Bangladesh Boiler Regulation- 1951

[Amended- 2007]

Office of the Chief Inspector of Boilers

91, Motijheel C/A, Dhaka- 1000.
 The Government of People’s Republic of Bangladesh
Ministry of Industries
Central Boilers board
Notification

No. P-11 (21)|48- In exercise of the powers conferred by section 28 of the Boilers Act, 1923 (V of
1923), the central Boilers Board is pleased to make the following Regulations, the same having
been previously published in the late government of India, Department of Works, Mines and
Power Notification No. EL-II|304 (1), dated the 27th September 1946 and No. EL-II|304 (2), dated
the 9th May 1947 as required by sub-section (1) of section 31 of the said Act, namely:-
1. Short Title and Commencement:-
(1) These Regulations may be called the Boiler Regulation, 1951.
(2) Those shall come into force on such as the Board may by notification in the official
Gazette appoint.
(3) They extend to The whole of Bangladesh.

2. Definitions.- In these regulations, unless there is anything repugnant in the subject or

context:
(a) The ‘Act’ means the Boilers Act, 1923.
(b) “Inspection Authority” means an authority recognized by the Boilers Board as
competent to grant a certificate in Form II and Form IIA.
(c) “Inspection Officer” means-
(i) In respect of material manufactured or boilers constructed in Bangladesh, an
officer appointed by the Inspecting Authority.
(ii) In respect of material manufactured of boilers constructed outside Bangladesh, an
officer acting on behalf of the Inspecting Authority.
(d) “Inspector” means an officer appointed in accordance with section 5 (1) of the Act.

CHAPTER I
GENERAL REQUIREMENTS, APPLICATION OF STANDARD CONDITIONS AND
EXCEPTIONS THERETO
3. (1) A boiler shall not be registered under sub-section (4) of section 7 of the Act and a
certificate shall not be issued under sub-section (5) of that section with reference to a
boiler, unless the standard conditions in respect of material, design and construction,
which are specified in the subsequent Chapters of these Regulations are satisfied in
respect of such a boiler.
(2) Not with standing anything contained in sub-regulation (1), the chief Inspector may
subject to the provisions of Regulation 7, register a boiler and order the issue of a
certificate authorizing the use thereof although the standard conditions are not fully
satisfied in respect of such boiler: provided that the Chief Inspector shall not register
such boiler or order the issue of such certificate, if a structural part of such boiler
which is subject to pressure is made of Bessemer process steel or of cast or malleable
cast iron.
(3) Where no specific provision is made in these regulations for design or manufacture of
any pressure part of the boiler, 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 international standards and foreign
codes likes B.S, ASME Boiler and pressure vessel code, TEMA, TRD, GOST, DIN,
JIS and ISO Boiler Code ISO/R-831 which are known to be commonly used in
industrially advanced countries.

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 STANDARD REQUIREMENTS
4. (a) Material- All plates, rivets and bars used in the construction of boilers shall be
tested and found to conform with the regulations hereinafter contained.
(b) Construction- All boilers during construction shall be under the supervision of an
Inspecting Officer or inspector.
(c) Inspecting Authority’s Certificate- For boilers imported into Bangladesh a certificate
from an inspecting Authority in Form II certifying that the material was tested and the
boiler built under its supervision shall be furnished to the Chief Inspector before or at
the time of submission of the application for registration. Together with such certificate
the Inspecting Authority may furnish a Memorandum of Inspection book in Form I
prepared in the manner prescribed by regulation 366 in respect of the inspection of the
boiler during construction and the hydraulic test applied on completion. In the case of
steel made and tested by well-known makers in Bangladesh or Great Britain the
certificate of the makers in Form IV as prescribed in Regulation 26 may be accepted in
lieu of a certificate from Inspecting Authority.
For the purpose of this Regulation, the Boilers Board shall decide whether a maker is
well-known or not.
(cc) Inspection of boiler to comply into any international standard or foreign code-
Notwithstanding anything contained in these regulations, the Inspecting Authority may
inspect any boiler made for export during the various stages of its construction so as to
comply with the requirements of any international standard or foreign code and may
grant a certificate in Form IIA.
(d) Certificates, etc. under section 14 (1) (c) of the Act- In advance of or along with an
application for registration of a boiler, the following certificates and drawings or
specification should be furnished to the Chief Inspector, namely:-
(i) A certificate in Form III of manufacture and test signed by the maker or by a
responsible representative of the maker of the boiler a description of the boiler, its
principal dimensions, particulars of the kind of material used in its construction,
the thickness of all plates, the diameter of and method of forming the rivet holes in
the shell plates, particulars of any departure from ordinary practice in making the
shell such as solid rolling or welding the hydraulic test to which the boiler was
subjected, the intended working pressure, the area of heating surface, the maximum
evaporative capacity, the year and place of make, and the works number of the
boiler.
There may be included in such certificate a further declaration that samples of the
angle, stay or rivet bars and rivets used in the construction of the boiler have been
certified by the makers to have been tested and found to comply with the
requirements of Chapter II: in which declaration the kind of material used and the
limits of tensile breaking strength with which the tests comply shall be stated with
sufficient precision to obviate the risk of confusion in making allowances. Where
such further declaration is included in such certificate, the certificates referred to in
clause (iii) of this sub-regulation shall not be required.
(ii) A drawing or print to a scale, in the case of large boilers of not less than ¾ inch to
the foot and, in the case of small boilers, of not less than 1½ inches to the foot,
showing the principal dimensions and a longitudinal section and end view of the
boiler, and bearing the works number of the boiler and the maker’s office stamp.
The drawing shall show details of riveting of longitudinal and circumferential
seams with pitch of rivets, cross spacing of rivet rows and diameters of rivet holes,
the radii of curvature of dished end plates, fillets of flanges and corners of bent

3
 plates and where gusset stays are fitted, the number and diameter of rivet holes in
each gusset stay.

(iii) A certificate from the steel maker and a certificate from the maker of the plates,
rivets or bars of the nature referred to in regulations 26 and 27 respectively. The
certificate from the maker of the plates, rivets or bars shall show the charge
numbers, the plate or bar numbers and the number and dimensions of the various
plates etc. tested their ultimate tensile breaking strength in tons per square inch of
section, the percentage of elongation and the length on which measured, the
number, kind and result of bend or other tests made and the date of tests:-
Provided that where an Inspecting Authority furnishes a certificate in Form II
together with a Memorandum of Inspection book in Form I in accordance with
sub-regulation (c), the certificates prescribed under clauses (i) and (iii) need not be
furnished to the Chief Inspector when application is made for registration of the
boiler. But should any question arise in respect of the fitness of the boiler for the
working pressure approved by the Inspecting Authority within a period of three
years from the date of their certificate, the owner shall, if requested by the Chief
Inspector, obtain and furnish the original documents specified in the said clauses.
(iv) Attention is drawn to additional information called for in certificate in Form III in
respect of fusion welded boiler drums, including the submission of copies of
photographs taken during the radiographical elimination of the welded seams and
their re-examination following removal of defects (if any).

(e) Maker’s stamp- The boiler shall have stamped upon its front plate in a conspicuous
position the following particulars:-

Maker’s name
Work’s number Year of make
Tested to lbs. on
W.P. lbs. Inspecting Officer’s or Inspecting
Authority’s Official stamps.

5. Modification of Formulae-
(i) Under the Regulations for determining the working pressure to be allowed on various
parts of boilers the material to which the formulae apply shall in the absence of express
provision to the contrary be steel complying with the requirements of Chapter II.
(ii) Where no test certificates for shell plates and rivets are produced, the material may be
treated as iron, if the Chief Inspector is satisfied that the material is of suitable boiler
quality. If in such cases the Chief Inspector is clearly satisfied that the material is of
good quality, a higher strength than that allowed for iron may be permitted but the
strength of the steel plates shell not save for special reasons be assumed to be more than
26 tons. In such cases S and S1 in equations 1, 3 and 4 of Chapter IV may be respectively
26 and 21 for steel and 21 and 18 for iron. For iron across the grain S may be 18.
(iii) Where end plates, furnaces flat plates, girders, gusset and other stays etc. are made of
steel or iron for which no test certificates are produced the working pressure as found
from the formulae, in which S is to be taken at the lowest limit prescribed for the part,
reduced by 15 percent shall except where such material is specifically provided for in
any formulae, be the working pressure permitted. For flat plates of copper, the working

4
 pressure as found from the formulae, reduced by 50 percent shall be the working
pressure permitted.
6. Standard specifications for material- The standard specifications for steel wrought iron
and copper plates and bars and for cast steel shall be those prescribed in Chapter II, but
certificates of tests of material for wrought iron (except for special wrought iron for screw
stays) copper and cast steel shall not be required unless special allowances are required.
Such special allowances shall be in the discretion of the Chief Inspector.

7. Boiler Shells not in accordance with standard conditions- When the standard conditions
are not complied with additions to the appropriate co-efficient as defined in Regulation 157
shall be made as follows:
(a) When there are no proofs of tests of steel, 15 percent of the standard co-efficient.
(b) When a boiler has not been inspected during construction by as Inspecting Officer and
certified by him, 10 percent of the standard co-efficient.
(c) When the workmanship is in any way doubtful and the Inspector is not satisfied that any
of the foregoing additions to the co-efficient would be sufficient to meet the
circumstances, such percentage of the standard co-efficient as the chief Inspector deems
fit.

8. Welding- The use of welding in the construction of boilers shall be permitted only where
specially provided for in the standard conditions.

CHAPTER II
MATERIALS OF CONSTRUCTION
STEEL PLATES, RIVETS AND BARS

9. Process of manufacture- Structural Steel for boilers shall be made by the open Hearth or an
electric process, acid or basic.

10. Chemical Analysis-

(a) The steel shall contain not more than 0.05 percent of Sulphur or of Phosphorus.
(b) A Sulphur print test shall be taken from the material of each charge used for rivet
bars for the purpose of ensuring that Sulphur segregates are not concentrated in the
core. The stage in manufacture at which this test is made shall be at the option of the
Steel Maker.
11. Freedom from Defects, etc- The finished material shall be sound and free from cracks,
surface flaws and laminations. Hammer dressing, patching or welding is prohibited, but this
does not prevent the removal of slight scale or shell by the use of Chisel, file or buff,
providing the material is not reduced to under the specified thickness.

5
12. Rolling Margin- No plate or rolled section shall be under the specified thickness at any part,
nor more than 5 per cent over the calculated weight, except that in the case of thin plates and
wide plates the weight tolerances shall be as set out in the table below.

Schedule of Percentage Rolling Weight Tolerance for Boiler Plates.

Width in inches
Thickness
under 48 to 60 to 72 to 84 to 96 to 108 to 120 to 132 to
48 under under under under under under under under
60 72 84 96 108 120 132 over
in. % % % % % % % % %
1/4 to under 5/16 ... ... 5 5 5 7 9 12 12 ... ...
5/16 to under 3/8 ... ... 5 5 5 6 7.5 10 11 12 ...
3/8 to under 7/16 ... ... 5 5 5 6 6 8 9 11 15
7/16 to under 1/2 ... ... 5 5 5 5 6 7.5 8 9 12
1/2 to under 5/8 ... ... 5 5 5 5 6 6 7.5 9 10
5/8 to under 3/4 ... ... 5 5 5 5 5 5 7 8 9
3/4 to under 1 ... ... 5 5 5 5 5 5 6 7 8
1 to under 2 ... ... 5 5 5 5 5 5 5 6 7
All the above margins will be taken over net theoretical weight.

13. Testing and Inspecting- The following tests and inspections shall be made at the place of
manufacture prior to dispatch; but, in the event of any of the material proving unsatisfactory
in the course of being worked into boilers, such material shall be rejected not withstanding
any previous certificate of satisfactory testing, and such further tests of the material from the
same charge shall be made as the Inspecting Officer in attendance may consider desirable.
14. Selection of test pieces- All test pieces shall be selected by the Inspecting Officer and tested
in his presence and he shall satisfy himself that the conditions herein described are fulfilled.
15. (a) Tensile test pieces- The tensile strength and ductility shall be determined from
standard test pieces (see App. B) cut lengthwise or crosswise from the rolled
material. When material is annealed or otherwise treated before dispatch, the test
pieces shall be similarly and simultaneously treated with the material before testing.
(b) (i) Plates, Angles and Tees- Wherever practicable, the rolled surface shall be retained
on two opposite sides of the test piece. The tensile stress and elongation shall be
determined on standard test piece A (see App. B).
(ii) Round Bars- Round bars may be tested full size as rolled, or they may be turned
down to a convenient size.
If tested 1 inch diameter or under test piece B (see App. B) shall be used. The sectional
area of the test piece shall not be less than ¼ square inch.
Where the test piece is over 1 inch diameter, test piece B, (see App. B) may be used.
Any straightening of the test pieces which may be required shall be done cold.

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16. Tensile Test- The ultimate tensile stress and elongation of the various classes of materials
shall be between the limits shown in the table below but a range of not more than 4 tons in
each class of material shall be permitted.
Should a tensile test piece break outside the middle half of the test gauge length the test may
be discarded and another test be made of the same plate or bar.
Ultimate Tensile
Description Strength Tons
Minimum Elongation per cent.
per
sq. in.
On Test On Test On Test
Piece A Piece B Piece B1
Plates for shells, butt straps and 26 23 ...
32(26-28-32)
gusset stays 30 20 ...
Plates for flanging or welding and
for combustion chambers and 24-30 23 .... ...
furnaces and drum ends.
stay, angle and the bars..... .... 26-32 23 23 28
26-30 20 20 24
28-32
Rivet bars.... 24-30 25 30
24-28 23 28
26-30

17. Number of Tensile Tests-

(a) Plates- For shell plates, but straps and gusset plates one tensile test piece shall be cut
from each end of every plate as rolled.
(b) For other plates such as end plates, furnace and flanging plates etc., one tensile test
piece shall be cut from one end of every plate as rolled.
(c) Angle, tee, rivet and stay bars- One tensile test shall be made from each 15 or part of
15 bars rolled of each section or diameter from the same charge, but not less than two
tensile tests shall be made unless the total number of bars rolled from the same charge
is 8 or less than 8 and the bars are of the same section or diameter, in which case one
tensile test shall suffice. For round bars of 1¾ inches diameter and under, the numbers
50 and 20 shall be substituted for 15 and 8 respectively for determining the number of
tests required.
18. Dump Tests- Short lengths equal to twice their diameter out from the rivet bars shall, when
cold, withstand without fracture being compressed to half their length. A dump test shall be
made for each Tensile Test.
19. Bend Tests-
(a) Cold Bends- Test pieces shall be sheared lengthwise or crosswise from plates or bars,
and shall not be less than 1½ inches wide, but for small bars the whole section may be
used. For rivet bars bend tests are not required.
(b) Temper Bends-
(i) The test pieces shall be similar to those used for cold bend tests. For temper bend
tests the samples shall be heated to a blood-red colour and quenched in water at a
temperature not exceeding 80 degrees Fahr. The colour shall be judged indoors in
the shade.
(ii) In all cold bend tests, and in temper bend tests on samples 0.5 inch in thickness and
above the rough edge or arise caused by shearing may be removed by filing or

7
 grinding and sample 1 inch in thickness and above may have the edges machined,
but the test pieces shall receive no other preparation. The test pieces shall not be
annealed unless the material from which they are cut is similarly annealed in which
case the test piece shall be similarly and simultaneously treated with the material
before testing.
(c) For both cold and temper bends the test piece shall withstand without fracture, being
doubled over until the internal radius is equal to 1½ times the thickness of the test piece
and the sides are parallel.
(d) For small sectional material these bend tests may be made from the flattened bar.
(e) Bend tests may be made either by pressure or by blows.
20. Number of Bend Test-
(a) Plates- A bend test shall be taken from each plate as rolled. For plates exceeding 2½
tons in weight one bend test shall be taken from each end. 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. The bend
tests from plates which have to be flanged or worked in the fire or which when in use
will be exposed to flame shall be temper bend tests.
(b) Angle Bars- A cold or a temper bend test shall be made from each angle bar rolled.
(c) Stay Bars- A cold or a temper bend test shall be made from every 15 stay bars as rolled
from each charge.
21. Manufactured Rivets-
(a) Quality of Material- Rivets shall be manufactured from steel complying with the
aforementioned requirements of this chapter in respect of rivet bars.
(b) Tests-
(i) The rivet shanks shall be bent cold, and hammered until two parts of the shank
touch, without fracture on the outside of the bend.
(ii) The rivet heads shall be flattened while hot, without cracking at the edges until
their diameter is 2½ times the diameter of the shank.
(c) Number of Tests- Up to half percent of rivets of each size shall be selected by the
Inspector or Inspecting Officer from bulk for the above tests.
22. Additional tests before rejection- Should the test pieces first selected by the Inspector or
Inspecting Officer not fulfill the test requirements two further tests of the same kind may be
made but should either of these fail the plates or bars from which test pieces were cut shall
be rejected. In all such cases further tests shall be made before any material from the same
charge can be accepted.
23. Branding- Every plate and bar shall be clearly and distinctly marked by the maker in two
places with an approved quality brand indicating that the material has complied with the
required test; and also with the number or identification marks by which they can be traced
to the charge from which the material was made.
24. Defacing of rejected material- In the event of the material failing in any case to withstand
the prescribed tests, the Inspector or Inspecting Officer shall see that the quality brand
stamped on the material has been defaced by punch marks extending beyond the brand in the
form of a cross, denoting that the material has been rejected.

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25. Facilities for inspection- The maker shall adopt a system of marking the ingots, billets,
slabs, plates, bars etc. which will enable all finished material to be traced to the original
charge and the Inspector or Inspecting Officer shall be given every facilities for tracing all
plates and bars to their respective charges and for witnessing the required tests, When he is
satisfied with the material and with the results of the tests he shall be furnished with two
copies of the advice notes of the material for his signature.
26. Steel not produced where rolled- Where steel is not produced in the works at which it is
rolled a certificate in Form IV shall be supplied to the Inspecting Officer deputed to witness
the testing of the material, stating the Open Hearth or Electric Process by which it was made
the name of the Steel Maker who supplied it, also the numbers of the charges for reference to
the books of the Steel Maker. The number of the charge shall be marked on each plate or bar
for the purpose of identification.
27. Maker’s certificate- Before the mill sheets are signed the maker shall furnish the Inspecting
Officer with a certificate in Form IV guaranteeing that the material has been made by the
Open Hearth or an Electric Process acid or basic and that it has been subjected to and has
withstood satisfactorily the test above described in the presence of the Inspecting Officer.

WROUGHT IRON STAY AND RIVET BARS

28. Rivet Bars- The tensile breaking strength shall be between 21 and 25 tons with an
elongation of not less than 25 percent Measured on the standard Test piece B (as rolled) or
30 percent measured on the Standard Test piece B1 (as rolled).
29. Manufactured rivets tests- To comply with regulation 21.
30. Stay Bars- The tensile breaking strength shall be between 21 and 25 tons with an elongation
of not less than 22 percent measured on the Standard Test Piece B or 27 percent measured on
the Standard Test Piece B1.
31. Stay Bars Bend tests- To comply with Regulation 19.
32. Special Iron for Screw Stays for Fire-boxes and Combustion Chambers- In order that
iron screw stays may be approved of the same size as would be required for mild steel, the
iron must withstand the following tests:
(a) Tensile Tests- The tensile breaking strength shall not be less than 21½ tons per square
inch, with an elongation of not less than 25 percent measured on the Standard Test
Piece B or 30 percent measured on the standard test piece B1.
(b) Bend tests- Test pieces either of the bar as rolled or turned down to 1 inch diameter
shall stand bending cold until the sides are parallel and the space between the two sides
is not greater than the diameter of the test piece.
(c) Number of Tensile test- The bars as rolled shall be placed in batches of twenty and
one tensile test shall be taken from each batch. If this is unsatisfactory two other bars
shall be selected for tests and should either of these fail the batch shall be rejected.
(d) Number of Bend Tests- One ordinary bend test shall be taken from each batch and a
similar test piece from each batch shall be lightly and evenly nicked on one side with a
sharp cutting tool and bent back at this point through an angle of 180 degrees by
pressure or by a succession of light blows. The fracture must be clean, fibrous free
from slag or dirt or any coarse crystalline structure. If either of these is unsatisfactory,

9
 two other bars shall be selected for test and should either of these fail the batch shall be
rejected.
(e) In all cases the selection of the test pieces shall be made by the Inspector or the
Inspecting Officers.

COPPER PLATES, STAY AND REVET BAR AND TUBES

33. Plates-
(a) Process- The copper shall be fire-refined or electrolytic, and hot-rolled from suitable
cakes.
(b) Chemical composition- The plates shall contain not less than 99 percent of copper and
between .3% and .5 % of arsenic.
(c) Freedom fro Defects- The plates shall be clean, smooth and free from defects and
shall have a workmanlike finish. They shall be thoroughly annealed.
(d) Rolling Margin- No plate shall be under the specified thickness at any part, nor more
than 5% over the calculated weight. The scrap margin, partly sheared and left attached,
shall be not less than 3 inches at the ends and 1½ inches at each side.
(e) Tensile Tests- One tensile test shall be taken from each plate as rolled. The tensile
breaking strength, from Standard Test Piece A, shall not be less than 14 tons per sq. in.
with an elongation of not less than 35%.
(f) Hot and cold bend tests- One hot (temperature between 1200º F. and 1400º F.) and
one cold bend test shall be taken from each plate as rolled.
For either hot or cold bend tests, the test piece shall withstand being doubled over without
fracture until the sides are touching and parallel.
34. Stay and Rivet Bars-
(a) Process- To comply with Regulation 33 (a).
(b) Chemical Composition- To comply with Regulation 33 (b).
(c) Freedom fro Defects- To comply with Regulation 33 (c).
(d) Rolling Margin- The bars in any part shall not be more than 1% over or more than
1̸2% under the specified diameter.
(e) Tensile Tests- The tensile breaking strength shall not be less than 14 tons per sq. in.
with an elongation of not less than 40% on the Standard Test Piece.
(f) Band Tests- To comply with Regulation 33 (f).
(g) Dump tests- A piece of rod in. long shall be placed on end and hammered or crushed
down cold to thickness of 3|8 in. without showing either crack or flaw on the
circumference of the resulting disc.
(h) Number of Tests- One bar, from which the required test specimens shall be taken
shall be selected at random from each batch of 50 (or part thereof) bars of each size
from each melt. Form each bar selected one tensile test, one cold bend test, one hot
bend test, and one hammering down test shall be made.

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35. Tubes-
(i) Process- The copper shall fire-refined or electrolytic and shall be made into tube either
by the hot rolling or cold drawing process. The tube shall be furnished by cold drawing.
(a) Chemical composition- To comply with Regulation 33 (b).
(b) Freedom from Defects- The finished tubes, both externally and internally shall be
sound, clean, smooth, well finished and free from surface defects and longitudinal
grooving and the ends must be clean and square.
(c) Tolerance- The actual weight of each tube shall not be more than 5% above the
calculated weight. Unless, otherwise specified, they shall be straight cylindrical of
uniform thickness and external diameter throughout.
(d) Treatment of Test Specimens- All test material, if not already in an annealed
condition shall be annealed before testing and shall comply with the mechanical tests
without further heat or mechanical treatment.
(e) Tensile Tests- The test pieces form tubes as finished shall show a finished strength of
not less than 14.5 tons per sq. in with an elongation of not less than 50% on a gauge
length of 2 inches.
(f) Bulging Test- A piece of tube, when cold shall withstand bulging with a parallel drift
without showing either crack or flaw until the diameter of the bulged end exceeds the
original diameter of the tube by not less than 25%.
(g) Flaring and Flanging Test- A piece of tube when cold shall withstand, flaring with a
suitable drift and flanging at right angles to the body of the tube without showing
either crack or flaw. The diameter of the flange shall exceed the original external
diameter of the tube by not less than 40%.
(h) Flattening and Doubling Test- A piece of tube shall when cold withstand without
showing either crack or flaw being flattened down until the interior surfaces of the
tube meet and then being doubled over on itself, that is bent through an angle of 180º.
For tubes over 4 in. if strips are used as test pieces they shall withstand when cold
without showing either crack or flaw being doubled over until the surfaces meet.
(i) Number of tests- From each batch of 100 tubes or part thereof of each diameter one
tube shall be selected a random from which the required test specimens shall be taken.
For each tube one tensile one bulging one flanging and one flattening and doubling test
shall be taken.
(j) Hydraulic test- All copper tubes shall be tested by an internal hydraulic pressure of
750 lbs. per sq. in.

COLD DRAWN SEAMLESS STEEL TUBES- (FOR DESIGNED STEAM

TEMPERATURE NOT EXCEEDING 850º F.)

36. (a) Material- The tubes shall be solid drawn and made of steel produced by and
Open Hearth or Electric process acid or basic and shall be certified as such by the
makers of the steel and tubes. The material of the tubes shall show on analysis not

11
 more than .04 percent of Sulphur or phosphorus and the manufacturer shall supply a
certificate of the analysis when required to do so.
Note- Where the material is used for designed steam temperatures about 750º F (399º c)
and not exceeding the 850º F (454º c) the steel shall be of non-segregated or fully killed
type.
(b) Annealing- The tubes shall be carefully annealed throughout their length after the
operation of drawing and the end shall be carefully annealed after the process of
swelling or reducing the diameter.
(c) Freedom form Defects- The tubes both internally and externally shall be sound,
clean, smooth, well finished and free from surface defects, rust, longitudinal seaming
and grooving. The ends shall be clean and square.
(d) Tolerance-
(i) Thickness- The tolerance in thickness shall be 5 percent below and 10 percent
above the specified thickness.
(ii) Swelled or Reduced ends- Where the ends of tubes are swelled or reduced the
thickness at the ends may be reduced or increased under or over the actual
thickness of the tubes by an amount strictly in proportion to the percentage of
such swelling or reducing and in addition to this allowance the tolerances
specified in para (i) of this sub-regulation shall also apply.
(iii) Diameter- The external diameter of the tubes measured at any point shall be not
greater than that specified, but may be less by not more than 1 percent.
(iv) Length- The length of the tubes shall be not less than that specified and not more
than ⅛ inch greater.
37. Selection of Tubes for test- Two percent of the tubes of each thickness and diameter and
only one for every 100 or part thereof above 400 tubes of such similar size shall be made
available to the Inspecting Officer for testing to the extent of such numbers.
38. Tensile test- Lengths or strips cut from the selected tubes shall without further annealing
comply with the following requirements:-
Ultimate Tensile
strength in tons per Minimum Elongation Percent
sq. in.
on 8 in. on 2 in.
Not ¼ in. ¼ in. less than
Not less less than
more thick and thick and ¼ in.
than ¼ in thick
than over over
Strips cut from tube &
tested in the curved 20 20 20 18 30
condition
Test length taken from
finished tube end tubes 20 28 35 35
to be plugged for grips.

39. Flattening test- A ring not less than 2˝ in length shall when cold withstand flattening
between parallel surfaces without showing either crack or flaw until the parallel surfaces are
a distance apart equal to three times the wall thickness of the tube.
40. Expanding test- the tubes shall when cold withstand being expanded by a roller expander to
the following increase in external diameter without showing crack or flaw:

12
 Thickness of tube S.W.G Crease in Diameter per cent
Up to 10 .. .. .. .. .. 12.5
Above 10-6 .. .. .. .. .. 9.5
above 6 .. .. .. .. .. 6.5

The expansion may be done in an equally graduated series of three tube holes.
41. Additional tests- Should a tube selected for testing purposes in accordance with Regulation
37 fail to satisfy the requirements of any one or more of the tests specified in Regulation s
38, 39 and 40 if so desired by the manufacturer, the tubes represented shall be re-annealed
and then retested in accordance with these Regulation s and if the repeat tests are satisfactory
the tubes shall be accepted provided that in other respects they fulfill the conditions of this
specification but if the tube again fails to satisfy the requirements the tubes which test pieces
represent shall be rejected.
42. Hydraulic test- Each tube shall withstand being tested at the maker’s works by hydraulic
pressure to 1000 lbs. per sq. in. or to not less than twice the working pressure to which they
will be subjected, whichever is the greater.
Where the working pressure to which the tubes will be subjected exceeds 1000 lbs. per sq.
in. the tubes shall withstand being tested by hydraulic pressure to 1000 lbs above the
working pressure.

HOT FINISHED SEAMLESS STEEL TUBES

(FOR DESIGNED TEMPERATURE EXCEEDING 850º F)
43. (a) Material- To comply with Regulation 36 (a).
(b) Annealing – The ends of all tubes shall be carefully annealed if they have been
submitted to a process of swelling or reducing the end dimensions.
(c) Freedom from defects- To comply with Regulation 36 (c).
(d) Tolerances- The tubes shall be or the dimensions specified, straight, cylindrical, of
uniform thickness and external diameter throughout subject to the working margins
given in the table below:
On external
outside diameter of tube On thickness On length
diameter
Plus Minus Plus Minus
Percent Percent Inch. Inch. Inch. Inch.
1 1
From 1 in. upto & including 2 in. ..
2 2 1 1 1 1
17 7 0
2 2 64 32
1/8
1 1
From 2 in. upto & including 4 in. .. 1 5 Percent Percent
2 2
1 1 1
Over 4 in. .... .... .... .... 17 7 1 1
2 2 2
(e) Selection of tubes for test- To comply with Regulation 37.
44. (a) Tensile test- Lengths or strips cut from the ends of selected tubes shall comply with
the following requirements:
Ultimate tensile Elongation per cent on 8
strength in tons per inches not less than

13
 sq. in.
Not more Not less ¼ in. thick Less than
than than and over ¼ in. thick
Strips cut from tubes and tested in their
22 28 20 18
curved condition.....................
Test lengths taken from finished tubes
20 28 25
(ends of tubes to be plugged for grips)

(b) Flattening test- To comply with Regulation 39.

45. Expanding test- The tubes shall when cold withstand expanding by a drift tapered not less
than 1 in 3 on the diameter to the following increases in external diameter without showing
crack or flaw:
Increase in Diameter
Thickness of tube S.W.G
percent
From 10 to 6 .. .. .. .. .. 15
Above 6 to 3 .. .. .. .. .. 12
Above 3 .. .. .. .. .. 9.5

46. Hydraulic test- To comply with Regulation 42.

LAPWELDED STEEL BOILER TUBES (FOR EXTERNTAL PRESSURE)

47. (a) Material- The tube shall be made from steel which shall show on analysis not
more than 0.05 percent of Sulphur or phosphorus. The manufacturer shall supply a
certificate of the analysis when required to do so.
(b) Annealing- The ends of all tubes shall be carefully annealed.
(c) Freedom from defects- To comply with Regulation 36 (c).
(d) Tolerances- The tubes shall be of the dimensions specified, straight, and cylindrical of
uniform thickness and external diameter throughout subject to the working margins
given in table below:
outside diameter of tube On diameter On thickness On length
Plus Minus Plus Minus Plus Minus
(inch.) (inch.) (percent) (percent) (inch.) (inch.)
1 1 1
Under 2 inch .. .. 10 10 1/8 0
2 64 32
1
2 inch and over .. .. 1% 1%
2

(e) Selection of tubes for tests- To comply with Regulation 37.

(f) Tensile test- To comply with Regulation 44 (a).
(g) Flattening test- To comply with Regulation 44 (b), the weld being placed 45º from the
horizontal.
48. Expanding test- The selected tubes shall when cold withstand being expanded by a drift or a
roller expander to the following increases in diameter without showing crack or flaw:

14
 Thickness of tube S.W.G Increase in Diameter percent
Upto 10 .. .. .. .. .. 9.5
Above 10 to 6 .. .. .. .. .. 7.5
above 6 .. .. .. .. .. 5

49. Hydraulic test- Every tube shall be tested at the maker’s works by hydraulic pressure to not
less than 1000 lbs. per sq. in. Any tubes failing to withstand this test shall be rejected.

WROUGHT IRON LAPWELDED BOILER TUBES

(FOR EXTERNAL PRESSURE)
50. (a) Material- The tubes shall be lap welded and shall be made from genuine charcoal
iron of the best quality.
(b) Annealing- The ends of all tubes shall be carefully annealed.
(c) Freedom from defects- To comply with Regulation 36 (c).
(d) Tolerances- The tubes shall be of the dimensions specified subject to the working
margins given below. They shall be straight and cylindrical of uniform thickness,
concentric and unless otherwise specified of uniform external diameter throughout.
The working margins shall be as follows:
On thickness- plus or minus one Standard Wire Gauge (S.W.G).
On external diameter- minus one percent on ends of tube plus or minus 1 percent on
body of tube.
(e) Selection of tubes for test- To comply with Regulation 37.
51. (a) Tensile test- The tubes or strips cut from the tubs shall show a tensile strength of 19
to 24 ton per sq. inch inclusive with a reduction of crop sectional area of the metal of
not less than 45 percent.
(b) Flattening test- To comply with Regulation 39.
52. Expanding test- The tubes shall stand bulging both hot and cold with a parallel drift
without showing either crack or flaw until the diameter of the bulged end exceeds the
original diameter of the tube by not less than 15 percent. When tested hot and by not less
than 10 percent when tested cold.
53. Crushing test- A piece of tube 2ʺ long placed on end shall when cold, withstand
hammering or crushing down without showing either crack or flaw until the length is
reduced to 1, 1|8ʺ.
54. Hydraulic test- Each tube shall be tested by an internal hydraulic pressure of at least 750
lbs. sq. inch and any tubes failing to stand this test shall be rejected.
STEEL CASTINGS
55. Scope- Steel castings shall be of the following grades, according to the purpose for which
they are to be used and as may be specified:
Grade I .. .. .. .. .. 35 to 40 tons per sq. in.
Grade II .. .. .. .. .. 28 to 35 tons per sq. in.

56. Process of manufacture- Steel for castings shall be made by the open Hearth or an Electric
process, acid or basic.

15
57. Chemical Analysis- Steel used for grades I and II castings shall not show on analysis more
than 0.06 percent of Sulphur or phosphorus as determined from the test samples and the
manufacturer shall supply an analysis of each cast when requested.
58. Heat treatment- All castings shall be heat treated to refine the crystalline structure
throughout the casting by heating to a uniform temperature not less than the normalizing
temperature and allowing to cool slowly from the maximum temperature in a practically
uniform manner or alternatively normalized by heating in a similar manner and allowing to
cool in still air.
59. Freedom from defects- All castings shall be free from twists, cracks, flaws and defects.
60. Repairs to defective castings- Castings shall not be repaired or welded without the specific
sanction of the Inspecting Officer. If required the castings shall be suitably re-heat treated to
remove internal stresses. Should a defect impair the strength of the casting, repair by
welding or otherwise shall not be permitted.
61. Number of tests- At least one tensile and one bend test shall be made from the casting from
each charge and when more than one casting is made from one charge, at least one tensile
and one bend test shall be made from the castings run from one common pouring head: but
separate tests shall be made from each casting or set of castings run form each separate
pouring head.
Test pieces shall not be cut off until they have been stamped by the Inspecting Officer after
the annealing has been completed.
62. Tensile test- The ultimate tensile stress yield point and elongation for grades I and II
castings shall be not less than shown in table below:
Minimum Minimum yield
Minimum
Grade ultimate tensile point in terms of
elongation
strength tensile strength
Tons per sq. in. percent percent
I .. .. .. .. .. 35 50 15
II .. .. .. .. .. 28 50 20

63. Bend test- Cold bend tests shall be made upon test pieces having a rectangular section of
one inch wide by 3|4 inch thick. The test pieces shall be machined and the edges rounded to
a radius of 1|16 inch. The test pieces shall be bent over the thinner section.
Bend tests may be made by pressure or by blows, and the test pieces shall without fracture
withstand being bent round a corner having a radius of 1 inch through angle not less than
that given in the following table:
Grade of casting Angle of Bend
I .. .. .. .. .. 90º
II .. .. .. .. .. 120º

64. Additional tests before rejection- Should a test piece first selected by the Inspector not
fulfill the test requirements, two additional tests of the same kind from the same casting or
group of castings shall be made. Should one of the additional test pieces fail to fulfill the
specified test requirements, the castings shall be rejected.
65. Waiving of test- No tests shall be made from unimportant steel castings or from steel
castings which are used for articles usually made of cast iron, if the scantlings are not
materially reduced below what would be required if cast iron were used.

16
 CARBON STEEL FORGINGS
(Other than seamless drums)

66. Process of manufacture- Carbon steel for forgings shall be made open Hearth or an
Electric process, acid or basic.
67. Chemical analysis- The steel shall contain not more than 0.05 percent of Sulphur or of
phosphorus.
68. Freedom from defects- The forgings shall be free from defects of any kind and shall be
finished to the prescribed dimensions. Defects in forgings shall not be repaired without the
previous sanction of the Inspecting Officer.
69. Heat treatment- Each forging shall be efficiently heat-treated unless during the last stage
of manufacture it has been finished at such a temperature as to ensure that the material of
the forging will have satisfactory mechanical properties.
70. Selection of test pieces- Sufficient material shall be left on each forging for test pieces. In
the case of a number of small forgings not less than two percent of the total or not less than
2 forgings from each cast.
71. Tensile test- The ultimate tensile stress and elongation shall be between the limits of 26 and
32 tons per sq. inch and 28% and 22% respectively determined on British Standard Test
Piece C, or Subsidiary Standard Round Test Piece (See Appendix B).
In no case shall the sum of the ultimate tensile stress and corresponding elongation be less
than 54.
72. Should a tensile test piece break outside the middle half of the test gauge length the test may
at the manufacturer’s option be discarded and another test be made of the same forging.
73. Bend test-
(a) Bend test pieces shall be of rectangular section 1 inch wide by 3|4 inch thick. The
edges shall be rounded to a radius of 1|16. The test pieces shall be bent over the
thinner section.
(b) The test pieces shall when cold be capable of being bent, without fracture through an
angle of 180º, the internal radius of the bend not greater than 1|4 inch.
Bend tests may be made by pressure or by blows.
74. Additional tests before rejection- Should either a tensile or a bend test fail, two further
tests of the type which failed may be made on test pieces cut from the same forging. If the
results obtained from these re-tests are satisfactory, the forgings shall be accepted, provided
that in other respects they fulfill the conditions laid down above for steel forgings. If these
re-tests do not give satisfactory results, the forgings represented may be re-heat-treated
together with the remainder of the test blocks and presented for further testings.
In all cases where final re-tests do not give satisfactory results the forgings represented by
the test pieces which fail shall be rejected.

