t = Minimum thickness

W.P = Maximum working pressure
f = allowable stress determined on the following basis:
(i) For temperatures at or below 454C the lower of the following two values:(ii) for temparatures above 454 C the least of the following three values :
Where t = working metal temparature

R = minimum tensile stength of the steel at room temperature temperature t)
Et = Yied point (0.2% proof stress at the temperature t)
Sc = The average stress to produce an elongation of 1% (creep) in 100,000 houres at temperature t
SR
The average stress to produce rupture in 100,000 hours at the temperature and in no case more than 1.33
times the lowest stress to produce rupture at the temperature,

D
= Outside diameter of pipe,
= Inside diameter of pipe,
= Efficiency factor,
=
1.0 for seamless and for electric resistance welded steel pipes and for electric fusion welded steel pipes comply with the
0.95 for electric fusion welded steel pipes complying with the requirements of Chapter II,
requirements of Chapter II in which the weld is fully radiographed or ultrasonically tested,
= 0.90 for welded steel pipes for values of t upto and including 22 mm,
=
0.85 for welded steel pipes for values of t over 22 mm and upto and including 29 mm,
0.80 for welded steel pipes for values of over 29 mm,
= 0.75 mm.
"Note:
In case Sc values are not available in Material Standard and such materials are known to have been used in boilers in
India or abroad, then for such materials the allowable stress may be taken as the lower
(ii) In table (3),for the figures "554 C the figures "454 C " shall be substituted.
(iii) in table 3,for the words letters and figures,
the following words ,letters and figures,shall be substitutes,namely:-
Regulation No. 351

In Table 4 , for the words,letter and figures
the following words ,letters and figures,shall be substituted ,namely:-
the following words ,letters and figures,shall be substituted ,namely:-
Regulation No. 352

The following regulation shall be substituted ,namely":352. Copper Pipes- (a) The material shall comply with regulation 35.
(b)Copper pipes may be used for maximum design pressures and temperature as given in the Table below;
TABLE- Minimum Design Pressures and Temperatures for Copper Pipes
Material
127 mm.
17.5 Kg/cm2
Nominal size
2070C
Straight
Solid drawn copper pipes (feed)
Maximum design
Solid drawn copper pipes (Steam)

Above 127 mm. and including
Up to and including 203 mm
12.3 kg/cm 2
2070C
21 Kg/cm2
Maximum design
Up to and including
or bend 203 mm (8 in.)
149C
(c)
Copper pipes shall not be used for superheated steam.
(d)
The maximum working pressure on such pipes shall be determined by the following formula
where,
W.P. = Working pressure is kg/cm2
t=
minimum thickness of tubes, that is nominal thickness less the permissible negative tolerance in mm.,
D = Outside diameter of pipe in mm.,
S=
maximum permissible design stress at the appropriate maximum design temperature in kg/mm2(See the table below) Maximum Design
Stress Value of S for Copper pipes (In kg per sq. mm)
Maximum design stress for temperature not exceeding
600C
1210C
1490C
4.31
3.5
4.9
1770C 2070C
2.66
1.75
Note:
Where the conditions of service are such that corrosion, erosion or mechanical damage to the surface to tubes may occur,
an appropriate thickness allowance shall be added to the minimum thickness of the tube.
Regulation No. 360
(i) In clause (b)
(a) for words and figures "Figure Nos .28 to 34 "the words and figures "Figure Nos .28 to 34 A " shall be substituted.
(b) after type '7' and the entry relating thereto, the following shall be added namely:"8 Socket welded flange Figure 34A"
(c) in the design conditions the following shall be added at the end namel:"Type 8 Flanges for all design pressure and temperature conditions.
This type shall be used only for pipes upto and including 51 mm (2 inches )nominal bore. These flange shall not be used where
severe erosion or corrosion is expected to occur"
(d) after figure 34,the following rigure shall be inserted namely:Regulation No. 360
(i) For clause (b) the following shall be substituted namely:"Where carbon steel socket welded pipes or valves and fittings are welded together such welds shall be effectively stress-relieved when the
wall thickness is 20 mm greater or carbon content of the steel exceeds 0.25 percent or pipes made of alloy steel in accordance with the
following".
(1)For carbon steel, a stress relieving heat treatment shall be performed by heating the part to at least 600 20C.
When required by the characteristics of the material, different temperatures may be necessary to obtain proper stress-relieving. The
part to be stress relieved shall be brought slowly up to the specified temperature and held at that temperature for a period proportionate on
the basis of at least 2 minutes per millimeter of the maximum thickness of the part (approximately one hour per twenty five millimeter of
thickness )and shall be left to cool in the furnace to a temperature which, for parts thickness greater than 20mm does not exceed 400C.
After withdrawal from the furnace, the part shall be allowed to cool in a still atmosphere
A temperature-time diagram of the stress-relieving process shall be provided when the Inspecting Authority requires it.
(2) For alloy steel a stress-relieving heat treatment shall be carried out on the basis of the composition of the alloy as shown in the table
below:TABLE
Type of steel
Range of Temperature
Mo
Cr Mo
1 Cr Mo
1 Cr Mo
2 Cr 1 Mo
620 C - 650 C
Time at temperature
Per 25 mm of thickness
of plate
1 Hour (1 hour Min)
620 C 660 C
1 Hour (1 hour Min)
625 C 750 C
1 Hour (1 hour Min)
Note : This wide range for the post -weld heat treatment temperature is necessary because of the marked dependence of the mechanical properties
of this steel on the tempering temperature .In production a definite temperature with a tolerance of
20C. would be selected to ensure that the mechanical properties upon which the design was based are in fact achieved.
Heat treatment shall be carried out by one of the following methods.
(i) Local heating using a portable muffle induction coils or other suitable heating appliance, Particular care shall be taken to apply
heat uniformly over the area to be treated. The use of procedures that do not provide adequate control for the purpose ,such as manual operation
of gas torches is not permissible .The temperature shall be maintained symmetrically over peri-pheral band of metal of a minimum with of three
times the with of the butt welded preparation .The temperature shall be measured by thermocouples pinned ,welded or otherwise suitably attached
the surface of the pipe and where necessary protected from flame impingement.
(ii) Heating in stationary furnace. The temperature of the joint shall be measured by thermo couples so disposed within the furnace as
to give a true measure of the joint temperature"
(ii) In sub -regulation (d) clause (4) relating to Tests for clause II pipelines , after sub-clause (iii) the following shall be inserted
,namely:"(iv) Notwithstanding anything contained in sub-clauses (ii) and (iii) the bend tests shall be dispensed with in case the welds have been nondestructiely tested in the following manner:A."Piping over 102 mm (4 in )bore :- Five per cent of the welds made by each welder on a pipeline with a minimum of two welds perrwelder selected at rendom shall be subjected to a non-destructive examination by radiographic or other approved methods.
B. Plping 102 mm (4 in) bore and under -One per cent of the welds made by each welder on a pipeline with a minimum of one weld per
welder selected selected at rendom shall be subjected to a non-destructive examination by radiographic or other approved techniques".
(iii) For clause (e) the following shall be substituted namely:"(e) socket weld joints:Socket weld joints may be used with carbon and low alloy steel pipes not exceeding 60.3 mm. outside diameter. Such welds shall not
be used where fatigue, severe erosion or severe corrosion is expected to occur. The working pressure of the socket weld fittings shall be
determined in accordance with equation 91 (regulation 350). The thickness of the socket weld fittings shall not be less than 1 times the nominal
thickness of pipe. The material shall be compatible with the associated piping".
Regulation No 361
(i) For clause (a) the following shall be substituted namely:(a) Pipes of thickness determined in accordance with equation 91 with increase of 12.5% shall not be bent to radii less than those given in the
following Table. Where smaller radii are necessary, further allowance shall be made for thinning at the back of the bend except where it can be
demonstrated to the satisfaction of the Inspecting Authority that the use oft b will not reduce the thickness below y t at any point after bending.
where t = min .thickness as per Eq 91
tb = min .thickness before bending .
Radii measured.to
Outside
diameter
mm
tb 1.125 t
all thicknesses
mm
center line of pipe

th 1.1 t
tb = 34.92 mm. or above
mm
20.9
63.5
33.7
76.2
42.4
101.6
48.3
114.3
60.3
152.4
76.1
190.5
88.9
228.6
101.6
266.7
114.3
304.8
127.0
355.6
139.7
381.0
152.4
431.8
168.3
457.2
193.7
635.0
219.1
711.2
244.5
812.8
1143.0
273.0
1016.0
1270.0
298.5
1117.0
1397.0
323.9
1219.2
1524.0
355.6
1498.6
1778.0
406.4
1727.2
2032.0
457.0
2032.0
2086.0
(ii)the thickness is at least
K 0.5
K-1
times the minimum thickness
required for the straight pipe to which the bend joined