COVERED ELECTRODES FOR METAL ARC WELDING

(For Hand Operation)

17
75. Construction- The metal electrodes shall be provided with a flux covering applied
externally by painting, spraying, dipping, wrapping or other method.
76. Application- The covered electrodes shall be suitable for metal are welding of mild steel
having a tensile strength not exceeding 33 tons per sq. inch.
77. Quality- The electrodes shall be uniform in quality and when used in accordance with the
appropriate instructions of the manufacturer shall be capable of flowing freely and smoothly
without producing an undue amount of “under cutting” in the parent metal adjacent to the
weld.
78. Covering-
(a) Strength- The covering shall be sufficiently robust withstand without damage the
normal conditions of transport, storage, handling and use to which the electrodes are
to be subjected.
(b) Uniformity- The covering shall be substantially uniform in outside diameter
throughout its length and shall fuse evenly.
(c) Stability- The stability of the covering shall be such that if the electrodes are stored
they shall after a period of three months be capable of giving results similar to those
at the date of dispatch from the supplier.
(d) Storage- the requirements of paragraph (c) above shall apply only if the electrodes
have been kept in their original packages in an enclosed dry storeroom.
79. Mechanical properties of All-weld Metal test pieces- The mechanical properties shall be
determined on all-weld-metal test specimens as follows:
(a) Tensile test- The tensile test shall be made on a specimen having a gauge length of
3.45 times the diameter of the test piece. The ultimate tensile stress, elongation and
reduction of area of the deposited metal shall be not less than the figures given in the
table.
(b) Impact test- Impact tests shall be made on a three notch specimen. At least two of
the three values obtained shall be not less than that given in the table.
Ultimate tensile stress elongation on 3.54 D Reduction of Area
(Tons per sq. in.) (percent) (percent) Impact value
min. min min.
28 20 35 30 ft. lb.

CHAPTER III
CONSTRUCTION AND WORKMANSHIP
GENERAL
80. Preparation of Plates- With the exception of guest plates the edges of all plates and butt
straps shall be planned or machined and the caulking edges shall be machined to an angle of
approximately 80 degrees with the surface of the plate.
81. Annealing after working in fire- All steel plates which are welded, dished, flanged or
locally heated shall be afterwards efficiently annealed.
82. Minimum thickness of plates- No boiler plate shall be less than 1|4 inch in thickness.

18
 SHELLS, ANGLE RINGS, BUT STRAPS, ETC.
83. Cylindrical shells- Each ring shall be bent while cold to cylindrical form to the extreme
ends of the plate. The bending shall be done entirely by machine and heating or hammering
is prohibited.
84. Position of Longitudinal seams- Each ring of plate forming the shell, barrel or drum shell,
where practicable be in one piece and have its longitudinal seam well out of line with those
of the adjoining rings. In Lancashire, Cornish and other types of boilers, where parts of the
shell are exposed to flame the longitudinal seams shall where practicable be in the steam
space arranged alternately on each side of the crown and clear of the brick work.
85. Circumferential and end seams-
(a) In Lancashire and Cornish boiler with flat end plates the strength of the seams
joining the end plates with the cylindrical shell be not less than 38 percent of that of
the solid plate. The strength of the intermediate seams of flat end boilers and all the
circular seams for dished-end boilers shall be 50 percent of that of the longitudinal
seams, but in no case less than 42 percent of the strength of the solid plate.
(b) In boilers of other type the strength of circumferential and transverse seams shall be
not less than 38 percent of that of the solid plate or not less than 50 percent of that of
the longitudinal seams, whichever is the greater.
(c) When the shell plate thickness exceeds 11|6 inch the intermediate circumferential
seams shall be double riveted.
86. Angle Rings- Angle rings for the attachment of end plates to shell plates and or flue
sections shall be rolled or machined so that they fit closely to the flat and cylindrical
surfaces to be connected and shall be machined on the caulking edges.
87. Thickness of Shell Angle Rings- Where shell plates and end plates are connected by means
of an external angle ring, the angle ring shall not be less in thickness than as follows:
(i) For shell plates up to and including 5/8 inch 10 percent in excess of the thickness of shell
in thickness. plate.
(ii) For shell plates exceeding 5/8 inch in 90 percent of the thickness of shell plate but not
thickness. less than 11/16 inch.

88. Welded shell plates-

(a) Except as provided for in chapter V where longitudinal seams are welded, the weld
shall be entirely covered by a butt strap or straps securely riveted to the shell.
(b) For small steam domes where the welding is done by hammer and the plates do not
exceed ½ inch in thickness the straps may be omitted.
(c) The strength of the weld shall be assumed to be 50 percent of that of the solid plate.
The thickness of a single strap or combined thickness of double straps shall not be
less than the thickness of the shell plate.
89. Longitudinal seams- The longitudinal seams shall be butt-jointed with double straps when
the diameter or working pressure exceeds the limits stated below:
When diameter When working pressure
Type of boiler exceeds exceeds
Feet. lbs.

19
 Loco Types .. .. 4 125
Vertical types .. .. 6 125
Other type .. .. 6 80

90. Butt straps- Butt straps shall be cut from the shell plates or, alternatively, all the butt straps
of each required thickness shall be cut from one plate. The lengths of the straps shall be
transverse to the direction to the direction of rolling of the plate. Straps shall be pressed or
bent in rolls to the shell curvature.
91. Thinning of Butt straps- Tinning of the ends of butt straps, which tuck under snell rings
shall be done cold by machine and not by heating or hammering. The shell plate shall be
notched out to receive the thinned end of the butt strap so, that there shall be no undue
thinning of the butt strap.
92. Local welding of Butt seams-
(a) As an alternative to the tucking of butt ends under the shell rings the ends may be
terminated at the edge of the shell rings or ends and electrically welded thereto.
(b) When the ends of the butt seams of shell rings are electrically welded for a distance
of not less than twice the overlap at the circumferential seams either or both internal
and external butt straps may be terminated either (1) at the edge of the adjacent shell
ring or end (in which case the butt strap and termination at the edge of the shell ring
or end shall be welded thereto in the manner described above) or (2) at the minimum
distance from the edge of the adjacent shell ring or end necessary for both
circumferential ring or end seam and end of butt strap to be adequately caulked. This
distance shall in no case exceed twice the thickness of the shell plate and when this
form of construction is employed the strength of the short welds in the butt seams of
the shell rings uncovered by a butt strap or straps may be assumed to be 100 percent.
(c) Only metal ore welding of the butt seams of shell rings shall be permitted.
93. Thickness of butt straps-
(a) Where the thickness of the shell plates does not exceed ¾ in. the thickness of both
the inner and the outer butt straps shall be equal to the thickness of the shell plate.
(b) Where the thickness of the shell plate exceeds ¾ in. the outer butt strap may be
made 0.875 of the thickness of the shell but not less than ¾ in. The inner butt strap
in such cases may be made 1|8 in. thicker than the outer butt strap or the same
thickness as the shell plate which ever is less.

END PLATES
94. Flat end plates-
(a) The end plates of boilers up to 10 feet in diameter shall be in one piece made from
one rolled plate. The peripheral flanging of end plates shall be done by machine.
Such flanging shall preferably be done in one operation, but where this is
impracticable sectional or creep machine flanging may be permitted, provided that
the plate is worked at a suitable temperature and the plate is heated to an adequate
distance beyond the portion under immediate treatment.
(b) Care must also be taken to see that the flanges are circular and of good surface, free
from local irregularities and that they are parallel and square with the flat part of the
plate. For the purpose of relieving internal stresses all plates which have been

20
 flanged or locally heated shall afterwards be efficiently annealed unless during the
last stage of manufacture they have been uniformly heated throughout.
(c) Flat portions of end plates on completion of all flanging and machining operations
shall be flat and free form set or distortion.
95. Strengthening of Flat End Plate at Manhole-
(a) In the end plates of Lancashire Boiler type the mud hole in the lower part of the
front end plate shall be fitted with a flanged riveted strengthening ring, the
thickness of the flat portion of which shall be not less than (1.5T+1|8 in.) where T
equals the thickness of the plate in inches.
(b) In boilers 7 ft. 6 in. diameter and above the mud hole frame shall be fitted with a
peak to reinforce the portion of the end plate between and below the furnaces and
this peak shall be securely riveted thereto with rivets of similar pitch to the
remainder of the frame.
(c) In all cases the front end plate gusset stays below the furnaces shall be places as
closely as possible to the mudhole frame.
(d) Where flat end plates are flanged for connection to the shell the inside radius of
flanging shall be not less than 1.75 times the plate thickness with a minimum of 1½
in.
96. End plates in steam space- When the end plates of boilers situated in the steam space are
liable to contact with hot gases the end plates shall be efficiently shielded from such contact.
97. Hemispherical Crowns-
(a) All segments shall be pressed in one heat to correct curvature. The adjacent plates
shall bed closely at the seams and wherever possible at the junction of two seams
the plates shall be machined down to provide a fair surface to the joint. If the
thinning is done by heating and hammering the plate shall be subsequently
annealed.
(b) The cylindrical portion of the crown shall be tangential to the hemispherical portion
and fit truly to the shell.
(c) Where hemispherical shell crowns are pressed form one plate they shall be pressed
to form by machine in progressive stages without thinning and on completion shall
be annealed.
98. Dished end crown plate-
(a) The inside radius to which a plate is dished shall not be greater than the external
diameter of the shell to which it is attached except in the case of Lancashire and
Cornish boilers when the radius shall not exceed 1½ tines the diameter of the shell.
(b) The inside radius of curvature of the flanges to the shell or firebox shall not be less
than four times the thickness of the crown or end plate and in no case less than 2½
inches.
(c) The inside radius of curvature to uptakes shall not be less than twice the thickness
of the crown plate in. no case less than 1 inch.
99. Tube plates- Smoke box tube plates shall be flanged for attachment to the barrel or shall be
flat and connected thereto by an external riveted angle ring.

21
100. Parts to be stayed-
(a) All flat tube plates except those of loco type boiler and of other boilers in which the
total gross area of surface occupied by tubes in any one plate being the sum of one
or more areas enclosed within lines touching the outsides of the outer rows of tubes
does not exceed 7 square feet, shall be stayed within the nests of tubes.
(b) The parts of tube plates which lie outside the nests of tubes shall be stayed or
supported wherever the size of the area of plate subject to steam pressure
necessitates staying or support either by marginal stay tubes or other means.
101. Flanging of end plates- All flanges shall be a good fit to the shell and flues.
Flogging and or hammering in the fitting of these parts is prohibited. The caulking edges
of all flanged plates shall be machined.

FURNACES
102. Furnaces in general-
(a) No furnace or firebox top whether plain or corrugated shall exceed 7|8 inch
thickness and all circular sectioned furnaces when new shall be as near the truly
circular form as the type of joint will permit.
(b) The use of Z angle rings for furnace foundation seams shall be prohibited.
103. Furnaces of Longitudinal Boilers-
(a) The sections of the internal flues shall each be in one plate and shall be bent while
cold to circular form and shall be welded longitudinally.
(b) The maximum permissible variation in diameter at any cross section shall not
exceed one half of the thickness of the plate.
(c) The welds shall be placed at the lower part of the flues and shall break joint in
successive sections by at least 12 inches.
(d) Each flange for the circular seams shall be formed at one heat by suitable
machinery.
(e) The sections shall be allowed to cool gradually to avoid internal stresses.
(f) The caulking edges of all flue flanges shall be machined.
(g) The circular seams shall be arranged so that they do not fall in line with those of
the adjacent flue or with the circumferential seams of the shell and are at leas 6
inches apart.
(h) When flues are flanged for attachment to both end plates the total length of each
completed flue shall not exceed the length of the shell measured from the inner
surface of the back end plate to the inner surface of the front end plate both
adjacent to the shell.
(i) Where the flues are flanged for attachment to the end plates, the end sections shall
be 1|16 inch thicker than the remaining sections except in cases where the
calculated thickness is over 13|16 inch, when the end section shall be ⅞ inch in
thickness.
(j) The flanged portion of furnace rings shall have a radius of curative of not less than
1¼ inches on water side.
104. Furnaces of vertical boilers-

22
 (a) The vertical portion shall be in one plate shall be bent to circular form in a similar
manner to the shell plates.
(b) Circular furnaces shell preferably be tapered a taper of 1½ in. in diameter per 1
foot of height being recommended. The minimum water space at the bottom
between the furnaces and the shell shall not be less than 3 in. for boilers up to 2 ft.
6 in. in diameter and shall be not less than 3½ in. for boilers 2 ft. in. in diameter
and over.
(c) Where hemispherical furnace crowns are pressed from one plate they shall be
pressed to form by machine in progressive stages without thinning and on
completion shall be annealed.
(d) Ogee flanging where integral with the fire-box or in a separate ring shall preferably
be formed at one heat by suitable machinery and shall be allowed to cool gradually
to avoid internal stresses.
(e) In no case shall the seam of a fire box be pierce for any openings.
105. Longitudinal seam- The longitudinal seams of furnaces may be either:
(1) Forge Lap Welded.
(2) Fusion Butt Welded.
(3) Reverted.
(4) Longitudinal seams furnace 5|8 in. thickness and over shall not be riveted.
106. Fusion welded longitudinal seams- Where the longitudinal seam is fusion welded the
following precautions shall be observed:-
(a) Plates over 5|8 in. in thickness may be beveled from both sides of each abutting
edge but the bevel need not necessarily be the same on each side (see Figs. 1 and
2). Plates less than 5|8 in. in thickness may be beveled from one side only of each
butting edge (see Figs. 3 and 4).
The include angle of the bevel shall be not less than 60, and the beveling may be
any one of the forms shown in Figs. 1-4.

23
 Fig.5- Fusion welding of cross tubes of vertical cross tube boilers-
(b) In order to obtain full penetration of the weld metal a gap shall be maintained
between the plates when they are being welded. Joints shall be welded form both
sides and the slag shall be removed after making each run. Before second side of
the joint is welded any slag or defect at the bottom of the first run shall be removed
by grinding, chipping or machining. There shall be no appreciable undercutting of
the plate.
(c) For the purpose of relieving internal stresses the plates adjacent to a fusion weld
shall be efficiently annealed after welding and when the firebox is forge welded it
should be allowed to cool gradually.
107. Furnace crown-
(a) The furnace crown seam shall not fall in line with any circumferential seams of the
boiler shell.
(b) The furnace crown shall be riveted to the uptake but the connections to the vertical
part of the firebox may be of welded construction which conforms to Regulation
106.

108. Cross tubes-

(a) Cross tubes shall be made from weldless or forge lap welded steel tubes. Where
welded tubes are used the longitudinal welds shall be so situated that they are not
exposed to the direct impact of the flame.
(b) The minimum thickness shall be 3|8 in.
(c) Where cross tubes are flanged and riveted to the furnace, the flanges shall be set to
the curvature and taper of he furnace and shall be a good fit before riveting.
(d) Where welded construction is employed the tubes shall be of sufficient length to
enter the furnace plate and be flush with the water side all rounds or project not
more than 5|8 in. into the water space at any part of the circumference. Where the
tubes are fusion welded in position, the firebox plates shall be suitably chamfered
and the joints shall be welded externally and internally (see Fig. 5).
109. Uptake-
(a) The uptake shall be formed from weldless, forge lap welded or fusion butt welded
steel tube and shall be securely riveted to the furnace crown plate and shell crown
plate.
(b) Welded uptakes shall be so arranged that the weld is directly facing the
longitudinal centre line of the manhole.
(c) Where the longitudinal seam is fusion welded the welding shall comply with
Regulation 106.
(d) In the case of boilers over 4 ft. diameter with flat crown and end plates and where
the outside diameter of the uptake is less than one-third of the internal diameter of
the shell, bar stays shall be fitted.

110. Loco Type Fireboxes-

24
 (a) The foundation seams shall be of riveted construction but all other seams may be
welded subject to the depth of the flanges being such that the welded seams fall
between the 1st and 2nd rows of screwed stays.
(b) The firehole mouthpiece may be similarly welded when the firebox are shell are
flanged for the purpose.
(c) The welding shall comply with Regulation 106.

STAYS
111. Bar stays- Bar stays shall not be welded at any part. They shall preferably have plus
threads the ends of the stays being upset or the middle portion being reduced for this
purpose. Stays bars which have been worked in the fire shall be subsequently annealed.
112. Longitudinal stays-
(a) Longitudinal and similar solid screwed stays shall be efficiently secured with nuts
at each end and not merely riveted over. Where they are over 12 feet in length
they shall be supported at or near the middle of their length.
(b) Where the stay is screwed through both plates the stay and holes shall have a
continuous thread and be fitted with nuts and washers on the outside. Where the
stay passes through clearing holes an internal nut and washer shall also be fitted.
Where the stay is not normal to the surface of the plate the washers shall be
shaped so as to form a true surface for the nuts or a knuckle joint may be fitted.
(c) In vertical boilers the stays shall either be screwed into both crown plates or
screwed into the furnace crown plate and passed through clearing holes in the
shell crown plate.
113. Nuts and washers for stays-
(a) The washers shall be at least 2¼ times the diameter of the treaded portion of the
stay and not less than 1|4 in. in thickness.
(b) The thickness of the external nuts shall be at least equal to the diameter of the
threaded portion of the stay. Where bar stays pass through clearing holes in end
plates, internal nuts of a thickness not less than two-thirds of the diameter of the
threaded portion of the stay shall be fitted.

114. Jointed stays- Where jointed longitudinal stays are fitted, they shall where practicable be
fitted with pins having an effective sectional area 25 percent in excess of that of the stay.
If the pins are slack in the holes the total slackness shall not be more than 1|16 inch. The
pins shall be as close as possible to the shoulder of the eye forging. The shoulder of the
forging shall be at least 1|2 inch wide all round i.e. the diameter at the shoulder shall be
not less than the diameter of the hole plus 1 inch.
115. Diagonal bar or rod stays- The sectional area of diagonal rod or bar stay shall bear the
same proportion to that of a direct stay as the length of the diagonal stay bears to the
length of the perpendicular line from the end of the diagonal stay to the surface supported.
The ends of diagonal stays shall not be bent but shall be attached to the plate with beveled
washers and nuts or with riveted tee, blocks or angles and shackle pins (see Regulation
144 for eyes and pins).
Screwed stays

25
116. Screwed stays-
(a) Screwed stays and the holes for these shall be screwed with a continuous thread.
(b) The screwed threads of the stay shall be clean, free from checks or imperfection
of full depth correct whitworth form and a good fit in the holes. The middle
portion shall preferably be turned down to the bottom of the thread.
(c) The stays shall be screwed with fine threads of not less than 11 threads per inch.
(d) The diameter of the stay over the threads shall not be less than 7|8 in. or twice the
thickness of the firebox plate, whichever is the greater.
(e) The pitch of the stays at the furnace of vertical boilers shall not exceed 14 times
the thickness of the furnace plate.
(f) Where the stays are not fitted with nuts, the ends shall be riveted over to form
substantial heads.
(g) Crown stays of Loco Type boilers shall be screwed through both plates and shall
be fitted with nuts on the fire side.
117. Axial drilling- All screwed stays less than 14 in. long should preferably be drilled with a
tell-tale hole 3|16 in. diameter to a depth of 1|2 in. beyond the inner face of the plate.
Stays which are obscure on one side should preferably be made from staybar.
118. Stay nuts-
(a) Nuts to screw stays in combustion chambers and fireboxes shall not be less than
3|4 inch thick for stays up to 1¼ inches diameter over threads 7|8 inch thick for
1⅝ inches and 1¾ inches stays, 1 inch thick for 1⅞ and 2 inches stays 1⅛ inches
thick for stays over 2 inches in diameter.
(b) The nuts shall be made of solid mild steel or of iron which shall be without weld
if exposed to flame.
119. Spacing of end stays- Allowance for curves etc.
For the tops of fireboxes and combustion chambers the distance between the rows of stays
nearest to the tube plate or firehole plate or back plate as the case may be and the
commencement of curvature of these plates at their flanges shall not be greater than the
horizontal pitch of the stays.

Girder stays
120. Girder Stays for Firebox and Combustion Chamber Crowns-
(a) Each girder shall be of the double plate interconnected type of sufficient strength
to support its proportion of the load on the crown plate independently of the
crown plate.
(b) The clear waterway between the crown plate and the underside of the girder bars
shall be as large as practicable but not less than 1½ inches deep.
(c) The ends of the girders shall not rest on the landing of the flat crown plate but
shall be carefully fitted to bed directly on the bends of the corners of the vertical
end or side plates.
(d) The toes of the girders shall be solid with the girder plates and not separate
pieces attached thereto.

26
 (e) Girders shall be properly attached to the roof plate by bolts or screws.
Note: Alternative methods of staying may be used or unstayed firebox crowns of
special or patented design of equivalent strength may be fitted. (See
Regulation s 211, 212 and 213)

Gusset stays
121. Gusset stays-
(a) Gusset plates shall be flat and perpendicular to the end plate. The gusset angles
shall be fitted to bed closely to the shell end and gusset plates. Cranking or
setting of the plates is prohibited.
(b) Gusset stays, where fitted shall comprise flat plates secured by double angles to
the shell and end plates respectively and shall be designed in accordance with
the following conditions:
122. (a) Breathing space- Gusset stays shall be so arranged as to allow sufficient
breathing space around furnace connection and tube nests.
(b) For Lancashire boilers the proportions shown in the table below are
recommended for the portion of the end plates above the furnaces and flues:

Thickness of end plates L= (Fig. 6) L= (Fig. 7)

In. In. In.
1/2 9 10
9/16 11 11
5/8 11 12
11/16 12 13
3/4
13/16
Above 13/16 12½ 13½

(c) Fig. 6 shows the breathing space recommended for the following conditions:
Flat end, furnace or flues flanged for attachment to end plate, furnaces and flues
formed with Adamson flanged seams.
(d) Fig. 7 shows similar conditions to Fig. 6 except that the end plate is flanged
outwards for the furnace or flue ring connection, the breathing spaces allowed
being 1 in. more than those for the same thickness of plate in Fig. 6.
(e) Where a corrugated section no less than 6 feet long is included in each internal
flue of a Lancashire boiler, the dimensions given in the table above may be
reduced by approximately 1½ in. throughout.

27
 (f) It is recommended that the breathing space below the furnaces and flues shall be
approximately one half the dimensions given in the table above. Where it is
desired to use any other arrangement which gives a greater or less degree of
flexibility, the amount of breathing space shall be specially considered and
modified as the necessity of the case requires.
(g) For gusset stays above tube nests as fitted in waste heat boilers without internal
furnaces a breathing space of 8 inches from the centre line of the top tubes to the
centre of the toe rivets of the gusset angles is recommended (see Fig. 7).
123. Gusset Angles- the gusset angles connection the stays to the shell and end plates shall be
at least 7|8ths of the thickness of the shell plate but shall be not less than 1|2 in. in
thickness.
124. Load on Gusset Stay- Each gusset stay supporting the end plate of a boiler shall be
designed to carry the whole load due to pressure on the area supported by it.
125. Gusset riveting-
(a) Rivets securing gusset stays shall be not less in diameter than the thickness of
the cylindrical shell plate and the riveting shall be arranged so that the strength
of the shell plate where drilled for the gusset rivets shall not be less than the
strength of the longitudinal seams.
(b) Not less than three rivets shall be used to connect any gusset plate to any angle
or any angle to the end plate or to the shell plate.

Tubes Subject to External Pressure

126. Steel and Wrought Iron Tubes- Both plain and stay smoke tubes may be made either of
wrought iron or steel and may be either lapwelded or weldless.
127. Fitting of Plain Tubes- Where stay tubes are not fitted, the ends of the tubes shall be
beaded over at the firebox and beaded or bell-mouthed at the other end. If bell-mouthed
the tubes shall protrude not less than ¼ inch beyond the tube plate.
128. Screw Threads of Stay Tubes- Stay tubes shall be screwed at both ends with continuous
threads and the holes in the tubes plates shall be tapped with continuous threads. The
pitch of the treads shall not be finer than 11 threads per inch. The stay tubes shall be
expanded by roller expanders and not made tight by caulking only.
129. Minimum Thickness of Stay Tubes- The minimum thickness of stay tubes in the body
or at the ends under threads shall not be less than 5|32nds of an inch.
130. Thickened Ends of Stay Tubes- If stay tubes are required to have their thickness
increased at the screwed ends so that the thickness at the bottom of the threads is
approximately the same as in the body of the tube the thickening shall be attained by
upsetting and not any welding process, and the tubes shall be annealed after the upsetting.
131. Load on stay tubes-
(a) Stay tubes shall be designed to carry the whole load due to pressure on the area
to be supported. In each case the areas to be calculated as follows:
(b) For a stay tube within the tube nest the net area to be supported shall be the
product of the horizontal and vertical pitches of the stay tube less the area of the
tube holes embarrassed. Where the pitch of the stay tube is irregular the area

28
 shall be taken as the square of the mean pitch of the stay tubes (i.e. one quarter
the sum of four sides of any quadrilateral bounded by four adjacent stay tubes)
less the area of the tube holes embraced.

(c) For a stay tube in the boundary row, the net area to be supported shall be the
area enclosed by lines passing midway between it and the adjacent points of
support less the area of any tubes embraced. The adjacent points of support may
be other stay tubes or the commencement of curvature of flanging or centre line
of the circle of rivets securing the end plate to the shell angle.

Tubes Subject to Internal Pressure

132. Steel tubes-
(a) All tubes which are subject to internal pressure of water or steam shall be either
cold drawn or hot finished seamless in accordance with Regulation s 36 to 42
or 43 to 46 respectively. Except as provided for in sub-section (b) below they
shall be without joint.
(b) Tubes, having an external diameter not exceeding two inches and a continuous
length in excess of the normal manufacturing lengths for seamless tubing may
be jointed.
Such joints may be flash, are or gas welded.
(c) Flash welding shall be undertaken on a welding machine of a type approved by
an Inspecting Officer and the external and internal fins caused by welding
removed.
(d) Are welded butt joints shall be made by the metallic shielded are process.
(e) When gas welding is employed the technique followed shall be approved by an
Inspecting Officer and all welds suitably heat treated.
133. Attachment of tubes of water tube boilers-
(a) All tubes shall be carefully drifted or roller expanded in the holes in the tube
plates. They shall project through the neck or bearing part in the holes by at
least a quarter of an inch and be secured from drawing out by being bell-
mouthed at each end to the extent of 1|32nd inch for each inch in diameter plus
2|32nds inch.
(b) The tube holes in the tube plates of drums, pockets or headers shall be formed
in such a way that the tubes can be effectively tightened in them. Where the
tube ends are not normal to the tube plates, there shall be a neck or belt of
parallel seating of at least 1|2 inch in depth measured in a plane through the
exit of the tube at the holes.
(c) The tubes shall be arranged so that there is sufficient accessibility for cleaning
them both internally and externally.
134. Copper tubes- Copper tubes up to 1 inch in external diameter may be used for small
boilers, such tubes shall not be less than 12 S.W.G thick.

29
 Headers, Mud boxes etc. of Water Tubes Boiler
135. (a) Headers, mud boxes etc. of water tube boilers may be of solid drawn or
welded steel, or of cast steel complying with the requirements of Regulation s 55 to
65.
(b) Each piece prior to being fitted in place shall be subjected to hydraulic test to double
the working pressure of the boiler into which it is to be fitted.
(c) (i) The sighting hole doors shall be substantial and capable of being removed and
replaced from time to time without loss of efficiency or safety.
(ii) The bolts by which they are held in place shall be fitted to them in such a way as
to satisfy the above conditions.
(iii) The doors shall be so designed that they will not blow out in the event of
breakage of the bolt.
(d) All flanges shall have a fillet with a radius of curvature at least equal to the thickness
of the necks to which they are attached.

Stand pipes, pads etc.

136. Stand pipes and pads- Stand pipes and pad pieces for carrying mountings shall be of cast
steel, wrought iron or mild steel, either pressed or welded and of substantial proportions.
They shall be carefully bedded on the shell and the riveting shall be pitched to ensure a
tight joint. The jointing faces to which the mounting are to be bolted shall be machined
and shall be level when the boiler is in its working position.
Pads shall have sufficient thickness to allow the drilling of stud holes for mountings
without the inner surface being pierced and the length of the screwed portion of the stud
in the pad shall be not less than the diameter of the stud.
137. Design of Stand Pipes- Where short stand pipes are used the bolting flanges shall be
forged solid with the bodies or attached by combined screwing and welding or by welding
alone. The thickness of the stand pipes shall comply with table below:
- Maximum permissible working pressure lbs. per Sq. In.
Up to 150 Above 150 and up to Above 250 and up to Above 350 and up to
250 350 600
Flange Thickness Flange Thickness Flange Thickness Flange Thickness
adjoining of body adjoining of body adjoining of body adjoining of body
drum drum drum drum
Stand pipes in
bore
In. In. In. In. In. In. In. In. In.
¾ ... ... ... ... ... ... ... ... 3/4 3/8
1 ... ... 7/16 3/8 1/2 3/8 3/4 3/8 3/4 3/8
1¼ ... ... 7/16 3/8 1/2 3/8 3/4 3/8 3/4 1/2
1½ ... ... 7/16 3/8 1/2 7/16 3/4 1/2 3/4 1/2
2 ... ... 7/16 3/8 9/16 7/16 3/4 1/2 7/8 5/8
2½ ... ... 7/16 3/8 9/16 7/16 7/8 5/8 7/8 5/8
3 ... ... 9/16 7/16 5/8 1/2 7/8 5/8 7/8 5/8
3½ ... ... 9/16 7/16 5/8 1/2 7/8 5/8 7/8 5/8
4 ... ... 9/16 7/16 5/8 1/2 7/8 5/8 7/8 5/8
4½ ... ... 9/16 7/16 5/8 1/2 7/8 5/8 7/8 5/8
5 ... ... 5/8 9/16 3/4 5/8 7/8 5/8 7/8 5/8
6 ... ... 5/8 9/16 3/4 5/8 7/8 5/8 7/8 5/8

30
 7 ... ... 5/8 9/16 3/4 5/8 7/8 5/8 7/8 5/8
8 ... ... 5/8 9/16 3/4 5/8 7/8 5/8 7/8 5/8
9 ... ... 5/8 5/8 3/4 5/8 7/8 5/8 ... ...
10 ... ... 5/8 5/8 3/4 5/8 7/8 5/8 ... ...
Pressed 5/8 ... 3/4 ... 7/8 ... ... ...
Saddles

138. Pressed plate Saddles- Where pressed plate saddles are employed they shall be formed to
bed closely to the boiler and be machined on the face joining the mounting and on the
edges. The studs for the attachment of mounting, if screwed through the saddle shall each
be fitted with a nut on the inside having a thickness equal to the diameter of the stud.
Where the stud holes do not penetrate through the saddle, the length of the screwed
portion of the stud in the plan shall not be less than the diameter of the stud.
139. Seating for mountings- For pressures not exceeding 125 Lbs. per sq. in. mountings with
screwed ends not exceeding 1 in. B.S.P.T may be used; the screwed portion of any such
mounting being an integral part thereof and the thickness at the bottom of the thread being
not less tan 3|16˝.
The mountings may be screwed:
(a) Directly into the boiler shell plate nuts being fitted on the waterside, or
(b) Into steel distance pieces the length of thread engaged being in no case less than the
bore of the mounting plus 1|4 in.
140. Attachment of mountings-
(a) Mountings may be attached directly to any shell or end plate where the plate is
of sufficient thickness to allow a suitable surface to be obtained for the
attachment of the boiler mountings.
(b) The minimum thickness at the hole in the shell or end plate shall be not less
than the thickness required for the maximum permissible working pressure,
considering the plate as being unpierced.
(c) Where the boiler mountings secured by studs the studs shall have a full thread
holding in the plate for at least one diameter. If the stud holes penetrate the
whole thickness of the plate, the stud shall be screwed right through the plate
and be fitted with a nut inside having a thickness equal to the diameter of the
stud. Where bolts are used for securing mountings they shall be screwed right
through the plate with their heads inside the shell or end plate.
(d) In cases where the thickness of shell or end plate is insufficient for this purpose
the mountings shall be jointed to suitable steel seatings. These seatings shall
take the form of short stand pipes, pressed plate saddles or forged pads as may
be most convenient. These short stand pipes or pads shall be secured to the
shell or end plate by riveting.
141. Attachment of water and pressure gauges- Water gauges and pressure gauge siphons
may be attached direct to the front end plates without the intervention of a pad or
standpipe, provided they are flanged and secured by studs. If the studs are screwed
through the plate, nuts shall be fitted on the inside of the plate.
142. Mounting on dished end plates-

31
 (a) In dished end boilers only where the thickness of the end plate is not less than
3|4 in. and where the minimum thickness of the stand pipe in any part
(inclusive of the thickness at the bottom of the screw thread) is not less than
3|8 in. the following construction as to stand pipes attached to end plates for
water and/or pressure gauges shall be permissible.
(b) Where the internal diameter of the stand pipes does not exceed 1 inch the stand
pipes may be expanded with the inner end bell-mouthed.
(c) Where the internal diameter of the stand pipes does not exceed 2 inches the
stand pipes may be screwed into the end plate with a taper or vanishing thread
and shall be seal welded at the inner end, or they may be expanded in a parallel
hole and seal welded on the both sides of the plate. In either case the inner end
of the stand pipe shall project not less than 1|4˝ from the plate surface to ensure
a secure weld. When the stand pipes are screwed the screwing shall not be
finer than 11 threads per inch.
143. Mountings on Flat Plates- Where the flanged mounting are attached direct to a flate
plate such mountings shall be provided with a substantial spigot the full thickness of the
boiler plate.
144. Bolts and Nuts- Bolts and nuts shall be machined where they come in contact with the
flanges and all holes in saddles and pads shall be drilled.
Note: In all cases where the boiler is lagged the joint of the mounting shall be clear of the
lagging surface.

Manholes, Mudholes etc

145. Access-
(a) Sufficient sight and cleaning holes shall be provided to permit of efficient
inspection and cleaning such holes shall normally be elliptical form and not less
than 3½ in. × 2½ in.
(b) At least one manhole or sight hole shall be provided in the upper part of the
cylindrical shall or in the shell crown or end plate and this shall not be less than:
In.
Boiler not exceeding 2 ft. 6 in. ... ... 9×7
Boiler over 2 ft. 6 in. diameter and not exceeding 3 ft. ... ... 12×9
Boiler over 3 ft. diameter & not exceeding 3 ft. 6 in. ... ... 14×10
Boiler over 3 ft. 6 in. diameter and not exceeding 4 ft. ... ... 15×11
Boiler over 4 ft. ... ... 16×12
(c) Where the size or construction of the boiler does not permit of entry for cleaning
and inspection sufficient cleaning holes shall be provided in the shell for these
purposes.
(d) Where cross tubes are fitted in vertical boilers one cleaning hole shall be
provided opposite both ends of tubes. At the bottom of the narrow water spaces
at least three cleaning holes shall be provided. The cleaning holes shall be so
arranged that the circumferential distance between them does not exceed 3 ft.
unless the foundation ring is sufficiently accessible to permit of cleaning and
inspection from the inside of the boiler.

32
 (e)
Cleaning holes or mudholes in Loco Type boilers shall be provided at each
bottom corner of the outer firebox casing above the fire hole ring and on each
side of saddle plate in line with bottom of barrel.
(f) In the case of small boilers or where the foregoing provisions are impracticable
the cleaning holes or mudholes shall be as nearly as possible in the corner of he
outer firebox casing and the holes as large as circumstances permit.
146. Compensating Rings and Frames for Openings in Shell-
(a) Compensating rings and frames for opening in shells shall be of wrought or cast
steel. The compensation provided shall preferably be flanged frames which shall
be fitted in all cases where the shell plate exceeds 9|16 in. thick. Flanged frames
shall be weldless and shall be flanged or pressed to provide a flat jointing surface
for the cover.
Note: Wherever practicable the frames should be riveted to the inside of the
shells so that the shorter axis is parallel to the longitudinal centre line of the
boiler.
(b) All compensating rings and frames shall be formed to bed closely to the surfaces
to be connected. Where attached to cylindrical shells and are 12 in. × 9 in. or
larger they shall be at least double riveted. All caulking edges shall be machined.
(c) The jointing surfaces of all flanged or pressed frames and all doors or covers
shall be machined.
147. Doors and cross bars-
(a) All internally fitted doors of manholes, mud holes and sight holes shall be of
wrought steel built up or pressed to shape and annealed or made from one
thickness or plate with a machined recess for the jointing material, or may be a
steel casting. Their spigot part or the recess frames shall not have a greater
clearance than 1|16th inch all round, i.e. the axis shall not be less than 1|8th inch
smaller than the holes in which they are fitted.
(b) The studs or bolts of large doors shall be screwed through the plates and riveted
over.
(c) Internal doors for openings not larger than 9 in. × 7 in. in size need only be fitted
with one stud which shall be provided with an integral collar and screwed
through the plate with a nut on the inside of the door. Internal doors for openings
not larger than 5 in. × 3½ in. may have the stud forged solid with the door or if
screwed be efficiently riveted to the doors.
(d) Cross bars shall be of substantial proportions and either solid steel forging or of
cast steel.
148. Raised Manhole frames and cover plates-
(a) Raised circular manhole frames not exceeding 16 in. in diameter shall be at least ¾
in. thick in all parts.
The circular cover plates and joint flanges for such frames shall be not less than;
1in. thick for pressures not exceeding 120 lbs. per sq. in.
1⅛ in. thick for pressures exceeding 120 lbs. but not exceeding 200 lbs. per sq. in.
1¼ in. thick for pressures exceeding 200 lbs. but not exceeding 250 lbs. per sq. in.
(b) External raised circular mouthpieces for working pressures above 100 lbs. per sq.
in. shall be formed in one piece, preferably without welds. Where a welded
mouthpiece is used it shall be formed from a suitable rolled section and forge

33
 welded the flanges being in one piece with the cylindrical portion. The height of a
welded mouthpiece shall not exceed one half the diameter of the opening. The
weld shall be made on the transverse centre line of the mouthpiece and not on a
lone paralleled to the longitudinal centre line of the boiler, and for pressures over
100 lbs. per sq. in. no account shall be taken of the welded mouthpiece as
compensation.
The jointing flanges of mouthpieces and covers shall be machined on the face and
edge and on the bearing surface for the bolts. Bolts and nuts shall be machined
wherein contract with the flanges and the joints should be formed inside and
outside the bolts to preclude the possibility of flange distortion. Cover plates shall
be dished outwards to a depth of approximately one-eighth of the internal diameter
of the frame.
(c) For pressures exceeding 250 lbs per sq. in. raised circular manhole frames shall not
be fitted.
(d) The cover plates shall be secured by at least sixteen steel bolts not less than 1 in.
diameter.
149. Position of manhole in shell- Manhole in cylindrical shells shall be placed as far as
possible from any riveted seams, preferably toward the back end of the boiler top.
150. Compensation rings to manholes-
(a) Compensation shall be provided in every case for the part cut out of a cylindrical
shell for a manhole. The strength of the section of compensating ring and of the
rivets securing it to shell compared with that of that of the part of shell cut out
shall not be less than the strength of the longitudinal seams.
(b) The spacing of the rivets shall be such as not to reduce the strength of the shell
plate below that of the longitudinal seams.
151. Compensation for cutting large holes in shell- Where holes are cut in cylindrical shell
for mountings the diameters of the holes being greater than 2½ times the thickness of the
shell plate plus 2¾ inches, compensation shall be fitted as in the case of manholes. Where
ordinary sized steel stand blocks or pad pieces are fitted and are securely riveted to the
shell no additional compensation for the hole cut in the shell shall be required. If,
however, the net section of the stand block or pad within four inches of the shell is less
than the section of the shell plate cut away a compensation ring shall be fitted. Where a
larger opening is cut in a cylindrical shell to receive another part of the structure the sides
where cut away shall be efficiently cross stayed or strengthened in some other effective
manner.
152. doubling plate and compensating rings-
(a) Compensation shall be provided such that the added sectional area, including
part of the frames within 4 inches of the shell and excluding rivet holes shall be
not less than the sectional area of the plat removed but when the pressure
exceeds 100 lbs. per square inch no account shall be taken of a welded frame as
compensation.
(b) Doubling plates and compensating rings shall be of mild steel without weld and
before riveting shall bed closely to the plates to which they are to be connected.

34
 Riveting
153. Rivet holes-
(a) Rivet holes shall not be punched, but shall be drilled full size from the solid
plate and wherever possible rivet holes shall be drilled in place with plates,
straps and ends bolted in position. After drilling the plates shall be separated the
burrs and the sharp edges of the holes shall be removed and the contact surfaces
of the plates shall be cleaned. All tacking holes shall be drilled to a size which
will allow the holes to be enlarged to the required rivet size by drilling on
reamering. All rivet holes shall be slightly countersunk under each rivet head.
(b) The diameter of the rivet hole shall be not more than 1|16 in. larger than the
standard diameter of the cold rivet as manufactured.
(c) Where sizes of rivets are mentioned the sizes refer to the diameter of the rivet
holes not to the diameters of the rivets used before closing.
154. Riveting-
(a) Rivets shall be closed by hydraulic machinery wherever the design of the boiler
permits; the rivets may be closed by hand or pneumatic hammer in positions
where hydraulic riveting is impracticable.
(b) Rivets shall be of sufficient length to fill the rivet holes and form sound and
substantial heads. The heads shall be finished concentrically with the rivet
shanks. Rivets shall be heated uniformly throughout their full length.
(c) Drift pins shall not be used with such force as to distort the rivet holes. If the
rivet holes are found not to be fair when the plates are bolted up for riveting the
holes shall be reamed fair before the riveting is commenced.
(d) For hydraulic riveting the pressure shall be the least necessary to ensure a tight
point, and only sufficient pressure shall be used to close the rivets properly and
securely without indenting buckling or otherwise damaging the plate. The rivets
shall be allowed to shrink while under pressure from the riveting machine.
155. Fullering and caulking- All seams shall be fullered inside and outside wherever
practicable and where caulking is found necessary this shall be done in such a manner that
the plates are not sprung or damaged.

CHAPTE IV
REGULATIONS FOR DETERMINING THE WORKING PRESSURE TO BE ALLOWED ON
VARIOUS PARTS OF BOILERS OTHER THAN FUSION WELDED AND SEAMLESS
FORGED DRUMS.
156. The maximum pressure at which a boiler may be used shall be determined in accordance
with the provisions of this chapter. The Regulation s in this chapter refer to material
subjected to steam temperature not exceeding 500º F.

35
 Shells
157. Formula for working pressure of shell-
(a) For cylindrical shells, barrels, steam and water drums and domes of boilers the
maximum working pressure per square inch to be allowed shall be calculated
from the following formula:
[Note: Where parts of drums of water tube boilers are perforated for tubes, the
working pressure shall be calculated by equation (55) under “Tube Plates”.]
(t ] 2)  S  J
W.P. = ... .... ... ... ... ... ... ... Eqn. (1)
CD
W.P is the working pressure in lbs. per sq. in.
t is the thickness of shell plates in 32nds of an in.
S is the minimum tensile breaking strength of the shell plates in tons per square
inch or whatever strength is allowed under Regulation 5.
J is the percentage of strength of the longitudinal seams of shell or of a line of
holes in the shell for stays, or rivets or of an opening the shell not fully
compensated whichever is least calculated by the methods hereafter
described.
C is a co-efficient as follows:
2.75 when the longitudinal seams are made with double butt straps and when
small shells are formed from solid rolled sections;
2.83 When the longitudinal seams are made with lap joints and are double
riveted;
2.9 When the longitudinal seams are made with lap joints and are double riveted;
3.0 When the longitudinal seams are welded and are fitted with a single butt
strap.
3.3 When the longitudinal seams are made with lap joints and are single riveted;
D is the inside diameter of the outer strake of plating of the cylindrical shell
measured in inches.
(b) The Factor of safety shall in no case be less than 4.
The actual factor of safety in each case may be found from the equation-
t
F= 1.4×C× With the best form of joint and least co-efficient (C) the
t ]2
factor of safety for shell plates ¼ inch to 1¾ inches in thickness, varies from
5.13 to 3.99.
(c) An addition of 10 percent shall be made to the appropriate co-efficient for shells
of boilers in which the longitudinal seams are lap jointed and are not accessible
to close visual inspection and for shell plates of externally fired boilers exposed
to the direct impact of furnace flame; provided that this addition shall not apply
to the steam and water drums of water tube boilers where the drums are not
close to the fire-grate and there are tubes between the fire-grate and the drum.

36
 (d) The above coefficient are standards and shall be used only for boiler open to
inspection by an Inspection Officer during the whole period of construction and
which are certified by him as having been constructed in accordance with the
standard conditions laid down in these Regulations.

158. Methods of calculating the strength of riveted joints-

(a) The percentage of strength of a riveted join (j) shall be found from the
following formula (i), (ii), (iii); (i) and (ii) are applicable to any ordinary type of
joint; (iii) is applicable only to that type of joint in which the number of rivets in
the inner rows is double that of the outer row. The lowest value given by the
application of these formulas is to be taken as the percentage of strength of the
joint compared with the solid plate.
100( P ] D)
(i) Plate percentage ... ... ... ... ... ... ... ... ... Eqn. (2)
P
100  A  N  C  S1
(ii) = Rivet percentage ... ... ... ... ... ... .. Eqn. (3)
P T  S
100( P ] D) 100  A  C  S1
(iii) + = Combined plate and
P P T  S
rivet percentage... ... ... ... ... ... ... ... ... ... ... ... ..Eqn. (4)
P is the pitch of rivets at outer row in inches,
D is the diameter of rivet holes in inches,
A is the sectional area of one rivet hole in square inches,
N is the number of rivets per pitch (P),
T is the thickness of plate in inches,
C = 1 for rivets in single shear as in lap joints and 1.875 for rivets in double
shear as in double butt strapped joints.
S1 is the shearing strength of rivets which shall be taken to be 23 tons per square
inch for steel and 18 tons per square inch for iron.
S is the minimum tensile breaking strength of shell plates in tons per square
inch or whatever strength is allowed under Regulation 5 of Chapter I.
In the first formula (i) D is the diameter of the rivet holes in the outer rows and
in the third formula D is the diameter of the rivet holes in the next rows. In the
last formula A is the area of one rivet hole in the outer row.
(b) When the sectional area of the rivet holes is not the same in all rows and when
some of the rivets are in double shear and others in single shear, the rivet
sections per pitch of each size or shear shall be computed separately and added
together to form the total rivet section.

37
159. When pitch exceeds maximum allowed- Should the pitch of the rivets exceed the
maximum pitch allowed, the permissible pitch shall be used in place of the actual pitch in
determining the percentage of plate section. No greater percentage than 85 shall be
allowed for any type of riveted joint.
160. Butt straps and spacing of rivets below requirements- Should the spacing of the rows
of rivets or the distance between edge of plate and rivet hole or the thickness of butt straps
be less than is specified in Regulations 163 and 165 the percentage representing the
strength of joint shall be modified as prescribed in those regulations.
161. Percentage of Welded and strapped seams- In determining the percentage of strength of
a welded seam covered by a strap or straps the formula and allowance in regulations 158,
159 and 160 shall be applied but 50 percent shall be added to the rivet percentage for the
weld.
162. Percentage to be allowed for Solid Rolled Shells- When small shells are rolled from the
solid, J in equation (1) shall be taken as 95 percent.
163. Thickness of Butt Straps- The minimum thickness of butt straps for the longitudinal
seams of cylindrical shell shall be determined by the following formula but all straps
should be of sufficient thickness to permit of efficient caulking and in any case shall not
be less than ½ inch in thickness.
Single butt straps having ordinary riveting:
1.125T=T1... ... ... ... ... ... ... ... ... ... ... ... ... ... Eqn. (5)
Single butt straps having every alternate rivet in the outer rows omitted:
( P ] D)
1.125× = T1... ... ... ... ... ... ... ... ... ... .... Eqn. (6)
( P ] 2 D)

Double butt straps of equal width having ordinary riveting:

.625T= T1... ... ... ... ... ... ... ... . ... ... ... . ... ... Eqn. (7)
Double butt straps of equal width having every alternative rivet in the outer rows omitted:
( P ] D)
.625× = T1... ... ... ... ... ... ... ... ... ... ... Eqn. (8)
( P ] 2 D)

Double butt straps of unequal width having ordinary riveting:

.75T = T1 (wide strap).. ... ... ... ... ... ... ... ... ... ... Eqn. (9)
.625T= T1 (narrow strap).. ... ... ... ... .. ... ... ... . ... Eqn. (10)
Double butt straps of unequal width having every alternate rivet in the outer rows omitted:
( P ] D)
.75T × = T1 (wide strap)... ... ... ... ... ... ... Eqn. (11)
( P ] 2 D)
( P ] 2 D)
.625T × = T1 (narrow strap)... ... ... ... ... ... ... Eqn. (12)
( P ] 2 D)

T1 is the thickness of the butt straps in inches. The other symbols have the same
significance as in Regulation 158.
Single and wide butt straps shall wherever practicable be on the inside of the shell.

38
 Should the thickness of butt straps be less than that above described, the least percentage
of joint as determined under Regulation 158 shall be reduced in the proportion of the
actual thickness to the prescribed thickness.

164. Maximum pitch of rivet in longitudinal joints- The maximum pitch of the rivets in the
longitudinal joints of boiler shells shall be:
C×T+1.625 = maximum pitch in inches .... .... .... ... ... ... ... ... ... ... .. ... Eqn. (13)
T is the thickness of the shell plate in inches.
C is a co-efficient as given in the following table:
Number of Co-efficient Co-efficient Co-efficient for
rivets per pitch for Lap for single Butt double Butt
joints strapped joints strapped joints
1 1.31 1.53 1.75
2 2.62 3.06 3.50
3 3.47 4.05 4.63
4 4.14 .. 5.52
5 .. .. 6.00

165. Spacing of rows of rivets:

(a) In joints, whether lapped or fitted with butt straps in which there are more than
one row of rivets and in which there is an equal number of rivets in each rows, the
distance between the rows of rivets shall be not less than-
Zig-zag riveting,
.33p + .67D = distance between centre lines of rows (R).... .... .... .... .Eqn(14)
Chain reuiting ,
2D = distance between centre lines of rows (R).... .... .... .... .... ...Eqn (15)
(b) In joints in which the number of rivets in the outer rows is one half of the number
in each of the inner rows, and in which the inner rows are chain riveted, the
distance between the outer rows and the nest rows shall be not less than as
required by equations (14) and (15) whichever is the greater, and the distance
between the rows in which there are the full number of rivets shall be not less than
2D (R).
(c) In joints in which the number of rivets in the outer rows is on half of the number
in each of the inner rows, and in which the inner rows are zigzag, the distance
between the outer rows and the next rows shall be not less than-
2P + 1.15D = distance between centre lines of
outer and next rows (R).... ..... .... .... .... ... ... ... ... ... ... .... Eqn. (16)
The distance between the rows in which there are the full number of rivets shall be
not less than-

39
 .165P + .67D = distance between centre lines or inner
rows (R) .... ..... .... .... .... .... .... .... .... .... ... ... ... ... .... Eqn. (17)
P is the pitch of the rivets in the outer rows.
D is the diameter of the rivet holes in inches or the mean of the diameters of rivet
holes when the distance to be determined is between two rows of rivets of
different diameters.
(d) Should the distance between row of rivets be less than as prescribed above the
plate percentage determined by equation (2) shall be modified thus-
actual distance
100[P – (2 – ) D]
prescribed distance
= modified plate
P
percentage .... .... .... .... .... .... .... .... .... ... ... ... ... . .... Eqn. (18)
(e) In all cases the clear space between a rivet hole and the edge of a plate shall not be
less than the diameter of the rivet holes i.e. the centre of the rivet hole shall be at
least 1½ diameter distant from the edge of the plate (E)-
Provided that if this condition be not observed the strength value of the rivets
affected shall be reduced in the proportion of the actual distance between the outer
edge of the rivets and the edge of the plate to the prescribed distance.
166. Circumferential and End Seams- The suitability of circumferential seams including the
seams joining ends to shells shall be verified by the following formula:
159  J  (t ] 2)
is equal to or greater than W.P.... .... .... ..... ... ... ... ..... Eqn. (19)
DC
Where WP = The working pressure in lbs. per sq. in.
D = The diameter of shell in inches, measured inside the outer ring of plates
J = Circumferential joint efficiency calculated by ... Eqns. 2 or 3.
C = 8.24 where the seams are made with lap joints and are treble riveted.
= 8.44 where the seams are made with lap joints and are double riveted.
= 9.60 where the seams are made with lap joints and are single riveted.
t = Thickness of plate in 32nds of an inch.
167. Compensation for Manholes other openings- The percentage of compensating section
shall be determine by the following formula:
220(W ] D)  Tr
] Percentage strength of compensating section.... .... .... .... ....Eqn. (20)
( L ] 2 D)  Ts
80  A  N
] percentage strength of rivet section .... .... .... .... ... ... ..... ... ..Eqn. (21)
( L ] 2 D)  Ts
W is the width of compensation ring in inches measured in the direction of the
longitudinal axis of the boiler.
L is the length of opening in shell in inches measured in the direction of the longitudinal
axis of the boiler,
D is the diameter of rivet holes in inches,

40
 Tr is the thickness of compensation ring in inches,
Ts is the thickness of shell plate in inches,
A is the area of one rivet hole in inches,
N is the number of rivets on one side of the longitudinal line. When the rivets are in
double shear 1.875 times the single rivet section shall be allowed.
Parts of raised manhole mouthpieces within four inches of the shell shall in addition to
the ring be included in the compensating section.
168. Uncompensated Holes- The maximum diameter of any uncompensated opening in a shell
shall be determined subject to the condition that the minimum thickness at the hole in the
shell or end plate shall be not less than the thickness required for the maximum
permissible working pressure, considering the plate as being unpiereced as follows:
D=½× ( D ] T )T ] N . ½× ( D ] T )T ] N .... .... .... ... . .... ... ... ... Eqn. (22)

where,
D = Maximum mean effective diameter of uncompensated hole in inches.
T = Thickness of drum shell in inches,
D = Internal diameter of drum in inches but not exceeding 60.
N = 3 where E does not exceed 0.50
3 ]1 ] E
in other cases ... ... ... ... ... ... ... ... ... ... . ... ... .. ... .Eqn. (23)
0.50

Where E. = The required thickness of a seamless unpierced shell

......E... ..... .... Eqn.(24)
T

DISHED END PLATES

169. Complete hemisphere without stays or other support made of one or more plates and
subject to internal pressure-
The maximum working pressure shall be determined by the following formula:
(t ] 2)  S  J
W.P = ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Eqn. (25)
CR
W.P. is the working pressure in lbs. per square inch,
t is the thickness of the end plates in 32nds of and inch,
S is the minimum tensile breaking strength of the end plates in tons per square inch or
whatever strength is allowed for them,
J is the least percentage of strength of the riveted joints of the plates forming the
hemisphere or securing it to the cylindrical shell.
R is the inner radius of curvature in inches.
C for single riveting is 3.3,

41
 C for double riveting is 2.9,
C for treble riveting is 2.83.
170. Dished ends subject to internal pressure:
(a) For unstayed ends of steam and water drums, tops of vertical boilers etc, when
dished to partial spherical form the maximum working pressure shall be determined
by the following formula:
15  S  (t ]1)
W.P = ... ... ... ... ... ... .. ... ... ... ... .. ... ... ... Eqn. (26)
R
W.P. is the working pressure in lbs per square inch.
t is the thickness of end plates in 32nds of and inch,
R is the inner radius of curvature of the end in inches which shall not exceed the
diameter of the shell to which it is attached,
S is the minimum tensile breaking strength of plate in tons per square inch, or
whatever is allowed for it.
(b) The inside radius of curvature at the flange shall be not less than 4 times the
thickness of the end plate and in no case less than 2½ inches.
(c) When the end has a manhole in it, (t = 5) shall be substituted for (t – 1) in the
formula.
(d) The total depth of flange of manhole from the outer surface in inches shall be at
least equal to:
] T ] W = depth of flange in inches... ... ... ... ... ... ... ... .. ... .. Eqn. (27)

Where T is the thickness of the plate in inches and W is the minor axis of the hole in
inches.
171. Dished ends subject to external pressure- In the case of unstayed ends for the co-
efficient 15 in equation (26) the co-efficient 12 shall be substituted, and R shall be the
outer radius of curvature of plate. For plates exposed to furnace flame the co-efficient
shall be 10.5.
172. Dished ends of Lancashire and Cornish type Boilers-
(a) For dished ends of Lancashire and Cornish boilers with external or internal flanges
for furnaces formed in one piece without stays and subject to internal pressure the
maximum working pressure shall be determined by the following formula:
22  S  (t ] L)
W.P. = .... ... .... ... ... ... ... ... ... ... ... .. ... .. Eqn. (28)
R
W.P is the working pressure in lbs. per square inch,
t is the thickness of the end plate in 32nds of an inch,
R is the inner radius of curvature of the end in inches which shall not exceed one
and a half times the internal diameter of the shell to which it is attached,
S is the minimum tensile breaking strength of the plate in tons per square inch or
whatever is allowed for it.

42
 (b) The inside radius of curvature at the flange shall be not less than 4 times the
thickness of the plate and in no case less than 3½ inches.

173. Dished shell and firebox crowns-

(a) In determining the working pressure in accordance with Regulation 170 and 171
no account shall be taken of the influence of the uptake tube in vertical boilers. If
dished crown plates having uptakes are fit for higher pressures when considered as
flat plates under Reg. 178 such higher pressure shall be allowed.
(b) The radius R of the dished part may be found as follows:
C2 ] H 2
R= ... ... ... ... ... .. ... ... ... ... ... .. ... .. Eqn. (29)
2H
C and H are the lengths in inches of half the base line or chord on which H is
measured and the height of the dish or camber at the middle of the chord
respectively.

FLAT END PLATES

174. Flat plates supported by solid screwed stays, marginal seams or flanges-
(a) For plain flat plates supported by solid screwed stays or riveted marginal seams or
flanges the maximum working pressure shall be as follows:
C (t ] 1) 2
W.P. = ... ... ... ... ... .. ... ... ... ... ... .. ... .. Eqn. (30)
A2 ] B 2
In this formula and in those following in the succeeding regulations relating to “Flat
Plates” unless otherwise specified:
W.P. is the working pressure in lbs. per square inch.
t is the thickness of the flat plate in 32nds of an inch,
t1 is the thickness of the washers, strips, doublings employed in 32nds of and inch,
A is the horizontal pitch of stays in inches,
B is the vertical pitch of the stays in inches,
C is a co-efficient which varies in value with the method of fixing the stays and
nature of the support.
Where the plates are exposed to the direct impact of flame the following values of C
shall be reduced 12½ percent.
C = 60 for stays screwed into the plate with their ends riveted over.
C = 90 for stays screwed into the plate and fitted with nuts on the outside,
C = 100 stays passed through the plate and fitted with nuts inside and outside,

43
 C = 110 for a riveted seam or flange in the flat plate securing it to the shell side
plate, end plate, furnace or uptake.
Where portions of plate are supported by stays or riveted seams or flanges having
various values of support, the value of C shall be taken as the mean of the points of
support concerned.

The support of a riveted seam shall be assumed to be at the line through the centers
of rivets in the nearest row and of a flange at the commencement of curvature. In the
latter case if the inner radius of curvature of the flange exceeds 2½ times the
thickness of the plate, the support shall be assumed to be at a distance of 2½ times
the thickness of the plate from the inner side of the flange.
(b) For portion of plate where the stays are irregularly pitched D2 shall be used instead
of A2 + B2 , D being the diameter in inches of the largest circle which can be drawn
passing through not less than three points of support, viz., the centres of stays or
rivets or the commencement of the curvature of flanging, whichever is applicable.
(c) For the tops and sides of combustion chambers and fireboxes the distance between
the rows of stays nearest to the back tube plate or the back or firehole plate
respectively and the commencement of curvature of these plates at their flanges
shall not be greater than the maximum pitch of the stays.
(d) For the tops of combustion chambers and fireboxes where they are joined to the
sides by curved portions if the outer radius of the curved portion is less than half
the allowable distance between the girders, the distance between the first girder and
the inner surface of the side plates shall not exceed the allowable distance between
the girders. If the radius of curvature is greater than half the allowable distance
between girders, the width of the flat portion measured from the centre of the
girder shall not be more than half the allowable distance between the girders.
(e) Where stay tubes are not fitted in nests of tubes as in the tube plates of loco-type
boilers and parts of plate outside the space occupied by tubes are supported in
accordance with Regulation 193(b) by screwed stays each stay in the row nearest
the tubes shall be of sufficient strength to support the plat up to the edges of the
tube holes in addition to its share of the plate on the opposite of the line of stays.
The working pressure for the plate between the tubes and stays shall be determined
by Eqn. (30). A being the horizontal pitch of the stays in the nearest row, B twice
the distance between the centre line of stays and a line touching the tubes opposite
them and C the co-efficient appropriate to the kind of stay.
175. Flat plates supported by stays and nuts and large washers or strips or doublings.
(a) Where the plates are supported by stays passing through them and are fitted with
nuts inside and washers and nuts outside the diameter of the washers being at least
3½ times that of the stay and their thickness at least two-thirds that of the plate but
not greater than that of the plate the maximum working pressure shall be:
100
W.P. ] [(t – 1)2 + .35t12] ... ... .. ... ... ... ... ... .. ... .. Eqn. (31)
A ] B2
2

(b) Where the washers have a diameter of at least two thirds of the pitch of the stays
and a thickness of at least two-thirds of the thickness of the plate, but not grater

44
 than that of the plate and are riveted to the plate in an efficient manner the
maximum working pressure shall be
100
W.P ] [(t – 1)2 + 3.5t12] ... ... .. ... ... ... ... ... .. ... .. Eqn. (32)
A ] B2
2

(c) Where the plate is stiffened by strips at least two-thirds of the pitch of the stays in
breadth which have a thickness of at least two-thirds of that of the plate but not
greater than that of the plate and are riveted to the plate in an efficient manner the
maximum working pressure shall be:
100
W.P ] [(t – 1)2 + .55t12] ... ... .. ... ... ... ... ... .. ... Eqn. (33)
A ] B2
2

(d) Where the plates are fitted with doubling plates having a thickness of at least two-
thirds of that of the plate but not greater than that of the plate and are riveted to
them in an efficient manner, the maximum working pressure shall be:
100
W.P ] [(t – 1)2 + .55t12] ... ... .. ... ... ... ... ... .. ... Eqn. (34)
A ] B2
2

176. Flat tube plates-

(a) For the portions of tube plates in the nests of tubes where stay tubes are required
and where the minimum thickness and cross section of tube plate are not less than
as prescribed in Regulation 192 the maximum working pressure shall be:
C (t ] 1) 2
W.P = ... ... .. ... ... ... ... ... .. ... ... ... ... .. ... .. Eqn. (35)
P2
P is the mean pitch of the stay tubes supporting any portion of the plate (being the
sum of the four sides of the Quadrilateral divided by four),
C = 70 for stay tubes screwed and expanded into the plate and no nuts fitted,
C = 85 for stay tubes screwed and expanded into the plate and fitted with nuts.
(b) No nuts shall be fitted to stay tubes at the combustion chamber or firebox end.
(c) Where the plates are exposed to the direct impact of flame, the co-efficient C shall
be reduced by 2½ percent and where the thickness or cross section of tube plate
between tubes is less than as prescribed in Regulation 192 the appropriate co-
efficient shall be reduced in proportion to the deficit.
(d) For the wide water spaces of tube plates between the nests of tubes and between
the wing rows of tubes and the shell the maximum working pressure shall be:
C
W.P. ] [(t – 1)2 + .55t12] ... ... .. ... ... ... ... ... .. ... Eqn. (36)
A ] B2
2

A is the horizontal pitch of stay tubes in inches measured across the wide water
space from centre to centre.
B is the vertical pitch of stay tubes in the bounding rows in inches measured from
centre to centre,
C = 60 for stay tubes screwed and expanded into the tube plates and no nuts are
fitted,

45
 C = 80 for stay tubes screwed and expanded into the tube plates and fitted with
nuts,
C = 70 for stay tubes screwed and expanded into the tube plates and nuts are fitted
only to alternate stay tubes,
t is the thickness of the flat plate in 32nds of an inch,
t is the thickness of the washers, strips or doublings employed in 32nds of an inch.
(e) Where the plates are exposed to the direct impact of flame, the co-efficient C shall
be reduced 12½ percent.

177. Plates supported by gusset stays-

(a) For the end plated of Lancashire Cornish, Vertical and Loco Type boilers and
other flat surfaces supported by irregularly pitched gusset stays, the maximum
working pressure shall be:
C (t ] 1) 2
W.P = ... ... ... ... ... .. ... ... ... ... ... .. ... Eqn. (37)
D2
D is the diameter in inches of the largest circle which can be drawn passing
through not less than three points of support, viz., the centre lines of rivets or the
commencement of the curvature of flanging which ever is applicable.
C = 100 for plates not exposed to flame,
C = 88 for plates exposed to flame.
(b) Where such plates are stiffened by suitable tee or angle bars securely riveted to the
plates within the circle D, the appropriate co-efficient may be increased thirty
percent Such stiffening bars shall be placed so as to transmit their load in a direct
manner to the gusset stays or shell plate.
(c) For the part of the end plate containing the manhole in Lancashire boilers the
maximum working pressure shall be:
C
W.P ] 2
[(t – 1)2 + (t1 – 1)2] ... ... .. ... ... ... ... ... .. ... ... Eqn. (38)
D
D is the diameter in inches of the largest circle which can be drawn enclosing the
manhole and passing through the centres of the rivets in end plates connecting the
shell and gusset angles and furnaces or to the commencement of curvature of
flanging, whichever is applicable where the circle passes through only three of the
possible five points of support mentioned the remaining two shall be embraced
within the circle.
t is the thickness of the end plates in 32nds of an inch,
t1 is the thickness of the base of the mouthpiece or flat ring in 32nds of an inch,
C = 90 where the manhole mouthpiece is either of mild or cast steel, and has a
turned-in flange of a depth, measured from inside of end plate of not less than 4
times the thickness of the end plate and a thickness not less than the thickness of
the end plate,
C = 70 where only a flat steel compensating ring is fitted.

46
 C is to be taken as the mean of the points of support through which circle passes in
accordance with Regulation 174 where there is no mouthpiece or flat ring and the
end plate is flanged around the manhole to the depth required in Regulation 182.

178. Flat crown plates of vertical boilers-

(a) For the flat crown plates of vertical boilers either with or without bolt stays,
Equation (37) shall be used in determining the working pressure with C = 80,
when the plates are not exposed to flame, and 70 when they are exposed to flame.
In this case D is the diameter of the largest circle in inches that can be drawn
passing through the centres of the rivets or bolt stays when fitted or the
commencement of the curvature of the flanging, whichever is applicable. Where
bolt stays are fitted with washers of the same thickness as the plate securely
riveted thereto, the circle shall pass through the centres of the washer rivets but
where the washers are not riveted or where none are fitted the circle shall pass
through the centres of the stays.
(b) Where the crown plate is flanges the inside radius of curvature at the flange shall
not be less than 4 times the thickness of the end plate.
179. Circle flat ends of drums etc. supported only at edges-
(a) For these ends C in Equation (37) shall be taken as 140 when the plates are not
exposed to flame and 122.5 when they are exposed to flame. In this case the circle
D shall pass through the centres of rivets or bolts securing the end to the shell or
where the end is flanged through the commencement of curvature.
(b) Where flanged the inside radius of curvature at the flange shall not be less than 4
times the thickness of the end plate.
180. Bar or bulb stiffened end plates and smoke box tube plates of Loco type boiler-
Where such plates instead of being supported by stays are stiffened in the steam space by
substantial tee or angle bars securely riveted to the plate and extending across the plate to
within the margin allowed by Equation (39) of where such plates are formed with a deep
bulb extending across the plate to well within the margin allowed for the support thus
given.
C shall be taken as equal to 80 to 70 for plates not exposed and exposed to flame
respectively. The margin or pitch for such stiffening shall be measured from the centre
line of rivets or commencement of curvature of bulb provided it is not more than 2 inches
from the centre line of bulb.
For the flat plate above the stiffener or bulb, C shall be taken as the mean of the values
appropriate for the points of support.
181. flat plate margin- The amount of support in relief of stays which may be credited to the
sides of shell furnaces, uptakes, firehole and foundation rings etc. to which flat plates are
attached shall not exceed that found by the following formula:
1 C (t ] 1) 2
 - width of margin in inches . ... ... ... ... .. ... ... Eqn. (39)
3 W .P.
W.P. is the intended working pressure in lbs. per square inch.

47
 C = 110 for plates not exposed to the direct impact of flame.
C = 96 for plates exposed to the direct impact of flame.
Where the plates are flanged the margin shall be measured from the commencement of
curvature or from a line 2½ times the thickness of the plate distant from the side of the
flange next the inner radius of corner whichever is less. In other cases the margin shall be
measured from the centre line of rivets in the nearest row of the seam by which the flat
plate is attached.
182. Manholes and Mudholes in Flat Plates- Where a flat plat is flanged to stiffen it at a
manhole or sighthole to permit the same working pressure as would be allowed upon an
unpierced plate the depth of the flange measured from the outer surface shall be at least
equal to-
T  W = depth of flange in inches ... ... ... ... ... ... ... ... ... .. Eqn. (40)

Where T is the thickness of the plate in inches, and

W is the minor axis of the hole in inches.

STAYS
183. Solid screwed stays- For screw stays to combustion chambers and fireboxes and for
longitudinal and cross stays the maximum working pressure for the stays is to be
calculated iron from the appropriate one of the following two formula:
C 1.28 2
W.P. ] [D ] ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Eqn. (41)
A N
2
C  D1
W.P. ] ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... .. Eqn. (42)
A
W.P. is the working pressure in lbs. per square inch,
D is the diameter of stay over threads in inches,
D1 is the diameter of body of stay at its smallest part in inches,
N is the number of threads of stay per inch.
A is the area in square inches supported by one stay [For area to be supported by stays
near tubes in firebox tube plates of locotype boilers, See Regulation 174 (e)]
C = 7100 for steel or special wrought iron screw stays to combustion chamber or
fireboxes,
C = 7500 for steel longitudinal or cross stays fitted with nuts,
C = 4700 for copper screw stays to fireboxes.
Where stays are made with enlarged ends and the body of the stay is smaller in diameter
than at the bottom of the thread the working pressure shall be calculated from the second
formula.
184. Stresses in steel joined stays-
(a) The section of least strength whether of stay rivets, shackle or pin shall be used in
calculating the working pressure for the stay. For parts in tension a stress of 9000

48
 lbs. per square inch of net section shall be allowed and for parts in shear a stress of
8000 lbs. per sq. inch of net section.
(b) Parts in double shear shall be allowed a section of 1.875 times the single section.

185. Stay tubes- For stay tubes whether of wrought iron or steel seamless or lap-welded the
maximum working pressure shall be calculated from the following formula:
5909 1.28 2 2
W.P ] [(D- ) -D1 ] ... . ... ... .. ... ... ... ... ... ... ... ... ... .. Eqn. (43)
A N
D is the diameter of the tube over threads in inches.
D1 is the internal diameter of the tube under the threads in inches,
N is the number of threads of stay per inch.
A is the area in square inches supported by one stay tube measured from centre to centre
of stay tubes. When the area contains tubes or parts of tubes their aggregate area
calculated from their smallest external diameter of body when in tension and smallest
internal diameter when in compression, shall be deducted from the area of the containing
figure and the remainder used as A in the formula.
186. Stays in tension and compression-
(a) The same stress shall be allowed in compression as in tension. The strength of
short stays in compression and not liable to bending may be calculated on the net
section of the stay at bottom of thread or in body whichever is less.
(b) The stress to be allowed on any stay or part of stay not provided for in foregoing
shall be the same as that allowed for stays or parts of stays of approximately like
kind in similar conditions.

187. Measurements of stayed areas in the end plates of loco type and vertical boilers-
When the areas supported by stays are semi-circular as in the upper parts of the end plates
and smoke box tube plates of loco type boilers or annular as in the crown plates of
vertical type boilers A in Eqns. 41 and 42 the area to be supported by stays shall in the
first case be the area of the plate contained within the margins credited to casing or barrel
sides, screw stays, fire door ring or tube stays as the case may be and in the second case
be the area of the annulus between margins credited to uptake and shell. When bolt
staying is necessary the stays shall be properly distributed; the aggregate stay section shall
then be used in the formula for calculating the working pressure.
188. Gusset stays- the maximum working pressure for gusset stays shall be calculated by the
following formula:
8500  C
W.P. ] ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... .. Eqn. (44)
A
C, the co-efficient is the number representing the least of the following:
(1) N1 × A1.
(2) N2 × A2. × 1.875.
(3) N3 × A3. × 1.875.

49
(4) N4 × A4.
(5) (G-N2D2) × (t-2) × .037.
(6) (G1-D3) × (t-2) × .037.

N1, N2, N3, N4, D1, D2, D3, D4, and A1, A2, A3, A4,
are respectively the number, diameters and sectional areas of the rivets in the joints of
each gusset stay the order of the joints being (1) angles to end plate, (2) end plate angles
to gusset. (3) shell angles to gusset and (4) angles to shell.
G is the depth in inches of gusset plate measured through the line of rivets attaching it to
the end plate angles.
G1 is the depth in inches of gusset plate measured normal to the slant edge of plate
through the rivet nearest to the end plate in the joint attaching gusset plate to shell angles.
t is the thickness of the gusset plate in 32nds of an inch.
A is the area in square inches of flat plat supported by the gusset stay which in the case of
Lancashire and Cornish boilers, shall be determined as follows:
(a) The margins allowed under flat plate regulations for shell and furnace shall be
marked on end plates and the lengths of the centre lines of gussets between them
measured, also the distance between each pair of gusset lines from the middle of the
smaller in a direction normal to the greater. If L and L1 be the lengths of two
adjacent gusset lines and if the distance between them be W, the area contained by
the gusset lines and the shell and furnace margin lines may be apportioned between
the stays thus:
W (3L ] L1 )
= Portion of area in square inches apportioned to L
8
line gusset ... ... ... ... . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ....Eqn. (45)
W (3L1 ] L)
Portion of area in square inches apportioned to L
8
line gusset ... ... . ... ... ... ... . ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... .Eqn. (46)
(b) The portion of the area on the other side of each gusset line shall except when of
triangular form, be found in like manner and its amount added to that already found
to form the total.
(c) For the triangular portions in the wing spaces the area shall be taken as half the
product of the length of gusset line into the perpendicular distance between it and
intersecting point where the marginal curves meet.

50
 BOLTS AND STUDS
189. (a) Bolts and studs connecting parts of boilers such as shell and plates, tube
plates, furnaces, uptakes, externally fitted manhole covers, mountings, etc. may be
made either of steel or good quality wrought iron.
(b) The maximum working pressure for the bolts or studs shall be calculated by the
following formula:
N C 1.28 2
W.P ] [D- ] .. ... ... ... ... . .. ... ... ... ... ... ... ... ... ... .. Eqn. (47)
A n

D is the diameter of bolt or stud over threads in inches,

N is the number of bolts or studs securing the part,
n is the number of threads of screw per inch.
C = 4700 for steel bolts or studs where the diameter over threads is not less than ¾.
C = 5600 for steel bolts or studs where the diameter over threads is greater than 7|8
inch.
C = 7000 for steel bolts or studs where the diameter over threads is greater than 7|8
inch.
When the material is iron a reduction of 15 percent shall be made in the working
pressure as calculated by the formula.
A is the area in square inches of the surface supported by the bolts or studs. for
jointed flanges the area shall be taken to extend to midway between the pitch line of
the bolts and the inner edge of the flange by which the part is secured.