where,
K = ratio of the radius of the bend (from center of curvature to center of pipe) to the inside radius of the pipe.
Note.
Gusseted Bends shall be used for pressure not exceeding 21 kilogram me per square centimeter and temperature not
exceeding 260 Degree Centigrade.
(d) For the forged bends, the radi shall be not less than those given below:Long radii forged bends
R = 1.5 x d
Short radii forged bends
R = 1.0 x d
The thickness at any point of the bend shall not be less than 87.5% of the nominal thickness of the bend. The thickness at any point of the bend
shall be such that the minimum thickness required by equation 91 is maintained throughout after finishing operation.
After regulation 361 the following new regulation shall be inserted namely:"361A. Butt-welding fittings.
The Butt-welding fittings shall confirm to the dimension & tolerance given in the table given below:
(Click here to view the Figure & Table)
(click here to view the Table For Tolerance of Steel Butt Welding Fittings)
(click here to view the Table For Steel Butt Welding Tees)
(click here to view the Table For Steel Butt Welding Reducers)
(click here to view the Table For Steel Butt Welding Fittings(Elbow))
Regulation No 362
(i) For clause (b) the following shall be substituted namely:"(b) External reinforcement:- If the thickness of the main or the branches of a single or multiple branch piece is less than that given by the
equation 91-a external reinforcement shall be provided .Such reinforcement may take the from of multiple radial plates of horse shoe from or the
form of collars or other reinforcement approved by the Chief Inspector, applied to or around the junction between the branch and the main "
(ii) In clause (c) in equation 91-A and 91-E for "C =1 .0mm (0.04)" the following shall be substituted namely:"C = 0.75 mm"
Regulation No 365
(i) In sub-clause (2) of clause (b) ,For the first paragraph, the following shall be substituted namely:"Each dished end shall be made from one rolled 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 line of weld shall be parallel to the horizontal axis of the vessels and the weld
shall be radiographed after forming .The shape of Dished End shall conform to the requirements or Regulation 275 .Dishing and perepherial
flanging shall be done by machine. Cold flanging shall not be adopted. All plates which have been dished, flanged or locally headed shall
afterwards be efficiently heat treated for the purpose of relieving internal stresses unless during the last stage of manufacture ,they have been
uniformly headed throughout a suitable temperature Care shall be taken to see that the flanges are cylindrical of good surface and free local
irregularities".
(i) in sub-regulation (b) in paragraph (3) for the sub-paragraph beginning with the words "The attachment of flat ends" and ending
with the figures and word "365/4 and 365/5" the following shall be substituted namely:"The attachment of flat ends shall be by one of the methods shown in Figure Nos 365/2,365/2a,365/3 and 365/4";
(iii) in sub-regulation (e) for the sentence "Method of attachment for branches secured by welding are shown in Figure 365/6 to 365/29"
the following sentence shall be substituted namely:"Method of attachment for branches secured by welding are shown in Figure 365/6 to 365/29A".
(iv) after figure No365/2 the following figure shall be inserted namely:(Figure 365/2A to be printed here )
(v) for figure No365/4 the following figure shall substituted namely:(Figure 365/4 to be printed here )
(vi) for figure No365/17 the following figure shall substituted namely:(Figure 365/17 to be printed here )
(vii) after figure No365/29 the following new figure shall be inserted, namely:(Figure 365/29A to be printed here )
(viii) In clause (f) (2) for the last paragraph beginning with the words and figure "ClassI" and ending with the words and flange "Chapter XII"
the following shall be insertted namely :"Class I and Class II shells shall be effectively stress relieved by heat treatment when the wall thickness exceeds 20 mm or the carbon content
exceeds 0.25% or the pipes are made of alloy steel".
Regulation No 370
The following regulation shall be substituted namely:"370 Flexibility:(a) The pipe shall be arranged so that the system is sufficiently flexible to absorb, the whole of their expansion and the imposed movement of the
connected equipment without the actual expansion stress (SE) exceeding the allowable stress range (SA) as is determined from the following
equation:SA=f (1.25 SC + 0.255H )
where,
SC = Basic material allowable stress at the minimum (cold) temperature,
SH =
Basic material allowable stress at maximum (hot) temperature,
SE =
Actual calculated expansion stress obtained from the stress analysis,
f=
Stress range reduction factors of cyclic conditions for total number N of full temperature cycles over the total number of
years during which the system is expected to be in operation as given in table below:
TABLE- Stress Range Reduction Factors

N
7000 and less
F
1.0
7000 - 14,000
0.9
14,000 - 22,000
0.8
22,000 - 45,000
0.7
45,000 - 100,000
0.6
100,000 and above
0.5
Notes: 1.
Value of Sc and SR shall be guaranteed by the manufacturer of steel from which pipes are made and furnished
to the pipe makers/Inspecting Authority until such time such values of Sc and Sh are incorporated in the Regulations.
2.
In case of imported pipes conforming to a recognised foreign standard or code the values of Sc and Sh may be taken from
the table of allowable stress as given in that code or the value may be determined on the basis given in that code.
3.
The sum of the longitudinal stress due to pressure, weight and other sustained load including bending stresses caused by
external. loads shall not exceed the allowable stress in the hot conditions (Sh). Where the sum of these stress is less than Sh, the
difference between Sh and this sum may be added to the term 0.25 Sh, in the above formula for determining the allowable stress
range SA.
4.
Calculation of the expansion stress, SE shall be based on modulus of elasticity at room temperature.
(b) Where practicable, the requisite flexibility shall be provided in the layout of the pipes without having recourse to special expansion bends or
expansion joint except for the safety valves discharge piping. Where lack of space or other considerations prohibits the use of this method,
expansion fittings like expansion joints or the bellows type of corrugated pipes may be used provided that the limitations imposed by maximum
design pressure, drainage etc., are taken into account. If the expansion fittings are used, detailed consideration shall be given to the design of
anchors, guides and ties to ensure that they adequately protect the expansion fitting and accommodate the additional loads due to pressure.
(c)
Notwithstanding anything contained. in clause (a) of this regulation the complete analysis of the piping system may be waived if the
system meets any of the following criteria:
(1) The piping system duplicates a successfully operating installation or replaces a system with a satisfactory service record.
(2) The piping system can be adjudged adequate by comparison with previously analysed system.
(3) The piping system is of uniform size with not more than two anchors and no intermediate restraints and satisfied the
following approximate criteria:-
where
D = Nominal pipe size in mm.,
Y=
in mm.,
Resultant of movements to be absorbed by pipelines
L = Developed length of line axis in meters,

U=
anchors) in meters.
Anchor distance (length of straight line joining
Notes: 1.
If the system is not meeting the above criteria or
where reasonable doubt exist as in the adequate flexibility of the system, shall be analysed on the basis given in clause (a) of this
regulation by simplified, approximate or comprehensive methods of analysis that are appropriate for the specific case.
2.
Approximate or simplified method may be applied only if they are used for the range or configurations for which their
adequate accuracy has been demonstrated.
3.
Data for thermal expansion, modulus of elasticity, poison's ratio, flexibility factors and stress intensity factors may be taken
from any code/ specification.
4.
Nominal diameter and nominal thickness may be used in the calculation of expansion stress.
Regulation No 374
(i) For clause (a) the following shall be substituted ,namely:"(a) Each completed pipe and fitting shall be tested by hydraulic pressure as per requirement of Ch apter II.
(ii) For clause (c) the following shall be substituted ,namely:" (c) The piping system shall, after erection, be subjected to a hydrostatic test pressure. The hydrostatic test pressure at any point in the piping
system shall not be less than 1.5 times the design pressure but shall not exceed the maximum allowable test pressure of any non-isolated
components such as vessels, pumps or valves. At no time during the hydrostatic tests shall any part of the piping system be subjected to a stress
greater than 90 per cent of its yield strength (0.2 per cent off set) at test temperature.
(iii) After clause (d) the following shall be inserted, namely:"(e)
Hydraulic testing of butt welded and socket welded joints shall be conducted either at makers work or at user's premises on
completion of fabrication of pipes by the Inspecting Authority"
(iv) after clause (e) the following shall be inserted , namely :" (f) Hydrostatic testing of fabricated pipes having attachments of flanges, fittings, butt joints, branch joints and weldolets shall be done at
manufacturer's works or alternatively at site at 1.5 times the design pressure. Where hydraulic testing of fabricated pipe joints is not carried
out at manufacturer's works, dye-penetrant test shall be carried out on the welded joints along with five per cent radiography of such joints".
Regulation No 376 (e)
(e) Fro sub-regulation (e) the following sub-regulation shall be substituted :"(e) No blank flange/plug shall be inserted between a safety valve chest and the boiler generally and where it is permitted by the Inspector the
blank flange / plug shall be removed in his presence".
Regulation No 379
(i) For clause (a) the following shall be substituted namely:"(a)
(i)
Subject to the provisions of sub regulation (e) of regulation 381, every boiler shall be hydraulically tested after erection at
site in presence of the Inspector to 11/4 times the maximum working pressure as certified by the Inspecting Authority in Form II, to be stamped
on the boiler, as free from any indication of weakness or defects.
(ii)
If all components of the boiler in the manufacturer's premises have not been tested hydraulically as per regulation 268,
the test, on completion, shall be taken to 1 1/2 times the maximum working pressure.
(iii)
The temperature of the water used as medium of pressure testing shall not be less than 2C and greater than 50C.
(iv)
The test pressure shall be raised gradually under proper control at all times so that it never exceeds by more than 6% of the
required pressure and maintained for 30 minutes whereupon the pressure shall be reduced to maximum allowable working
pressure and maintained for sufficient time to permit close visual inspection for leakage of pressure parts".
(ii) For clause (I) the following shall be substituted namely:"(I)A hydraulic test shall also be taken granting an increased pressure certificate and after repairing a boiler. However, in the case of minor
repairs to the Water Tube boilers where NDT has been carried out, hydraulic testing may be dispended with provided NDT is
carried out by an approved method".
Regulation No 380.
In clause (c) for para 2 the following shall be substituted namely:"In the case of water tube boiler or boilers fitted with super heater, the feed water connection and stop valve need not be shut off and if the total
valve area is lifted and found to be adequate by calculations, the requirement of the accumulation test may be assumed to have been satisfied if
the valves on each boiler and all valves shall lift so that all steam which can be discharged with a pressure rise not exceeding 10% of the designed
working pressure".
Regulation No 382.
In clause (a) in the list of States /Union Territories with their distinguishing letters,
(i) after the entry "Bihar ------- BR " the following entry shall be inserted ,namely:"Daman and Diu ------ DU."
(ii) after the entry
"Gujarat -------- GT"the following shall be inserted :"Haryana ------- HA."
(iii) (a) The entry "Madras ----- M" shall be omitted ;and
(b) After the entry 'Rajasthan ------ RJ" the following shall be inserted ,namely:"Tamil Nadu ----- T."
(iv) after the entry "Manipur ------- MA the following shall be inserted,namely:"Meghalaya ------ ML."
(v) After the heading Orissa and the entry relating thereto the following shall be added "Pondicherr ----- PY."
Regulation No 385.
The following regulation shall be substituted namely:-
"385 Regulation fee -The fee required to accompany an application under sub-section (1) of section 7 of the Act. shall be:
Rs
For boiler rating not exceeding
For boiler rating exceeding
10
10
30
50
70
90
110
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
but not exceeding