TUBE PLATES
190. Compression of tube plates
(a) For firebox or combustion chamber tube plates which are subject to compression
due to the pressure on the roof plate the maximum working pressure shall be:
C  ( P ] D)  t
W.P ] .. ... ... ... ... ... .. ... ... ..... ... ... ... ... .. Eqn. (48)
L P
t is the thickness of the tube plate in 32nds of an inch.
P is the pitch of the tubes in inches, measured b horizontally where the tubes are
chain pitched, and diagonally where the tubes are zigzag pitched and the diagonal
pitch is less than the horizontal.
D is the internal diameter of the plain tubes in inches,
L is the internal length of he firebox or combustion chambers in inches, measured at
top between tube plate and firehole plate or back plate, or between tube plates in
double ended boilers with combustion chambers common to two opposite furnaces.
C = 875 for steel and 437.5 for copper.

51
 Provided that the above formula shall not apply in the case of fireboxes where the
girders do not rest on the tube plate or where the roof plate is stayed direct to the
outer shell or to girders supported by the shell.
(b) Where girders rest on the side plates or the roof plate is so formed that the load is
carried both by side and end plates in no case shall the compressive stress on the
plates exceed 14000 lbs. per square inch for steel or 7000 lbs. per square inch for
copper.
191. Parts to be stayed
(a) The stiffness of tube plates and pitch of stays within the nests of tubes where stay
tubes are required and where marginal stay tubes are required in support of blank
spaces adjacent to or between the nests shall be determined by flat plate rules
under Regulation 176.
(b) Tube plates within the nets of tubes whether fitted with stay tubes or not small
comply with the requirements of Regulation 192 in regard to thickness and cross
section between tubes.
192. Minimum thickness and cross section- To provide a secure attachment for plain tubes in
the tube plates the thickness and cross section of the plate between the tube holes shall not
be less than:

Steel tube plate,

.125D + .2 = minimum thickness in inches... ... ... ... ... ... ....Eqn. (49)
.17D + .25 = minimum cross section in square inches... ... ... .... Eqn. (50)
Copper tube plate,
.2D + .4 = minimum thickness in inches... ... ... ... ... ... .. .. . . Eqn. (51)
.527D - .263 = minimum cross section in square inches... .... ... .. Eqn. (52)
D is the diameter in inches of the tube at the part of the attachment to tube plate.
Where the thickness and cross section of the tube plates are less than the minimum the
appropriate co-efficient in Eqn. (53) shall be reduced in proportion to the deficit.
193. Holding power of plain tubes-
(a) Where tube plates are not specially stayed in nests of tubes, the working pressure
based on the holding power of the tubes, shall not exceed that found by the following
formula:
CD
W.P. ] .. ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... .. ... Eqn. (53)
A
D is the diameter of tube at the part of attachment to tube plate in inches.
A is the area in square inches of tube plate supported by each tube which generally
may be taken as the product of the horizontal and vertical pitches of the tube less the
area of the tube itself.
C = 470 for tubes expanded into parallel holes in steel or iron tube plates.

52
 C = 530 for tubes expanded into taper holes in steel or iron tube plates.
For copper tube plates or copper or tubes the appropriate co-efficient should be
reduced 20 percent.

(b) In the unstayed tube plates of loco type boilers and in other tube plates in which stay
tubes are not required the support afforded by the plain tubes shall not be taken to
extend beyond the lines enclosing the outer edges of the tubes. Parts of flat plate
outside this line shall either lie in the plate margin or be separately supported. No
account need be taken of the stiffness of tube plate in the nests of tubes when the
above conditions are fulfilled.
Ordinarily the requirements of this clause are applicable only to expanded smoke and
water tubes in flat continuous tube plates containing more than one row of tubes.
(See Reg. 133 for attachment of tubes in Water Tube Boiler).
194. Tube plates other than ends of vertical boilers forming parts of outer shell.
(a) When vertical boilers have a nest or nests of horizontal tubes so that there is direct
tension on the tube plates due to the vertical load on the boiler ends or to their acting
as horizontal ties across the shell 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 plates.
(b) Each alternate tube in the outer vertical rows of tubes shall be a stay tube. The tube
plates between the stay tubes shall be in accordance with the rules for tube plates and
in addition considered as part of shell the maximum working pressure:
17.24(t ] 2)  ( P ] D)  S
W.P. ] ... .. ... ... ... ... ... ... ... ... ... .. ... Eqn. (54)
R P
t is the thickness of the tube plate in 32nds of an inch,
P is the vertical pitch of the tubes in inches,
D is the diameter of the tube holes in inches,
S is the minimum tensile breaking strength of the tube plates in tons per square inch.
or whatever is allowed for them.
R is the radial distance of the centre of the outer row of tube holes from the axis of
the shell in inches.
195. Curved tube plates of water tube boiler-
For tube plates forming part of cylindrical drums the maximum working pressure shall
be:
33.3(t ] 4)  E  S
W.P ] ... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... Eqn. (55)
D
t = thickness of tube plate in 32nds of an inch,
E = Efficiency of the longitudinal joint or the ligament between the tube holes whichever
is less.

53
 S = Minimum tensile stress of the tube plate in tons per sq. in or whatever is allowed for
it,
D = Inside diameter of the drum in inches.

196. Ligament efficiency-

(a) Where a drum shell is drilled for tube in a line or lines parallel to the axis of the drum
but not forming a staggered arrangement the ligament efficiency E (i.e, proportionate
strength of the plate through tube holes) shall be determined as follows:
(i) Where the distance between centre of adjacent tube holes is constant:
P]D
E] .... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... Eqn. (56)
P
(ii) Where the distance between centre of adjacent tube holes is not constant:
41 p ] p2 ] 5d
E] ..... .. ... ... ... ... ... ... ... ... ... .. ... ... .... Eqn. (57)
4 p1 ] p2

When applying the above formula the double pitch (P1 + P2) chosen shall be that
which makes E a minimum and in no cases shall P2 be taken as greater than 1.3P.
In the above formula:
E = Ligament efficiency (expressed as a fraction) i.e. proportionate strength through
tube holes.
P = distance between centres of adjacent tube holes in inches.
P1 = The shorter of any two adjacent pitches in inches.
P2 = The longer pitch of the two adjacent pitches in inches.
d= Mean effective diameter of tube holes in inches after allowing for any serrations
counter boring or recessing.
The circumferential pitch between parallel rows of tube holes measured on the mean
of the external and internal drum diameters shall be such that the circumferential
ligament efficiency is equal to or greater than half the ligament efficiency on the
longitudinal axis.
(b) Where the tube holes are arranged in zigzag or staggered formations the efficiency of
the ligament (E) shall be the smaller of the value obtained from the following
formula:
2( pd ] D)
E] ... .. ... ... ... ... ... ... . ... ... ... ... ... ... ... ... ... ... Eqn. (58)
P1 Pc

or
P1 ] D
E] ... .. ... ... ... ... ... ... ... ... ... .. ... .. ... ... ... ... ... ... .. Eqn. (54)
p1

Pd = Diagonal pitch of tube holes in inches,

54
 P1 = Longitudinal pitch of tube holes in inches,
Pc = Distance between tows of tubes measured circumferentially.
D = Diameter of tube holes in inches.

TUBES SUBJECT TO INTERNAL PRESSURE

197. The maximum working pressure for the tubes shall be:
170(t ] 8)
W.P. ] ....... .. ... ... ... ... ... ... ... ... ... .. .... .. .. . . . .. .... Eqn. (60)
D
t is the thickness of tube in 100ths of an inch,
D is the external diameter of the tube in inches.
Minimum thickness of tubes shall comply with Regulation 319 (c).

Header and Section Boxes of Water Tube Boiler

198. See Eqn. 93.... Reg. (321)

Boiler Tubes (Smokes) Subject to External Pressure

199. Steel and wrought iron tubes-
(a) The maximum working pressure for the tubes shall be:
100(t ] 6)
W.P ] ... .. ... ... ... ... ... ... ... ... ... .. .... .... .... .... Eqn. (61)
D
t is the thickness of the tubes in 100ths of an inch,
D is the external diameter of the tubes in inches,
(b) No tube shall be less than 12 S.W.C (.104ʺ) thick.
200. Brass and Copper Tubes-
The thickness of tapered brass and copper smoke tubes for locomotive boilers shall in the
case of tubes of an external diameter of 1⅞ to 1½ inches inclusive be not less than 12
S.W.G. (.104 in.) at the smoke-bow end and 10 S.W.G (.128 inch) at the other; and in the
case of tubes meter of 1½ 1 diameter of 2 to 2⅜ inches inclusive, the thickness at the
smoke of an external not be less than 11 S.W.G (.116 inch) and at the other end not bex
end shall W.G. (.144 inch).

FURNACES
201. Plain Furnaces of Horizontal Boilers- For plain furnaces or furnaces strengthened by
adamson or other joints and for the semi-cylindrical tops of fireboxes and bottoms of
combustion chambers where the sides are securely stayed the working pressure shall not
exceed the smaller of the values obtained from the following formula:

55
 C (t ] 1) 2
W.P. ]  ... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... Eqn. (62)
D ( L ] 24)

C1
W.P. ]  1[10(t-1)-L] ... .. ... ... ... ... ... . ... ... .. ... ... ... ... ... ... Eqn. (63)
D

D is the external diameter of the furnace or chamber top or bottom in inches.

t is the thickness of the furnace plate in 32nds of an inch,
L is the length of the furnace or other part in inches measured between points of
substantial support, i.e. centres of rows of rivets in end seams or commencement of
curvature of flange whichever is applicable,
C = 1450 where the longitudinal seams of steel furnaces are welded and 1300 where they
are riveted,
C = 725 where the longitudinal seams of circular copper fire-boxes or furnaces are fitted
with double butt straps and 650 where they are lapped.
C1 = 50 where the longitudinal seams of steel furnaces are welded and 45 where they are
riveted.
C1 = 25 where the longitudinal seams of circular copper fire-boxes or furnaces are fitted
with double butt straps and 22.5 where they are lapped.
202. Corrugated Furnaces of Horizontal Boilers- The maximum working pressure to be
allowed on corrugated furnaces shall be determined by the following formula:
C(t ] 1)
W.P. ] ... .. ... ... ... ... ... ... ... ... ..... .... . .... ..... ...... ...... .... ...Eqn. (64)
D
D is the least external diameter in inches measured at the bottom of the corrugations on
the water side,
t is the thickness of the furnace plate in 32nds of an inch measured at the bottom of the
corrugation or chamber,
C = 480 for the Fox, Morrison, Deighton, Purves and other similar furnaces and 510 for
Leeds Forge bulb Suspension Furnace.
203. Plain Furnaces of Vertical Boilers- The same formula as for the plain furnaces of
horizontal boilers shall be used but where the furnaces are tapered the diameter to be
taken for calculation purposes shall be the mean of that at the top and of that at the bottom
where it meets the substantial support from flange or ring. The length for the same
purpose shall be the distance from the centre of the row of rivets connecting the crown
and the body of the furnace to the substantial support at the bottom of the furnace, or to a
row of screwed stays connecting the furnace to the shell provided that the pitch of stays at
the furnace does not exceed 14 times the thickness of the furnace plate when the stays are
riveted at their ends or 16 times when the stays are fitted with nuts. Such screwed stays
shall be in diameter over the threads not less than twice the thickness of the furnace plate
and in no case less than ⅞˝ diameter se reg. 116(d).

56
204. Hemispherical Furnaces of Vertical Boilers- When furnaces are hemispherical in form
and subject to pressure on the convex side and are without support from stays of any kind
the maximum working pressure shall be:
275(t ] 1)
W.P ] ... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... Eqn. (65)
R
t is the thickness o the lip plate in 32nds of an inch,
R is the outer radius of curvature of the furnace in inches.
205. Corrugated fireboxes of Vertical Boilers- For the semi spirally corrugated fireboxes of
“Sentinel” standard motor wagon boilers the working pressure shall be determined by the
following formula:
C (t ] 1)
W.P. ] ... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... Eqn. (66)
D
t is the thickness of the firebox plate in 32nds of an inch,
D is the mean of the external diameters of firebox measured over the plain part at each
end at commencement of curvature of flange,
C = 390.
206. Foundations of Vertical Boiler Furnaces-
Where circular furnaces or fireboxes of vertical boilers are not connected to the shell
crown by uptake tube, smoke tubes or bolt stays and the whole load on the firebox
vertically is borne by the bottom part of the firebox where it is connected to the shell the
working pressure for the part, if firebox is joggled out to meet the shell or if an ogee ring
is fitted shall not exceed that found by the following formula:
140(t ] 1) 2
W.P ] ... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... .... ... Eqn. (67)
D( D ] D1 )

t is the thickness of the joggled firebox plate or ogee ring in 32nds of an inch,
D is the inside diameter of the boiler shell in inches,
D1 is the outside diameter of the joggled firebox at the commencement of curvature above
joggled part or the outside diameter of the firebox where it joins the ogee ring.
207. Foundations of Loco type Boiler Fireboxes- Where the firebox roof in loco type boilers
is not stayed direct to the external casing crown or to girders carried by the casing or is
not connected to the casing by slings in accordance with Regulation 210 (c) and the
whole load on the firebox vertically is borne by the bottom parts of the firebox where
connected to the external casing the working pressure for the parts if plates are joggled
out to meet the casing or if an ogee ring is fitted, shall not exceed that found by the
following formula:
70(t ] 1) 2  ( L ] W )
W.P. ] ... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... Eqn. (68)
L  W (W ] W1 )

t is the thickness of the joggled firebox side plates or fire hole plate (whichever is less),
ogee ring in 32nds of an inch.

57
 L is the length of firebox casing in inches measured between the water sides of front end
plate and saddle plate at the foundation seam,
W is the width of firebox casing in inches measured between the water sides of casing
side plates at the foundation seams,
W1 is the width of firebox in inches measured between the water sides of fire box side
plates at the commencement of curvature above joggled part or where it joins the ogee
ring.
Where only a comparatively narrow strip of the firebox roof is stayed directly to the
casing crown the area so stayed shall be deducted from the area represented by L × W in
the bottom line of the formula:
Thus, [(L×W-A) (W-W1) and so used in Equation (68) in determining the working
pressure for the parts, “A” being the area in square inches of the part of rood supported by
the casing crown.
208. Cross Tubes- The working pressure of the tubes shall be determined by the following
formula:
200(t ] 7)
W.P. ] ... .. ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... Eqn. (69)
D
W.P = working pressure in lbs. per sq. inch,
t = the minimum thickness in 32nds of an inch,
D = the internal diameter in inches of the cross tube.
209. Uptakes of Vertical Boilers- The working pressure for uptake tubes of vertical boilers
shall be determined by Eqn. 62 and 63 but only half the least pressure so found is to be
allowed for uptake tube.

SUPPORTS FOR COMBUSTION CHAMBER AND FIREBOX CROWNS

210. Girders supporting the tops of fireboxes and combustion chambers.
(a) For girders supporting the tops of fireboxes and combustion chambers the
maximum working pressure shall be calculated from the following formula:
C  t  D2  S
W.P. ] ... .. ... ... ... ... ... ... ... .. ... ... ... ... ... .Eqn. (70)
( L ] P )  D1  L

t is the thickness of the girder at centre when a forging or casting or the sum of the
thickness of the plates where the girder is made of two plates measured in 32nd of an
inch,
D is the least depth of the girder at or near the middle in inches,
L is the distance in inches between the end or side plates which support the girders
measured in the direction of the girders.
P is the pitch of the stays supported by the girder in inches,
D1 is the distance apart of the girders, centre to centre in inches,
S is the minimum tensile breaking strength of the plates forming the girder in tons
per square inch, or whatever is allowed for them,

58
 N
C] × 21, where the number of stays in each girder is odd,
N ]1
N ]1
and × 21, where the number of stays in each girder is even,
N ]2
N being the number of stays to each girder.
(b) Where girders are supported in any other way than by the end or side plates of the
firebox or combustion chamber the calculations for determining the working
pressure shall be made in accordance with the actual conditions of support.

In such cases the length of the strip of firebox or combustion chamber top plate to
be supported by the girder shall subject to the limit imposed on the distance of the
nearest stay be taken as equal to the product of the number of bolts carried by the
girder into the pitch of the bolts. A maximum nominal stress of 14000 lbs. per
square inch on girder section shall be allowed for steel.
(c) Slings, links, pins, rivets, and connections to shell of slung girders shall be
sufficient to carry the whole load that would otherwise be carried by the girder and
each girder must be equally slung or supported. For stresses allowed on the sections
see Regulation 184.
(d) In the case girders supported at the ends only by angle bars riveted to the casing
crown the length L may when the girder extends over the full breadth of the angle
face, be taken as the distance between the centres of the angle faces. When this
distance does not exceed that of L in the formula, the pressure shall be determined
in the ordinary way. The supporting angle and rivets shall be of sufficient section
for the intended purpose. For stresses allowed or the sections see Regulation 184.

PATENT FIREBOX ROOFS OF LOCO TYPE BOILERS

211. Marshall Type- For messrs. Marshall sons and company’s patent stayless roof for
fireboxes of loco type boilers made of steel in which the centre lines of the corrugations
meet the centre lines of the end riveted seems at points not farther distant from the side
plates than one half the inner radius curvature of the corner formed by the roof and side
plate in order to ensure that the thickness and height of the pressed diagonal corrugations
of the camber are satisfactory the working pressure shall not exceed the smaller of the
values obtained from the following formula:
25000(t ] 1)  H 2
W.P. ] .. .. ... ... ... ... ... ... ... .. ... ... ... ... ... ... Eqn. (71)
W  L  W 2  L2

55(t ] 1) 2  (W ] W 2 ] L2 ) 2
W.P. ] .. .. .. ... ... ... .. ... ... ... ... ... .Eqn. (72)
W 2 ] L2
t is the thickness of the roof plate in 32nds of an inch,
H is the height of the corrugation at its highest part measured perpendicularly on one side
of the plate in inches,
W is the width of the roof plate between the flat of side plates at top less the inner radius
of curvature of corner of roof and side plate in inches, i.e. W+ radius = internal width of
firebox at top.

59
 L is the length of one roof plate between centre lines of rivets in inches.

212. Garrett Type-

For messrs. Richard Garrett and son’s corrugated stayless roof for fireboxes of loco type
boilers made of steel in which the side corrugations are parts of true circles and the radius
of the middle corrugation is not more than about ¼th of the radius of the outer
corrugations and the corrugations are cambered longitudinally, the working pressure shall
not exceed the smaller of the values obtained from the following formula:
C (t ] 1) 2
W.P. ]  .. .. ... ... ... ... ... ... ... .. ... ... ... ... ... ... .Eqn. (73)
R ( L ] 24)

C1
W.P. ] ]
10(t ] 1) ] L].. .. ... ... . ... ... ... .. ... ... ... ... ... ... .Eqn. (74)
R
t is the thickness of the corrugated plate in 32nds of an inch,
L is the length of the roof plate between centre lines of rivets in inches,
R is the external radius of the side corrugations at the middle of the length in inches,
C = 363 where the roof and side plates are in one piece and 325 when they are riveted,
C1 = 12.5 where the roof and side plates are in one piece and 11.25 where they are riveted.
213. Fowler Type-
(a) For Messrs. John Fowler and company’s (Leeds) corrugated roof for fireboxes of
loco type boilers made of steel in which the crown of the roof is transversely curved
and corrugated in the style of Fox’s corrugated furnace and the roof plate if not solid
with the side plates of the firebox , is securely riveted thereto and to the flanges of the
tube plate and firehole plate and there is a now of suitably size and spaced screw
stays below the commencement of corrugations on each side attaching the roof plate
to the external casing when the conditions hereunder are complied with the working
pressure shall not exceed the smaller of the values obtained from the following
formula:
C (t ] 3)
W.P. ] .. .. ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... Eqn. (75)
R
C1 (t1 ] 1)
W.P. ] .. .. ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... Eqn. (76)
W
t is the thickness of roof plate before corrugations are formed in 32nds of an inch.
t1 is thickness of side plates of firebox to which roof plates attached in 32nds of an
inch,
R is the radius of transverse curvature or camber of middle part of corrugation
measured from the bottom of corrugation on water side in inches,
W is the width of firebox in inches measured over water sides of side plates at the
seams attaching them to roof plate.
C = 240

60
 C1 = 875
(b) The corrugations measured from top to bottom on one side shall not be less than
three times the thickness of the finished plate in depth and not more than 12 times the
thickness of the finished plate apart.
(c) The inner radius of corner at sides where corrugations merge into the flat sides shall
be not less than 4 times the thickness of the finished plate.
(d) The length of the plain parts at ends of roof between the centre lines of riveted seams
and commencement of curvature of corrugations shall not exceed that allowed for flat
plate margins under Regulation 181.

CHAPTER V
FUSION WELDED AND SEAMLESS FORGED DRUMS FOR WATER TUBE BOILERS
AND SUPER HEATERS
GENERAL REQUIREMENTS
214. Where applicable the general terms of Chapter I relating to certificates from Makers,
Inspecting Authorities etc., and of chapter III concerning construction should be allowed.

Material of Construction
215. Material for Fusion Welded Boiler Drums-
(a) The requirements of regulations 9 to 20 so far as they relate to plates shall apply to
steel plates for fusion welded boiler drums excepting that the ultimate tensile stress
and elongation of the materials shall be between the limits shown in table below and
shall be specified for each component part of the boilers.
Description Utimate tensile Minimum elongation
stress Tons per percent Test piece
square inch A or B
Plates for drum shells (i.e. wrapper plates
and tube plate)........................................... 88-32 20
Drum ends stand or branch pipes and 26-30 23 for 26-30 tons per
seatings for mountings or sq. in.
28-32 20 for 28-32 tons per
sq. in.

(b) Plates over 2˝ in thickness being fabricated shall be uniformly heat treated to produce
grain refinement. Heat treatment involving quenching in a liquid medium is not
permitted.

SEAMLESS FORGED DRUMS

216. Process of manufacture- Carbon steel for seamless steel drums shall be made by the
open hearth or an electric process, acid or basic.
217. Chemical Analysis- The steel shall contain not more than 0.05 percent of sulphur or of
phosphorus.

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218. Freedom from defects – The drum shall be free from surface defects and shall be
machined to the prescribed dimensions.
Defects in forgings shall not be required without the previous sanction of the inspecting
officer.
219. Heat treatment- Each drum shall be efficiently heat treated:
(a) At various stages during manufacture as required.
(b) On completion of the forging process but prior to the hydraulic test.

220. Mechanical Test- Material shall comply with the mechanical tests herein specified.
Sufficient material shall be left on the open ends of each forging to enable tangential test
pieces to be taken. These tests shall consist of not less than one tensile and one bend test
from each open end. In the case of drums with open ends the test material shall not be
parted off before heat treatment. If the drums are closed in at the ends the test rings shall
be parted off immediately before this operation; subsequently the test rings and the
forging shall be similarly and simultaneously heat treated in the same furnace.
221. Selection of Test pieces-
(a) All test pieces shall be selected by the authorized Inspector and shall be tested in
his presence and he shall satisfy himself that the conditions herein described are
fulfilled.
(b) Tensile Tests- The ultimate tensile stress and elongation shall be between the limits
shown below. A range of not more than 4 tons per sq. in. for any forging shall
apply, such range to be specified for each drum.
(i) Ultimate tensile stress 28 to 38 tons per sq. in.
(ii) Elongation 29 percent 19 percent determined on British Standard Test Piece C,
or a subsidiary standard round test piece (see Appendix B)
In no case shall the sum of the ultimate tensile stress and corresponding elongation
be less than 57.
Should a tensile test piece break outside the middle half of the test gauge length the
test may be discarded and another test be made of the same drum.
(c) Bend Test pieces- Bend test pieces shall be of rectangular section 1 in. wide by ¾-
in. thick. The edges shall be rounded to a radius of 1|16. The test pieces shall be
bend over the thinner section.
(d) Bend tests- The test pieces shall when cold be capable of being bent without
fracture through an angle of 180º the internal radius of the bend being not greater
than that specified in table below:
Internal radius of
Ultimate tensile stress, Tons per square inch.
bend. inches.
up to 32 .. .. .. .. .. ¼
Above 32 and up to 36 .. .. .. .. .. ⅜
Above 36 to up to 38 .. .. .. .. .. ⅝

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 Bend tests may be made by pressure or by blows.
222. Additional tests before rejection- Should either a tensile or a bend test fail, two further
tests of the type which failed may be made on test pieces cut from the same test rings. If
the results obtained from these re-tests are satisfactory, the drum shall be accepted
provided that in other respects it fulfils the conditions of this chapter. If these re-tests do
not give satisfactory results the drum represented may be re-heat treated together with the
remainder of the test rings and presented for further testings.
In all cases where final re-tests do not give satisfactory results the drum represented by
the test pieces which fail shall be rejected.
223. Discard- Sufficient discard shall be made from the top and bottom of each ingot to ensure
soundness in the portion for forging.
224. Forging- The forging shall be made from a solid cast ingot, punched, bored or trepanned
or alternatively, hollow cast ingots may be used. The resultant wall in the case of the solid
cast ingot or the wall of the hollow ingot as cast shall be reduced in thickness by at least
one-half in the process of forging.
225. Tubes- (a) Tubes shall be of cold drawn weldless or hot finished weldless
steel and shall comply with regulations 36 to 46.
Headers- (b) header and similar pressure parts shall be of forged steel, seamless steel
tube or of cast steel, to comply with the appropriate Regulations in Chapter II.
226. Pipes- Pipes forming an integral part of the boiler unit shall comply with the Regulations
of Chapter VIII.
227. Steel castings- Steel castings for pressure parts shall comply with regulations 55 to 65 (28
to 35 tons per square inch.)

Fusion Welded Drums

228. Definition of term ‘Fusion Weld’- The term ‘Fusion Weld’ is for the purpose of this
chapter, applicable to all welded joints made by the metal-arc process with covered
electrodes or other electric are process in which the are stream and the deposited weld
metal are shielded from atmospheric contamination.
It is intended that this Chapter shall apply to the single run or heavy run welding process
and that welded boiler drums manufactured by that process shall divergence is necessary
solely, because of special requirements essential for the most efficient utilization of that
process. Thus all regulations governing quality of material construction, workmanship
and testing (both non-destructive and otherwise) are applicable.
When welded drums ordered to this chapter are made by the single run or heavy run
process it will be understood that regulations 233 and 248 do not apply in their entirety.
229. 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 over and
arranged, so that the 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

63
 systematic supervision of the welding work, and the welding operators are to be
subjected by the works official 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 an efficient testing laboratory which should
include apparatus suitable for carrying out tensile, bend and impact tests, micro
examination of specimens and X-ray examination of the actual joints in pressure
vessels. The works should also be equipped with a suitable heat treating furnace
having satisfactory means for temperature control, but as an alternative arrangement
may be made whereby the drums can be heat treated elsewhere.
230. Constructional details and preparation for welding- The manufacturer shall supply the
Inspecting Authority with a fully dimensioned sectional drawing in full detail the
construction of the drum(s) for approval before putting the work in hand.
A full sized dimensioned sketch of the weld grooves for the longitudinal and
circumferential seams shall be shown on the drawing.
Full sized dimensioned sketches shall also be shown of the details of the joints for stand
pipes, branch pipes and seatings and the position of these joints relative to the
longitudinal and circumferential seams and other openings shall be indicated.
231. Preparation of plates- The edges of all plates shall be prepared and surfaced by
machining or chipping.
Before welding is commenced the grooves shall be thoroughly cleaned of rust, oil or other
foreign matter.
Before welding of the joint is commenced (apart from tack welding), the surfaces of the
plates at the longitudinal and circumferential seams shall at no part be out of alignment
with one another 1 more than 10 percent of the plat thickness but in no case exceeding 1|8
in. for longitudinal joints or 3|16 in. for circumferential joints.
232. Cylindrical shells of drums- Each drum shell plate shall be of cylindrical form to the
extreme edges of the plate. The bending shall be done entirely by machine and local
heating or hammering is prohibited. Where the plates are bent to a diameter less than 40
times the plate thickness they shall be efficiently heat treated after bending to relieve
internal stresses unless during the last stage of bending they have been uniformly heated
throughout.
233. Method of making welded joints- The seams shall be welded from both sides of the
plate. Before the second side of the plate is welded the metal at the bottom of the first side
shall be removed by grinding, chipping or machining.
Additional runs of metal shall be deposited at both surfaces of the welded seams so that
the weld metal at the level of the surfaces of the plate is refined as far as possible. The
surfaces of the welds shall there after be machined or ground so as to provide smooth
contours and to be flush with the respective surfaces of the plate. There shall be no
undercutting at the junctions.
The positions of the welds shall be marked permanently to facilitate their location.
Not less than two runs of metal shall be deposited at each weld affixing stand pipes
branch pipes and seatings.
Each run of weld metal shall be thoroughly cleaned and freed from slag before the next
run is deposited.
234. Type of welded joints- The longitudinal and circumferential seams shall be made with
butt joints of the single or double U or Vee type.

64
235. Number of joints- Where having regard to the approved design the dimension are such
that the shell cannot be made from a single plate, it shall be made with the minimum
number of joints and the longitudinal seams in successive rings shall not fall in line.
236. Position of tube holes- Tube holes shall not be located in a welded joint. The distance
between the edge of a hole and the edge of a longitudinal or circumferential seam shall be
not less than 1 in. where the plate has a thickness less than 1 in. In plates 1-in. to 2-in.
thickness the minimum distance shall be not less than the thickness of the plate. For plates
of thickness greater than 2 in. the minimum distance shall be 2-in.
Note- The edge of the weld shall be considered as the edge of the weld groove as
machined in the plate prior to welding.
237. Circularity of drums- The difference between the internal diameters of the drum
measured at any cross section and the nominal internal diameter of the drum should not
exceed 1 percent of the latter.
Any departure of profile measured on the outside of the drum with a gauge of the
designed form of the exterior of the drum and of length equal to a quarter of the internal
diameter shall not exceed the percentages given in table below:
Percentage of nominal
Nominal internal diameter of drum
internal diameter
Inches
Up to and including 36... ... ... ... ... ... ... ... ... . 0.375
Over 36 up to and including 45 .. .. .. .. .. ... ... ... . 0.35
Over 45 ... ... .. ... ... ... ... ... ... ... ... ... . ..... ... 0.3
Flats at the welded seams shall not be permitted and any local departure from circularity
shall be gradual.
238. Mechanical test and test plates for fusion welded seams-
(a) Fusion welded joints shall comply with the mechanical tests herein specified.
Not less than one set off test plates shall be provided in represent the welding of each
longitudinal seam.
The test plates may be attached at each end of the longitudinal seam or the set may
be located at one end only.
(b) Where the drum shell is formed in two more courses, the staggered longitudinal
seam shall be regarded as a continuous longitudinal seam, provided the welding be
effected in one reasonably continuous operation and by the same operator or
operators.
(c) Where there are circumferential seams only or where the method of welding the
circumferential seams differs from that employed for the longitudinal seams the
method of providing the test plates shall be decided by the Inspecting Authority.
(d) The test plates shall be of a size sufficient for the preparation of the test pieces
specified in Regulation 239 (a) and for any repeat test pieces that may be required.
The material for each set of test plates shall be out from the respective plate or plates
forming the appropriate seam and before being cut shall be stamped by the
Inspecting Officer.
(e) When the analysis of the plates is approved by the Inspecting Authority and is
considered sufficiently similar, the test plates may be cut from one drum shell plates
only.

65
 (f) In the case of insufficient material being available on the shell plate to permit the
cutting of test pieces, these shall be acceptable if they are made from another plate
provided it is made from the same cast.
(g) The weld groove in the test plates shall be similar to that adopted for the
corresponding edges of the longitudinal seam and the respective fusion faces shall be
in continuous alignment. The test plates shall be reinforced or supported during
welding in order to prevent undue warping.
The weld metal in the test plates and the seam shall be of the same grade of electrode
and shall be deposited continuously at the same operation.
(h) The weld in any test plate shall not be repaired unless agreed by the Inspecting
Authority and the repairs shall be done in such a manner as will ensure that the
repaired seam in the test plate is still representative of the material in the main seam.
(i) Where it is desired to straighten test plates which have warped during welding they
may be straightened at a temperature below the temperature of heat treatment of the
drum to which they belong. Straightening shall take place before final heat treatment.
(j) For heat treatment see Regulation 248.
(k) If any defects in the weld metal of a test plate are revealed by radio graphical
examination the position of these shall be clearly marked on the plate and test pieces
shall be selected from such parts of the test plates as may be decided by the
Inspecting Authority.
239. Selection of Test Pieces-
(a) From the test plate or plates on each longitudinal seam test pieces shall be selected
for the following tests the specimens being cut out as shown in Figs. 8 and 9 and
stamped by the Inspecting Officer for identification:
(i) One tensile test specimen for the welded joint.
(ii) One all –weld metal tensile test specimen.
(iii) Two bend test specimens.
(iv) Two Izod impact test specimens.
(v) One specimen for micro and macro examination.
The remainder of each set of test plates shall be retained for any re-tests required.
Any specimen for re-test shall be cut from the same set of test plates as the original
specimen.
(b) Surfaces of tensile bend and Izod impact corresponding with the outside or inside
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 a exceed 1|32 in.

66
 Fig. 8 Details of test plates.
1. Tensile test for joint.
2. Tensile test for all-weld metal.
3. Bend tests, outer and inner surfaces of plate (at weld)
4. (a) Izod impact test, outer surface of plate.
(b) Izod impact test, inner surface of plate.
5. Micro and macro specimen.

Fig. 9 Details of test plates.

1. Tensile test for joint.
2. Tensile test for all-weld metal.
3. Bend tests, outer and inner surfaces of plate (at weld)
4. (a) Izod impact test, outer surface of plate.

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 (b) Izod impact test, inner surface of plate.
5. Micro and macro specimen.
240. Tensile Test Pieces-
(a) Welded joint- The dimensions of the specimen shall be in accordance with the
sketch in Fig. 10. Specimen 1 and the specimen shall be cut transversely to the
welded seam. When the capacity of the available testing machine does not allow the
full specimen to be tested, two narrower tensile specimens shall be substituted. These
specimens shall be the full thickness of the plate at the welded joint and their breadth
shall be as great as the testing machine will reasonably allow provided the effective
cross sectional area of the test piece is not less than 1½ sq. in. (see Fig. 10.
Specimen1a)
(b) All weld metal- The dimension of the specimen shall be in accordance with the
sketch in Fig. 11, Specimen 2. The specimen shall consist entirely of deposited metal
and shall be cut longitudinally from the seam.

Specimen 1 : Tensile test for joint

Specimen 1a : Tensile test for joints (Thick plates)

68
 Fig. 10.
Fig. 10 Tensile Test Pieces.
T= Thickness of plate.
b = Breadth of test piece.
Specimen 1. Not less than T and in no case less than 1½ sq. in.
Specimen 1a. T × b not less than 1½ sq. in.
W = Width of weld groove.
P = Parallel length, minimum = 3 × W.
r = Radius at shoulder, minimum = ½ in.

Specimen 2.
Fig. 11. Tensile test pieces: all-weld metal

Diameter D Cross-sectional Gauge length G Parallel length P Radius at shoulder

area A minimum R minimum
in. sq. in. in. in. in.
0.798 0.500 0 2.82 3.18 0.70
0.564 0.200 0 2.00 2.25 0.50
0.505 .20 1.79 2.01 0.45
0.479 0.18 1.70 1.91 0.42
0.452 0.16 1.60 1.80 1.40
0.437 1 1.55 1.74 0.39
0.424 0.1 1 2 1.50 1.69 0.37
0.399 0.1 5 0 1.41 1.58 0.35
0.357 0.100 0 1.26 1.42 0.31

241. Tensile tests-

(a) Welded joint- The ultimate tensile stress shall be not less than the lower limit
specified for the plate (see table under Reg. 215).

69
 (b) All weld metal the ultimate tensile stress shall be not less than the lower limit
specified for the plate (See table under Reg. 215).
The elongation shall be not less than 20 percent 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 percent.

242. Bend Test pieces-

(a) Two bend test specimens shall be made. The specimens shall be rectangular in
section and shall be cut transversely from the weld so as to have a width equal to
one-and-a-half times the thickness of the specimens. The corners of the specimens
shall be rounded to a radius not exceeding 10 percent or the thickness of the
specimen.
(b) Where plate thickness do not exceed 1, ¼ in. the thickness of the specimen shall be
equal to the full thickness of the test plate. Where the plate thickness exceeds 1, ¼-
in. the specimen shall in all cases have a thickness of at least 1, ¼ in. The specimen
to be tested with the outer surface of the weld in tension shall be prepared by
cutting to waste the metal local to the inner surface of the weld so that the desired
specimen thickness is obtained (see Fig. 12, Specimen A). The specimen to be
tested with the inner surface in tension shall be prepared by cutting to waste the
metal local to the outer surface of the weld so that the desired specimen thickness is
obtained (see Fig. 12, specimen B). Where the thickness of the plate permits, both
specimens may be cut from the same piece of plate, the specimen being located in
the plate one above the other (see Fig. 12, Specimen C).

70
243. Bend Tests- One specimen shall be tested with the surface corresponding to the outer
surface of the drum in tension and the other with the surface corresponding with the inner
surface of the drum in tension. The specimens are to be mounted on supports the faces of
which are apart by a distance not more than 5.2 times the thickness of the specimen and
shall be pushed through the supports by a former having a diameter equal to three times
the thickness of the specimen.
On completion of the test no crack or defect on the outer surface of the specimen shall be
greater than 1|16 in. measured across the specimen or 1|8 in. measured along the length of
the specimen. Premature failures at the corners of the specimen shall not be considered
cause for rejection.
244. Izod Impact Test- The dimensions of the two specimens shall be in accordance with Fig.
13, Specimens 4a and 4b.
One specimen shall have the notch cut at the middle of the outer surface of the weld and
other at the middle of the inner surface of the weld.
The test shall show a minimum Izod impact test value of 30 ft. lb.

71
245. Additional tests before rejection-
(a) Should any of the test specimens taken in accordance with Reg. 238 to 244 fail to
meet the specified requirements one re-test shall be allowed for each specimen
that fails, provided the following minimum figures have been obtained:
(i) Reduction in area 30 percent.
(ii) Any other test except the bend and impact tests 90 percent of the specified
requirements.
(b) If a cold bend specimen should fail to meet the specified requirements, two re-
tests shall be taken from the same test late and these shall comply with the
requirements of Regulations 242 and 243.
(c) If an Izod impact test fails to meet the specified requirements two re-tests shall be
taken from the test plate, one each side of the original specimen and separated
from it by not more than 5 mm. Both re-tests shall show a minimum Izod impact
test value of 30 ft. lb.
(d) If it be found there is insufficient metal to permit the preparation of specimens for
re-test from the remainder of the test plate from which the original specimen was
taken, the specimen for re-test may be cut from the test plate relating to the
opposite end of the same longitudinal seam.
246. Non destructive Tests-
(a) Micro and macro examination- A specimen the full thickness of the plate and not
less than half-an-inch wide may be taken from each set of test plates by the
Inspecting Authority for the purpose of micro and macro examination.
(b) Radio graphical Examination- Every portion of the longitudinal and
circumferential welded joints of the drum shall be subjected to radio graphical
examination.
The method employed in obtaining the radiographs shall be such as to show clearly
defects having a magnitude equal to 2 percent of the thickness of the welded joint.
To determine whether this result is being obtained an indicator of approved form
which includes a portion equivalent to not more than 2 percent 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
correlated to the particular part of the joint represented.

72
 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 Regulation 247 and be
radiographed again.

Repairs to Welded Seams after Radiographical Examination.

247. (a) General- Any repair to a weld carried out by the manufacturer shall first be
agreed to by the Inspecting Authority.
Where defects occur in distributed positions in a seam, repairs to the extent of 15
percent of the total length of the seam shall be permitted to replace the defective
welding.
Where the defects are located in a single continuous length, the permissible extent of
repair shall be decided by the Inspecting Authority.
(b) Longitudinal Seams- Where the weld metal in any way fails to comply with the
requirements specified the whole of the weld metal may be removed and the seam
re-welded provided that-
(i) The original test plates are similarly treated, or
(ii) New test plates of the same thickness as the joint and of similar quality of
material are attached to the end of the seam and re-welded with it.
In either case the plates shall be tested in accordance with regulations 238 to 246
and the requirements for heat treatment shall be in accordance with regulation 248.
(c) Circumferential Seams- With regard to the extent of permissible repair and when
agreed by the Inspecting Authority a circumferential seam shall be treated in the
same manner as a longitudinal seam. The Inspecting Authority shall be entitled to
call for representative tests for a re-welded circumferential seam.
(d) Removal of Defects- Defects shall be cut out by chipping or machining only and not
by burning out the defective part.
(e) Examination before Re-welding- Where a defective part has been cut out, the
Inspecting Authority shall be entitled to make an examination before re-welding.
(f) Process Used for Repair- Only metallic are welding shall be used for repairs.
(g) Radiographical Examination after Repairs- All repaired areas shall be subjected
to radiographical examination.
(h) Specimen representing repairs- The inspecting authority shall be entitled to call
for specimens representing any welded repair, for the purpose of examination and
test.
(i) Diagram of welded repairs- On completion of all welded repairs the manufacturers
shall if requested supply for record purposes a detailed diagram showing the
position, length, depth and width of all such repairs.

Heat Treatment
248. (a) After the completion of the welding of the seams and the welding on of the stand
pipes and including welding repairs but before the hydraulic test, each drum shall be
heat treated for stress relieving; during this heat treatment the official test plates shall
be lying inside the drum.

73
 (b) Where the shell is subjected to a primary stress relieving treatment identical to the
final heat treatment to be given to the drum, the test plates may be placed inside the
shell during the primary treatment and thereafter cut up and tested without waiting for
the final treatment of the drum.
(c) Where the shell is not subjected to primary stress relieving treatment or is subject to a
primary stress relieving treatment which is not identical with the final heat treatment,
the test plates may be placed inside any other drum of comparable dimensions which
is to be heat treated in accordance with this Chapter. The heat treatment is to take
place in the furnace in which the drum relating the test plates will eventually be given
its final heat treatment.
(d) Temperature charts shall be submitted to indicate that the test plates and the drums they
represent have been subjected to identical heating, soaking and cooling treatment.
(e) For this heat treatment the drum shall be placed in a furnace sufficiently large to
accommodate the whole drum. The furnace shall be slowly raised to a temperature
between 600º C. and 650º C. and the drum shall remain until it has uniformly reached
this temperature. Such temperature shall be sustained for 75 to 90 minutes for 1 inch
thickness of metal. The drum may be allowed to cool in the furnace but if with drawn
shall be screened from draughts whilst cooling.
(f) Alternative procedure for the heat treatment of the drum may be submitted to the
Inspecting Authority for approval.
(g) In special cases it may be permissible to heat treat the test plates separately from the
drum provided the inspecting authority is satisfied with the means adopted to ensure
that the following factors will be the same for the drum as for the test plates.
Rate of heating.
Maximum temperature.
Time held at maximum temperature.
Conditions of cooling.
Hydraulic and Hammer Tests
249. Each drum on completion of all welding and after heat treatment shall be subjected to a
hydraulic test pressure of one-and-a-half times the boiler drum maximum permissible
working pressure and while the pressure is applied the welds shall be given a thorough
hammer test throughout their length, care being taken to avoid damage to the surface of
the plates.
After this the pressure shell be raised to twice boiler drum maximum permissible working
pressure and be maintained for a length of time sufficient to enable an inspection to be
made of all seams and connections, but for not less than half-an-hour.

INSPECTION AND TESTING

250. Inspecting and testing of boilers during construction- The Inspection Authority shall
have access to works of the manufacturer at all reasonable times and shall inspect the
manufacturer of the boiler at the following stages and may reject any part that does not
comply with the requirements of these Regulation. In case of any doubt the Inspecting
Authority may examine at any stage other than the stages stipulated below. The

74
manufacturer shall give at least 4 days notice to the Inspecting Authority/Inspecting
Officer before reaching each stage. Before undertaking any of the stage inspections the
Inspecting Authority/Inspecting Officer shall satisfy himself that the testing
equipment/instrument has properly calibrated.
I. At the steel works : When the fillets, plates, angles, bar, skelps or any other parts to be
used in the construction of the boiler are ready for examination and marking off of the
mechanical test specimen and before they are cut from the parent plate or plates, and
when test specimen have been machined and are ready for testing. For imported materials.
Regulation 4 will be applicable.
II. At The pipe/tube maker’s and fabricator’s works :
(a) When the billets or skelps are ready for identification.
(b) When the pipes/tubes are ready for examination and selection of mechanical test
pieces;
(c) When the test specimens are ready for testing;
(d) When the pipes/tubes are ready for hydraulic test. For parts manufactured from
tubes/pipes at Fabricator’s works either by manipulation or fabrication as may be
required by the Inspecting Authority and in all cases of fabrication by welding after
the weld preparation has been made, the components have been assembled and tack
welded in position for final welding, and hydraulic test after completion of
fabrication. For imported materials, Regulation 4 will be applicable.
III. At the boiler manufacturer’s works:
1. Water tubes Boilers :
(a) Fusion welded Drums and Headers.
(b) Seamless Drums And Headers.
(c) Riveted Drums.
(d) Headers for Water Tube Boilers of Riveted Construction.
(e) Tubes and Integral Piping.
A. Fusion welded drums and headers :
(i) When plates have been received at the boiler makers works to compare
identification markings with those recorded on the steel makers certificates of
manufacture and tests and to check the test results furnished by the steel makers
in respect of mechanical and chemical properties, and when the test plates are
ready for marking for identification before they are cut from the parent plate or
plates.
(ii) When the cylindrical shell plates are formed to shape with the edges for welding
and set up in readiness for commencement of welding when test plates are
attached.
(iii) When the welding of main cylindrical shell is completed and the shell checked for
circularity and the radiographic or ultrasonic test records are available for
scrutiny.
(iv) When the end-plates are for identification with the mill certificates and cut for the
end-shape forming operation.

75
 (v) When the plates are formed to shape with weld edges prepared and set on the
cylindrical shell in readiness for the circumferential welding operation.
(vi) When the welding of the end-plates to the cylindrical shell is completed and the
radiographic or ultrasonic test records are available for scrutiny.
(vii) When each plain shell drums or header is prepared to receive compensation
plates and attachments and a representative number stand pipes, tube or tubes are
set up ready for welding.
(Viii) When all welding on each drum is complete, the Inspection Authority shall
check the record of heat treatment and the marking off preparation and testing of
specimens from the test plates.
(ix) At hydraulic test, followed by external and internal examination and stamping. On
thick drums of high carbon or alloy material further non-stamping. On thick
drums of high carbon or alloy material further non-destructive examination shall
be done on drums, nozzle and stub weld after stress-relief.
(x) Any drum having tube holes drilled subsequently to the hydraulic test shall be
further examined on completion of this work and prior to dispatch form the
manufacturers work.
B. Seamless Drums and Headers :
(i) When material is ready for identification with the steel makers certificate of
manufacturer and test, also when each cylinder is prepared for forming, or
welding of separate end closures and identify test plate material.
(ii) When each plain shell drum or header is prepared to receive compensation plates
and attachments and representative number of standpipes, tubes or tube stubs are
set up ready for welding.
(iii) When all welding on each drum is complete and the radiographs or ultrasonic test
records are available. The Inspection Authority shall check the record of heat
treatment and the marking off, preparation and testing of specimens form the test
plates.
(iv) At hydraulic test, followed by external and internal examination and stamping. On
thick drums of high carbon or alloy material further non destructive examination
shall be done on drum nozzle and stub welds after stress relief.
(v) Any drum having tube holes drilled subsequently to the hydraulic test shall be
further examined on completion of this work and prior to dispatch from the
manufacturer’s work.

C. Riveted Drums :
(i) When cylindrical shell plates are ready for identification with plate mill
certificate at boiler maker’s works and cut to size ready for forming to cylindrical
shape.
(ii) When the drum shell plates are bent to the circular form and drum ends are
flanged.

76
 (iii) When the drum shell and drum ends are drilled and when rivets are ready for
testing.
(iv) When the drum seams are in process of riveting.
(v) When the boiler drums are ready for hydraulic test.
D. Headers for Water Tube Boilers of Riveted Construction :
(i) When cylindrical shell plates are ready for identification with plate mill
certificates at boiler maker’s works and cut to size ready for forming to
cylindrical shape.
(ii) When the test ring is ready for stamping and marking off the test specimens for
identification and before they are cut from header.
(iii) When the test specimens are ready for testing.
(iv) When the header is ready for hydraulic test.
E. Tubes and integral piping :
(i) When the tubes are ready for identification with the tube maker’s certificate at
the boiler maker’s works and a representative number of tubes and pipes are
prepared at the ends and set up ready for welding.
(ii) When records for non destructive tests on a percentage of butt welds is made
avilable and all attachments have been welded to the tubes and piping.
2. Shell type Boilers :
(a) Welded Construction :
(i) When plates have been received at the boiler maker’s works to compare
identification markings with those recorded on the steel makers certificate of
manufacture and test and to check the test resulted furnished by the steel
maker’s in respect of mechanical and chemical propertied, and when test plate
are ready for marking for identification before they are cut from the parent plate
or plates.
(ii) When drum of shell plates and end plates have been formed with the plate edges
prepared for welding and when test plates are attached.
(iii) When the first run has been deposited along with principal seams and test plates,
when these seams have been completed on one side and prepared for welding
for welding on the other side, and on completion of welding.
(iv) When radiographic or ultrasonic test records are available for scrutiny.
(v) When weld test specimens have been prepared from the test plate previously
selected, to witness the required test.
(vi) When opening have been prepared, and when stand pipes are similar connections
have been tack welded in position and subsequently on completion.
(vii) When post weld heat treatment done.
(viii) On completion of manufacture during hydraulic testing and again after testing
to inspect internally and externally.

77
(b) Riveted Construction :
(1) Lancashire Cornish and Multitubular horizontal boilers
(i) When cylindrical shell plates are ready for identification with plate mill
certificates at boiler maker’s works and cut to size ready for forming to
certificates at boiler makers works and cut to size ready for forming to
cylindrical shape, the Inspecting Authority shall also identify weld test plate
material.
(ii) When the shell and flue plates are bent to the circular form and before the later
are welded and flanged.
(iii) When the weld grooves are machined and flue sections are being welded.
(iv) When the end plates have been dished and flanging operation completed.
(v) When the shell and end plates are being drilled and the flue sections have been
welded, flanged and drilled and when the rivets are ready for testing.
(vi) When the shell and flue seams are in process of riveting and the tubes holes are
ready for reception of tubes.
(vii) When the boiler has been prepared for a final internal and external examination.
2. Vertical Cross tube and multitubular boilers
(i) When cylindrical shell plates are ready for identification with plate mill
certificates at boiler maker’s works and cut to size ready for forming to
cylindrical shape. The Inspecting Authority shall also identify weld test plate
material.
(ii) When the shell and flue plates are bent to the circular form and before the later
are welded and flanged.
(iii) When the weld grooves are machined and flue sections are being welded.
(iv) When the end plates have been dished and flanging operations completed.
(v) When shell and end plates are being drilled and the flue section have been
welded, flanged and drilled and when the rivets are ready for testing.
(vi) When the shell and flue seams are in process of riveting and the tube holes are
ready for the reception of tubes.
(vii) When the boiler is completed and filled with water in readiness for the
hydraulic test.
(viii)When the boiler is prepared for a final internal and external examination.

(c) Headers for boilers of riveted construction :

(i) When cylindrical shall plates are ready for identification with plates mill
certificates at boiler maker’s works and cut to size ready for forming to
cylindrical shape.
(ii) When the testing ring is ready of stamping and the marking off of the test
specimens for identification and before they are out from the header.

78
 (iii) When the test specimens are ready for testing.
(iv) When the header is ready for hydraulic test.

IV. Valves and mountings :

(i) When the Steel casting Steel forging iron casting bronze casting etc. are ready
for examination and selection of test specimens.
(ii) When the test specimens are ready for test.
(iii) When the parts are machined and ready for dimensional check in accordance
with drawing approved by the Inspection Authorities.
(iv) When the fittings are ready for hydraulic test.
V. Identification marks :
Each boiler shall be permanently and clearly marked on the front end plate with-
(a) Manufactures identification Mark.
(b) Inspection Authority’s stamps.
(c) Date of hydraulic test and the year of manufacture.
(d) Hydraulic test pressure.
(e) Permissible Working Pressure.

Relations for determining the working pressure of water tube boilers with fusion
welded and seamless forged drums

SHELLS
251. Shells of steam and water drums- The working pressure of drum shells (i.e. wrapper and
tube plates) shall be determined by the following formula:
2
fE ( D1 ]D 2 )
W.P. ] 2
... ... ... ... ... ... ... ... ... ... ... .... ... ... ... Eqn.(77)
( D1 ] D 2 )

In the above formula:

79
 D1 = Maximum external diameter of drum in inches.
D = Maximum internal diameter of drum in inches.
W.P = Boiler working pressure in lbs. per sq. in.
f = Permissible working stress in lbs. per sq. in. at working metal temperature in the table
in Reg.252.
E = Efficiency of ligaments between tube holes or other openings in shell.
In the particular case of an unpierced wrapper plate of a fusion welded drum E = 1 and f =
permissible stress on butt weld from the table in Reg. 252 column B.
252. The maximum permissible stresses for drum shell shall be as given in the table below:
Permissible stress for steel having an ultimate tensile stress in tons per square
inch of:
Working
metal
temperature
28-32 32-36 34-38
Wrapper Wrapper Tube plates of Seamless Seamless
plates of plates of fusion welded forged drums forged drums
seamless fusion welded and seamless lb./sq. inch lb./sq. in.
forged drums drums (stress forged drums
lb./sq. in. on butt welds) lb./sq. in.
lb./sq. inch
Up to A B C D E
470ºF. 15 300 12 000 14 000 16 000 17 000
480ºF. 15 300 12 000 14 000 16 600 16 000
490ºF. 15 300 12 000 14 000 15 600 16 200
500ºF. 14 800 11 700 14 000 15 400 15 900
550ºF. 13 200 10 300 12 500 13 700 14 200
600ºF. 11 600 9 200 11 100 12 200 12 600
650ºF. 10 300 8 200 9 800 10 800 11 300
700ºF. 9 200 7 300 8 800 9 700 10 100
750ºF. 8 300 6 600 8 000 8 700 9 100
800ºF. 7 500 6 000 7 200 7 800 8 200
850ºF. 6 950 5 400 6 600 7 100 7 400
900ºF. 4 600 3 700 4 600 4 600 4 600

Intermediate values may be inter-polated.

The working metal temperature shall be taken as:
(a) For saturated steam, water and muddrums the saturation temperature corresponding
to the pressure WP plus 50ºF.
(b) For super heater drums; the designed maximum steam temperature for that drum plus
50ºF.
Where the drums are adequately protected from the gases of combustion or swept by such
gases in the third or subsequent pass of a boiler, the working metal temperature shall be
taken as the saturation or designed maximum steam temperature as defined above,
whichever applies. A covering of refractory or insulating material which may be liable to
become dislodged shall not be deemed adequate protection.

80
253. The ligament efficiency of drum shells shall comply with Reg.196.
254. Longitudinal Stress- The maker of the boiler and the Inspecting authority concerned
shall be responsible for ascertaining that the longitudinal stress, resulting from the
combination of stresses arising from internal steam pressure, the self weight of the drum
and its contents, and all externally applied loads shall not exceed the permissible working
stress corresponding to the working metal temperatures included in Regulation 252.
255. Intermediate Boiler Drum Supports- Where a boiler drum is supported at intermediate
points in its length at a distance greater than one internal diameter from the end of the
parallel portion of the drum shell, the shell shall be thickened locally to the supports or so
designed that when the local stresses set up by the supports in the drum shell are added
algebraically to those caused by the internal steam pressure and supported loads, the
maximum resultant stress does not exceed the permissible working stress at the working
metal temperature.
END PLATES
256. Dished Drum Ends- the working pressure of unstayed drum ends dished to partial
spherical form and subject to pressure on the concave side, shall be determined by the
following formula:
(a) Drum ends having no unreinforced opening with a greater dimension than four
times the plate thickness:
37  S  (t ] 3)f
W.P. ] ... ... ... ... ... ... ... ... ... ... ... Eqn. (78)
D K  F
(b) Drum ends having a central manhole opening:
37  S  (t ] 4)f
W.P. ] ... ... ... ... ... ... ... ... ... ... ... Eqn. (79)
D K  F
Where t = Thickness of drum end in 1|32 in (see Reg. 259).
W.P = Boiler working pressure in lbs. per sq. in.
D = Outside diameter of drum end in inches.
h = External height of dishing in inches.
h
K = A factor dependent upon the ratio and obtained from the curve shown in
D
Fig. 14.
S = Minimum ultimate tensile stress of plate in tons per sq. in.
F = The permissible stress in lbs. per sq. in. for the plate material for working
metal temperatures up to 50ºF (see Table below).
f = the permissible stress in lbs. per sq. in. at the working metal temperature of the
drum end (see table below).
(c) The working metal temperature shall be taken as
(i) For drum ends of saturated steam, water and muddrums, the saturation
temperature corresponding to the pressure W.P.
(ii) For drum ends supper heater drums, the designed maximum steam temperature
for that drum.

working metal Permissible stress of steel having an ultimate tensile stress of:
temperature
24-28 tons 26-30 tons 28-32 tons
per sq. in. per sq. in. per sq. in.

81
 Up to lb. per sq. in. lb. per sq. in. lb. per sq. in.
500ºF. ... ... 10 900 12 500 14 000
550ºF. ... ... 9 900 11 200 12 500
600ºF. ... ... 8 900 10 000 11 100
650ºF. ... ... 8 000 8 800 9 800
700ºF. ... ... 7 300 8 000 8 800
750ºF. ... ... 6 600 7 200 8 000
800ºF. ... ... 6 000 6 500 7 200
850ºF. ... ... 5 400 6 000 6 600
900ºF. ... ... 4 600 4 600 4 600
Intermediate values may be interpolated.

257. Shape of drum- The shape of drum end shall conform to the following:
(a) The inside radius of dishing R. shall be not greater than the outside diameter D.
(b) The inside corner radius r shall be not less than D|8 or five times the plate thickness
whichever is the greater.
(c) The external height of dishing h may be determined as follows:
D D
h = R2 ] ( R2 ] )  ( R2 ] ] 2r2 ) ... ... ... ... ... ... ... ... Eqn. (80)
2 2
Where R2 = Outside radius of dishing in inches (see Fig. 15)
r2 = Outside corner radius i.e, the heel radius in inches (see Fig. 15)

82
258. Where, owing to other governing features in the design of the boiler, it is not practicable
to conform to the foregoing requirements as in the case of small drums in which a
manhole may be formed in one or each end, the following formula should be applied:
(a) The working pressure of drum ends dished to partial spherical form and subject to
pressure on the concave side shall be determined of the following formula:
(i) Drum ends having no unreinforced opening with a greater dimension than four
times the plate thickness.
15  S (t ] 1)f
W.P. ] ... ... ... ... ... ... ... ... .... ... ... Eqn. (81)
RF
(ii) Drum ends having a central manhole opening:
15  S (t ] 5)f
W.P. ] ... ... ... ... ... ... ... ... .... ... ... Eqn. (82)
RF
Where t, F, f, P and S are as defined in Reg. 256 and R = the inside radius of
dishing in inches.
(b) The shape of drum ends shall conform to the following:
(i) The inside radius of dishing R shall not be greater than the outside diameter D.
(ii) The inside corner radius r shall not be less than 2.5 in. or four times the plate
thickness, whichever is the greater.
259. General
(a) The thickness ‘t’ is the thickness of the plate after pressing and is applicable over
the whole area of the drum end plate up to the point where the dishing radius joins
the corner radius From this point a gradual thinning is permissible up to a maximum
of 10 percent of the thickness‘t’ at the point where the corner radius joins the
straight portion of the flanged drum end plate. This permissible reduction in
thickness applies also to the flange for the manhole opening. In no case however
shall be thickness of the edge of the flange for connection to the shell be less than
the thickness of a seamless unpierced shell of the same diameter and material.
(b) The depth of the manhole flange shall comply with Eqn. (40)

83
 Stand Pipes
260. Compensations-
(a) Except for those cases where no compensation in necessary as defined in Regulation
168 adequate compensation for the hole cut for stand pipe shall be provided.
Compensation shall be considered adequate when the equivalent cross sectional area
provided is not less than 1.25 times the cross sectional area obtained by multiplying
the diameter of the hole cut in the shell by the thickness required for an equivalent
unpierced drum shell.
(b) The equivalent cross sectional area provided shall be calculated as follows:
(1) The cross sectional area of the wall of the stand pipe up to a point 4 in. from the
outside surface of the drum shell, but proportionately reduced in the ratio of the
ultimate tensile stresses of the metals composing the stand pipe and the drum
shell.
(2) The cross sectional area of the welding fillets external to the drum shell.
(3) The area obtained by multiplying the difference between the actual drum shell
thickness and the thickness of an equivalent seamless unpierced drum shell by a
length 2(3+T). (See Fig. 17)
(c) In cases where the total compensation obtained by the sum of the areas given above
is less than the total compensation required, a compensating plate shall be fitted to
the drum shell at the stand pipe and secured by fillet welds as shown in Fig. 18.
(d) The minimum thickness of the flanges and of the body of stand pipes shall be in
accordance with the table under Reg. 137.
261. Attachment of stand Blocks-
(a) The method of attachment shall be in accordance with that shown in figs. 16, 17, 18
or 19 and after the welding the parts shall be heat treated. The hole drilled in the
shell plate for the reception of the stand pipe shall be 1|8 in. greater in diameter than
the outside diameter of the stand pipe where this is secured by filled welds only as
in Fig.16 and 17.
(b) Electrodes shall comply with the requirements of Regs. 75 to 79 (covered
Electrodes for Metal Are welding).
(c) Where one side of a double Vee weld has been completed, the under surface of the
original first run of metal shall be chipped out before welding on the other side is
commenced.
(d) The final finish of the weld shall be such that change of section from shell to nozzle
is gradual and free from sharp notches.

84
Fig. 16 Minimum weld attachment for stand pipes 2 in. bore and under.

85
Fig.18- Minimum weld attachment for standpipe over 4 in. bore where compensating ring is required
and for attachment of flange to stand pipes 6 in. bore and over (alternative to flange attachment
shown in Fig.19)

Fig.19. Minimum weld attachments for stand pipes over 4 in. bore where a compensating ring is not
required and minimum weld attachment of flange to stand pipes over 4 in. bore.

86
 Chapter VI
Valves, Gauges and Similar Fittings
262. Requisite Mountings and Fittings- Every boiler shall be fitted with the following:
Two safety valves (minimum diameter 3|4˝)
Two independent means of indicating the water level;
A steam pressure gauge;
A steam stop valve;
A feed check valve;
Two means of feeding the boiler when the heating surface exceeds. 150 sq. feet;
A blow down cock or valve;
A fusible plug when boiler have internal furnace;
An attachment for inspector’s test gauge;
A manhole where the size and construction permit and such mud holes or sight-holes as
are necessary for effectively cleaning the boiler.
262A. Additional Requirement for Automatic Boiler-
(1) General In addition to the requirements mentioned in Regulation 262. every automatic
boiler shall comply with the following requirements, namely-
(a) In the event of failure of automatic control devices, the boiler shall be capable of being
brought under immediate manual control.
(b) When the control alarm and tripping devices are housed in chambers External to the
boiler there shall be isolating valves for isolating the steam and water connections of
the chambers from the boilers which shall be-
(i) Capable of being locked in open position.
(ii) Mounted with the spindle horizontal to avoid the possibility of air lock if screw
down stop valves are fitted on the water connection.
Provided that where sequential control water valves are fitted the steam isolating
valve may be omitted.
(c) Where the control alarm and tripping devices are housed in chambers external to the
boiler the steam and water connection of the chambers shall be not less than 25 mm
bore.
(d) The boiler shall have a provision-
(i) to test the operation of the control or alarm devices of the chamber;
(ii) to blow separately through the water connection and the chambers to prevent the
accumulation of deposits.
The means provided for flowing through shall be of sequential vales or
equivalent devices so arranged that the water connection to the boiler can not be
shut off unless the drain connection to the chambers are open.
(e) The boiler shall have a drain system with a visual indication of flow. Tundishes of
adequate size, placed in a prominent position shall be used wherever practicable.

87
 (f) Where the boiler is provided with electrical equipment for water level and firing
control. It shall have this equipment’s so designed that for any deviation from design
set point or for any malfunction or any fault in the circuit caused both in the fuel and
air supply the boiler to be automatically shut off. The positive means requiring manual
resetting shall be provided to cut off the fuel and air supplies to the boiler if there be a
failure of electricity supply to water level and /or firing control equipment. All
electrical conductors, equipment and electronic devices in connection with water level
and firing controls shall be properly isolated and protected against danger including
adequate protection against the ingress of moisture and the effects of high temperature.
(g) All automatic boilers shall have automatic water level alarm and firing controls which
can be tested regularly without altering the level of water in the boiler and may be
incorporated in the automatic control system.
(h) A perceptible water level which are arranged for automatic working and not intended
for continuous supervising shall be provided with an entirely independent and
separately operated overriding control in addition to the water level and firing control
specified in sub-Regulation 2 and 3.
(i) The overriding control mentioned in clause (h) shall-
(i) be cut off fuel supply to the burners or the fuel and air supply to solid fuel stoker
and operate an audible alarm with flickering signal when the water level in this
boiler falls to a predetermined low water level.
(ii) be of the lock-out type and so that control of 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/electronic control circuit.

(j) Where the overriding control mounted externally to the boiler it shall-
(i) be provided with its own chamber;
(ii) comply with the requirements of clause (e).(f).(g) and (h).
(2) Automatic water level control- Automatic water level controls which shall regulate the
feed water supply to the boiler in order to maintain effectively the level of water in the
boiler between predetermined limits may be-
(a) float or displace operated; or
(b) operated by electrical probe; or
(c) operated by other approved principle subject to satisfaction of the Inspecting
Authority.

(3) Automatic firing control- Automatic firing control shall comply with the following
requirement, namely-
(a) At all times they shall control effectively the supply of fuel and air to the adequate
requirement.
(b) It shall shut off the fuel supply to the burners or the fuel and air supply to the stocker
under the following namely-
(i) Flame failure or pilot flame failure in the case of gas oil or pulverized fuel fired
boilers. This control shall be of the lockout type required to be manually reset.
(ii) Failure to ignite the fuel at the within a predetermined time. The control shall be of
the lock out type required to be manually reset.

88
 (iii) When the water level in 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 boiler pressure to predermined value.
(vi) When the outlet steam temperature in a forced flow once through boiler increase to a
predetermined value.
(4) Nothing of sub-regulations (1), (2), and (3) shall not apply to once-through forced
circulation boiler.

2. General Requirements
Materials, Temperature and Pressure Limits
263. (a) Materials- The materials used in the manufacture of the bodies of the fittings shall
comply with the following requirements:
(i) Steel castings shall comply with 28 tons grade II. See Regns. 55 to 65.
(ii) Temperatures above 400ºF.
(iii) Steam pressures exceeding 160 lbs. per sq. in. (gauge).
(iv) Feed valves and scum valves directly attached to boilers for less than 16 tons
per sq. in. with an elongation of not less than 8.0 percent measured on
standard test piece C.
(v) The seats and dishes of valves shall be made of non-corrodible metal.

(b) Limits of Cast Iron- Cast iron shall not be used for:
(i) Temperatures above 400ºF.
(ii) Steam pressures exceeding 160 lbs. per sq. in. (gauge)
(iii) Feed valves and scum valves directly attached to boilers for pressures above
160 lbs. per sq. in. (gauge).
(iv) Blow-down fittings.
(C) Limits of Bronze Fittings- Bronze shall not be used for steam temperature above
425ºF.

Method of Construction
264. Castings-
(a) All castings shall be smooth, sound and free from flaws cracks or other injurious
defects. Variation in thickness at any part shall be gradual, and substantial fillets
shall be provided.
(b) The body of a boiler mounting shall be connected to the boiler flange by a strong
and stiff neck. In no case shall the thickness of the neck of bronze mountings be
less than 3|16 inch for sizes up to and including 3|4 inch bore or 1|4 inch for sizes
over 3|4 inch bore.

89
265. Packing of Cocks- The bodies of all cocks shall be asbestos packed and of substantial
design and those over one inch bore shall have special provision, other than the gland for
securing the plug.
266. Covers and Spindles-
(a) Valves of 1½ inch bore and over directly connected to boilers and other valves of
2½ inch bore and over where fitted with a cover shall have such cover secured by
bolts or studs and the screwed portion of the spindle shall be outside the stuffing
box. All valves for super heated steam shall be fitted with an external screwed
spindle.
(b) Where the covers of valves are secured by studs, the studs shall be screwed into the
body with a full thread for a length of at least one diameter. The stud holes shall
not penetrate into the pressure space of any casting.
(c) Valves with screwed cover shall be fitted with a suitable locking device to prevent
rotation of the cover.
267. Direction of operation- Valves shall be clearly marked to indicate the direction of flow.
Valves directly connected to boilers shall be fitted with indicators to show clearly whether
the valve is closed or open and all valves shall open by anti-clockwise rotation.
268. Moving Parts- The valves and spindles shall be efficiently guided and means shall be
provided in every case to prevent them leaving their guides. The working parts shall have
sufficient clearance to ensure freedom of movement under all conditions of service.
269. Flanges-
(a) Flanges shall be in accordance with B.S.S No. 10, part 2, 3, 4 or 5.
(b) In the case of safety valves the drilling, thickness and bolting of inlet flanges shall
be in accordance with B.S.S. No 10 for the appropriate pressure and material and
for the diameter of flange adopted. In the case of outlet flanges the pressure taken
shall be the pressure on the outlet side of the valve.
(c) For the purpose of determining particulars of flanges for blow down and scum pipe
fittings, the design pressure of the fittings shall be assumed to be the working
pressure of the boiler.
(d) All flange shall be machined on the face, spot faced or machined at the back, and
the bolt holes shall be drilled.
270. Valve Seatings- Where separate seats are fitted they shall be efficiency secured. Means
shall be provided in every case to prevent the valves leaving their guides.
271. Chests, etc, in General-
(a) All chests and fittings shall be smooth, sound and free from flaws, cracks or other
injurious defects. After completion they shall withstand satisfactorily a hydraulic test
to at least twice the working pressure of the boiler for which they are intended.
(b) The working pressure and thickness of the chest shall be determined by the
following formula:
C (t ] X )
W.P. ] ... ... ... ... ... ... ... ... .... ... ... Eqn. (83)
D

90
 W .P.  D
t]  X ... ... ... ... ... ... ... ... .... ... ... Eqn. (84)
C
D is the internal diameter of the chest in inches,
t is the thickness of the chest in 32nds of an inch,
C is a co-efficient from the following table,
X is a provision for tolerance etc., from the following table:
Table of Values of C. & X.
Material of Casting C X
Cast iron at least 9 tons tensile strength ... ... ... ... 160 6
Bronze at least 14 tons tensile strength ... ... ... ... 175 4
Cast steel 28/35 tons tensile strength
For temperature up to 550ºF ... ... ... ... 350 8
For temperature up to 600ºF ... ... ... ... 315 8
For temperature up to 650ºF ... ... ... ... 280 8
For temperature up to 700ºF ... ... ... ... 265 8
For temperature up to 750ºF ... ... ... ... 252 8
For temperature up to 800ºF ... ... ... ... 236 8
For temperature up to 850ºF ... ... ... ... 220 8
For temperature up to 900ºF ... ... ... ... 154 8
Intermediate values may be interpolated.

SPECIAL REQUIREMENTS
Safety Valves
272. General- Safety valve ordinary high lift and full lift shall be so constructed that breakage
of any part will not obstruct the free and full discharge of steam from the boiler.
273. Definitions-
(a) An ordinary safety valve is a valve which lifts automatically at least D|24, where
D = diameter of valve seating.
(b) A high lift safety valve is a valve which lifts automatically at least D|12, where
D = diameter of valve seating.
(c) A full lift safety valve is a valve which lifts automatically distance giving a discharge
area round the edge of the valve seating equal to the area through the valve orifice,
when the valve is fully lifted, after deducting the area of guides or other obstructions.
274. Minimum Aggregate Area-
(a) Saturated Steam- The minimum aggregate area of the orifices through the seatings
of the safety valves on each boiler (including high steam and low water safety
valves) shall be found by the following formula:
E
A= ... ... ... ... ... ... ... ... ... ... ... .Eqn. (85)
CP
Where A= for ordinary and high lift safety valves the aggregate are in square inches
of the orifices through the seatings of the valves.
= for full lift safety valves the nett area in square inches through the after
deducting the area of guides or other obstructions when the valves are fully lifted.

91
 E = total peak load evaporation in lbs. per hour (including evaporation from water
walls, steaming economizer and other heating surface in direct communication with
the boiler for which the boiler is specified. In no case however shall the evaporation
as calculated for this purpose be based on less than 6 lbs. per hour per sq. ft. of
heating surface (exclusive of super heater and non-steaming economizer).
P = absolute pressure in lbs. per sq. in. to which the safety valve is set.
C = a constant as follows:
Spring loaded valves Weight loaded valves
Type of Valve
direct and Lever C direct or Lever C
Ordinary Valves ... ... ... ... 4 4.8
High lift Valves ... ... ... ... 8 9.6
Full lift Valves ... ... ... ... 16 6
*Subject to the application of Eqn. 85 the term “boiler” shall include any super
heater fitted to the boiler without an intervening stop valve.
For water tube boilers of evaporative capacity greater than 10,000 lbs. of water per
hour C. May be increased as follows:
Spring loaded valves Weight loaded valves
Type of Valve direct and Lever direct or Lever
C C
Ordinary Valves ... ... ... ... 4.8 4.8
High lift valves ... ... ... ... 9.6 9.6
Full lift valves ... ... ... ... 20 20
Where two valves are loaded by a single spring the above areas shall be increased by
50 percent.
(b) Super heated Steam- If the valves have to pass superheated steam the area shall be
determined in accordance with the following formula:
 1.5T 
As = A 1  .. ... ... ... ... ... ... ... .... ... ... Eqn. (86)
 1000 
Where As = area in sq. inch for superheated steam.
A = area in sq. inch for saturated steam.
T = degree of superheat in deg. Fahr.
275. Over pressure- The valves shall be so designed that the maximum peak load evaporation
for which the boiler is specified will be completely discharged with a rise in pressure of
not more than 10 percent of the safety valve blow-of pressure.
276. Pressure Drop- The valves shall shut down at a pressure (a) not more than 5 percent and
(b) not less than 2½ percent below the safety valve blow-off pressure. For valves less than
1¼ inch diameter the limits shall be increased to (a) 10 and (b) 5 percent respectively.
Valves for superheated steam and for water tube boilers of an evaporative greater than
10,000 lbs. of water per hour shall be exempt from the minimum requirements (b).