but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
but not exceeding
300
400
450
550
650
750
850
950
1100
1200
1350
1600
1800
2100
2250
2500
2700
3000
3150
3400
3600
30
50
70
90
110
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
Above 3000 for every 200 or part thereof an additional fee of Rs 100 /- shall be charged ;
Provided that the chief Inspector may direct that no fee shall be payable in respect of a fresh application made in persuance of
sub-section (2) of section 14 of the Act"
After Regulation 387 the following new regulation shall be inserted ,namely:387 A.MAINTENANCE OF RECORED :(a) "The Inspecting Authority shall maintain the recoreds pertaining to the bolier or the Economiser as the case may be including all the
certificates in the prescribed forms, namely, Form II, Form III, Form III-A, Form III-B, Form-C, Form -IV -A, and FormVIII and the copies of
the approved drawing for a period of at least 3 year after registration of the boiler .Thereafter these recored may be sent to the owner of the boiler
by the Inspecting Authority.
(b) The owner of a boiler or economieser shall maintain the records pertaining to the boiler or economieser as the may be
including the certificates Form II, III A, IIIB, IV and VII and the copies of the approved drawing for the entire life of the bolier or economieser
as the case may be.
(c) In the event of any transfer of the ownership the recoreds mentioned above shall be transferred to the new owner and
the new owner will maintain the recored in accordance with the provision of clause (b) above
(d) The manuf acturer of boiler or economieser or steam pipe shall maintain the recored pertaining to the boiler or economieser or steam pipe as
the case may be including the certificate in Form II,IIIA,IIIB,IIIC IV,IV-A,VIIand VIII and the copies of the approved drawing for a period of at
least 5 years"
After Regulation 391,the following new regulation shall be inserted ,namely:"391A Ageing of boiler :(a) Shell Type Boiler :
(i) In order to take the ageing effect on boiler the working pressure of the parts of them as calculate from the formulae in these regulation shall be
reduced as par the table given below:TABLE
Age of boiler
Exceeding (in years)
Maximum permitted
Working pressure
Percent .
25
35
45
50
60
70
80
90
100
95
90
85
80
70
60
50
40
30
(ii) For those boiler the plates of which have already been cut and tested under regulation 7 and this regulation shall be given a further
lease of life of 50 years from the date of the boiler .The working pressure that shall be allowed after the testing shall be reduced as per the table
given below :
TABLE
Period after
Date of test (in years)
Maximum working
10
20
30
40
50
Pressure allowed
(Percentage) .
90
80
70
50
30
(b) Water Tube Boilers:(i) The boiler which areoperting at a temperature of 400C and above including utitity / industrial boiler and all boiler and all boiler
parts operating in the creep range of the boiler shall be non-destructiveely tested after they are in operation for 100,000 hours for assessment of
the remanent life of the parts;
(ii) The parts of a boiler when it completes a life of 25 years are to be tested for assessment of the remanent life of such parts .If results are
acceptable as per the standard laid down by the Central Boilers Board a certificate shall be issued by the Chief Inspector of Boiler for extending
the life of the boiler for a further period of 10 years or such less period as recommended by the Remanent Life Assessment Organisation .This
assessment of remanent life shall be carried out thereafter every five years by the oranisation working in the filed of boiler and remanent life and
extension thereof after suchorganisation is approved by the Central Bolier Board .Such organisation shall work in close coordination with the
office of the Technical Adviser (Boilers) in the filed of remanent life assessment and extension The working pressure of such boiler may be
reduced on the recommendations of such approved organisation."
Regulation No 393.
Submission of manufacturing drawings and the particulars of boiler in advance
" (a) In the case of land boilers made in India for use in the States, the manufacturing drawings and the particulars of materials, design and
construction of boilers shall be submitted by the makers of the boilers to the Inspecting Authority of the State, where the principal parts of the
boilers will be manufactured, for examination and approval before commencement of the manufacture of boilers.
(b ) In the case of boilers made outside India for use in the State, the manufacturing drawings and particulars of the material, design and
construction, of boilers shall be submitted initially to the Inspecting Authority in the country of manufacture for examination and approval.
The manufacturing drawings and the particulars of materials, design and construction in the case of fired boilers of steam generating
capacity 100 Tons/hour and above and that of Waste heat boiler of 20 Tons/hour and above shall then be submitted to the Technical Adviser
(Boilers) for selection of latest materials with high strengths and use in high temperature and pressure, energy conservation and increased thermal
efficiency and remote control and instrumentation for the safety of the Boilers. Thereafter, the manufacturing drawings and the particulars of
materials, design and construction shall be sent to the Chief Inspector of Boilers of the State where the boiler will be installed and used, for final
examination and approval before commencement of manufacture so as to avoid question arising at the time of erection and registration of the
boiler.
(c)
The Inspecting Authority or the Chief Inspector or both, as the case may be, shall, after examination of the manufacturing drawings
and the particulars intimate to the proposer whether they are satisfied with the materials, design, construction and fitness of the parts for the
intended pressure and, if not, what modification is necessary therein. When the manufacturing drawings and the particulars of boilers have been
approved, the Inspector in making his examination shall see that the design and the particulars of construction as approved have been carefully
followed and that the material corresponds with the approved particulars.
(d) The fees for the scrutiny of the manufacturing drawings and the particulars of the materials design and construction of boilers under subregulations (a) or (b) shall be on the scale prescribed in regulation 385 subject to a maximum of rupees 20,000/-. When the manufacturing
drawings have been scrutinised and in respect of them alterations have been suggested and the same are resubmitted for scrutiny, separate fee at
the rate of l0 % of the fee for the first scrutiny of the drawings shall be payable if the manufacturing drawings contain alterations other than those
previously suggested.
(e)
The arrangement drawings showings the broad details of modifications or conversions of the existing boiler shall be subject to the
approval of the Chief Inspector of Boilers of the State where the boiler is intended for modification or conversion is registered.
(f)
If the detailed manufacturing drawings are got approved by the Inspecting Authority of the State where parts will be manufactured and
inspected, no separate compliance of sub-regulation (e) is required".
"393-A.FEE FOR SCRUTINY OF MANUFACTURING DRAWINGS ETC.
(a) The fee for scrutiny of the manufacturing drawings and the particulars of materials design and construction of boiler under sub-regulation
(a) or (b) of regulation 393 shall be on the scale prescribed in regulation 385. When the manufacturing drawings have been scrutinised and in
respect of them alterations have been suggested is resubmitted for scrutiny , separate fee on the same scale shall be payable if the manufacturing
drawings contain alterations other than those previously suggested.
(b) The procedure laid down in clause (a), above shall be followed in the case of structural alterations addition or renewal of any part of a
boiler".
Regulation No 395.
For sub -regulation (b) the following shall be substituted namely:"(b) (i) The fees for examination of plans and the particulars of materials, design and construction of steam pipes before the
commencement of manufacture of the steam pipes shall be at the rate of Rs. 30/- for 30 meters of piping or part thereof, subject to a
minimum of Rs. 50, inclusive of all fittings excepting the fittings like de-superheaters, steam receivers, feed heaters and separately fired
superheaters. For any fittings like de-superheaters, steam receivers, separators and flanges, the fees shall be Rs. 150.00 for each category
of such identical fittings.
(ii) The fees for examination of lay out plans of steam pipes shall be Rs. 20/- per 30 metres of piping or part thereof, subject to a minimum
of Rs. 50/- inclusive of all fittings, except fittings like de-superheaters, steam receivers, feed heaters and separately fired superheaters. For
any fittings like de-superheaters, steam receivers and separators, the fee shall be Rs. 150.00 for each such fittings".
Regulation No 395A.
(i) In clause (i) of sub-regulation (1) for the word "Three" the word "four " shall be substituted.
(ii) For sub-regulation (3) the following shall be substituted, namely:"(3) For inspection of tubes and pipes, the fees shall be charged at the rate of Rs. 100/- per metric tonne or a fraction thereof ".
(iii) After sub-regulation (3) the following sub-regulation shall be inserted namely:"(4) Fees for inspection of boiler at the side of construction shall be charged at the rate of four times the registration fee.
(5) For inspection of forged pipe fittings, the fees shall be charged at the rate specified for forged and cast flanges under clause (i), of subregulation (2) of Regulation 395C.
(6)
For inspection of pipe fittings other than forged pipe fittings, the fees shall be charged as under:-
(a)
Up to and including 50 mm, for 100 kg. or a fraction thereof
Rs.25/-
(b) Over 50 mm and up to and including 100 mm for 450 kg. or fraction thereof
(c) Over 100 mm for 900 kg. or a fraction thereof
Rs.125/-
Rs.225/-
After Regulation No395 A,the following new regulations shall be inserted, namely:Regulation No 395 B.
Fees for inspection of Pipes:
(a)
For the pipes of nominal bore not exceeding 100 mm inclusive of all fittings, excepting fittings like de-superheaters, steam
receivers, feed heaters and separately fired super he attars Rs. 100/- for 30 meters of pipe or part thereof.
(b)
For pipes of nominal bore exceeding 100 mm inclusive of all fittings excepting fittings like de-super heaters, steam
receivers, feed heaters and separately fired superheaters Rs. 250/- for 30 meters of pipe or part thereof.
(c)
Fees for inspection of fittings like de-super heaters, steam receiver, feed headers and separately fired superheaters
Rs..250/- for each such fittings.
Regulation No 395 C.
Fees for Inspection of Valves- Fees for inspection of valves shall be charged as under:
"(1) Subject to a minimum inspection fee of Rs. 300 per inspection for the valves, the inspection fee shall be charged as under:(a) Up to 25mm Rs. 5 per piece.
(b) Above 25mm and up to 50 mm Rs. 10 per piece.
(c) Above 50mm and up to 100 mm Rs. 20 per piece.
(d) Above 100 mm and up to 250 mm Rs. 100 per piece
(e) Above 250 mm Rs 200 per piece
(2) Fees for Inspection of flanges shall be charged as under:
(i) For forged and cast flanges, the fees shall be charged as under:(a) up to and including 25 mm for a batch of 50 or part thereof Rs. 60/(b) up to and including 25 mm for a batch of 100 or part thereof Rs.110/(c) over 25 mm up to and including 50 mm for a batch of 50 or part thereof Rs.120/(d) over 50 mm up to and including 100 mm for a batch of 25 or part thereof ..Rs.120/(e) over 100 mm up to and including 250 mm for a batch of 10 or part thereof .Rs.130/(f) over 250 mm for a batch of 5 or part thereof .Rs.150/(ii) for plate flanges the fees shall be charged at half the rate as charged for forged and cast flanges.
Regulation No 395 D.
Fees for inspection of components of Valve- The fees for inspection of components of valves shall be charged as under:(i)
50% of the Inspection fees of the valves shall be charged by the Chief Inspector of the State where the components of the
valves, are manufactured, for inspection of the components manufactured in a State other than the State where the valves are assembled
and remaining 50% of the inspection fees shall be charged by the Chief Inspector of the State where the valves are assembled, for
inspection of assembly and final inspection of the valves.
(ii)
Where the inspection, so far as the material testing is concerned, has been carried out by a "Well Known Foundry" or
"Well Known Forge" full inspection fees shall be charged by the Chief Inspector of the State where the valves have been assembled and
finally tested.
(iii)
Where the components of the valves are inspected and tested in the same manufacturing work where the valves are
assembled and finally tested, full inspection fee shall be charged by the Chief Inspector of the State where the manufacturing work is
located.
(iv)
In case, in a State, components are manufactured by one firm and finally fittings and assembly of the valves are made by
another, both the firms shall pay inspection fee on 50: 50 basis.
Regulation No 395 E.
as under-
Fees for inspection of feed water heaters and other fittings- Fees for inspection of feed water heaters and other fittings shall be charged
(i)
Fees for inspection of feed water heaters shall be equal to the registration fee of the boiler subject to a maximum of
Rs. 5000./(ji)
Fees for inspection of other fittings like desuperheaters, steam receivers and separately fired superheaters shall be charged
equal to half the registration fee of the boiler to which the steam pipe or feed pipe, as the case may be, is attached subject to a maximum
of Rs. 2500/-.
Note:
In case of fittings, like de-super heaters, feed heaters and separately fired super heaters, which are parts of the steam pipes
or feed pipes attached to a battery of the boilers, the fees shall be charged equal to half the registration fee of any one of the boiler of the
battery of the boilers.
Regulation No 395 F. Markings:show-
(a) Carbon steel tubes or pipes which are both over 50 mm outside diameter or over 1000 mm in length shall be marked legibly to
(i) The identification symbol for the type of the steel;
(ii) The brand of the manufacture; and
(iii) whether seamless or electric resistance welded tubes or pipes.
(b) In the case of Carbon steel tubes or pipes less than 50 mm. outside diameter or less than 1000 mm in length, the information
specified in Clause (a) of this regulation shall be marked on a tag securely attached to the bundle or box.
(c) For alloy steel tubes or pipes markings shall not be stamped on the body of the tubes or pipes. The information specified in subregulation (a) of this regulation shall be stamped on the end face of plain end pipes or on the rims of flanges or on identification plates suitably
attached to the pipes or tubes. Inspection or identification marks may be painted on the alloy steel tubes or pipes provided iron oxide base or
titanium base paints are used.
(d) Tubes or pipes conforming to a foreign standard or code, which have been accepted by the Board under Regulation
3 (2), marking shall be stamped in accordance with the provision of that standard or code, as the case may be.
Regulation No 395 G.
Fee for inspection of spares and scantlings:The fee for inspection of scantlings shall be charged as under:(a)
For outside surface area not exceeding 10 sq.ft (0.93m2 ) ----
Rs. 300.
(b)
For outside surface area exceeding 10 sq.ft (0.93m2 ) but not exceeding 30 sq.ft (2.97m2 ) ---- Rs 400.
(c)For OSA exceeding 30 sq.ft (2.97m2 ) but not exceeding 50 sq.ft (4.65m2 ) ---- Rs 450.
(d) For OSA exceeding 50 sq.ft (4.65m2 ) but not exceeding 70 sq.ft (6.50m2 ) ---- Rs. 550.
(e) For OSA exceeding 70 sq.ft (6.50m2 ) but not exceeding 90 sq.ft (8.36m2 ) ---- Rs. 650
(f)
Rs. 750.
For OSA exceeding 90 sq.ft (8.36m2 ) but not exceeding 110 sq.ft (10.22m2 ) ----
Regulation No 506.- For clause (b ) ,the following shall be substituted, namely :-
(b) On analysis, the sulphur and phosphorous content shall not exceed the following percentages:-
Components
Sulphur percent Max
Phosphorous percent Max
Tubes
0.15
1.00
Headers
0.15
1.00
(c) Minimum Manganese content shall be related to sulphur content by the following formula:
(% Sulphur x 1.7) + 0.3 = % Manganese.
Which must be shown to be satisfied by routine quality control laboratory analysis. In any event the Manganese shall not be less than 0.5 per cent
and shall be within the range 0.5 per cent and shall be within the range 0.50-0.90 per cent. Phosphorus content shall be kept as low as
economically possible but in no circumstances shall it exceed 1.0 per cent.
Regulation No 519.- For clause (i ) ,the following shall be substituted, namely :-
(i) Hydraulic Test- All valves and mountings shell withstand satisfactorily a hydraulic test to the same pressure as will be applied to
the economiser during its registration.
Regulation No 519.For the word feet ,the word meters shall be substituted.
Regulation No. 533.-The following regulation shall be substituted, namely :-
533. Registration fees- An application for registration of Economiser shall be accompanied by appropriate fee as specified below:Rs.
For economiser rating not exceeding
50
250
For economiser rating exceeding
50
but not exceeding
100
300
100
but not exceeding
150
350
150
but not exceeding
200
400
200
but not exceeding
250
450
250
but not exceeding
300
475
300
but not exceeding
350
500
350
but not exceeding
400
550
400
but not exceeding
450
600
450
but not exceeding
500
650
500
but not exceeding
600
700
600
but not exceeding
700
750
700
but not exceeding
800
800
800
but not exceeding
900
850
900
but not exceeding
1000
900
Above 1000 rating for every 200 or part thereof, an additional fees of Rs.50/-shall be charged.
Regulation No 534.- (i) In clause (a) , the following shall be added at the end , namely:The engraving shall be done within a period of two months from the date of receipt of the registry number.
(ii) After clause (b) , the following clauses shall be added , namely:(c)
The engraving shall be completed and ready for verification within thirty days from the date of receipt of the engraving slip
from the Chief Inspector of the State.
(d) Economisers having registry devices different from those prescirbed in clauses (a) and (b) shall have such devices crossed out or
erased and engraved a new inconformity with those prescribed in the clauses aforesaid. The original numbers of such economisers shall
be retained in the new device, provided that in the case of econornisers operating in an area which consequent upon the reorganization
of State forms part of another State. A number once allotted shall not be used again in another economiser.
Regulation No 534B.- The following regulation shall be substituted, namely:534B . Submission of Plan& of Feed Pipes(a) The fees for the scrutiny of plans and particulars of the material, design and construction of feed pipes, before commencement of manufacture
of the feed pipes shall be at the rate of Rs. 30 for 30 meters of piping or part thereof, subject to a minimum of Fs. 50, inclusive of all fittings
excepting fittings like feed water heaters. For any such fittings like feed water heater, the fees shall be equal to the registration fees of the boiler
to which feed pipe is attached subject to a maximum of Rs. 1500.
(b) The fees for scrutiny of layout plans of feed pipes shall be Rs. 20 for 30 meters of piping or part thereof, subject to a minimum of Re. 50;
exclusive of fittings like feed water heater for any such fittings like feed water heater, the fee shall be Rs. 510.00 for each such fittings.
After Regulation No.536, the following new regulation shall added, namely:Regulation No 536A.536A. Equipment of Workshop - (a) The welding plant and equipment are to be of good quality and maintained in an efficient
working condition. The welding apparatus is to be installed under cover and arranged so that welding work may be carried out in positions free
from draughts and adverse weather conditions. The procedure is to be such that there is regular and systematic supervision of the welding works,
and the welding operators are to be subjected by the works officials to periodic tests for quality of workmanship. Records of these tests are to be
kept and are to be available to the Inspecting Officers for scrutiny.
(b) The works should be equipped with welding plant equipment and quality control personnel However, the equipments for destructive,
nondestructive testing and heat treatment is not necessary. The manufacturer can be tie-up for these facilities outside and a letter from the party
with whom he makes a tie-up should be made available to the Chief Inspector of Boilers of the State Inspecting Authority or his representative
should be allowed to inspect the material in the laboratory of the party during the test.
Regulation No 545.(i)
(cc)
after sub-regulation (c) , the following sub-regulation shall be inserted , namely:In the construction of unfired boiler when the dished ends do not forms a part of the heating surface, cold spun dished ends
conforming to 1S: 2825 may be used.