92
277. Attachment of Boiler-
(a) All the safety valves of a boiler may be fitted in one chest but, with the following
exception, such chest shall be separate from any other valve chest.
In the case of boilers with overhead engines where the cylinder casting is mounted
directly on the shell, the safety valves may be attached to the engine cylinder
casting, provided that the passage way to the valve complies with the above rules.
(b) The chest shall be connected to the seating by a strong and stiff neck, the passage
through which shall have a cross sectional area at least equal to the sum of the sum
of the areas of the valves.
(c) Safety valves shall be mounted so that the axis of the valve is vertical.
(d) Shut-offs or obstructions of any description shall not be placed between the boiler
and the safety valve.
278. Openings in shell- No accessories other than those integral with the Safety Valve shall
obstruct the openings in the boiler shell. Discharging steam shall have direct across to the
safety valve without following through internal pipes.
279. Discharge passage- Steam safety valves- The area of the waste steam passage both in the
E E
valve itself and in the escape pipe shall be not less than sq. in. for ordinary valves,
4P 6P
E
sq. in. for high lift valves and sq. in. for full lift valves.
9.6 P
Where E and P are as defined in Reg. 274.
280. Drainage- For each enclosed safety valve chest a means of draining shall be provided.
The drain pipe shall be laid with a continuous downwards gradient clear of the boiler to a
place where the discharge is visible and cannot do injurious to any person.
281. Moving Parts- The valves and spindles shall be efficiently guided and means shall be
provided in every case to prevent their lifting out of their guides. The working parts shall
have sufficient clearance to ensure freedom of movement under all conditions of service.
The spindle shall not be fitted with a stuffing box.
282. Bearings for Levers- The bearings of the levers of lever valves shall be so designed as to
allow of free working of the valve under all conditions of service. Where the lever is
mounted on pin bearings, the holes in the lever shall be bushed with non-corrodible metal
or the pins shall be of non-corrodible metal.
283. Attachments of weights and springs-
(a) In a lever and weight safety valve the weight shall be in one piece and attached to
the lever in such a way that the safety valve cannot be overloaded.
(b) In the case of spring loaded safety valves, washers or ferrules shall be fitted under
the adjusting screws so that the valves cannot be overloaded when under steam.
Where springs are in tension, links or other suitable stops shall be fitted to prevent
the spring being extended a greater amount than that corresponding to a valve lift
of D|4.
Where D = diameter of valve seating.

93
284. Easing Gear- Safety valves shall be so arranged that they can be eased off their seats
when under pressure and the easing lever shall positively lift the valve.
285. Lift- Safety valves shall be capable of being lifted a distance such that the area of the
discharge edge shall be not less than the minimum aggregate area, A in Reg, 274.
286. High and low water alarms shall be adjusted so that the alarm is sounded with the water
level visible in the gauges.
287. Final setting- Each safety valve shall before leaving the maker’s works be justed to blow-
off at the specified pressure.
springs
288. Material-
(a) The springs shall be manufactured from steel made by the acid or Open Hearth
process and shall show an analysis of the following composition:
Carbon : not less than 0.9 percent and not more than 1.2 Percent.
Manganese : not less than 0.45 percent and not more than 0.75 Percent.
Silicon : not more than 0.30 percent.
Sulphur : not more than 0.05 percent.
Phosphorus : not more than 0.05 percent.
The manufacturer shall supply an analysis of each cast when required to do so.
Should independent analysis be required these shall be made at the rate of one per
cast.
(b) All springs shall be formed hot and shall be hardened in oil and suitable tempered.
289. Dimensions- The compression or extension of safety valve springs required to load the
valves to the set pressure shall not be less than one quarter of the diameter of the valve,
due consideration being paid in the case of spring loaded lever safety valves to the ration
of leverage.
The portion of unloaded length to external diameter of the spring shall not exceed 4 to 1.
290. Determination of working pressure- The maximum working pressure to be allowed for
round, square and rectangular section for steel shall be determined by the following
formulae:
Round or square sections
C d3
W.P. ] ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Eqn. (87)
D A
Rectangular Sections
2 2
CB H
W.P. ] ... ... ... ... ... ... ... ... . ... ... ... ... Eqn. (88)
AD(3B1.8 H )
Where
d = Diameter of round or side of square steel,
B = Breath of wire (inches),
H = Depth of wire (inches),
W.P. = Working pressure in lbs. per sq. in.
D = Mean diameter of coil (inches),
C = constant as follows,
A = Area of the valve.

94
 When compression or extension of the spring Square round Rectangular
to give the required loading is equal to wire wire wire
C C C
¼ diameter of the valve ... ... ... ... 12 080 11 240 71 250
½ diameter of the valve ... ... ... ... 16 100 14 980 94 970
Full diameter of the valve ... ... ... ... 19 320 17 990 114 000
Note- The above constants are based on a maximum allowable safe stress on the section of springs under
compression to D/4 to be taken as 80000 lbs. per sq. in.
291. Tests- Compression springs shall not show any permanent set after being compressed coil
to coil six times in a quick acting, scrag. Extension spring shall not show a permanent set
after being tested to 25 percent in excess of the load necessary under working conditions
to lift the valve.
292. Extension Springs- Extension springs shall be made from round section wire.
293. Number of Effective Coils- the number of effective or free coils in a compression or
extension spring shall be determined from the following formula:
(i) For Round or Square Wire-
K C d4
N] ... ... ... ... ... ... .... ... ... Eqn. (89)
S  D3
(ii) For rectangular wire-
66 B 3 H 3 k
N] ... ... ... ... ... .... ... ... Eqn. (90)
( B 3 ] H 2 ) SD 3
Where N = Number of effective coils.
K = Compression of extension in inches as set pressure.
C = 22 for round 30 for square steel.
d = diameter or side of square steel in 16ths of an inch.
S = Load on spring in lbs. at blow-off pressure.
D = Mean diameter of coil in inches,
B = Breadth of wire in 16th of an inch,
H = Depth of wire in 16ths of an inch.
294. Spacing of Coils- The space between the coils when the valve is lifted one-fourth of its
diameter shall be not less than 1|16 in.
The springs shall be coiled in such a manner as ensures the coils being uniformly spaced
and the sides to be parallel to the axis of the spring.
295. Finishing of Ends- Compression springs shall have their ends ground flat and smooth and
at right angles to the axis of the spring over the full circumference so that when placed on
end the springs will stand perpendicular.

95
 Stop valves
296. Lever Valves- Where the valve is operated by means of a lever, whether hand or
mechanically controlled the lever shall be of ample strength and the bearings shall be so
designed as to allow of free working of the valve under all conditions of service.
297. Steam Stop Valve-
(a) A steam stop valve shall be fitted between the boiler and the steam pipe and except
in the case in which a super heater forms an integral part of the boiler itself (e.g. in
the Babcock and Wilcox water tube boiler) between the boiler and the super heater.
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.
(b) Steam stop valves shall be attached direct to the boiler shell or to suitable pads or
stand blocks riveted to the shell, and the neck of the valve chest shall be reasonably
short and of strong construction. Provided that in the case of a larger boiler in which
it is proposed for the purpose of drainage or owing to obstruction to connect the
steam pipes to the steam stop valve at a higher level than would be obtained under
this Regulation , a vertical stand pipe not exceeding 5 diameters in height will be
permitted between the stop valve and the boiler. Such stand pipes shall be of strong
construction and of wrought iron mild steel or cast steel. The flanges of wrought
iron or mild steel shall be riveted or welded to the pipes and there shall be no
branch on the stand pipe for any other connection.
Provided also that in the case of a large boiler in which it is desired to fit a tee piece
for the purpose of providing a branch connection between the stop valve and the
boiler such a tee piece may be so fitted. The tee piece shall be of strong
construction, of wrought iron, mild steel, or cast steel and shall not exceed 2½
diameters in height. A stop valve shall be fitted direct to each tee piece branch.
(c) No stop valve of the wedge type shall be employed for steam service.

Blow-Down Cock or Valve and Pipes

298. General- The blow-down cock or valve shall be of substantial construction. The waste
pipe attached to the cock or valve shall not be connected to a pipe common to another
boiler. The pipe shall not be bound fast in earth or brick-work.
299. Blow-down Mountings-
(a) Each boiler shall be fitted with a suitable below-down valve or cock placed at or as
near as particable to the lowest point of the boiler.
(b) For locomotive, vertical and marine type boilers the valve or cock shall be attached
direct to the boiler or to a suitable pad or stand pipe. For water tube boilers the
valve or cock shall be outside the brickwork with a substantial steel pipe between it
and the mudbox.
(c) For Cornish and Lancashire boilers the cock or valve may be attached to a cast
steel elbow pipe or substantial section bolted to a suitable stand pipe or pad riveted
to the boiler. But cast iron elbow pipes shall not be permitted.

96
300. Blow-down Valve or cock-
(a) Each valve or cock shall be fitted with a device which shall indicate clearly its
open and closed positions and any key or similar device for operating the valve or
cock shall be such that it cannot be removed unless the valve or cock is fully
closed.
(b) The locking feather shall be secured by welding.
(c) Cocks fitted with taper plugs shall be of the bolted cover type with separate
packing glands.

Water Gauges
301. (a) Every boiler shall have tow independent means of indicating the water level
in it and have marked on it, when applicable, in a contiguous position easily seen,
the level of the highest part of the furnaces, firebox or combustion chamber as the
case may be.
(b) All boilers 3 ft. dia. and over shall be fitted with two glass water gauges. For small
boilers where there is difficulty in fitting two glass water gauges two test cocks may
be fitted in place of the second glass water gauge.
(c) The lowest visible part of the glass of the water gauge and lower test cock shall be
fixed at a safe working level. For locomotive type and vertical boilers this shall not
be less than 2 inches above the highest part of the firebox roof plate.
(d) Glass water gauges shall be so placed as to be easily seen and reached by the boiler
attendant. The fittings of glass water gauges and test cocks shall be of substantial
make with large passage ways through them and so constructed that an instrument
can be passed through the opening. The gauge cocks when open shall have their
handles in a vertical direction and each handle at its junction with the plug shall be
plainly marked with a deep line to indicate the direction of the passage way through
the plug. When detachable handles are provided arrangement shall be made to
prevent fitting of the handles.
302. Drains- A drain cock or valve with a suitable discharge pipe shall be fitted to each water
gauge.
303. Protectors- Where tubular glass water gauges are fitted substantial protectors shall be
provided. The glass shall be suitably treated to prevent splintering.
304. Glass Size- Tubular water gauge glasses shall be not less than ½ inch and not more than
¾ inch outside diameter.
305. Safety Devices- Water gauge glass mountings shall be fitted with self-closing devices in
the bottom arm and it is recommended that a similar device should be fitted in the top
arm.
306. Gauge columns- Where the gauges are mounted on a column there shall be connecting
passage between the top and bottom arms of the column unless valves or cocks are fitted
between the column and the boiler.

97
307. Isolating Cocks- Where isolating cocks or valves connecting water gauge pipes to the
boiler are fitted, they shall be not less than 1 inch bore and of the bolted cover type with
separate packing gland.
Pressure Gauges
308. Dials-
(a) For pressures up to and including 500 lbs. per sq. in. pressure gauge dials shall be
graduated in pounds per square inch from zero to twice the pressure as nearly as may
be practicable.
(b) For pressure exceeding 500 lbs. per sq. in. the range of 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
1000 lbs. per square inch.
(c) The scale on the dial shall be clearly and permanently marked “lbs. per sq. in.”
(d) The dial of each pressure gauge shall have marked upon it in red the maximum
permissible working pressure.
(e) Where the gauge 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
gauges shall be calibrated within an accuracy of + 1 percent of the working pressure.
Boiler pressure gauges shall be not less than 6 inch in diameter except in the case of
small boilers where a gauge not less than 4 inch in diameter may be used.
(f) The travel of the pointer of dial gauges shall not exceed 325º.
309. Connection- All pressure gauges shall be fitted with a siphon pipe and a cock or valve
integral with or adjacent to the gauge in such manner that the gauge may be shut off and
removed whilst the boiler is under steam.
310. Gauge Cocks- The handles of the gauge cocks shall be parallel to the pipes in which they
are located when the cocks are open and marks shall be cut on the shank of the cock
indicating open position.

Test Connections
311. Inspector’s Pressure Gauge Attachment- Every boiler shall be fitted with a valve or
cock carrying in a vertical position a receiving screw for the attachment of the inspector’s
pressure gauge. The receiving sockets shall be tapped with ¾ in. British Standard
Whitworth screw thread and shall be fitted with an easily removable cap.

Fusible Plugs
312. General- Fusible plugs shall be of sufficient height and fitted in such a position as to give
early protection to all parts of the boiler liable to damage by the direct application of
furnace heat in the event of shortness of water.
Note: for example: In Lancashire Boilers the fusible plugs should be in the crowns of the
furnaces from 12 to 18 inches in front of the brickwork fire bridge.
313. Type- Fusible plugs shall consists of an outer body with a central passage, the smallest
part to be not greater than ½ inch for plugs suitable for pressure up to 100 lbs. per sq. in.
and not greater than 3|8 inch for plugs for pressures exceeding 100 lbs. per sq. in. The

98
 passage shall be closed by a plug secured by an annular lining of fusible alloy so that the
plug may be dropped clear of the lining melts.
The portion of the body carrying the fusible metal should preferably be detachable from
the base to allow of easy replacement without removing the whole fittings from the boiler.
314. Material- The non-fusible portions of the plug shall be of bronze except where the nature
of the boiler water precludes the use of a non-ferrous material. The fusible metal shall be
an alloy melting readily at a temperature not less than 150ºF. in excess of the saturated
steam temperature at the maximum permissible working pressure of the boiler.
315. Attachment to boiler- Wherever practicable fusible plugs shall be screwed into the boiler
plates from the waterside. The screwed portion shall have threads of Whitworth from not
more than 11 per inch.

Feed Valves
316. General-
(a) Feed check valves shall be of the non-return type.
(b) Where the valve is not of screw-down non-return type a separate screw-down valve
shall be provided.
(c) The discharge from the feed check valve or from the internal feed pipe (if provided)
shall be above low water level and in the case of Lancashire and Cornish boilers
shall be at least 5 ft. beyond the fire bridge.
317. Operating Position- Fedd check valves or regulating valves shall be so arranged as to
enable them to be satisfactorily operated from the boiler room floor.

Chapter VII
SUPER HEATERS
TUBES

318. Material and construction, See Reg. 132.

319. The working pressure of tubes shall be determined by either of the following formula:
(a) For tubes up to and including a final steam temperature of 600º F
170(t ] 8)
W.P. ] ... ... ... ... ... ... ... ... ... ... ... ...Eqn. (91)
D
(b) For tube for steam temperatures above 600º F and not exceeding 850º F.
170(t ] 8) 150
W.P. ]  ... ... ... ... ... ... ... ... ...Eqn. (92)
D 48 ] 17T
Where t = thickness of tube in 1|100 in.
W.P = The working in lbs. per sq. in.
D = Outside diameter of tubes in inches.

99
 T = Final steam temperature in ºF.

(c) In no case shall the thickness of tubes be less than those given in the table below:
Outside diameter Weldless tubes
Hot Cold
finished Drawn
S.W.G S.W.G
Up to and including 2˝ ... ... ... ... ... ... ... ... 10 13
Over 2˝ up to and including 3˝ ... ... ... ... ... ... 10 12
Over 3˝ up to and including 3½˝ ... ... ... ... ... 10 10
Over 3½˝ up to and including 4½˝ ... ... ... ... 9 9

When tubes are bent, the resulting thickness of the tubes at the thinnest part shall be
not less than that required for plain tubes.
(d) Where for any reason there is a danger of undue external erosion the thickness of the
tube shall be suitably increased.

Headers and Similar Pressure Parts

320. Material construction. See Reg. 135.
321. Rectangular Headers Symmetrical in Form.
(a) The working pressure shall be determined by the following formula:
f (t ] 1) 2
W.P. ] ... ... ... ... ... ... ... ... ... ... ...Eqn. (93)
b2  C
Where W.P. = The working pressure in lbs. per sq. in.
t = The thickness in -1|32 in.
b = The breadth in inches between the supporting sides of the header less one inside
corner radius ‘r’, this being the corner radius of the rectangular box from which the
header is pressed or of the header casting which shall be not less than ¼ in. In no
case, however shall ‘b’ be taken as less than 0.9 of the breadth between the
supporting sides.
C = 300 for wrought steel and 350 for steel castings: where the sides are corrugated
or otherwise reinforced by substantial supports so that the length of the flat portion
between the corrugations or supports does not exceed ‘b’, ‘C’ shall be taken as 175
for wrought steel and 200 for steel castings.
f = The permissible stress at working metal temperature lbs. per sq. in. see table
below.
(b) If the faces of the headers are machined locally at the tube holes or hand holes, the
thickness at that part may be as much as 6|32 in. less than given by Equation 93 but
irrespective of the thickness obtained by the use of the formula, the thickness of the
headers at the tube holes in 1|32 in. shall be not less than:

100
 t ] 3  d ] 8 ... ... ... ... ... ... ... ... ... ... ... ... Eqn. (94)
Where d = The diameter of the hole in inches, and in no case shall the thickness be
less than 10|32 in, except that in small patches not exceeding one-half a sq. in. in
area, the thickness may be 50 percent of the thickness obtained by Equation 93.
(c) The permissible stress at working metal temperature shall be given in the table
below:
Working metal Permissible stress in lbs. per sq. in.
temperature
Wrought steel having an ultimate Cast steel
28-35 tons
tensile stress in tons per sq. in. per sq. in.
24-28 26-30 28-32 32-36 34-38
1 2 3 4 5 6 7
Up to
470ºF 10 900 12 500 14 000 16 000 17 000 10 000
480ºF ... ... 10 900 12 500 14 000 16 000 16 600 10 000
500ºF ... ... 10 900 12 500 14 000 15 400 15 900 10 000
550ºF ... ... 9 900 11 200 12 500 13 700 14 200 10 000
600ºF ... ... 8 900 10 000 11 100 12 200 12 600 9 000
650ºF ... ... 8 000 8 800 9 800 10 800 11 300 8 000
700ºF ... ... 7 300 8 000 8 800 9 700 10 100 7 556
750ºF ... ... 6 600 7 200 8 000 8 700 9 100 7 200
800ºF ... ... 6 000 6 500 7 200 7 800 8 200 6 750
850ºF ... ... 5 400 6 000 6 600 7 100 7 400 6 300
900ºF ... ... 4 600 4 600 4 600 4 600 4 600 4 400
Intermediate valves may be interpolated.
The working metal temperature shall be taken as:
(d) For saturated steam, water drums, muddrums and headers, the saturation temperature
corresponding to the pressure WP plus 50º F.
(e) For super heater headers the designed maximum steam temperature for that header
plus 50º F.
(f) Where headers are adequately protected from the gases of combination or swept by
such gases in the third or subsequent pass of a boiler, the working metal temperature
shall be taken as the saturation or designed maximum steam temperature as defined
above, whichever applies. A covering of refractory or insulating material which may
be liable to become disloged shall not be deemed adequate protection.
322. Headers Irregular in form- In cases where the headers are of such regular form as to
render impracticable the application of a formula for the determination of thickness, the
manufacturer shall show the suitability for the headers for the working conditions by

101
 indicating practically the maximum internal hydraulic pressure which a header, made to
the same design and of similar material, will withstand without permanent deformation.
The maximum working pressure for similar headers may then be determined by the
following formula:
Permissible stress at working metal temperature.
W.P = P1×F×C ... ... ... ... ... ... ... ... ... ... ... ... Eqn. (95)
Where W.P. = The working pressure in lbs. per sq. in.
P1 = The maximum internal hydraulic pressure withstood without permanent deformation.
F = 1.75 for wrought steel and 2 for cast steel.
C = 15500 for wrought steel of 24 tons per sq. in. minimum ultimate tensile stress,
= 16500 for wrought steel of 26 tons per sq. in. minimum ultimate tensile stress,
= 18000 for wrought steel of 28 tons per sq. in. minimum ultimate tensile stress,
= 21000 for wrought steel of 32 tons per sq. in. minimum ultimate tensile stress,
= 22000 for wrought steel of 34 tons per sq. in. minimum ultimate tensile stress,
= 15500 for cast steel of 28 tons per sq. in. minimum ultimate tensile stress,
323. Cylindrical Headers- Where cylindrical headers are provided their working pressure
shall be determined by Equation 77.

Chapter VIII
STEAM PIPES AND FITTINGS
324. Steam pipes may be of wrought iron, wrought steel, cast steel and in some cases of
copper. Steel pipes may be solid drawn (cold or hot finished) or lap welded. Wrought iron
pipes may be lap welded. Copper pipes shall be solid drawn and no pipe made from the
electrode position of copper on a mandrill shall be used for steam delivery.

MATERIAL
325. Steel pipes-
(a) These pipes shall be made by the open hearth or an electric process acid or basic.
Where the material is used for designed steam temperatures above 750ºF, the steel
shall be of non-segregated or fully killed type.

(b) The material from which these pipes are made shall conform to the following
requirements:

102
 Table- 1
Kind of Pipes Ultimate tensile Minimum elongation % Sulphur Phosphorus
stress in tons maximum maximum
per sq. in % %
On 8˝ On 2˝
Not Not ¼˝ less ¼˝ less
less more thick than thick than
than than and ¼˝ and ¼˝
over over
(A) (i) cold drawn
weldless and (ii) Hot
finished weldless steel
pipes. Strips cut from
the pipes and tested in
their curved
condition..... ... .... .. 23 30 20 18 32 30 ... ...
Test lengths taken
from finished pipes
(ends of pipes to be
plugged for grips)...... 23 30 25 23 ... ... .05 .05
(B) Hydraulic (water
23 for ½˝ thick and over 20 for
gas lap welded steel)
less than ½˝ and not less than ¼˝ .05 0.5
Selected samples cut
18 or less than ¼˝
transversely.... ... .... 22 28
(C) Roll Lapwelded
steel.
Strips cut from the
pipes and tested in
their curved
condition........ ...... ....
.06
22 28 20 18 32 30 .06
Test lengths taken
from finished pipes
(ends of pipes to be
plugged for grips)...... 22 28 25 23 ... ...
326. Condition of pipes- All pipes shall be commercially straight, free form longitudinal
seaming, grooving, blistering or other injurious surface marks. The ends of the pipes shall
be out
Mechanical Tests
327. Flattening Test- (For pipes up to and including 4-in. nominal bore). A ring not less than
2˝ in length cut from one end of each selected pipe shall when cold withstand, without
showing either crack or flaw, being flattened between two parallel flat surfaces until when

103
 the pressure is released the interior surfaces of the test piece remain at the middle a
distance apart equal to 4 times the thickness of the pipe.
328. Cold bend test (for pipes over 4-in. nominal bore).
(a) A strip 1½˝ wide cut circumferentially from one end of each selected pipe shall when
cold withstand, without showing either crack or flaw, being doubled over in the direction
of original curvature round a bar, the diameter of the bar being:
For pipes up to and including 3|8˝ thick... ... 3 times the thickness.
For pipes over 3|8˝ thick... ... ... ... ... ... 4 times the thickness.
Bend test on the weld-
(a) A strip 1½˝ wide cut circumferentially from one end of each selected pipe with the
end near the middle of the strip, shall when cold withstand, without showing either
crack or flaw being doubled over in the direction of original curvature round a bar,
the diameter of the bar being equal to eight times the thickness of the test piece, the
weld being placed at the point of maximum bending.
(b) Additional test (c) should a pipe selected for testing fail in any one or more of the
tests specified above, two further tests of the same kind may be made from the same
or other pipe. Should either of these fail, the pipes represented may be reheat treated
and then retested. If the repeat tests are satisfactory, the pipes shall be accepted
provided they comply with other requirements but if failure again occurs, the pipes
which the test pieces represent shall be rejected.
329. (a) The process of welding lap jointed seams shall be by hammering or rolling the joint.
(b) On completion of any work which involves heating whether for welding the joint,
welding on flanges hot bending the pipe or for any other purpose, the pipe shall be
carefully annealed.
330. The pressure and temperature limits within which pipes, tees, branches etc, shall be used
shall be in accordance with table 2.

WORKING PRESSURE OF STEAM PIPES

331. Steel and Wrought Iron Pipes- The maximum working pressure allowed on steel or
wrought iron pipes shall be determined by the following formula:
t
W.P. = 2Sc - 9 . ... ... ... ... ... ... ... ... ... ... Eqn. (96)
1.125
100D
t = Minimum thickness in hundreths of an inch,
W.P. = Working pressure in lbs. per sq. inch.
D = Outside diameter of pipes in inches.
S = Allowable stress in lbs. sq. inch as specified in table 3,
e = Efficiency factor.
1. For weldless steel pipes,
.9 for welded steel or iron pipes for valves of ‘t’ up to and including 7|8˝.

104
 .85 for welded steel pipes for values of ‘t’ over 7|8˝ and up to and including 1⅛˝.
.8 for welded steel pipes for values of ‘t’ over 1⅛˝.
332. Cast steel pipes
(a) The material shall comply with regulations 55 to 65, i.e. 28 tons minimum tensile
stress.
(b) The maximum working pressure allowed on cast steel pipes shall be determined by the
following formula:
 0.97t ] 0.015d ] 0.25 
W.P. = 2S   ... ... ... ... ... ... ... ... ... ... ... Eqn. (97)
 d 1 
t = Minimum thickness
W.P. = Working pressure in lbs. per sq. in.
d = Internal diameter of pipe in inches,
d1 = External diameter of pipe in inches,
S = Allowable working stress in lbs. per sq. in. as specified in table (4).
333. Copper pipes-
(a) The material shall comply with Regulation 35.
(b) copper pipes may be used for a working pressure not exceeding 180 lbs. The external
diameter shall not exceed 5 in.
(c) Copper pipes shall not be used for super heated steam.
(d) The maximum working pressure on such pipes shall be determined by the following
formula:
 t 
 ] 3 . ... ... ... ... ... ... ... ... ... ... Eqn. (98)
W.P. = 50 1.125 
D
t = Minimum thickness in hundreth of an inch.
W.P. = Working pressure in lbs. per sq. in.
D = Outside diameter of pipe in inches.

TABLE 2
(MAXIMUM PERMISSIBLE W.P. AND TEMPERATURE)
Material Method of Maximum Maximum Form.
Manufacture permissible pressure permissible
in lbs. per sq. in. temperature in ºF.
Mild Steel.... Cold drawn No restriction
900 Straights bends
or tees, etc.
weldless
Hot finished Do. 900
weldless
Hydraulic Do. 900 Do.
Water-gas-
lapwelded
Roll lap-welded 250 425 Straights, bends or
tees, etc.
Wrought Do. 250 425 Do.
Iron

105
 Cast Steel Castings No restriction 900 Straights, bends or
tees, etc.
Copper Solid drawn Up to and including Straights and bends
5ʺ......180

Table 3
Maximum permissible working stress in lbs. for cast steel (Values of S).
Maximum permissible working stress in lbs. per sq. in. for design temperature in °F.
over
Pipes 425 550 600 650 700 750 800 850 875 900
Up to and including
425 550 600 650 700 750 800 850 875 900
Cold Drawn 11200 11200 10000 8900 8400 8000 7500 7000 5860 4880
Weldless steel,
Hot finished
weldless steel.
Hydraulic (water 10000 10000 9000 8000 7560 7200 6750 6300 5280 4400
gas Lap-welded
steel)
Roll Lap-welded ..... ...... Not used for these temperatures.
Steel
Lap-welded Iron ..... ...... Not used for these temperatures.

Table 4
Maximum permissible working stress in lbs. for cast steel (Values of S).
Permissible working stress in lbs. per sq. in. for design temperature in ºF.
Over
550º 600º 650º 700º 750º 800º 850º 875º
Up to and including
550º 600º 650º 700º 750º 800º 850º 875º 900º
10000º 9000º 8000º 7560º 7200º 6750º 6300º 5280º 4400º

ATTACHMENT OF FLANGES
334. Flanges of Iron and Steel Pipes-
(a) Flanges of iron and steel pipes may be made of cast steel wrought iron or wrought
steel made without a weld. They may be secured to the pipes by screwing riveting or
welding.
(b) No flange or blank flange of cast iron shall be attached directly to main steam pipes or
form part of main steam piping.
(c) Blank flanges shall be of mild steel or cast steel and shall be of the same thickness as
the flanges to which they are attached.

106
 334-A. Screwed on flanges- The pipes may be screwed into flanges with a disappearing
thread and expanded. Such screwed and expanded flanges may be used for steam for
a maximum pressure of 450 lbs. per sq. in. and|or a maximum temperature of 750ºF.
Screwed and expanded flanges may be in addition be seal welded.
335. Loose Flanges- Loose flanges may be used where the points are made by metal to metal
faces integral with the ends of the pipes. Alternatively these joints may be welded or seal
welded. The loose flanges shall conform to B.S. appropriate for the working pressure.
When the joint is formed by integral flanges these after machining shall not be of less
thickness than the pipes.
336. Riveted on flanges-
(a) Riveted on flanges shall only be used for pipes of 7˝ bore and above and for a
maximum pressure of 350 lbs. per sq. in. and|or a maximum temperature of 750º F.
(b) The shear stress in the rivets shall not exceed 6000 lbs. per sq. in. when calculated by
the following formula:
(O  P )
Sr. ] ... ... ... ... ... ... ... ... ... ... ... ... ... Eqn. (99)
A
Where sr. = The shear stress in the rivets in lbs. per sq. in.
A° = Cross sectional area, calculated on outside diameter of pipe in sq. inches.
P = Working pressure in lbs. per sq. in.
N = Number of rivets.
A = Area of rivets holes in sq. in.
(c) The stress in the pipe shall not exceed that specified in Table 3 when calculated by
the following formula:
A P
Sp ] ... ... ... ... ... ... ... ... ... .... Eqn. (100)
( A ] A1 ) ] ( N  d  t )

Where Sp = the stress in the pipe in lbs. per sq. in.

A0 = P and N have the values given above and
A1 = cross sectional area, calculated on inside diameter of pipe in sq. inches.
d = diameter of rivet hole in inches.
t = minimum thickness of pipe in inches.
(d) The flanges hub thickness shall not be less than 0.2 in. thicker than the minimum
thickness of the pipe.
(e) The distance from the edge of the hub to the centre line of the rivets shall be not less
than one and a half times the diameter of the rivet hole.
(f) The pipes shall first be properly, expanded in to the flanges or alternatively the
flanges shrunk on to the pipes the rivet holes shall than be drilled through the pipe
and hub, and the hole afterwards countersunk to remove burrs.
(g) After riveting the flange hub shall be fullered at the back.
337. Welded on flanges-

107
 (a) Where flanges are welded on, the welding shall be carried out by the oxy-acetylene
or electric process.
(b) The proportions of welds shall be as indicated in Figs. 20 to 24 the respective
working condition for each type being as follows:
Fig. 20, 21 and 24 : for all pressure and temperature conditions.
Fig. 22 : for pressure condition up to 250 lbs. and temperatures not exceeding 700ºF.
Fig. 23: for pressure condition up to 150 lbs. and temperatures not exceeding 500ºF.
(c) (i) Electric welds made in accordance with figure 24 shall be stress relieved.
(ii) Similar welds made in accordance with Figs. 20 or 21 shall be stress relieved
when practicable.
(iii) Flanges for use at temperatures over 700ºF which are welded by the oxy-
acetylene process shall be normalised.
(d) For sizes up to and including 12˝ bore bossed or hubbed flanges may be used in Figs.
22 & 23.
(e) Welded on flanges may be screwed on to pipes prior to welding.

A t but not less than ¼ in. and not more than ¾ in.
B t
C t but not less than ⅜ in.
D 1½ t but not less than ⅜ in.
E 1½ t but not less than ⅜ in.
t but not less than ⅜ in. and more than ¾ in.
t but not less than ¼ in.

108
 Fig:

A ½ t but not less than 3/16 in.

B ¼ in. for Tubes up to and including 5/16 in. thick.
t-1/16 in. for Tubes over 5/16 in. thick and up to and including 9/16 in.
t-1/8 in. for Tubes over 9/16 in. thick and up to and including 7/8 in.
t-1/4 in. for Tubes over 7/8 in. thick and up to and including 1 in.
C t but not less than ⅜ in.
D 1½ t but not less than ⅜ in.
E 1⅓ t but not less than ⅜ in.
F t but not less than ⅜ in. and not more than ¾ in.
G t but not less than ¼ in.

A 1½ t but not less than ⅜ in.

B 1½ t but not less than ⅜ in.
C t
D t but not less than ¼ in.

Fig.22. For pressure conditions up to 250

lbs. and temperature not exceeding
700 F.

109
 A ¼t but not less than 1/16 in.
B 2t
C t
D t

A t + 1/16 in.
Where t is not greater than ½˝.
B 1/16 in. min.
C 1/16 in. min.
Where t is greater than ½ inch ‘U’ shaped grooved as shown may be used.
15 min.
r 1/8 in.
h 1/8 in. max.
g 1/8 in. min. t ¼ in. max.
B 1/16 in. min.

338. Flanges of Copper Pipes- Flanges of copper pipes may be made or brass or bronze.
When flanges are attached to copper pipes by brazing they shall be secured in such
additional way (e.g. by riveting the ends of forming a conical end so as to fit into a
conical bore in the flange that the resistance to withdrawal from the flange does not
depend wholly on the brazing.
339. Standard Flanges- The size and thickness of flanges and the number and size of their
bolts should be as prescribed by the British Standards Institution.
340. Joints- These Regulations provide for ordinary bolted flange joints. Special types of joints
may be used, subject to the approval of the Chief Inspector.

STEAM PIPE FITTINGS AND CONNECTION

341. Wrought bends-
(a) Wherever practicable the radil of bends (on centre line) shall be not less than those
given below:

110
 Bore up to and including 6 in. R = 3×d
” over 6 in up to and including 9˝ R = 3.5×d
” ” 9 in ” ” 12˝ R = 4×d
” ” 12 in ” ” 15˝ R = 4.5×d
” ” 15 in ” ” 18˝ R = 5×d
” ” 18 in ” ” 20˝ R = 5.5×d

Bore up to and including 6 in.

Where d = the bore of the pipe.
R = Radius of bend to centre line of pipe.
(b) The thickness of pipes from which such bends are made shall be not less than 12½
percent greater than the minimum thickness required by equation 96. Where smaller
radil are necessary further allowance shall be made for thinning at the back of the
bend. Alternatively some special form of construction shall be adopted to prevent
undue thinning.
342. Branches, Tees etc.- Branches etc., shall be flanged and be either flanged and riveted or
welded to the pipe from inside as well as outside when practicable, alternatively to the
welding on the inside of the pipe an approved type of reinforcement or mechanical lock
may be provided.
Where a branch is of equal size to the main pipe the opening shall be reinforced.
343. Blow-down pipes-
(a) Blow-down pipes which can be subjected to full boiler pressure shall be considered as
saturated steam pipes at that pressure.
(b) Where Blow-down pipes are run separately to tank or sump, they shall be considered
as saturated steam pipes at half the working pressure of the boiler.
344. Valve Chests-
(a) Chests of stop-valves, isolating valves, reducing valves, steam traps etc, forming parts
of wrought iron or wrought steel main steam piping when for use with saturated
steam up to a gauge pressure of 160 lbs. per square inch or a temperature of 400ºF.
may be made of cast iron, cast steel or wrought steel in accordance with the
requirements of Regulation 271.
(b) When super heated steam is used above 400ºF. or when pressures are above 160 lbs.
per sq. in gauge such chest shall be made of cast or wrought steel or other approved
material in accordance with the requirement of Regulation 271.
345. Steam Receivers, separators etc for temperature exceeding 500ºF.
(a) If such vessels are fusion welded the manufacture and tests shall conform to Chapter
V.
(b) The working pressure of all parts shall be determined by the appropriate formula
given in Chapter V.
(c) All mountings for the above and for connected steam pipe ranges shall be of cast
steel or other approved material.
346. Steam Receivers, separators etc. for temperature not exceeding 500ºF.

111
 (a) The shells of steam receivers, steam separators, steam driers, catch waters, drop legs,
interceptors etc. may be made of steel plates or steel castings.
(b) (i) When fabricated of steel plates the seams may be riveted or welded.
(ii) When riveted the working pressure for the parts shall be determined by the
formula prescribed for corresponding parts of boilers and the hydraulic test
pressure to which the vessel shall be subjected on completion shall be that
prescribed for boilers.
(iii) Except where such vessels are fusion welded in accordance with chapter V the
longitudinal weld of vessels exceeding 15˝ internal diameter shall be covered by
a butt strap.
(iv) For such welded seams the standard co-efficient C. of regulation 157 to be used
in determining the working pressure shall be 3.0 for both welded and strapped
seams. The strength percentage to be allowed for the weld shall be 50 and J. the
strength percentage to be allowed for welded and strapped seams shall be
determined in accordance with Regulation 161.
(v) Branches for attachment of steam piping shall be flanged and be either flanged
and riveted or welded to the vessel.
When welded this shall be done inside as well as outside where practicable.
Alternatively to the welding on the inside of the vessel an approved type of
reinforcement of mechanical lock may be provided.
Where a branch is of equal size to the vessel the opening shall be reinforced.
(vi) All welded vessels shall be stress relieved.
(c) (i) Where made of cast steel the shell shall comply with the requirements of Regs. 55
to 65.
(ii) The working pressure for flat end plates of cast steel shall be determined by the
formula for flat end plates of wrought steel.
(d) Suitable arrangements for drainage shall be fitted to all vessels intended for use in the
separation of condensed steam. Where automatic drainage is not provided a glass
water gauge of substantial make to indicate the water level in the vessel and a
substantial drain cock or valve shall be fitted.
347. Screwed and Socketed Joints- Couplings or sockets may be used on pipes up to 4 in.
internal diameter with pressures up to 120 lbs. per square inch gauge and up to 5 in.
diameter with pressure up to 120 lbs. per square inch gauge. In all other cases, flanges
with bolts and nuts shall be used.
348. Other Fittings and Mountings-
(a) Valve chests of bronze for stop valves up to 3 in. diameter of bore may be attached
directly to iron and steel steam pipes when pressures do not exceed 120 lbs. per sq.
in. gauge and when steam is saturated. The attachment may be by direct screwing to
the steam pipe or by means flanges.
(b) Drain cocks and valves may be attached to steam pipes either by flange and bolts or
be screwed in to a boss formed on the pipe.
349. Reducing Valve- Where a reducing valve is installed in a pipe line, the pipe line, the pipe
line and accessories on the low pressure side of the reducing valve shall be protected by a
suitable safety valve or valves so adjusted as to permit the steam to escape as soon as the

112
 safe working pressure is exceeded or by a suitable appliance for cutting off automatically
the supply of steam as soon as the safe working pressure is exceeded.
350. Flexibility-
(a) The piping shall be arranged so that the system is sufficient flexible to absorb the
whole of the expansion.
(b) The necessary degree of flexibility shall be obtained by the use of special expansion
bends. The use of sliding expansion joints is prohibited.
351. Pipe work supports- All pipe work shall be adequately supported in order to permit free
movement for expansion and contraction and the amount of such movement shall be
proportioned throughout the whole of any main by the provision of anchors at suitable
points. Where pipes may be subject to vertical movement, spring supports designed to
carry the load under all conditions shall be provided. It is desirable that points of supports
should, as far as practicable be arranged adjacent to the pipe joints. Slings are in general
preferable to roller supports and these latter should be used only where necessary. All
pipe supports should as far as practicable be of mild steel and pipe anchors either of mild
steel or cast steel.
352. (a) In the case of steam mains, attention should be paid to the adequate provision of
drainage points in the form of drain pockets. Drainage points connected to steam trap
shall be provided wherever water can collect under working conditions. Hand drains shall
be provided at all points at which water can collect in any portion of the steam main, by
valve leakage or other means, when shut down or when warming up prior to use.
(b) Where practicable a suitable gradient shall be provided in the pipe work to ensure the
passage of condensed water in the direction of flow of steam towards the drainage point.
(c) It is recommended that a by-pass should be fitted at each steam trap.
(d) Where the volume of water deposited is likely to be of serious proportions separators
should be installed. Such separators shall be furnished with a steam trap which shall be
connected to it by means of a three-way cock one end of which is connected to a manually
operated drain.
353. Freedom from rust and other foreign matter- All pipes valves and fittings shall be
thoroughly cleaned as far as possible of rust and other foreign matter before erection and
pipe lines shall be blown through with steam or air before being put into service.
354. Test Pressures-
(a) Each completed pipe and fitting shall be tested by hydraulic pressure at the
manufactures work to twice the maximum permissible working pressure. It is
inadvisable to submit a complete steam pipe installation to any hydraulic test.
(b) Pipe and fittings with flanges for steam pressures exceeding 100 lbs. per sq. in shall
be tested with blank flanges bolted or clamped on. All other pipes if straight may be
tested between the heads of an ordinary hydraulic pipe testing machine.
(c) Special arrangements shall be made, according to circumstances, for testing bends
and other fittings where not flanged.