(ii)
In figure XII/10 and figure XII/11, below the dimension shown as 2TE, the following shall be inserted , namely:-
51mm(2 in.) Minimum.

(f)
(iii)
in sub-regulation (e) paragraph(V), after the word and figures, Figure XII/12 , the following word, letter and
figures shall be inserted, namely:- or XII/12A,
(iv) after figure XII/12, the following figure shall be inserted, namely:(a)
Shall to end plate seams

Reverse side fillet weld may be omitted when the shall outside diameter is less than 1800mm
(b) Furnace to end plate and reversal chamber tube plate seams
The reverse side fillet weld may be omitted when the furnace is less than 750mm outside diameter and the seam is protacted by a
refractory lining.
Note: The above requirements for reverse side fillet welds are dictated by consideration of accessibility for welding but whenever it is
generally practicable to insert a fillet weld of the requiste quality for full circumference of the seam then the weld should be inserted. It is
preferable of complete the fillet weld before welding from the other side whenever it is practicable to do so.
Regulation No. 546.- (i) For clause (c), the following shall be substituted, namely:(c) The longitudinal welds shall be placed at the lower of the flue and shall break joint in successive sections at least by 150mm.
(ii) for sub-regulation (g), the following sub-regulation shall be substituted, namely:(g) The minimum mean internal diameter of furnaces shall not be less than those given in Figure XII/20A depending on the net heat input. (click
here to view the Figure (F20a) )
(gg) Where furnace flue is made up of plain or corrugated sections or both, they may be connected to each other by fusion butt welded
circumferential seams.
(ggg) (i) Plain furnaces shall not exceed 3 min length except in the case of reverse flame boilers, which are considered to be inherently flexible
or as provided in clause.
(ii). In all other cases flexibility shall be provided in the furnace by means of corrugations or blowing hoops or stepping of a minimum of 150
mm in the diameter of the furnace. ( See figures XII/20B to XII/20F)

(click here to view the Figure (F XII/20B) )
(click here to view the Figure (F XII/20C) )
(click here to view the Figure (F XII/20D) )
(click here to view the Figure (F XII/20E) )
(click here to view the Figure (F XII/20F) )
If corrugations are used to provide flexibility, at least one-third of the furnace length shall be corrugated.
Breathing spaces as per sub-regulation (i) of regulation 590 shall be provided for boilers made as per this clause.
(ii)
Notwithstanding the provisions of clause (i), plain furnaces longer than 3 m. are allowed to be used in a boiler when the length
between boiler end plates do not exceed 6.5 meters provided that breathing spaces used in this case are in accordance with sub-regulation (ii)
of regulation 590.
(ii) After figure XII/20, the following figures shall be inserted, namely:(click here to view the Figure (F XII/21) )
(click here to view the Figure (F XII/22) )
(iv) in sub-regulation (i), after the words
completion of all welding occurring at the end, the following shall be added namely:in accordance with regulation 562
(v) in sub-regulation( j ), for the word, letters and figures and XII/16, the following word, letter and figures shall be substituted, namely:XII/16 and XII/16A;
(vi) after figure XII/16, the following figure shall be inserted, namely:-
NOTE 1 The plate edge radius of not less than e/2 is only required when furnace end is exposed to a flame or comparably high temperature.
e.g. at the entry to the reversal chamber.
2 The front end of the furnace can protrude beyond the weld provided that the protrusion and the weld area adequately insulated
to prevent overheating.
All dimensions are in millimeters.
Attachment of furnace to end plate or reversal chamber.
Fig XII/16A
Regulation No. 547.- In sub-regulation (a), in the opening paragraph, for the words The welding shall be stress-relieved, the following
shall be substituted, namely:The welding shall be stress-relieved in accordance with regulation 562.
Regulation No. 550.- In clause (a), after sub-clause(a) (ii) the following note may be inserted, namely:-
Note :- Cleaning hole for the purpose of this regulation means a machined cylindrical hole having a diameter not exceeding that of bar stay by
more than 2%.
(i) sub-regulation (b), in paragraph(ii), for the words, letters, brackets and figures (SeeFigure XII/41 ), the following words, letters, figures and
brackets shall be substituted, namely:-
(See Figure XII/41 and XII/41A).

(ii) after figure 41, the following figure shall be inserted, namely:(click here to view the Fig.XII/41A)
Regulation No. 554.For figures XII/53,XII/54 and XII/56, the following figures shall respectively be / substituted, namely:(click here to view the Fig.XII/53)
(click here to view the Fig.XII/54)
Regulation No. 555.(i) in sub-regulation (d), in second paragraph, in sub-paragraph

(ii) for the words and figures Figures XII/84 to XII/89, the following words and figures shall be substituted, namely:Figures XII/84 to XII/89 and XII/93.;
(iii) in figure XII/85, after figure C, the following figures shall be inserted, namely:(click here to view the Fig.XII/85D)
(click here to view the Fig.XII/85E)
(click here to view the Fig.XII/85F)
Regulation No. 561.In sub-regulation (b),
For clause (ii), the following shall be substituted, namely: Tensile test:(a) (i) Welded Joint- The dimensions of the reduced tensile section shall be as shown in figure 60-1(a).
(click here to view the Figure ( F XII/60) )
The width of the reduced section shall be at least 25 millimeters.
(ii)
If the thickness of the plate does not exceed 30 millimeters, the thickness of the specimen shall be equal to the plate thickness and the
plate surface of the specimen shall be machined to take away the surface irregularities of the plate and the weld.
(iii) If the plate thickness exceeds 30 millimeters, the tensile test shall be carried out on several reduced section specimens, each having a
thickness of at least 30 millimeters and width at the effective cross-section of at least 25 millimeters. These specimens shall be taken out of the
test piece in such a way that the tensile test covers the whole thickness of the weld joints as shown in figure 60-1(b).
Figure ( F XII/60) ) The tensile strength shall not be less than the lower limit specified for the plate.
(click here to view the
(b) All weld metal- The dimensions of the all weld metal tensile test specimen shall be those given in figure 63.(click here to view the Figure
( F XII/63) )
The diameter shall be the maximum possible consistent with the cross section of the weld but in no case more than 20 millimeters, the gauge
length shall be equal to five times the diameter. The tensile strength shall not be less than the lower limit specified for the plate. The elongation
shall not be less than 20 per cent on a gauge length of four times the square root of the cross-sectional area of the specimen, and the reduction in
area not less than 35 per cent.
(ii) for clause(v), the following clause shall be substituted, namely:(v)
Macro and Micro Examination- A specimen of the full thickness of the plate and not less than 13 millimeters wide shall be provided
from each set of test plates for the purpose of macro and micro examinations.
Microetching of a complete cross-section of the weld including the heat affected zone, should show satisfactory penetration, fusion and absence
of significant inclusions or other defects.
Should there be any doubt as to the condition of the weld as shown by marco-etching, the area concerned is to be microscopically examined for
defect investigation.
(iii) For figure XII/60, the following figure shall be substituted, namely:(iv) For figure XII/63, the following figure shall be substituted, namely:(v) For sub-clause (viii) of clause(b), the following shall be substituted, namely:(viii) Radiographic Examinations- Every portion of the longitudinal and circumferential butt-welded seams of the shell of the boiler shall be
subjected to radiographic or ultrasonic examination. Where ultrasonic examination is used, it shall be demonstrated to the satisfaction of the
Inspecting Authority that the equipment and the technique used are satisfactory. The manufacturer shall ensure that the operator employed is
competent to use the equipment, apply the technique and interpret the results of the examination.
The methods employed in obtaining the radiographs shall be such as to show clearly differences equal to 2 per cent of the thickness at the welded
joints. To determine whether this result is being attained an indicator of approved form which includes a portion equivalent to not more than 2 per
cent of the joint thickness shall be placed in the vicinity of the weld so as to make a record on each radiograph. Each section of every weld shall
be marked so that the radiographs can be easily corrected to the particular part of the same represented.
The examination shall be made from the original films and the acceptability of the welds shall be decided by the Inspecting Authority. The
welds deemed unsatisfactory shall be rejected or dealt with under the condition of regulation 560 and can be radiographed again. The films
shall be retained by the manufacturer for a reasonable period for reference and be available to the Inspecting Authority, if required.
Note:
(1) Magnetic Particle Flaw Detection:- Magnetic methods of flaw detection shall be employed wherever possible for ferritic steel.
(2) Dye-Penetrant Flaw Detection- Dye-penetrant or equivalent methods of flaw detection shall be employed for Austenetic or other
non-magnetic steel.
(vi) After sub-clause(vi) of clause (c), the following shall be inserted, namely:(vii) Radiographic or Ultrasonic Examination- Each longitudinal an d circumferential seams in class II boiler (including shell to end plate)
shall be subjected to spot radiographic or ultrasonic examination.
(vii) For sub-clause (d), the following shall be substituted, namely:(d) Test for Class ill Boiler(i) Specimens for the following tests shall be selected from the test plate or plates and stamped by the Inspecting Officer for identification.
1. One forward bend test.
2. One reverse bend test.
(ii) Radiographic or Ultrasonic Examination- Each longitudinal and circumferential seams in class III boiler (including shell to end plate) shall
be subjected to spot radiographic or ultrasonic examination.
Regulation No. 562.- The following regulation shall be substituted, namely:562. (1) Heat Treatment- All boilers constructed to Class I or Class Il requirements shall be stress-relieved by heat treatment after completion of
all welding and before hydraulic test if any plate is 20 mm thick or greater or carbon content of the steel exceeds 0.25% of the material used in
the construction of boiler is alloy steel.
For Carbon steel a stress relieving heat-treatment shall be performed by heating part to at least 600 20 0C. When required by the characteristics
of the material, different temperatures may be necessary to obtain proper stress relieving. The part to be stress-relieved shall be brought slowly up
to the specific temperature and held at that temperature for a period proportionate on the basis of at least 2 minutes per millimeter of the
maximum thickness of part (approximately one hour per 25 mm of thickness) and shall be left to cool in the furnace to a temperature which, for
the parts with a thickness greater than 20 mm does not exceed 4000C. After withdrawal from a furnace the part shall be allowed to cool in a still
atmosphere. A temperature-time diagram of the stress-relieving process shall be provided for a welded shell or drum and a similar diagram for
other welded pressure parts when the Inspecting Authority requires it. During heat treatment the Official test plates shall be inside the boiler.
Where the shell is subjected to a primary stress relieving treatment identical to the final. heat treatment to be given to the boiler, the test plates
may be placed inside the shell during primary treatment and thereafter cut up and tested without waiting for the final treatment of the boiler.
Where the shell is not subject to primary stress relieving treatment or is subjected to primary stress relieving treatment which is not identical with
the final heat treatment, the test plates may be placed inside any other boiler of comparable dimensions which is to be heat treated in accordance
with this Chapter.
Temperature charts shall be submitted to indicate that the test plates and boilers they represent have been subjected to identical heating, soaking
and cooling treatment.
Note:
Other stress-relieving heat treatment at a temperature as low as 5500C may be adopted, provided attention is given to the holding time
in order to ensure a sufficient degree of stress-relieving.
(2) Where the welded joint connects parts that are of different thickness, the thickness to be considered in applying the limiting thickness of 20
mm for carbon -steel shall be the following nominal thickness including corrosion allowance.
(i)
(ii)
the thinner of two adjacent butt welded component including shell to end connection
the thickness of the shell in connections to flat ends;
(iii) the thickness of the shell or end in nozzle attachment welds;

(iv)
the thickness of the nozzle at the joint in nozzle to flange connections;
(v) the thickness of the pressure part at the point of attachment where a non-pressure part is welded to a pressure part, in case of butt welds;
(vi) the thickness of the fillet weld at the point of attachment where a non-pressure part is welded to a pressure part, in case of fillet welds.
(3) Notwithstanding anything contained in sub regulations (1) and (2), if the thickness of the small component of boiler exceeds 20 mm and the
weld recess also exceeds 20 mm. local stress relieving to the satisfaction of the Inspecting Authority shall be permitted.
Regulation No. 564.The following regulation shall be substituted, namely:564.
271.
She11- (a) The working pressure of cylindrical shells for Class I boilers shall be determined in accordance with regulations 270 and
(b) The working pressure of cylindrical shells for Class II and Class III boilers shall be determined by the following formula:
where,
t is minimum thickness of shell plate in mm.
WP is working pressure in kg/cm,

D is maximum internal diameter in mm,
S is minimum tensile strength of plate in kg/mm2,
C is a constant, as given below.
In no case, however, shall be the factor of safety of the shell be less than 4 or the plate thickness be less than specified in Table XII / 3 given
under Regulation 563.
C = 27 where Class II requirements are complied with,
C = 23 for Class III boilers when stress relieved,
C = 21 for Class III boilers when no stress relieved.
Where boilers have a nest or nests of horizontal tubes, so that there is a direct tension on the tube plates due to the vertical load on the boiler
ends or to tube plates acting as horizontal ties across the shell:
(i) each alternate tube in the outer vertical row of tubes shall be a stay tube.
(ii) the thickness of the tube plates and the spacing of the tubes shall be such that the section of metal taking the load is sufficient to keep the
stress within that allowed on the shell plate, as determined by the following formula:
where,
T is the thickness of the tube plate in mm.
WP is working pressure in kg/cm2,
S is the minimum tensile strength in kg/mm2,
D is twice the radial distance of the center of the outer row of tube holes from the axis of the shell m mm,
J is the percentage strength of the plate through the tube holes, i.e.
p is the vertical pitch of tubes in mm,

d is the diameter of the tube holes in mm.
Note:
The tube plates between the stay tubes shall comply with the requirements for tube plates
(see Regulation 577).
Regulation No.573.- The following regulation shall be substituted, namely:573. Standpipes and branches- (a) The thickness and bolting of all flanges for joining the mountings and fittings shall be in accordance with
the dimensions as laid down in Appendix E to these regulations. In no case, however, shall the thickness of flanges be less than 13 mm.
(b) (i)
The Wall thickness of nozzles and other connections shall not be less than that s-Red for the applicable loading, namely,
(ii)
The pressure loading shall be determined by regulation 564, but in no case shall the thickness be less than that calculated
internal pressure, bending and static loads.
by the following formula:
t .04D + 2.5 mm
(equation XII / 10 )
where,
t is the thickness of standpipe and D is the outside diameter of connection. If the branch is connected by screwing, the thickness 't' shall
be measured at the root of the thread.
(c) Where a double flanged steam pipe is tapered, the thickness of flange joining the boiler and fitting shall correspond to the bore of pipe at the
flange connection in accordance with Appendix E to these regulations.
Regulation No. 574.- The following regulation shall be substituted, namely:574 . Stayed Flat Surfaces (other than Crowns of Vertical Boilers)- Stayed Heads/Braced and Stayed Surface: For various braced and
stayed flat plates and those which by these regulations require staying as flat surfaces with braces or stay bolts of uniform diameter symmetrically
spaced, the thickness should be calculated by the following formula: namely:-
Where,
P = design pressure in kgf/cm2

e = thickness, in mm.
d =diameter of the largest circle taken between staying points of the plate (in mm) (click here to view the Figure)
f1= 0.85 f (f as defined in regulation 271), kgf/cm2
e1 = additional thickness equal to 0.75 mm (0.03 in)

C = coefficient having the following values:-
(1) C = 0.33 for flanged connections;

Note: d, is the diameter of the largest circle taken from the commencement of the curvature of the flange.
(2) C =
0.40 for stays screwed in plate with nut or screwed and welded, or plain end strength welded on the outside;
(3) C =
0.33 for screwed bar stays with washer of not less than 3.5 times the diameter of bar stay;
(4) C =
0.31 for screwed bar stays with reinforcing plate, washer and nut on the outside.
Notes:
1. If the plate is stayed in any other way, average valued of C shall be taken into account.
2. If the plate is flame swept, the thickness shall be increased by 10%.
3. The welding materials used in the manufacture of these plates shall not have the ultimate tensile strength less than that of the plate used.
Regulation No. 575.- The following regulation shall be substituted, namely:575.
Flat crown plates for vertical boilers-
(i) Flat crown plates shall be supported by the uptake and/or bar stays.
(ii) The inside radius of curvature of the flange to the shell or fire box shall be not less than four times the thickness of the plate and in no case
less than 63 mm where the plate is flanged for attachment to the uptake, the inside radius of curvature of the flange shall be not less than twice the
thickness of the plate and in no case less than 25 mm.
(iii) The thickness of flat crown plates shall be determined in accordance with Regulation 574.
Regulation No. 576.- The following regulation shall be substituted, namely:576. Wide water spaces between and around tube Nests- The thickness of plate at wide water spaces shall be calculated as per regulation 574
taking
A- is width of the wide water space between the tube nests in mm measured from center to center of the tubes: and
B- is pitch of the tubes in the boundary rows of the wide water space in mm.
Regulation No. 577.- The following regulation shall be substituted, namely:577.
Flat tube plates and tubes nests- (a) Stay tubes and plain tubes:
(i) Stay tubes are tubes having a weld depth equal to the nominal tube thickness plus 3 mm as shown typically in figures XII/68A(i) to (iv). (click
here to view the Figure ( F XII/68A) ) These stay tubes are not required within tube nests except when the tube nests comprise tubes which are
expanded only as shown typically in figure XII/67A(iii).
(ii) If tube nests comprise plain tubes which are expanded and beaded, expanded and belled as shown typically in figure XII/67A (iv) (click here
to view the Figure ( F XII/67A) ) or expanded and welded (as shown typically in figures XII/67A (i) and (ii)), welded stay tubes ((as shown
typically in figures XII/67A(i) to (iv)) (click here to view the Figure ( F XII/67A) ) shall be used in boundary rows in sufficient numbers to
carry the flat plate loadings outside the tube area.
(iii) For plain tubes and stay tubes exposed to flame or gas temperatures exceeding 600 0C, the ends of welded tubes shall be dressed flush with
the welds and the ends of the expanded tu6es shall be as shown in figures XII/67A (iii) and (iv). (click here to view the Figure ( F XII/67A) )
If not so exposed, the ends of welded tubes shall extend a maximum of 10 mm beyond the weld or, in the case of expanded tubes, the tubes
shall project beyond the tube plate up to a maximum of 15 mm.
(iv) Each stay tube shall be designed to carry its due proportion of the load on the plates which it supports. The thickness of stay tubes welded
into tube plates shall be such that the axial stress on the thinnest part of the tube does not exceed 70 N/mm 2.
(b) Parts of flat plates within tube nests- If stay tubes are used within tubes nests, the thickness of the tube plate shall be calculated in accordance
with regulation 574.
Regulation No. 579.- For sub-regulations (b) and (c), the following sub-regulations shall be substituted, namely:(b) The thickness of tubes under external pressure shall be calculated as under:
where,
t = minimum thickness of tube in mm.
WP = External working pressure in kg/cm2 (g)
D =Outside tube diameter in millimeters
C = Corrosion allowance to be taken as
0.75 millimeter but for stainless steel C=0
Higher value may be adopted if desired by user.

F = allowable stress as per regulation 338.
(c)
In no case the thickness of straight tubes under external pressure shall be less than as specified below:-(Click here to view the Table).
(b) Internal Pressure :

The thickness of tubes under internal pressure shall be calculated as under
where,
WP = Internal working pressure, kg/crn2 (g), and other symbols as per clarifications indicated at (a) above.
In no case the thickness of straight tubes under internal pressure shall be less than listed below:-(Click here to view the Table).
Regulation No. 581.(i)
For clause (a) the following clause shall be substituted, namely:-
(a)
Minimum thickness of stay tubes- The minimum thickness of stay tubes shall be as per regulation 148.
(ii)
sub-regulation (b),-
(i)
for the last paragraph, the following shall be substituted, namely:Welded attachment of stay tubes be as shown in Figures XII/67, Figures XII/67A, Figures XII/68, Figures XII/68A and XII/69.
(ii)
after figure XII/67, the following figure shall be inserted, namely:-
(iii)
after figure XII/68, the following figure shall be inserted, namely:-
(click here to view the Fig.XII/67A)