113
 INSPECTION
CHAPTER IX
REGULATIONS FOR THE REGISTRATION AND INSPECTION OF BOILERS
355. The procedure to be followed in connection with application for the registration of a
boiler and with examinations of boilers under the Act shall be regulated in accordance
with the provisions of this Chapter read with the relevant sections of the Act.

356. Preparation for Inspection-

(a) At every examination of a boiler for the grant or renewal of a certificate, the boiler
shall be empty and thoroughly clean in all its parts. Except as provided for in sub
Regulation (f) all doors of manholes, hand holes and sight holes and cleaning plugs
and all caps in the headers and mud drums of water-tube boilers all fire-bars, bearers,
front plates, bridge plated, fire bridges brick arches, oil fuel burners and mechanical
stoker fittings shall be removed. All valves and cocks comprising the boiler
mountings shall be opened up and taken apart and the valves or cocks ground, when
necessary before the Inspectors visit.
(b) Provision shall if required by the Inspector be made for the removal of lagging or
brick-work or other concealing part and for the drilling of plates and for verifying the
pressure gauge and safety valve dimensions and weights.
(c) Al smoke tubes, exterior of water tubes, smoke boxes and external flues shall be
swept clean.
(d) Provision shall be made for the effective disconnection of all steam and hot water
communication with any other boiler under steam as prescribed in chapter X of these
regulations. This shall be effected either by the removal of a length of pipe from the
steam and feed piping or by the inserting of substantial blank flanges. Where blank
flanges are employed they shall be inserted between the flange of the chest and the
pipe attached to it.
(e) No blank flange shall be inserted between a safety valve chest and the boiler.
(f) At alternative annual inspections and subject to a minimum or three bottom rows or
all tubes subject to the first pass of heat being opened up for inspection, the Inspector
may at his discretion relax the preparation for inspection called for under (a) above in
favour of boilers having an evaporative capacity of 2,00,000 lbs. per hour and over,
and fed with water treated to the satisfaction of the Inspector.
357. Hydraulic Test- Every new boiler shall be hydraulically tested in the presence of an
Inspector or Inspecting Officer.
358. Preparation for Hydraulic Tests-
(a) The chests of all mountings subject to steam pressure shall be in place and shut tight
or blank flanged.
(b) The safety valves shall either be jammed down or removed and the chest-opening
blank flanged.
(c) The attachment for the inspector’s pressure gauge and the nipple for connecting the
Inspector’s test pump hose shall be in order.

114
 (d) All doors shall be properly jointed and tighted up. The boiler shall be completely
filled with water care being taken to allow air to escape and if possible a preliminary
test not exceeding the working pressure of the boiler shall be taken before the
Inspector’s visit to test the tightness of the joints.
(e) When a boiler is hydraulically tested for the first time it shall entirely be cleared of
lagging or brickwork; at subsequent tests the lagging or brickwork portions thereof
shall be removed if required by the inspector.
359. Procedure of hydraulic tests-
(a) Subject to the provisions of sub-regulations (e) regulation 361. every new boiler shall
be hydraulically tested in the presence of an Inspector to not less than twice the
approved working pressure when such working pressure does not exceed 100 lbs.
per square inch; when the approved working pressure is above 100 lbs. per square
inch, the hydraulic test procedure shall be 1½ times the working pressure plus 50 lbs.
per square inch.
(b) The boiler shall satisfactorily withstand such pressure without appreciable leakage or
undue deflection or distortion of its parts for at least ten consecutive minutes. If the
test is not satisfactory the working pressure allowable by calculation shall be suitably
reduced unless the owner desires to make such alternations as will enable the boiler
to withstand satisfactorily the hydraulic test; in which case the boiler shall again be
examined after the alternations have been made, the pressure recalculated if
necessary and the boiler tested to the satisfaction of the Inspector.
(c) At the first hydraulic test of a boiler prior to the issue of an original certificate
deflection measurements shall be made before during and after test of each furnace
length fire box and flat end or either plates.
(d) After the application of the hydraulic test the Inspector shall carefully examine the
boiler inside and outside and satisfy himself that it has satisfactorily withstood the
test.
(e) In any case in which the safe working pressure to be allowed for a boiler cannot,
owing to peculiar construction of any of its parts, be determined by calculation in the
ordinary way the inspector shall under the direction of the Chief Inspector subject
the boiler to hydraulic test for the purpose of determining the fitness of such parts.
The amount of the test pressure to be applied in such a case shall not exceed the test
pressure prescribed for the least working pressure found by calculation for other
parts of the boiler or the intended working pressure whichever is less.
(f) Should any part of the boiler show undue deflection or indication of permanent set
during the progress of the test the pressure shall be released immediately such
indications are observed. The working pressure for the part shall be 40 percent of the
test pressure applied when the point of permanent set was reached. This procedure
shall apply to any boiler at any test.
(g) Hydraulic tests of boilers at subsequent examinations shall except when the Inspector
expressly requires otherwise, be made after the inspection. The test pressure to be
applied to boilers at such subsequent examination shall be from one and a quarter to
one and a half times the working pressure of the boiler.
(h) When the internal construction or size of a boiler does not permit of the Inspector
getting inside it or of examining closely all its parts he shall see it tested by hydraulic

115
 pressure to one and a half times the working pressure at each inspection for the grant
or renewal of a certificate.
(i) Water tube locomotive type and all tubular boilers shall be hydraulically tested at
each inspection for the grant or renewal of a certificate unless such test is waived
under the orders of the chief inspector.
(j) The Inspector may if he considers it necessary, apply a hydraulic test to any boiler at
any inspection.
(k) Except in the case of small portable an vehicular boilers which do not require re-
erection or building in brickwork the hydraulic test of all boilers shall be conducted
only after the erection of the boiler in situ, and all boilers shall after re-erection in a
position different from that in which they were last examined be hydraulically tested.
(l) A hydraulic test shall also be taken before granting an increased pressure certificate
and after repairing a boiler unless the Chief Inspector authorizes the Inspector to
waive such test.
(m) When carrying out hydraulic tests Inspectors shall use pressure gauge supplied by
the Chief Inspector.
360. Steam Tests-
(a) Every newly registered boiler and every other boiler of which the working pressure
has been altered shall before the issue of an original or renewal certificate for such
boiler be tested under steam to the satisfaction of the inspector.
(b) At the time of test the safety valves shall be left free and capable of being adjusted
to the approved working pressure.
(c) After adjustment of the valve to the correct blowing pressure the boiler shall be
tried under full steam and firing for at least ten minutes with the feed water shut off
and the stop valve closed during which time the Inspector shall note the
accumulation of pressure and other details of the test as well as the loading and
adjustment of the safety valves.
(d) On completion of the safety valve test the Inspector shall satisfy himself that the
water gauges are in working order and that the feed apparatus is capable of
suppling boiler with sufficient water.
(e) Where the Local Government does not require a person-in-charge of a boiler to hold
a certificate of competency the Inspector may when he thinks fit satisfy himself by
questioning or by practical test whether the person-in-charge of the boiler
understands the use and purpose of the water gauges the pressure gauge the safety
valves, the fed water supply and blow-down.
(f) When witnessing safety valve tests, inspectors shall use the standard pressure
gauges supplied by the Chief Inspector unless the boiler pressure gauge has since
the time of inspection been tested and found correct with an authorised testing
machine.
(g) No steam gauge shall be used without a syphon filled with water between it and the
boiler.

116
 (h) When the accumulation of pressure at a steam test exceeds ten percent of the
maximum working pressure the area of the safety valves shall be considered
insufficient and a certificate shall be refused until the safety valve area is increased.
(i) An inspector may when visiting a factory for any purpose verify the correctness of
the safety valves and pressure gauge of any boiler under steam by comparison with
his standard pressure gauge.
361. Procedure for Registration-
(a) On receipt of an application for registration under section 7(1) of the Act, the
Inspector shall when the boiler has been properly for examination proceed to
measure in complete detail all its parts ascertain the working pressure allowed by the
regulations by making a series of calculations of the strength of the various parts
such calculations being based on his measurement and if he is satisfied with the
correctness of the maker’s certificate on the dimensions and other particulars relating
to the material and construction as tested therein [vide section 14 (1) (c) of the Act
and Regulation 4]. In making his calculations he shall after examination of the
material take due account of the workmanship and details of the construction of each
part. In his examination the Inspector may if he deems necessary bore the plates or
other parts to ascertain their thickness and in making his calculations he shall be
guided by the requirements of Chapters IV and V of these Regulations.
(b) If no formula or co-efficient applicable to any part is contained in Chapter IV or V of
the Regulations the Chief Inspector shall in his discretion determine the fitness of
such part.

(c) The strength of the weakest part so calculated or determined subject to any
discretionary power exercised by the Chief Inspector shall determine the permissible
working pressure of the boiler. After inspecting the boiler and ascertaining by the
prescribed calculations the maximum pressure at which the boilers may be worked
the Inspector shall hydraulically test and steam test it in accordance with the
requirements of Regulations 359 and 360 and may issue a provisional order under
section 9 of the Act in form V.
(d) The Inspector shall enter the above particulars and dimensions of the boiler and
calculations of strength of the various parts, together with details of the hydraulic
and of the steam tests in a memorandum of inspection book (read Regulation 366)
which together with all the maker’s papers for the boiler shall be submitted to the
Chief Inspector with the Inspector’s report under sub-section (3) of section 7 of the
Act in Form I.
(e) Where a certificate in Form II and a memorandum of inspection book in Form I are
furnished by an Inspecting Authority in accordance with sub-Regulation (c) of
Regulation 4, the Inspector shall on receipt of an application for registration under
section 7(1) of the Act proceed to make such examination and measurement of the
boiler as will satisfy him that the boiler is the one certified by the Inspecting
Authority and that it has sustained no damage in transit for which purpose he may if
he considers it necessary subject the boiler to hydraulic test in accordance with
Regulation 359.
The Inspector shall if he is satisfied with the condition of the boiler accept the
particulars and approved working pressure entered in Form I by the inspecting

117
 Authority as if they had been ascertained and entered by himself and shall issue a
provisional order to enable the boiler to be worked.
He shall make such entries in respect of his examination of the boiler in the
memorandum of inspection book as may be required and shall submit the book and
Inspecting Authority’s certificate and drawing of the boiler with his report to the
Chief Inspector as prescribed under sub Regulation (d).
361A. Registration of boilers where requisite valid documents for registration are
not furnished-
(1) For the purpose of registration of boilers where all the requisite valid documents
for registration are not furnished, necessary tests including physical, chemical
and metallographic test shall be carried out in the testing laboratory of
Bangladesh University of Engineering and Technology (BUET) or in Bangladesh
Atomic Energy Commission and if the results are satisfactory the boiler shall be
registered.
(2) In every cases depending on the type and design of a boiler, the Chief Inspector
shall decide the number of rest pieces and the location from where those test
pieces are to be cut out.
(3) When the workmanship of a boiler is in any way doubtful the Chief Inspector
shall reduce percentage of the working pressure of the parts of the boilers, as the
Chief Inspector deems fit.

362. Engraving of registry number-

(a) The registry number of every boiler shall, within a period of one month after its
registration, be cut in the from plate it, in such position as pointed out by the
Inspector. The device shall be distinguished by the following letters:
ÒBA:BO/evtetÓ
The distinguishing letters shall be engraved above a number and separated there
from by a horizontal line two and a half inches in length. The letters and figures
shall be one inch in height and of suitable breadth, provided that in the case small
boilers the letters and figures of the device may in the discretion of the Chief
Inspector be reduced to 3|8 in height. The whole shall be enclosed in a rectangle,
the upper and lower sides of which shall be three inches apart and one quarter inch
clear of the top of the letters and the clear of the top of the figures respectively as
indicated below:
ÒBA:BO/evtet
2001/2001”
The side lines shall be an equal distance clear from the figures. The engraving shall
not be less than 1|64th inch in depth.
(b) The engraving shall be complete and ready for verification within thirty days of the
first inspection of the boiler.

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 (c) Boiler having registry devices differing from those prescribed herein shall have
such devices obliterated, altered or cut a new in conformity with those prescribed
above. The original number of such boilers shall be retained in the new device. A
number once allotted to a boiler shall not be used again for another boiler.
363. Measurement of heating surface-
(a) For the purpose of regulating the area of the safety valves and the amount of
registration and inspection fees the “heating surface” of a boiler shall be the total
surface of all plates and tubes exposed to heat on one side and in contact with water
on the other measured on the water or the fire side whichever is larger.
(b) For Lancashire and Cornish boilers the total heating surface shall include the wetted
surface of the furnaces between the end plates the fire surface of cross tubes where
fitted and the part of the external shell below the side flue covers. In estimating the
areas furnaces shall be considered as plain cylinders: the area of their wetted surface
shall be taken as their mean external circumference × the length of the boiler
between end plates. For the shell the width of that part of the circumference below
the flue covers shall be taken as = 2D and this width × the length between end plates
shall be taken as the area of shell heating surface. The part of the surface of the back
end plate exposed to heat shall be omitted from the calculation.
Example- The formula for the total heating surface of a Lancashire boiler having
plain furnaces without cross tubes is as follows:
H.S. in square feet = 2L (3.14d. + D); L is the length of the boiler between end
plates in feet d is the mean external diameter of the furnaces in feet and D is the
internal diameter of the largest belt of shell in feet.
(c) For steam and water drums of water tube boilers the heating surface of the drum
shall be taken as half the external mean circumference multiplied by the clear length
of drum between the outer brick walls or centres of cross boxes as the case may be.
The heating surface of the tubes shall be taken as the external surface of the tubes
between tube plates or headers. The heating surface of the headers shall be omitted
from the calculation. Internal Economisers shall be deed as component heating
surface.
(d) For marine boilers of the fire-tube type the heating surface shall include the wetted
surface of the furnaces between the tube plates (considered in the same way as for
Lancashire boilers) the wetted surface of the combustion chambers (less the area of
the tube holes) and the wetted surface of the tube plates. The parts of the front tube
plate exposed to heat shall be omitted from the calculation.
(e) For locomotive type boilers the heating surface shall include the wetted surface of
the fire-box above the foundation ring (less the area of the tube holes and the fire-
hole and ring) and the wetted surface of the tubes between tube plates. The smoke
box tube plate shall be omitted from the calculation.
(f) For vertical boilers of ordinary type the heating surface shall include the wetted
surface of the fire-box above the foundation ring (less the area of fire-hole and ring
and tube holes if any) and the surface of any cross of other tubes and uptake below
the lowest water level shown in the gauge glass.
(g) For any other heating surface not provided for in the foregoing instructions the same
general procedure shall be observed.

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 (h) No deduction shall be made of stays etc, in calculating the heating surface.
364. Boiler rating- The boiler rating shall be the number of square feet (to the nearest whole
figure) in the heating surface of the boiler as determined under Regulation 363.
365. Registration fee- The fee required to accompany an application under sub-section (i) of
section 7 of the Act shall be:
Tk.
For Boiler Rating not exceeding 100 2,500/-
For Boiler Rating exceeding 101 but not exceeding 300 3,500/-
For Boiler Rating exceeding 301 but not exceeding 500 4,500/-
For Boiler Rating exceeding 501 but not exceeding 700 5,000/-
For Boiler Rating exceeding 701 but not exceeding 900 5,500/-
For Boiler Rating exceeding 901 but not exceeding 1100 6,000/-
For Boiler Rating exceeding 1001 but not exceeding 2000 6,500/-
For Boiler Rating exceeding 2001 but not exceeding 4000 7,000/-
For Boiler Rating exceeding 4001 but not exceeding 6000 7,500/-
For Boiler Rating exceeding 6001 but not exceeding 8000 8,000/-
For Boiler Rating exceeding 8001 but not exceeding 10000 8,500/-
For Boiler Rating exceeding 10000 9,000/-

Provided that the Chief Inspector may direct that no fee shall be payable in respect of a
fresh application made in pursuance of subsection (2) of section 14 of the Act.

366. Memorandum of Inspection Book-

(a) A Memorandum of Inspection Book shall be prepared for each boiler in Form I. In
this book the inspector shall enter in ink all particulars and dimensions of the boiler
with the calculations for the various parts in details, particulars of hydraulic test and
steam test and his inspection notes.
(b) At subsequent inspections, Inspectors shall enter the dates of the inspections
hydraulic tests and steam tests when such are made with their notes thereon.
(c) Inspectors should also enter in the Memorandum of Inspection Book the general
condition of the boiler and of repairs to what extent boilers have been cleared of
brick work etc., a report of all casual visits, visits for inspection of repairs for
inspection of main steam pipes and reports on accidents etc, in this way the
Memorandum of Inspection Book will provide a useful record of the boilers history
for the information and guidance of Inspectors at subsequent inspection.
(d) On submission of the memorandum book to the Chief Inspector he will in the case
of newly registered boilers check all particulars and calculations and approve of the
working pressure that is to be permitted. In the case of old boilers the Chief
Inspector will examine the Inspectors notes of inspection and proposals made for
repairs or reduction or pressure. A pressure once approved for the boiler should not
be altered without the written authority of the Chief Inspector.
367. Registration book-

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 (a) A registration book or copy of Memorandum of Inspection Book containing all the
particulars required for registration shall be maintained in the office of the Chief
Inspector in Form I and any orders passed by him regarding the boiler shall be
entered in the registration book under his initials.
(b) The Chief Inspector should also copy into the Registration Book the notes of
subsequent inspections entered in the Memorandum of Inspection Book.
368. Transfer of Memorandum of Inspection Book and Registration Book- On a boiler
passing from one province to another the Memorandum of Inspection Book and the
Registration book shall on the request of the Chief Inspector of the province to which the
boiler has been transferred be forwarded to that officer who shall take over their custody
and maintain hem as herein before prescribed.
369. Grant of Certificate-
(a) A certificate for the use of a boiler shall be granted in Form VI. In the certificate
shall be entered the maximum pressure at which the boiler shall be worked the load
to be placed on the safety valves or the thickness of washers or ferrules required as
safeguard against over-loading the date and pressures of the last hydraulic test of the
boiler and when applicable of the main steam pipes prescribed.
(b) The inspector shall also enter in the remarks column of the certificate his
requirements if any with regard to the hydraulic test removal of lagging brickwork
or other concealing parts for the next inspection and his requirements regarding the
repair or renewal of any part that may be considered fit for the period of the
certificate.

370. Procedure at annual thorough inspections-

(a) At such inspections of a boiler the Inspector shall gauge and record the circularity of
furnaces of boilers having cylindrical furnaces. In adamson type furnaces be shall
take a vertical and a horizontal gauging of at least the three first furnace rings and
record the result in the Memorandum of Inspection book. He shall sound gusset stay
rivets to detect shack or broken rivets and shall examine gusset angles for fracture.
He shall examine the waterside of the end plates around the shell lines, furnace
flanges, at the toes of gusset stays, the bends of furnace flanges and shall test screw
stays and smoke tubes. He shall test the fit of all internally fitted manhole and other
doors. He shall examine all mountings internally and externally.
(b) Deep grooving in the bends of the flanged out furnace mouths of end plates is a
common defect when the water is bad and is difficult to detect.
(c) The Inspector should whenever the size permits go inside it and make a thorough
inspection of all its internal parts. Before doing so he should of course satisfy
himself that proper provision has been made for disconnecting the boiler from any
other boiler under steam. Should he find that proper provision for disconnection has
not been made or that the boiler has not been properly cleaned or scaled or that it is
unreasonably hot he should decline to proceed with the inspection and should report
the facts to the Chief Inspector for orders. When a boiler is of such a size or its
construction is such that the Inspector cannot go inside it, there should be sufficient
sight-holes or hand holes provided to enable him to see the principal internal parts if

121
 any important part of a boiler is so constructed that the inspector cannot examine it,
he should report the facts to the Chief Inspector for orders.
(d) Particular attention should be paid to the external parts of boilers in the way of
seating blocks, especially when the situation is damp. Saddle tanks and engine
fittings of locomotive type boilers should be removed to facilitate the inspection of
the parts underneath at the first inspection and at any reasonable period afterwards if
the Inspector cannot otherwise satisfy himself as to the condition of those parts.
(e) If the inspector decides that a boiler in one or more of its parts is no longer fit for the
pressure approved for it, he must without delay report his proposals for reducing the
pressure to the Chief Inspector and at the same time submit his calculations for the
wasted parts for check and approval of pressure.
(f) With regard to the pitting and wasting of shell plates, the Inspector should bear in
mind that shell plates may become reduced in thickness to an appreciable extent and
still be stronger than longitudinal seams.
371. Calculation of Wasted Shell-
(a) When any part is wasted and the Inspector is doubtful of its fitness for the pressure
he shall cause one or more small holes to be bored and from them ascertain the
average thickness of the parts from which he can satisfy himself by calculation in
accordance with the formula applicable to the part Such gauging and calculations he
shall enter in the Memorandum of Inspection Book.
(b) In making calculations for a wasted part of a boiler shell e.g. along the line of seating
blocks of a Lancashire boiler, the Inspector shall use the following formula:

2t 1  S
W.P. ] ... ... ... .... .... .... ..... ..... .... .... .... ... Eqn. (101)
D F
t1 = thickness of wasted plate where thinnest.
S = minimum tensile strength of material of shell in lbs. per sq. in.
D = internal diameter of shell in inches.
F = factor of safety which shall not to be less than 4.

372. Repairs to boilers-

(a) Extensive repairs such as the renewal of furnaces and plates parts of shell, fire-boxes,
girders etc. Should be supervised so far as is other duties permit by the Inspector
when the fire boxes and smoke tubes of locomotive tube boilers are withdrawn, the
opportunity should be taken inspect the internal parts which are otherwise
inaccessible to close inspection.
(b) Repairs to boiler shell be effected either by patching or by removing a strip of worn
or damaged plate and inserting the new strip with covering straps over the
longitudinal butt ends the strength of the riveted joints to be not less than that of the
longitudinal joins of the shell.

122
 (c) Patches for fire-exposed plates shall be fitted metal to metal without joint of any
description. The affected part shall be cut out, leaving the corners of the hole well-
rounded. Patches shall be secured, wherever possible by properly spaced rivets with
a width of plate at least equal to the diameter of rivet between the edge of the rivet
hole and the edge of the plate. Where riveting is impracticable the plate shall be
secured by well fitting countersunk headed screw pins.
(d) The thickness of a patch plate shall not be less than the original thickness of the plate
which it is used to patch.
(e) Bulged or distorted furnaces of circular section may if the bulge or distortion is not
too great be pressed back to shape.
(f) Circular furnaces of horizontal boilers that have become distorted under ordinary
working conditions to a greater extent than the thickness of the furnace plate i.e,
when the difference between two cross gauging exceeds the thickness of the plate
may be strengthened by fitting anti-collapse rings round the furnace at the middle of
the length of the furnace.
(g) Anti-collapse rings shall be of substantial section either of single or double angles
bolted back to back with screw stays not less than 7|8th inch in diameter and about 7
inches in pitch passed through flat of angle and screwed into the furnace the ends
being either rounded or riveted over on the fire side and fitted with nuts at the other.
The stay bolts shall be fitted with ferrules not less than 1 inch in depth between
furnace and angle ring.
(h) Welding shall not be accepted for the repair of any part of a boiler for which
welding is forbidden for a new boiler under these regulations. Boiler shells shall not
be repaired by welding beyond the filling up of a small isolated corroded or pitted
part or the making up of wasted edges of openings.
(i) Cracks or grooving in dished or flat end plates of cylindrical shells or in the bends of
furnace flange in a circumferential direction may be veed out and welded.
(j) Wasted parts of circular furnaces and fire-boxes and fire exposed flat plates as in
rectangular fire-boxes and combustion chambers may be cut out and be replaced by
new piece welded in or they may be built up by welding. Longitudinal cracks in
circular furnaces and fire-boxes and cracks in rectangular fire-boxes and combustion
chambers may be welded.
(k) No stay shall be welded.
(l) The end of the roof stay where it passes through the curved portion of the outer
casing plate may be welded a slight chamber being provide in the outer casing plate.
(m) For the purposes of these regulations renewed parts which deemed to be parts of a
new boiler intended for use at the pressure at which the boiler under renewal is used.
373. Submission of plans of boiler-
(1) In the case of land industrial boilers upto 200 m2 heating surface and upto 11
kgs/cm working pressure made in Bangladesh for use in this country the
manufacturing drawings and the particulars of materials, design and construction of
boilers shall be submitted by the maker of the boilers to the Chief Inspector of for
boilers having more than 200 m2 heating surface and more than 11 kg/cm2 working
pressure to the Inspecting Authority where the principle parts of the boiler to be

123
 manufactured/assembled for examination and approval before commencement of
the manufacture of boilers.
(2) In the case of boilers made outside the country for use in Bangladesh the
manufacturing drawings and the particulars of the materials design and construction
of boilers shall be submitted initially to the Inspecting Authority for examination
and approval. Thereafter the manufacturing drawings and the particulars of
materials, design and construction of boilers shall be submitted to the Chief
Inspector of boilers for examination before imported of boilers so as to avoid
questions arising at the examination of the finished boilers.
(3) 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
proposers 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 or Inspecting Officer in making his examination
or inspection during the construction of boilers 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.
(4) The fees for the scrutiny of the manufacturing drawings and the particulars of the
materials design and construction of boilers under sub-regulations (1) or (2) shall be
on the scale prescribed in regulation 365. When the manufacturing drawings have
been scrutinized and respect and in respect of them alternations have been
suggested and the same are resubmitted for scrutiny separate fee at the rate of 10
percent of the fee for the first scrutiny of the drawings shall be payable if the
manufacturing drawings contain alternations other than those previously suggested.
(5) The above procedure shall be followed in the case of extensive repairs or
alternations to boilers but no fee shall be leviable for examination of such plans and
particulars.
373A. Inspection fees for boilers and parts thereof constructed in Bangladesh- The
inspection fee or Boilers during construction shall be calculated on the following
basis-
(i) At four time the registration fee for a boiler of Riveted construction.
(ii) At four times the registration fee for a Boiler of Welded Construction.
(iii) At three times the registration fee for small industrial Boiler.

STEAM PIPES
374. Inspection of steam pipes-
(a) Steam pipes shall be inspected and hydraulically tested before erection in place, the
test pressure to be that prescribed in the standard conditions for steam pipes. A
certificate from an inspecting authority or a recognised maker stating that this has
been done may be accepted. If the inspector is satisfied with the test the pipes may
be erected in position at the steam test of the boiler he shall examine them under
steam pressure. No separate certificate for the steam pipes shall be issued, nor shall
a separate fee be charged for their inspection.
(b) At subsequent inspection of the boiler or at any other time, the Inspector may make
an external inspection of the steam pipes and for this purpose may require a part of
the lagging at the flanges to be removed and the pipe made bare. If as a result of this

124
 inspection the Inspector is of opinion that the pipes or any portions of them are in an
unsatisfactory condition he shall report the matter to the Chief Inspector who may
require the whole of the lagging to be removed and may require any pipe or pipes to
be hydraulically tested. The test pressure at such hydraulic test shall be not less than
twice the working pressure of the boiler.
(c) The date and hydraulic pressure to which steam pipes were subjected shall be
entered in the certificate for the boiler and such entries shall be continued from time
to time in the renewal certificate for the boiler.
375. Submission of plans of steam pipes- Plans of steam pipes shall be submitted to the Chief
Inspector before construction or at the time of registration of the boiler for his decision
whether the pipes and their arrangement comply with the regulations.
Chapter X
SAFETY OF PERSON INSIDE BOILERS
376. Safety of persons working inside boilers-
(a) No person shall be compelled or allowed by the owner or person in charge to go
inside a steam boiler for any purpose whatsoever unless the boiler is effectively
disconnected in the manner herein after prescribed from any steam or hot water
communication with any other boiler.
(b) Effective disconnection shall be made either by the removal of the boiler stop valve
or of a length of piping from all steam and hot water connections with any other
boiler, vessel or pipe containing steam or hot water or by the insertion of substantial
blank flanges between the boiler stop valves and piping. The shutting of a stop
valve, stop cock or automatic isolating valve alone shall not be deemed to constitute
compliance with this Regulation.
(c) The owner of a boiler to which this Regulation is applicable shall obtain the
approval of the Chief Inspector in writing to the method of disconnection which he
proposed to use and shall be responsible for ensuring that the method so approved is
followed in practice.
377. Penalty- Whoever contravenes the provisions of sub-regulation (a) of regulation 376 shall
be punishable with fine which may extend to one hundred rupees.
378. The Boilers Regulations, 1924 are hereby repealed but the repeal shall not affect anything
done there under.

CHAPTER-XA
SMALL INDUSTRIAL BOILER
GENERAL

379. 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 22.76 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

125
 (b) a coil type boiler or a once through boiler or a water tube boiler having the
conditions specified in clause (a) about except that-
(i) the limitation of pressure shall be 7 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/cm2, and the volumetric capacity of
particular pressure parts shall not exceed the limits specified in the respective clauses
above subject to an aggregate of 500 liters.
380. Extent to which variation from the standard conditions laid down in the preceding
Chapters is permissible- In respect of small industrial boiler, the following variations
from the standard conditions laid down in the preceding Chapters shall be permitted,
subject to the conditions specified below namely-
(a) Materials :
(i) 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.
(ii) Steel plates used in the construction of the small industrial boilers must comply
chapter II of these regulation and plate for shell and heads shall be not less than 8
mm in thickness.
(iii) Heads of parts of small industrial 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.
(iv) 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.
(b) Design, construction, workmanship and the method of computing the maximum
allowable working pressure-
(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 boilers stress relieving is not compulsory but
radiography of welded joints is required to confirm the quality of welded joints
(iii) In the small Industrial Boilers unflanged steel tube plate may be inserted into the
shell and welded for the entire thickness as shown in figure below with a fillet weld
having a throat not less than 1¼ times the thickness of the shell or tube sheet
whichever is smaller.

126
 (iv) The minimum thickness of unflanged welded tube sheets shall be 10 mm.
(v) The temperature of the heating element of electrically heated steam small industrial
boilers shall be so controlled that it shall not exceed 650º C.
(vi) The tubes shall be made of steel.
(vii) The tube holes shall be drilled full size with shells but starps and ends bolted up in
position or may be punched at least 1.3 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 metalwith pins
fittings the holes and with tack bolts.
(c) Inspection and testing- The small Industrial Boilers shall be subject to inspection
during construction and after completion by an Inspecting Authority or Chief Inspector of
Boilers. The inspection of the small industrial boiler shall be made at the following stages.
A. Small industrial boiler of shell type:
(i) Material identification and inspection,
(ii) Inspection of each component after completing welding & drilling.
(iii) Assemble of boiler.

(iv) Hydraulic test:

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

(d) Certificates and Maker’s Stamps-

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 small industrial boilers all information can not be
visibly stamped on the boiler plate, maker’s certificate accompanying the boiler

127
 shall contain the necessary details, but in all cases name, works number and the
yare of the making must be stamped or exhibited on the small industrials boiler.
381. Valves, Gauges, Fittings and Fee supply-
(1) Washout Plugs, etc, for clearing-
(a) Every boiler shall be fitted with at least 3 brass wash plugs of not less than 2.5 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.
(b) Boilers not exceeding 300 mm internal diameter may have two 2.5 mm opening for
cleaning one of which may be used for the attached of the blow off valve. The
openings shall be opposite to each other, wherever possible. All threaded openings
in the boiler shall be provided with riveted or welded reinforcement, if necessary, to
give four full threads therein.
(c) Electric boilers of a design employing removable top cover flange for inspection
and cleaning need not be fitted with washout openings and washout plug. Level
gauges are not required for once through boilers.
(2) Every boilers shall be provided with at least one feed pump or other feeding device
except where it is connected with a water main carrying pressure to feed the boiler or
where the steam generator is operated with no extraction of steam (closed system). In
the later 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 1.3 mm in
diameter.

(3) 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 kgs/cm2 . All these fittings
except safety valves shall certified by manufacturers of the fittings themselves.
(a) Feed Pipe- The feed pipe shall be provided with a check valve and a stop valve of a
size not less than that of the pipe. The feed water may be delivered to the boiler
through the openings of the same size in the shell as that of the blow off connection.
(b) Blow off- Each boiler shall be equipped with a blow off connection, not less than
18 mm in size located to drain the boiler water from the lowest water space
practicable when the boiler is under pressure. Feed water shall not be introduced
through the opening or connection needed for the water column, water level
indicator or the gauge cock.
(c) Water Level Indicator/Water Gauges- 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.

128
 (d) 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 connection shall be through siphon.
(e) Safety Valve- Each boiler shall be equipped with two safety valves in series 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 percent 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 atmosphere.
The electrically hearted boilers shall be effectively earthed with a lead of substantial
cross section.
382. Registration, Operation and Maintenance of small industrial boilers-
(1) The Registration & inspection fees for small industrial boilers will be determined as
per existing rules and regulations.
(2) The certificate of manufacture and test for Small Industrial Boilers shall be
furnished in Form XII appended these regulations;

FORM I
(Regulation 366 and 367 of 1951)

BOILERS ACT, 1923

BOILER INSPECTION DEPARTMENT

BOILER
REGISTRY NUMBER

129
 MEMORANDUM OF INSPECTION
OR
REGISTRATION BOOK

Miscellaneous
District..................................................................................................................................................
Owner...................................................................................................................................................
Address of Factory.................................................... ..........................................................................
..............................................................................................................................................................
..............................................................................................................................................................
Nearest Railway Station.......................................................................................................................
Work of Factory ...................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
BOILER REGISTERED at...............................................on...............................................................
REGISTRY BOOK No...............................................PAGE...............................................................
REGISTRY NUMBER............................................Verified on.........................................................
APPROVED WORKING PRESSURE..........................................................................................lbs

130
BOILER RATING ............................................INSPECTION FEE.....................TK........................
REGISTATION BOOK filed at.............................................. on.......................................................
..............................................................................................................................................................
Remarks on transfers etc.......................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................

PROVISIONAL ORDER AND CERTIFICATE RECORD

Fee Date of Date Certificate Period Working Boiler Remarks

Payment of No. of pressure Rating and
Inspection and Date. Certificate Initial of
Inspector

131
 PARTICULARS AND DIMENSIONS
Type of boiler.............................................................leading dimension............................................
Maker.........................................................Intended working pressure ..............................................
Place and year of make....................................maker’s number...........................................................
Description of boiler.............................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
Facsimile of
Maker’s stamp
Position of stamp..................................................................................................................................

MAKER’S CERTIFICATES
Boiler Name...........................................................................................................
Maker
132
 Manufacture, hydraulic test to ............lbs. drawing No.......received.........
Inspecting Name...........................................................................................................
Authority Tests of material construction supervision, hydraulic test, received..........
Steel Name..........................................................................................................
Plates
maker
Process...............................received...........................................................
Name..........................................................................................................
Bars
Process...............................received...........................................................
Name..........................................................................................................
Rivets
Process...............................received...........................................................
Rolling Plates..................................received..........................................................
Mill

Bars....................................received..........................................................
Rivets.................................received...........................................................

TEST RESULTS

Shell......................T.................to..................tons. E..........to..............% in................ins

PLATES

Gusset Stays..........T.................to..................tons. E..........to..............% in................ins

Girders...................T.................to..................tons. E..........to..............% in................ins

End and Side..........T.................to..................tons. E..........to..............% in...............ins

133
 Fire and Flanged....T.................to..................tons. E..........to..............% in................ins

...............................T.................to..................tons. E..........to..............% in................ins

...............................T.................to..................tons. E..........to..............% in................ins

Bar.........................T.................to..................tons. E..........to..............% in................ins

STAYS

Screw.....................T.................to..................tons. E..........to..............% in................ins

Bar.........................T.................to..................tons. E..........to..............% in................ins

RIVETS

Manufactured........................................................................................................................

Plates.....................................................................................................................................
BENDS

Bars.......................................................................................................................................

BRANDING Plates.............................................................................................................................

.......................................................... analysis...............................................................

............................Phos.............................................................Sulph.............................

............................%.....................................................................%...............................

PARTICULARS AND DIMENSIONS- contd.