(click here to view the Fig.XII/68A)
Regulation No. 590.The following regulation shall be substituted, namely:590. Breathing space- Breathing spaces as provided in clause (i), (ii) or (iii) shall be provided depending on the design of the boiler with special
attention to the provisions of sub-regulation (ggg) of regulation 546 regarding furnaces.
(a)
(i) For boilers as per clause (i) of sub-regulation (ggg) of regulation 546:
Arrangement of stays: Stays shall be arranged to give sufficient breathing space around the furnace connections and tube nests (see
figures XII/75 and XII/77), (click here to view the Figure ( F XII/75) ) (click here to view the Figure ( F XII/77) ) and shall divided the unstayed
areas equally.
(b)
Multi-tubular boilers: For both the front and rear attachment of furnaces, the breathing spaces between furnace and tube nests or
between spaces between furnace and tube nests or between furnace and shell shall be a minimum of 50 mm or 5% of the shell inside diameter,
whichever is larger, with a maximum requirement of 100 mm.
Clearances between the furnace and wet-back wrapper plates shall not require consideration as breathing spaces.
In the case of reverse flame boilers, the breathing space at the front end between furnace and tube nests shall be not less than 50 mm and the
breathing space formed by the outer-annular area of the furnace rear plate shall be not less than 50 mm or 5% of the shell inside diameter, whichever is larger, with a maximum of 100 mm.
Breathing spaces between gusset or link stays and tube ends shall be not less than 100 mm.
Clearances between the tubes and wet-back Wrapper plates shall not require consideration as breathing spaces.
Breathing spaces between tubes and shells shall not be less than 40 mm.
Breathing spaces between gusset or link stays and furnaces shall be not less than 200 mm except that for shell outside diameters exceeding 1800
mm and furnace lengths exceeding 6000 mm they shall be not less than 250 mm and for shell outside diameter less than 1400 mm and furnace
lengths less than 3000 mm they shall be not less than 150 mm.
All other breathing spaces shall be a minimum of 50 mm or 3% of the shell inside diameter, whichever is larger, with a maximum requirement of
100 mm.
(c)
Cornish and Lancashire boilers: In Cornish boilers, the circle defining the breathing spaces shall be as shown in figure XII/73 (click
here to view the Figure ( F XII/73) ) i.e. the distance AB between the center of the stay circle and the center of the flue shall be not less than
3e+63, where, e is the thickness of the end plate in millimeters.
Note: For Lancashire boilers, the proportions shown in table XII/6A given below are recommended for the portion of the end plates above the
furnaces and flues.
It is recommended that the breathing space below the flue be approximately one-half of the dimensions given in table XII/6A.(Click here to view
the Table).
(ii) For boilers as per clause (ii) of sub-regulation (ggg) of Regulation 54~ Stays shall give breathing spaces around the furnace connections and
tube nests (see figure XII/70 to XII/77, XII/80,XII/80A, XII/80B, XII/80C and XII/80D) and equally divide the unstayed areas. Breathing spaces
between furnaces and tube nests shall be a minimum of 50 mm or 5% of the shell outside diameter, whichever is larger, but need not be more
than 100 mm.
(click here to view the Figure ( F XII/80A) )
(click here to view the Figure ( F XII/80B) )
(click here to view the Figure ( F XII/80C) )
(click here to view the Figure ( F XII/80D) )
Breathing spaces between furnaces and shells shall be as given in Table XII/6B or XII/6C as applicable, but shall be not less than 50 mm or,
for bowling hoop furnaces, not less than 75 mm as measured from the outside diameter of the bowling hoop.
For the boilers having more than one furnace, breathing spaces between furnaces shall be not less than 120 mm.
Breathing spaces between gusset or link stays and furnaces shall be not less than 200 mm, except for;
Shell outside diameter
or furnace length
Shell outside diameter or
furnace length
> 1800 mm)

> 6000 mm)250 mm
< 1400 mm)
< 3000mm )..150 mm
Breathing spaces between gusset or link stays and tube nests shall be not less than 100 mm.
When unflanged flat and plates as used, the breathing spaces between gussets or link stays and furnaces shall be increased as follows:
Increase 200 mm to 220 mm
All other breathing spaces shall be a minimum of 50 mm or 3% of the shell outside diameter whichever is larger but need not be more than 100
mm.
Table XII / 6B (Click here to view the Table).
Breathing spaces between furnaces and shells when tube plate thickness does not exceed 25 mm. (See Table XII/6C also)
Note:
But not less than 50 mm or, for bowling hoop furnaces 75 mm
When the actual thickness of the end plate exceeds 25 mm the breathing spaces in accordance with Table XII/6B shall be increased in accordance
with Table XII /6C
Breathing spaces between furnaces and shells when the thickness does not exceed 25 mm.
(iii)
For boilers not covered under the above clauses of this regulation:-
Gusset stays shall be arranged to give sufficient to give sufficient bearing space around the furnace connections and the tube nests (see
Figures XII/70 to XII/77, XII/80, XII/80A to XII/80D. The proportions shown in table XII/6D are recommended for the portion of the end plates
above the furnaces and the flues. (Click here to view the Table).
The breathing space below the flues shall be approximately one-half the dimensions given in Table XII/6.
For gusset stays above the tube nests, as fitted in multitubular waste heat boilers without internal furnaces, a breathing space of 20.3 mm from the
center line of the adjacent tubes to the toe of the gusset angle or plate, may be maintained. For the back end stays below the furnaces of
multitubular dry back boilers, a breathing space of 152 mm may be maintained where the flues are constructed in accordance with regulation 546.
Where the flues are constructed of corrugated sections welded together, a breathing space of 114 mm may be maintained.
Regulation No. 591.After the first paragraph, the following shall be added, namely:Welded gusset stays and braces may be used for welded Lancashire, Cornish and Cylindrical Horizontal Multitubular boilers provided their
method of attachment is approved by the Inspecting Authority.
Regulation No. 592.(i)
For regulation 592, the following regulation shall be substituted, namely:-
592. Furnaces, furnace components, wet back reversal chambers and fire boxes of cylindrical form subject to external pressureFurnaces :
(a) Maximum furnace diameter- The mean diameter of furnaces shall not exceed 1800 mm.
(b) Notations:
b is the pitch of the furnace corrugations (in mm);
C is the corrosion allowance = 0.75 mm;
d
is the mean diameter of furnace (in mm) (see note 1);
d max is the maximum mean diameter of the furnace (in mm);

d minis the minimum mean diameter of the furnace (in mm);
e is the furnace plate thickness (in mm);
E
is Young's modulus of elasticity (in kg/cm2) at the design temperature.
Et is the specified minimum elevated temperature yield stress or the 0.2% proof stress at the design temperature (in kg/cm2 );
F
is the cross-sectional area of a longitudinal section of the corrugated furnace wall, of length b and thickness (e-c) (in mm 2) [see figures
XII/94 (a) to (g)]
I
is the second moment of area of one complete corrugation about its neutral axis, excluding the corrosion allowance (in mm 4);
Is
is the second moment of area of plain stiffener section (see figures XII/21 & XII/22) about its neutral axis, including a length of the
furnace of 0.55 ~ on each side of the stiffener (in mm') (see note 2);
L
is the distance between the center of two effective points of support (in mm) (see note 3);
P is the design pressure (in kg/cm2)

S1 is the factor of safety:
=
2.5 for furnaces in class l and class II boilers
3.5 for furnaces in class III boilers
2.0 for furnaces and wrapper plates not exposed to flame.
S2is the factor of safety:

=
3.0 for class I and class II boilers
3.9 for class III boilers
is the percentage out of roundness to be taken as 1.5 for plain furnaces and 1.0 for corrugated furnaces;
W is the depth of corrugation (in mm).

Note 1:
For corrugated furnaces, mean diameter is equal to inside diameter plus full depth of one corrugation referred to in Fig XII/94 which is
equal to the inside diameter +e+ W
Note 2:
When calculating Is, it is only necessary to take into account a corrosion allowance on the furnace gas side.
Note 3:
support.
Stiffeners complying with figures XII/21 and XII/22 boiler and reversal chamber end plates are considered to be effective points of

Note 4: The design temperature of the furnace = ts + 4e + 15 saturation temperature plus four times the thickness of the furnace plus 15.
(c)
Evaluation of Young's modulus at the design temperature. Value of E shall be obtained from the following table (by linear
interpolation if required). (Click here to view the Table).
(a)
Plain furnaces- The design pressure of plain furnaces shall be the lower of those obtained using equations XII/25 and XII/25A as
follows, but the thickness shall be not less than 7mm and shall not exceed 22 mm:
Equation XII/25 and XII/25(A) may be expressed in terms of thickness using equation XII/26 and XII/26(A) respectively as follows and the
greater of the thickness obtained shall be used.
If the furnace / combustion chamber has tubes radially to it. The thickness of that portion of the furnace is to be increased by the value of
ligament efficiency.
(e)
Furnace components : The thickness of furnace components, e.g. ash drop-out tubes and fuel inlet connections, shall be calculated in
accordance with sub-regulation (d) with a minimum thickness of 10 mm and a maximum thickness of 22 mm.
(f)
Corrugated furnaces : The design pressure of corrugated furnaces shall be determined using the equation XII/28 but the thickness shall
be not less than 10 mm and shall not exceed 22 mm. Calculated value of I and F for some of the corrugations are given in figure XII/94 for other
shapes and sizes calculations need to be made from basic principles.
(click here to view the Figure ( F XII/94 - A,B,C) )

(click here to view the Figure ( F XII/94 - D,E) )
(g)
Tolerances and allowances : The calculated wall thickness contains a fixed allowance of 0.75 mm for corrosion and wear. For
corrugated furnaces, the calculated wall thickness shall be the minimum thickness of the finished furnace. For plain furnaces and reversal
chambers, allowance shall be made to take account of any minus tolerances on the plate thickness.
(h) Out-of- roundness : The percentage out-of-roundness is as follows:-
This shall be included in the calculation as u= 1.0 for corrugated furnaces and u=1.5 for plain furnaces.
(i) Stiffeners.
(i) Stiffeners shall have second moment of area not less than that given by the following equation:
(ii) If the stiffeners are made in sections from bar or plate, the abutting ends shall be prepared so as to ensure that full penetration welds
are made.
The thickness of the stiffening ring shall be kept to the minimum required (for limiting dimensions see figures XII/21 and XII/22).
(iii) Bowling hoops are considered as effective points of support. The minimum pitch of bowling hoop centers shall be not less than 500
mm. If bowling hoops are used, the furnace thickness shall be calculated from sub-regulation (d). The dimensions of bowling hoops shall be in
accordance with figures XII/95 (a), (b) and (c) and their second moment of area determined from the tables given in these figures, shall be not
less than required by sub-regulation (i).
(click here to view the Figure ( F XII/95 - a,b,c) )
(iv) If corrugated furnaces are equipped with several stiffeners, e.g. one on each corrugation or on each second corrugation, the crosssectional area and the second moment of area of the stiffeners shall also be taken into consideration when using the equation XII/28. A height of
not more than four times the furnace thickness shall be used for the calculation.
(1) Circular reversal chambers:
(i) The thickness of wrapper plates of cylindrical reversal chambers of horizontal multitubular boilers shall be calculated in accordance
with the equations given in sub-regulation (d). The thickness shall be not greater than 35 mm and shall be not less than 10 mm.
(ii) The thickness of access tubes shall be calculated in accordance with sub-regulation (d) with a minimum thickness of 10 mm.
(ii)
after figure XII/93, the following figures shall be inserted, namely:-
Regulation No. 601.- The following shall be substituted, namely

601. Hydraulic and Hammer Tests.
(a) (i) Class I Boilers.- Each class I boiler shall , on completion of all welding and / or repairs and after heat treatment, be subject to a
hydraulic test of 1.5 times the design pressure without any indicated of weakness of defect.
(ii) Class II & Class III Boilers:- Each class II & class III boiler shall be tested to a pressure twice the design pressure.
(b) (i) The test shall be witnessed by the Inspecting Authority or Inspecting Officer.
(ii) The test pressure shall be maintained for a period not less than 30 minutes.
It is important in the interest of safety that the boiler be properly vented, So as to prevent formation of air pockets, before the test
pressure a s applied.
Note:1. It is recommended that the temperature of the water should not be less than 7 C during the hydraulic test .
2. It is further recommended that before the boiler is approached for close examination, The pressure shall be reduced to not less
than 1.1 times the design pressure and not more than 0.9 times the hydraulic pressure.
3. On completion of hydraulic test, release of pressure shall be gradual.
4. Deflection of different pressure shall be examined carefully and there shall not be any permanent set after release of pressure.
(c) If any repairs are found to the necessary duing or subsequent to the hydraulic pressure test, the boiler shall again be subjected
to the pressure test specified above after completion of the repairs and after any heat treatment.
Note:- Observations and remarks of Inspecting Authority / Inspecting Officer should be recorded for filming with marker's papers.
Regulation No 605A.- After Regulation 605 the following Regulation 605A shall be inserted: 605A. Issue of Duplicate Certificate- (i) In case of loss of a certificate issued to a welder in Form XIII, a duplicate certificate may be issued
by the Competent Authority who issued the original certificate provided that the Competent Authority is satisfied with the genuineness of the
case.
(a)
(ii)
Fee for issue of duplicate certificate shall be Rs. 25.00
Regulation No 607.- For clause (b), the following shall be substituted, namely:(b) Re-validation of Certificate- The certificate may be extended from time to time for a period not exceeding twenty-four months at a time
on completion of a requalification of test (see Regulation 610) to the satisfaction of the Competent Authority. In case the welder is employed in
another State at the time of revalidation of a certificate, he may appear for a requalification test before the Competent Authority of that State
for extension of his certificate.
Regulation No 609.
(i)
In sub-regulation (a), for the word X-Ray, the word radiographic shall be substituted.
Regulation No 611.(ii) For clause (d), the following shall be substituted, namely:(d) Welded Tube Joints- A test length approximately 203 mm long shall be cut from the tube with the welded joint disposed approximately at
the center. After visual examination, one test piece not exceeding 13 mm, for tubes 6 mm. in thickness and below and thrice the thickness of
the tube for thickness of over 6 mm. shall be cut longitudinally.
The test shall not be less than 76 mm in length on either side of the weld. The light excess of internal head may be filed until it is not more than
0.8 round of the general surface. The test piece shall then be bent back with the root in tension through 90 degree round a former of diameter
equal to three times the thickness of the tubes. With regard to alloy steel pipes and tubes, the bend test specimen shall be bent without being
straightened, but after removal of the weld reinforcement down to the level of but not below the surface, round a former of diameter 41 and
through and angle of 90 degree. The bending may be carried out by blows or by pressure, care shall be taken to ensure that the former is so
positioned that the weld is maintained at the crown of the bend. The test specimen shall be capable of being bet through 90 degree without
signs of failure, although slight premature failure at the edges of a specimen need not be considered a cause for rejection. The opening out of a
slight defect due to incomplete root penetration or lack of root fusion need not be considered a cause for rejection; provided the defect has
sound metal at the back and on either side of it.
Regulation No 616.The following regulation shall be substituted, namely:Fees for examination of welders:Fees for examination of welders under these regulations shall be Rs. 50/- and this shall be borne by the applicant. In addition, the applicant shall
bear all other expenses like cost of material and workshop and testing facilities as fixed by the Competent Authority.
For Chapter XIV, the following Chapter shall be substituted, namely:-
CHAPTER XIV
(Regulations made under clauses (a) and (aa) of section 28 of the Act)
SMALL INDUSTRIAL BOILERS
GENERAL
618. Scope.- This chapter shall apply to the design, construction, inspection, registration, operation and maintenance of small industrial boilers.
619. Definition In this Chapter, small Industrial Boiler means
(a)
A shell type boiler generating steam for use external to itself under pressure up to 7 kg/cm2 and having a volumetric capacity
exceeding 22.75 liters, but not exceeding 500 liters 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 liters.
Provided that in case of boilers having combined features of clauses (a) and (b), the working pressure shall be restricted to 7 kg/cm 2 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 liters.
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 un flanged steel tube plate may be inserted into the shell and welded for the entire thickness as
shown in Figure XIV/1 (click here to view the Figure) with a fillet weld having a throat not less than 1.1/4 times the thickness of the shell or
tube sheet whichever is smaller.
(ii) The minimum thickness of un flanged welded tube sheets shall be 10 mm.
(iii) The temperature of the heating element of electrically heated steam boilers shall be so controlled that it shall not exceed 650 0C.
(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 subject to inspection during construction and after completion by an
Inspecting Authority. The inspection of the boilers shall be made at the following stages.
A.
(i)
Shell type Boilers:

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
(v)
A test coupon shall be provided by the maker for conducting root and face bend tests.
B.
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 Maker's stamps
allowable working pressure of the boiler.
(a) The certificate and maker's stamp shall be in conformity with the provisions of Chapter 1 of these regulations.
(b) If owing to small size of the boiler all information cannot be visibly stamped on the boiler plate, maker's 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.
621. Values, 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 maybe used for the
attachment 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 rivetted 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
(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
openings and Washout plug. Level gauges are not required for once through boilers.
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
(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
may be delivered to the boiler through the openings of the same size in the shell as that of the blow off connection.
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 Gauge- Every 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 the top of the
furnace tube sheet.
(iv)
Pressure Gauge- The steam 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 Valve- Each boiler 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 per cent 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.
622. Registration, Operation and Maintenance.(a)
The fee required to accompany an application under sub-section (1) of section 7 of the Act shall be Rs. 100 per boiler. Annual
(b)
The certificate of manufacture and test for small industrial boilers shall be furnished in Form XVII appended to these regulations.
Inspection fee shall be Rs.100/-.
(c)
The operator for these boilers shall be a pass in Class X or equivalent.
Regulation No.623.
The following regulation shall be substituted, namely:623.
Application.- This chapter shall apply to Heat exchangers, Converters, Evaporators and similar vessels in which steam is generated
and to the vessels which are connected fittings of a steam pipe and the gauge pressure of which is exceeding 1Kg/cm 2:
Provided that nothing in this chapter shall apply to such chambers of Heat Exchangers where no steam is generated.

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What are the key changes made to the Indian Boilers Regulations 1950?

What are the key changes made to the Indian Boilers Regulations 1950?

What are the mounting and fittings required for boilers as per the regulations?

What are the mounting and fittings required for boilers as per the regulations?

INDIAN BOILERS REGULATIONS 1950

PROCEDURE FOR RECOGNITION OF COMPETENT AUTHORITY, INSPECTING AUTHORITY, WELL-KNOWN MATERIAL

(i) The plates shall have a steel maker's stamp.

tensile strength at room temperature in Kgf/ mm2

C=2.2 for only gauge length or L=5 do or 5.65A0

thickness of tube (9 mm).

Outside diameter (D) of the

Increase of outside diameter of

Drift expanding test

C=2.2 for only gauge length or L=5 do or 5.65 A0

thickness of tube (mm).

Drift expanding test

Outside diameter (D) of the

Increase of outside diameter of

Upto and including 63.5 mm

C=2.2 for only gauge length or L=5 do or 5.65 A0

Rm = measured tensile strength at room temperature in Kgf/mm2

Rm = measured tensile strength at room temperature in Kfg/mm2

a maximum specified Chromium content of 3.0%,

For carbon steel:(i)

( = angle of center line of cylinder to center line of diagonal holes.)

The breaking elongation in percent shall be not less than

d0 =original diameter of round test piece.

following shall be substituted, namely: -

relevant details shall be furnished.

For clause (b), the following shall be substituted, namely: -

(iv) Three notched-bar impact test specimens.

4, notched-bar impact test specimen.

For clauses (a) and (b), following shall be substituted, namely: -

length shall be equal to five times the diameter.

For clause (a), the following shall be substituted, namely: -

The following regulation shall be substituted, namely: -

For the V notch specimen, at a temperature of 502C

In clause (a), the following shall be inserted at the end, namely: -

shown in the table below: -

(Click here to view the Table).

(click here to view the Figures)

(click here to view the Figure(F23e &23F)

End plate with Manhole-

P = Maximum working pressure, Design pressure;

C = an additive thickness equal to 0.75

(click here to view the Figure(F27C)

(click here to view the Figure(F27D)

Failure of forced or induced draught fans or any automatic flue damper.

+ (v) Increase in furnace pressure to a predetermined valve.

Carbon Molybdenum castings

(Where D=diameter of the mandrel and t=thickness of test piece)

% Elongation on gauge length = 5.65A

Minimum Charpy Impact Values kgm/cm2

(Where t= thickness of the test piece; D=diameter of the mandrel).

Chemical composition (%)

(Where D= diameter of the mandrel: t=thickness of the test piece)

Minimum yield point kg/mm2

% Elongation on gauge length 5.65 A

180 on D=3t 150o on D=3t