Plates, ...................................................................................................................................
Branding

..............................................................................................................................................
Analysis.
..............................................................................................................................................................
.............................................................................................................................................................
............................Phos.........................................................................Sulph........................................
% %
..............................................................................................................................................................
.............................................................................................................................................................

CYLINDRICAL SHELL
(a) (b) (c)
Shell Barrel Steam and
or water
Mud Drum or
Drum Dome
Names of parts ... ... ... ... ... ...

134
 Number and material of each ... ... ... ... ... ...
Length between end plates ... ... ... ... ... ...
Length between end seams ... ... ... ... ... ...
Diameter inside largest belt ... ... ... ... ... ...
Thickness of plates ... ... ... ... ... ...
Number of belts of plating ... ... ... ... ... ...
First or top belt, inside or outside ... ... ... ... ... ...
Position (O’clock) ... ... ... ... ... ...
Kind L.S.B., D.B., W. ... ... ... ... ... ...
Riveting S., D.T.C., Z., H., M ... ... ... ... ... ...
No. of rivets per inch ... ... ... ... ... ...
Longitudinal Seams

Pitch of rivets ... ... ... ... ... ...

Diar. of holes, outer rows ... ... ... ... ... ...
Diar of holes, inner rows ... ... ... ... ... ...
Distance between rows, outer ... ... ... ... ... ...
Distance rivet centre to edge ... ... ... ... ... ...
Distance between rows, inner ... ... ... ... ... ...
Outer butt strap, width × ... ... ... ... ... ...
thickness
Inner butt strap, width × ... ... ... ... ... ...
thickness

No. of seams (end inner) ... ... ... ... ... ...
Circumferential Seams

Kind L., S.B., D.B.W.F.&B. ... ... ... ... ... ...
Riveting S.D.T.C.Z.H.M ... ... ... ... ... ...
No. of rivets per pitch ... ... ... ... ... ...
Pitch of rivets ... ... ... ... ... ...
Diar of holes ... ... ... ... ... ...
Distance between rows ... ... ... ... ... ...
Distance rivet centre to edge ... ... ... ... ... ...

PARTICULARS AND DIMENSIONS- Contd.

SHELL, END PLATES AND LONGITUDINAL STAYS

135
Parts and material hereunder
..............................................................................................................................................................
.............................................................................................................................................................
Flat, dished, hemispherical (in.............................................. pieces), not stayed, not flanged
Plate

Diameter (outside), front.................. back, ....................... crown,............. largest circle........

Radius of curvature from...................back,..................... crown ............................................
Radius of corner of flange, shell...............furnace................... uptake...................................
Plate thickness, front................. back ............... crown, tube plate F......... B.........................
Attach. to shell, crown or front,..............................................................................................
Attac, shell.......................back end,.........................................................................................
Attach, to uptake or furnace crown or front............................................................................
Attace, to furnace flue, back end, ..........................................................................................
Shellangle...............×..................×.................... riveting, S., D., pitch ............. holes.............
Furnace or uptake riveting, pitch circle,........................... pitch.........................holes.............
Heml, end, sectors, no............... riveting S.D.,.................... pitch.................... holes............
Steam space doubling plate, front............................................ back.....................................
Stays

Steam space stiffens or bultb, front.......................................... back.......................................

.................................................................................................................................................
.................................................................................................................................................
.................................................................................................................................................
Gusset stays. No. F.E. top ..........bottom ................ B.E.top;.................... bottom.................

Longd. stays No. ....................... diar.................... threads, ............ nutted...........................

Longd, stays, pitch,.......... V. .............H...................... circle................... washer..................
.................................................................................................................................................
Diagl. stays .............................................................................................................................
.................................................................................................................................................
........................................................................................................................................................................
MANHOLES, HAND AND SIGHT HOLES, DOORS AND STAND BLOCKS
Parts and material hereunder .......................................................................................................................
.........................................................................................................................................................................
.........................................................................................................................................................................
No. and position .....................................................................................
Manholes

Framed or plate flanged .....................................................................................

Boiler opening, length × width .....................................................................................
Frame opening length × Width .....................................................................................
Frame inside, outside, raised, pressed .....................................................................................

136
 PARTICULARS AND DIMENSIONS- Contd.
MANHOLES, ETC.- Contd.

Frame Solid, welded, cast ...................................................................... ..............

Frame section on longtl. axis ...................................................................... ..............
Manholes-contd

Door, type and thickness ....................................................................................

Door, if inside, spigot clearance ..................................................................... .............
Bolts, no., diar, threads nuts ...................................................................................
Bolts, pitch circle. ...................................................................... .............
Compensation ring, width × thickness ...................................................................................
Riveting S.D.T. no. rivets, diar, holes ....................................................................................

No........................ dimension.................................. position.................................................

Sightholes

Compensation rings fitted........................... section ...................................×...........................

Doors, type, .....................bolts, diar,............................. thread, spigot clearance...................
Cleaning plugs No............................... diar ........................................ position......................
.......................................................................................................................................

Height ............... diar (outside) top .................. bottom ........................ thickness................

Blocks. etc.

Standpipe below stop valve,................. height ............... diar (outside) .............. thickness
Flanges ....................................................................................................................................
..................................................................................................................................................
.................................................................................................................................................
.................................................................................................................................................

FIREBOX CASING
Parts and material hereunder : ...........................................................................................................
.............................................................................................................................................................
Length overall bottom,........................................ width overall, bottom...............................
Plates

Height, foundn, seams to inside of crown plate,....................................................................

Crown, arched or flat, riveted to or one piece with sides, diar,.............................................
Plate thickness, front,............... sides,.............. saddle,.................. crown.............................
Radius of corner of flange, front,.......................... saddle,.........................crown..................
Riveting, front to side, S, D, pitch........................... holes............... spacing.........................
Riveting saddle to sides S, D, pitch.......................... holes............... spacing........................

137
 Cross stays, No......................Diar,........................... threads.......nutted, riveted, pitch.........
.......................................................................................................................................

PARTICULARS AND DIMENSIONS- Contd.

RECTANGULAR FIREBOX, COMBUSTION CHAMBER, GIRDERS SMOKE OR WATER TUBES
AND SCREW STAYS
Parts and material hereunder: ..............................................................................................................
.............................................................................................................................................................
Length inside, bottom, ..........top........... width inside, bottom,............ top........................
FIREBOX OR COMBUSTON CHAMBER

Height, foundn, seam or chbr. bottom to roof,......radius of curve, chbr bottom........roof side......
Roof, flat, curved, cambered, corrugated, styled to shell or girders, type,........................
Plate thickness, firehole or chbr, back,............ sides,............... roof.................................
Plate thickness bottom,.................. tubeplate F,............B,........... Roof and sides in one...
Attacht to firebox casing at bottom....................................................................................
Attacht to firebox casing at firehole...................................................................................
Foundn. ring, section....................... riveting, pitch,.......................bolts...........................
Firehole, section......................riveting, pitch............................bolts.................................
Firehole, opening..............×........... distance of centre, above foundr., seam,....................
Side seams, distance between,......... riveting pitch,................bolts...................................
............................................................................................................................................
............................................................................................................................................

Firegrate dimensions ........................................ type,........................................................

Girders

Type............... section............... no.................. lengthwise, crosswise, rest on .................

Distance apart,....... Bolts, no........ pitch,....... diar,.........threads, mutted, screwed into
girder
Slings. no............distance apart,...............× .........section.........× pines diar,..................
slings attacht to shell..........................................................................................................
............................................................................................................................................
No, plain,..................stay,...................length between tube plates,.............. make............

138
 Tubes Plain, diar, (out)...............thickness............ F.E. expd, bead frld. S.E. Expd, head or......
Stay, diar (out)...............thickness............ F.E. expd, bead nutted. S.E. Expd, nutted......
Stay, diar, (out),over threads, F. E,.........S.E,...............threads,............... nuts...................
Pitch of plain tubes, V,............. H................... D .................. C.7., straight curved, lie.....
Pitch of stay, tubes, ,............ × ................... × ....................× ........... marginal pitch......
............................................................................................................................................
Tube plate, no. of rows, ... V,............H................ Pitch V,.......... H,...............
Screw stays

F. hole or back or rows, ... V,............H................ Pitch V,.......... H,...............

Sides, no. of rows ... V,............H................ Pitch V,.......... H,...............
Roof, no. of rows ... L., Wise.........C., Wise.......... Pitch, L.,......... C,....
Bottom, no. of rows ... L., Wise.........C., Wise.......... Pitch, L.,......... C,....
Ordinary stays, diar,.............. threads,...... nuts,.......... riveted, bodies turned to........... in
Marginal, diar,......................threards, ......nuts,.......... riveted, bodies turned to..............
Roof, diar,.............................threards, ......nuts,.......... riveted, bodies turned to..............

PARTICULARS AND DIMENSIONS- Contd.

CIRCULAR FURNACE, CROWN AND UPTAKE
Plates and material hereunder: .........................................................................................................
.............................................................................................................................................................
No of furnaces,.................................................. Type......................................................
No of rings in each........................................ longtl. seams...........................................
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Length R
between
centre
L
Inside R
diameter

L
Horizontal Vertical Furnaces.

Plate R
thick
ness
L
position R
of cross
tubes
L

139
 Flanges, type...............................riveting, pitch, ..................... holes..............................
Caulking ring............. × ...............Radius of corner................ Flange width................
Crosstubes, no each furnace............... longtl. seam.................... riveted, welded to flue
Crosstubes, diar, (outside), top................bottom..................... thickness.......................
Attacht. to shell at bottom................................................................................................
Attacht to shell at firehole
Foundn, ring, section.............................riveting, pitch.......................... holes ................
Firehole rings, section.............................riveting, pitch.......................... holes ..............

Firehole opening..........................distance of centre above foundn. seam.......................

Screw stay. no of rows.............pitch, V,.........H,............nearest row o foundn. seam.....
screw stays, diar, ...........threads,.......... nuts........... riveted, bodies tured to................in
..........................................................................................................................................
..........................................................................................................................................
Firegrate dimensions,............................................type...................................................
Crown

Flax, dished, hemispherical, not stayed, not flanged, Diar, (outside).............................

Radius of curvature,.............corner of flange, furnace,....... uptake......argest circle.......

Plate thickness, crown,...........ogee ring............... boltstay pitch circle...........................
Attacht. to furnace or ............................................ to uptake..........................................
Uptake riveting, pitch circle,..................pitch.................. holes......................................
..........................................................................................................................................

Cylindrical tapered, flanged.................. longtl. seam.......... length between seams.......

Thickness,..............Diar.(outside), top....................bottom...................Liner not fititted

.................................................................................................................................
..........................................................................................................................................

\
PARTICULARS AND DIMENSIONS- Contd.
WATER TUBES, HEADERS, BOXES AND SUPERHEATER

Parts and material hereunder ..........................................................................................................................

Main tubes, no.................................................................... make....................................

Diar, (outside), .......................thickness....................... length between headers or plates
Tubes.

Pitch, V, .................H.................... D.......................... C.Z. Straight, curve, Lie..............

Ends expanded, beaded, belled to.................in, in...................................................
Downtake tubes, no......... diar (outside).........×............ thickness.........length (exposed)
..........................................................................................................................................
Headers

Headers, no, ........ section (outside),...............×.............thickness,.............solid, welded,

Staggered or straight Lie,...............................no. tubes in each,......................................

Boxes

Caps round, oval, square, inside, outside, Bolts, diar..............threads, nuts....................

140
 Mudbox, Length,..........section (outside).....................thickness,...............solid, welded

Cross boxes, no..............section (outside).....................thickness,...............solid, welded

Super heater Tubes, no,...........diar (outside)...................... thickness......................make.....................

Straight, curved, Lie, ..................................................................... Position....................

Ends expanded, beaded, belled to ................................... in., in.................................
Description of superheating system,.................................................................................
...........................................................................................................................................
...........................................................................................................................................
...........................................................................................................................................
Firegrate dimensions .............................................. type. ...............................................
...........................................................................................................................................

DESCRIPTION OF INTEGRAL ECONOMISERS

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

PARTICULARS AND DIMENSIONS- Contd.

DESCRIPTION OF INTEGRAL ECONOMISERS- Concld.

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

141
 ..........................................................................................................................................................

..........................................................................................................................................................

MOUNTING AND FITTINGS

Number Diameter Type Material Bolted to
safety
Valves, etc. Chests

safety
M.Stop
A. Stop
Feed
Blow Down
Scum
Injector
Water gauges, No, ................. type.............................Test cocks No...................
Miscellaneous Fittings.

Water gauges, top of lower nut is.................... inches above.................................

Test cooks, bottom cock is...............................inches above..................................
Pressure gauge, type ............................diar.................ins. range......... ............lbs.
Pressure gauge, maker ...............no..................red line at .............................. lbs.
Tester attachment, type.................screw........................ position..........................
Fusible plug, type.....................................position.................................................
Blow down elbow, material.................waste pipe, separate, connected to............
Centre of feed inlet is ....................inches above........................on right, left side
Feed appartus.........................................................................................................
................................................................................................................................
Additional fittings
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
CALCULATIONS
SHELL, BARREL, S. & W. DRUM, F.C. CROWN, DOME, M. DRUM, RIVETED JOINT
Parts Joints Fig. No. Longitudinal Joint Fig. No. Circumferential
(A) P.....D.....T..... P.....D.....T.......
N. C. S1 N. C. S1
(B)

142
 (C)
Actual Rule Actual Rule

Max.
Pitch

Outer
Rows

Inner
Rows

Edges

Wide
strap

Narro
w
strap
Plate 100( P ] D)
= %
% P 100( P ] D)
= %
P
Rivet 100  A  N  C  S1 100  A  N  C  S1
= % = %
% P T  S P T  S

Comb 100( P ] 2 D) 100  A  C  S1

] =%
d. % P P T  S

Worki (T ] 2)  S  J
t.......S........J........C......D......W.P. = = lbs.
ng CD
Pressu
re
Least pressure..............................lb.

CALCULATIONS- Contd.
FLAT END PLATES AND GUSSET STAYS
PLATE STIFFNESS
Dimensions Front Back FRONT END

143
 t .. .............. ............. (t ]1) 2
Thick W.P. = = lbs.
D2
ness
t .. .............. .............
I-I .. .............. ............. Around Manhole
[(t ]1) 2 ] (t1 ]1) 2 ]
Diameter of circles (D)

W.P. = = lbs.
D1
I-II .. .............. .............
II-III .. .............. .............
III .. .............. .............
IV .. .............. .............
IV-V .. .............. ............. BACK END
(t ]1) 2
W.P. = = lbs.
D2
Over Furnaces .. .............. .............
Below Furnaces .. .............. .............
Manhole .. .............. .............

AREAS (A) SUPPORTED BY GUSSET STAYS

Dimensions Front Back
.............. ............. Gussets FRONT END Areas
Length of Lines

Mid .............. ............. I = Sq. in.

I .............. ............. II = ”
II .............. ............. III = ”
III .............. ............. IV = ”
Distance between

IV .............. ............. V = ”
V or Mid .............. ............. BACK END
Lines

I-I .............. ............. I = ”

I-II .............. ............. II = ”

II-III .............. ............. III = ”
III-Apex .............. ............. IV = ”
IV-Apex .............. ............. V = ”
IV-V or Mid .............. .............

PLATE MARGINS

110  (t ] 1) 2 96(t ]1) 2

1/ 2  = ins. 1/ 2  = ins.
W .P. W .P.
LEAST PRESSURE......................... lbs.

144
 CALCULATIONS-Contd
FLAT END PLATES AND GUSSET STAYS
Gusset Stay Particulars
Gusset Plate,
hickness................tons.................................angles...................×...........................×........................
GUSSET N1 N2 N3 N4 D1 D2 D3 D4 G G1 Toe Rivets
Number I. F
and
Diameter
of Rivets
and Section
of Stays
B
II. F
B
III. F
B
IV. F
B
V. F
B

GUSSET STAY CALCULATIONS

CO- I II III IV V
EFFICIENT(C)
N1 × A1 F
B
N2 × A2 × 1-75 F
B
N3 × A3 × 1-75 F
B
N4 × A4 F
B
(G - N2D2) (t - 2) .037 F
B
(G1-D3) (t - 2) .037 F
B
WORKING 8500×C F
PRESSURE
B
A F
B

145
Least Pressure...................... lbs.

CALCULATIONS- contd.

LEAST PRESSURE...................... lbs.

146
 CACULATIONS – contd.
SAFETY VALVES
(A) (B) (C)
No. valves each chest
Type
Diameter of valve
Diameter of neck
Diameter of outlet

Weight B .. ................... Balanced Lever ( )

[W .P.( A ] a ) ] V ] V to F
= ins
B
Unbalanced Lever ( )
[W .P.( A ] a ) ] V ]V to F ] (G to F ) L
= ins.
B
L .. ..................
V .. ..................
B. to f. .. ..................
Distance
G. to F. .. ..................
W. to. f. .. ..................

Small Valve ( )
W.P. × a ( ) =
Ordinary Type.
Unbalanced Lever ( )
(W .P.  A ] V )V to F ] (G to F ) L
= ins.
B

Weights DEAD WEIGHT VALVES ( )

W.P. × A =
lbs.

147
 Plates ....................
Casing
....................
Valve
....................

SPRING LOADED VALVE. ( )

Range of compression ..........................Inches...........................Load compression...............................ins.
L = (A × W.P.)..........................; D = .......................... C= ............................; T = ..............................;
d =.......................; B =......................... , H = ..................., W.P. = ........................, A = .......................
A=
Round Section Rectangle Section
Cd 2
CB 2  H 3
W.P. = W.P. =
D A AD(3B ] 18 H )

REQUISITE AREA OF SAFETY VALVES.

E
E = .......................; C = ........................ ; P = ................................. ; A=
CP

CALCULATIONS- Concld.
HEATING SURFACE.

Total Heating Surface........................................................................................................sq. ft.

Boiler Rating..............................................................................................................................

Calculations made by............................... on submitted on..................................................

Calculations checked by.......................... on.........................................................................
Least Pressure, that for...............................=.......................................................................lbs.

148
 Approved working pressure.....................................................................................................
Chief Inspector’s Remark and Signature..................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................

HYDRAULIC TEST (REGISTRATION)

Inspector....................................... Date of test......................Test pressure ...................... lbs....................
Duration of Test........................... mins.......... Boiler pressure, gauge No................... used at test.............
Boiler pressure gauge compared with ..................................on............................ found...............................
Position of Boiler at test.................................................................................................................................
Brick work........................................................................... Lagging.............................................................
Condition of boiler under test.........................................................................................................................
Condition of boiler mountings under test.......................................................................................................

RIGHT HAND
Ring Nos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Furna
ce
Gauge
ings
Before Test V
H
During Test V
H
After Test V
H
Bulging V
H
Permit. Set V

149
 H

LEFT HAND
Ring Nos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Furna
ce
Gauge
ings
Before Test.. V
H
During Test. V
H
After Test... V
H
Bulging....... V
H
Permit. Set.. V
H

FRONT END BACK END sketch position of gauge points.

Gauge Points A B C D A B C D
Plate
Gaugeings
Before Test ... ... ... ...
During Test ... ... ... ...
After Test ... ... ... ...
Bulging Test ... ... ... ...
Permit. Set ... ... ... ...

STEAM TEST (REGISTRATION)

Inspector.......................................................................................Date of test....................................
Approved working.....................................lbs Test Pressure...................................................lbs.
Inspector’s pressure gauge............................................Boiler pressure gauge No.............................
Boiler connections .....................................................Condition of fire.............................................
Fuel used......................................................................... Draught......................................................
Safety valves lifted at (A) .................lbs. (B) .............................. lbs. (C).................................. lbs.

Beginning 5 mins. 10 mins. 15 mins. Difference.

150
 Timing Test ... ...

Height of water in glass ... ...

Pressure by Inspector’s gauge ... ...

Pressure by Boiler gauge ... ...

Accumulation of pressure, 100(-) = %

Accumulation of safety valves efficiently relieve boiler ?..................................................................
Condition of boiler under steam..........................................................................................................
Condition of mountings under steam..................................................................................................
Loading of valves at blowing pressure (A).........................................................................................
Loading of valves at blowing pressure (B).........................................................................................
Loading of valves at blowing pressure (C).........................................................................................
Thickness of washers of ferrules........................................................................................................
............................................................................................................................................................
Feed pump or injector worked..........................................................................................................
Water gauges tested..........................................................................................................................
Boiler attendant................................................................................................................................
Limit of load on safety valves to be entered in certificate...............................................................
...........................................................................................................................................................
...........................................................................................................................................................
...........................................................................................................................................................

NOTES ON WORKING OF BOILERE

Boiler is used for ................................................................................................................................
Constant, intermittent or seasonal work..............................................................................................
Is boiler relieved by spare boiler ?......................................................................................................
How long worked between cleanings ?...............................................................................................
Most suitable for time inspection........................................................................................................
Pump available for hydraulically testing boiler ?................................................................................
Nature of water....................................................................................................................................
Fuel used............................... are printed instructions kept near boiler?.............................................
Period between clearings approved by inspector................................................................................

151
 STEAM PIPES
PLAN OF BOILERS AND MAIN STEAM PIPES

STEAM PIPES- contd.

PARTICULARS AND DIMENSIONS
Situation...............................................................................................................................................
Ry Nos. of connected boilers...............................................................................................................
Main steam pipes include..............................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
Pipes, material ................................................................... diameter (outside).............................................
Pipes, thickness ............................................................... ins., make...........................................................
Pipes, attachment of flanges..........................................................................................................................
Pipes, made by ................................................................................ installed in...........................................
Drainage.........................................................................................................................................................

152
........................................................................................................................................................................
........................................................................................................................................................................
Pipe covering....................................................................................................................................
Provision for disconnection from other boilers................................................................................
Main steam.......................................................................................................................................
Auxy. Steam.....................................................................................................................................
Blow down.......................................................................................................................................
Feed delivery....................................................................................................................................

CALCULATIONS
W.P..................................................

STEAM PIPES- Contd.

RECORD OF INSPECTIONS AND TESTS

First inspection inside and outside ....................................................................... on......................

First hydraulic test (to..................... lbs.)............................. by............................. on......................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................

INSPECTORS NOTES- Contd.

........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
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........................................................................................................................................................................

153
........................................................................................................................................................................
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PARTICULARS OF BOILER ATTENDANT-Contd.

Grade. Name. No. and year. Date of
of certificate employment

154
 FORM-II
Inspecting Certificate in During Construction

DESIGN AUTHORITY
We hereby cer type
Boiler; length Inches
Diameter Inches, working
Pressure Built by
Messrs at

155
under shop Number was constructed under out supervision and inspected at various stages of
construction by the Inspecting Officer and that the construction and workmanship were
satisfactory and in accordance with the Standard Conditions for the design and construction of land
boilers under the boilers Act, 1923.
The boiler is stamped of the front end plate with our stamp as shown hereunder:
MAKER’S NAME
Works number Year of Make
Tested to lbs. on
W.P. lbs. Inspecting Officer’s or
Inspecting Authority’s
Official Stamp

The boiler on completion was subjected to a water pressure test of lbs.; per square inch in the
presence of the Inspecting Officer on 19 and satisfactorily withstood the test.
Samples of the plates, stays angle and rivet, bars used in the construction of the boilers were tested
in the presence of the Inspecting Officer and were found to comply with the test prescribed in
Chapters II and V of the Regulations relating to Standard Conditions for the design and
construction of boilers under the Boiler Act, 1923.
We have satisfied ourselves that the construction and dimensions of the boiler are as shown in the
maker’s drawing no. signed by us, and that the particulars entered in the maker’s certificate of
manufacturer in Form III countersigned by us, are correct to the best of our knowledge and belief.

Signature of
Inspecting Authority
Dated: this day of 19

FORM IIA
Inspecting Authorities certificate of inspection during construction in respect of a boiler made to
International standard or foreign code for export.
[Regulation 4(cc)]
DESIGNATION OF THE INSPECTING AUTHORITY
We hereby certify that the ..............type boiler; length................. diameter ............
working pressure.................built by Messrs..................... under Shop No................... was
constructed under our supervision and inspected at various stages of construction by the Inspecting
Officer and that the design, construction and workmanship were satisfactory and in every respect
in accordance with................ code Specification. The boiler is stamped as under.
MAKER’S NAME

156
Works number Year of make
Tested to on
Working pressure Inspecting Officer’s or
Inspecting Authority’s
Official Stamp.

The boiler on completion was tested to ................. in the presence of the Inspecting Officer
on ............... and it satisfactorily withstood the test. Details of tests and inspections are furnished
with certificate.
We have satisfied ourselves that the design, construction and dimensions of the boiler are as
shown in the Maker’s Drawing No.............. approved and signed by us, and that the particulars
entered in the Marker’s Certificate of manufacture are correct to the best of our knowledge and
belief. Maker’s certificate, signed by them and counter signed by us, as required by the ..............
Code/Specification is enclosed.

Signature of Inspecting Authority

Dated.........................................this..............................Day of...............................20........................

FORM III
WORKS ADDRESS
Constructions Certificate of Manufacture and Test
[Regulation 4(d)]
1
Description Type of boiler Length overall Diameter inside largest belt
Intended working pressure lbs. shop number of boiler
Year of Manufacture Total heating surface Sq. ft. Grate area
sq. ft. Description of Boiler
Total Evaporation lbs. P.H.
2 Boiler constructed under supervision of
Inspecting Boiler hydraulically tested and internally inspected after test by

157
 Authority
3 Shell seams The longitudinal seams are and have rows of
Construction rivets in inside strap and rows of rivets in outside strap, Rivet holes are
and inch diameter and number per pitch of
Workmanship inches.
Butt strap cut from plates and bent to required curve in The
Circumferential seams joining rings of shell are and riveted.

FORM III- contd.

WORKS ADDRESS
Constructions Certificate of Manufacture and Test
[Regulation 4(d)]
3 Rivet holes are inch diameter and number per pitch of
Construction inches. The shell and seams are and riveted, Rivet holes are
and inch diameter and number per pitch of inches.
Workmanship Details of seams as in drawing No.
contd. Furnace Seams.- The longitudinal seams are The cross seams joining rings are
of type riveted.
Workmanship. All rivet holes in cylindrical shell and furnace flues were drilled in
place after plates were bent; plates afterwards taken apart, burrs removed and rough
edges of holes cleaned before riveting. Riveting wherever practicable done by
machine.
All fire-worked plates efficiently annealed after completion of operations. welded
parts of boiler are welding process.
No part of boiler proper including doors, mouthpieces and stand bricks is made of
cast iron or malleable cast iron.
Fusion welded drums- The construction is in accordance with chapter V of Boiler
Regulations.
Number of longitudinal seams in each ring.
Details of repairs to seams during construction, if any.
Details of Heat Treatment.-

4 Boiler Parts and Material Smelter Maker Inspecting Remarks

Fittings Officer
Particulars Plates
of Material Plates
used Rivet bars
Stay
Angle
Bolts
Tubes
Girders
Manhole doors
Manhole Compn. ring
Sighthole doors

158
 Stand blocks
Stop Valve Chests
Safety Valve Chests
Feed Valve Chests
Blow down elbow pipe
Water gauge mountings
Note: Under “Material” enter against appropriate item:- “Steel, Siemes Martin; open hearth, acid (or
basic) process”; “Wrought iron, Brand.......” “Cast Steel, Process..........” etc. and under “Remarks” a
brief explanation of process or manufacture where necessary, e.g. “Solid drawn”, “Lap welded”, “Solid
pressed”. Tested by makers.................lbs. per square inch, etc.

FORM III- contd

Thickness of Plates, etc, and tensile Test Limits
5 Part of Boiler Thickness Tensile Elongation Gauge Brand and
of plates in strength limits to % length number on
32nd or diameter limits to inches plate
in inches tons
Cylindrical Shell
Shell Plates. Butt straps
Steam and water drawn
Barrel (Loco.)
Firebox Causing Crown (Loco.)
Dome
Mud drum

Shell End Front End

Plate Back End
Shell Crown
Dome End
Mud Drum End
Saddle (Loco.)
Firebox Casing Sides (loco.)
Doubling Plate

Flanged and Furnace, Circular (plain) (6) Certified that the particulars entered herein
fire exposed Furnace, Circular (plain) in manuscript by us are correct and that the
plate parts and fittings in sections 4 and 5 against the
Furnace, Circular (corrugated)
names of which entries are made, have been
Firebox Crown used in the construction and fittings of the
Firebox side boiler.
Firebox Front
Firebox tube
Uptake
Smokebox tube

The particulars shown against the various parts

used are in accordance with the maker’s
certificates in our possession.

159
 Tube Cross Tubes The design of boiler in section and end view
with principal parts fully dimensioned is that
Water Tubes
shown in drawing.......................No.................
Smoke Tube (plain) The boiler has been designed and constructed
Smoke Tube (stay) to comply with the regulations under the
Super heater Boilers Act, 1923 for a working pressure of lbs.
Headers per square inch at our works above named and
satisfactorily withstood a water test of lbs. per
Cross boxes
sq. inch on the day of 19 in the presence of our
Mud boxes responsible representative whose signature is
appended hereunder.

Maker
Stay and Gusset stay (plates)
Bolts. Longitudinal
Cross
Screw

FORM III- contd

Stays and Firebox Roof slings Signature of Engineer Signature of Maker of
Bolts-contd Firebox Roof pins who witnessed test. Secretary of Firm.
Girder Bolts
Shell Angle Bolts
Uptake Angle Bolts
Manhole Bolts Designation
Sight hole Bolts
Dated at the day of 19
Miscellaneous Firebox Girders
End plate Stiffeners
Shell Angle Signature of Inspecting Authority
Furnace Angle
Uptake Angle NOTE- The drawing of the boiler and steel
Gusset Angle maker’s certificate of manufacture and
Manhole Compn. Ring results of plate tests for tensile strength
Manhole Frame elongation and bending must
Manhole Cover accompany this certificate and if boiler
Sighthole Compn. Ring has been built under the supervision of
Sighthole Doors and Inspecting Authority their
Stand Blocks certificate in Form II must be attached.

FORM IV
STEEL MAKER’S CERTIFICATE OF MANUFACTURE AND RESULTS OF TESTS
[Regulation 4(c)]
DESIGNATION OF ROLLING MILLS
We hereby certify that the material described below has been made by by the
electric, open hearth, acid, basic, process and rolled by us and has been satisfactorily tested in the

160
presence of your Inspecting Officer, our Test House Manager. In accordance with the Standard
tests.

Date of Tests 19 Signature or Initials

Ordered by Test House Manager
Order Number Date
Boiler Number

FORM IV-contd
RESULTS OF TESTS
Charge Number Part Number Size of Plates Tensile Elongation Bend
Number of of of Piece breaking in inches tests.
Plates Boiler strength in per cent.
tons per
sq. inch
Length Breadth Thickness
ft. In. ft. in 32nds
in. in

Counterfoil No.
No.

[Regulation 361 (c)]

161
 PROVISIONAL ORDER UNDER SECTION 9 OF THE BOILER ACT OF 1923
FORM V

are here by permitted to use the boiler (registry No.) are here by permitted to use the boiler
boiler rating made by (registry No. ) boiler rating made by
and bearing Maker’s number at a maximum and bearing Maker’s number at a maximum
Pressure of lbs. pressure of lbs.
Per square inch pending the issue or refusal of a per square inch pending the issue or refusal of a
certificate within six months from the date hereof. certificate within six months from the date
hereof.
After which period this order will become void.
after which period this order will become void.

Dated: Inspecting of Boilers Dated: Inspecting of Boilers

N.B.- This order must be produced on demand by

any authorised person and surrendered to the
Chief Inspector on receipt of orders.

162
 FORM VI
...........................................BOLER INSPECTION DEPARTMENT
CERTIFICATE FOR USE OF A BOILER
[Regulation 369]
Registry Number of Boiler Type of Boiler

163
Boiler Rating Place and Year of Manufacture
Maximum continuous evaporation
Name of Owner
Situation of Boiler
Repairs
Remarks
Hydraulically tested on To lbs. sq. inch

I hereby certify that the above described boiler is permitted by me/the Chief Inspector under the
provisions of section 7/8 of the Boiler Act, No. V of 1923, to be worked at a maximum pressure of
lbs. to the square inch for the period from
The loading of the safety valve is not to exceed
I further certify that the main steam pipe was tested hydraulically to a pressure of lbs. per
square inch last on Fee Tk. paid on..
Dated at
This day of 19

Inspector
Countersigned
Chief Inspector
See reverse for “condition”

CONDITIONS
(Reverse of Form VI)
(1) No structural alteration, addition or renewal shall be made to the boiler otherwise than in
accordance with Section 12 of the Act.
(2) Under the provisions of Section 8 of the Act this certificate shall cease to be in force:-

164
 (a) On the expiry of the period for which it was granted; or
(b) When any accident occurs to the Boiler; or
(c) When the boiler is moved, the boiler not being a vertical boiler the heating surface of
which is less than two hundred square feet, of a portable or vehicular boiler; or
(d) When any structural alteration, addition or renewal is made in or to the boiler; or
(e) If the Chief Inspector in any particular case so directs when any structural alteration,
addition or renewal is made in or to any steam pipe attached to the boiler; or
(f) On the communication to the owner of the boiler of an order of the Chief Inspector or
Inspector prohibiting its use on the ground that it or any steam pipe attached thereto is in
a dangerous condition.
Under Section 10 of the Act a boiler may continue to worked beyond the period of the certificate
issued for it provided the owner has applied for a renewal of the certificate before the expiry date
and none of the cases specified clauses (b), (c), (d), (e), apply to the boiler.
(3) The boiler shall not be used at a pressure greater than the pressure entered in the certificate as
the maximum pressure not with the safety valve set to a pressure exceeding such maximum
pressure.
(4) The boiler shall not be used otherwise than in a condition which the owner reasonably believes
to be compatible with safe working.
N.B.:- Details regarding this boiler are recorded in Registration Book No................ of which a
copy may be obtained on payment on application to the Chief Inspector.

APPENDIX A
DIAGRAMS OF RIVETED JOINTS WITH FORMULAE
SINGLE RIVETED JOINTS

LAP JOINT. ONE RIVETE PER PITCH

165
 Max Pitch = 1.31 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  S
Rivet % = ” (3)
P T  S
E = 1.5 × D Reg. 165

F. 2 SINGLE BUTT STRAP ONE RIVET PER PITCH

Max Pitch = 1.53 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  S
Rivet % = ” (3)
P T  S
E = 1.5 × D Reg. 165
Butt Strap = 1.15 × T Eqn. (5)

DOUBLE BUTT STRAP. ONE RIVET PER PITCH

Max Pitch = 1.75 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  1.875S
Rivet % = ” (3)
P T  S
E = 1.5 × D Reg. 165
Butt Strap = .625 × T Eqn. (7)

DOUBLE RIVET JOINTS

LAP JOINT. TWO RIVETS PER PITCH
Max Pitch = 2.62 × T + 1.625 Eqn. (13)

166
 100( P ] D)
Plate % = ” (2)
P
100  A  2  S1
Rivet % = ” (3)
P T  S
R = .33P + .67D ” (14)
E = 1.5 × D Reg. 165

LAP JOINT. TWO RIVETS PER PITCH

Max Pitch = 2.62 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  2  S
Rivet % = ” (3)
P T  S
R = 2×D ” (15)
E = 1.5 × D Reg. 165

SINGLE BUTT STRAP. TWO RIVETS PER PITCH

Max Pitch = 3.06 × T ×1.625 Eqn. (13)

100( P ] D)
Plate E = ” (2)
P
100  A  2  S
Rivet % = ” (3)
P T  S
R = .33P + .65D ” (14)
E = 1.5 × D Reg. 165
BUTT STRAP = 1.125 × T Eqn. (5)

DOUBLE RIVETED JOINTS

SINGLE BUTT STRAP. TWO RIVETS PER PITCH

Max Pitch = 3.06 × T + 1.625 Eqn. (13)

167
 100( P ] D)
Plate % = ” (2)
P
100  A  2  S
Rivet % = ” (3)
P T  S
R = 2+D ” (15)
E = 1.5 × D Reg. 165
BUTT STRAP = 1.125 × T Eqn. (5)

SINGLE BUTT STRAP. THREE RIVETS PER PITCH

Max Pitch = 4.05 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  3  S1
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .2P +1.15D ” (16)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAP = 1.125 T × Eqn. (6)
( P ] 2 D)

DOUBLE RIVETED JOINTS

SINGLE BUTT STRAP. TRHEE RIVETS PER PITCH
Max Pitch = 4.05 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  3  S1
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .33P + .67D ” (14)
or 2 × D whichever is greater ” (15)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAP = 1.125 T × Eqn. (6)
( P ] 2 D)

DOUBLE BUTT STRAPS. TWO RIVETS PER PITCH

Max Pitch = 3.5 × T + 1.625 Eqn. (13)

168
 100( P ] D)
Plate % = ” (2)
P
100  A  2  1.875  S1
Rivet % = ” (3)
P T  S
R = .33P + .67D ” (14)
E = 1.5 × D Reg. 165
BUTT STRAP = .625 ×T Eqn. (7)

DOUBLE RIVETED JOINTS

DOUBLE BUTT STRAPS. TWO RIVETS PER PITCH
Max Pitch = 3.5 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  2  1.875  S1
Rivet % = ” (3)
P T  S
R = 2×D ” (15)
E = 1.5 × D Reg. 165
BUTT STRAP = .625 ×T Eqn. (7)

DOUBLE BUTT STRAPS. TRHEE RIVETS PER PITCH

Max Pitch = 4.63 × T + 1.625 Eqn. (13)
100( P ] D)
Plate E = ” (2)
P
100  A  3  1.875  S
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  1.875  S
Combined % = + ” (4)
P P T  S
R = .2P + 1.15D ” (16)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAP = .625 T × Eqn. (8)
( P ] 2 D)

DOUBLE BUTT STRAP. THREE RIVETS PER PITCH

Max Pitch = 4.63 × T + 1.625 Eqn. (13)

169
 100( P ] D)
Plate % = ” (2)
P
100  A  3  1.875  S1
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  1.875  S1
Combined % = + ” (4)
P P T  S
R = .33P + .67D ” (14)
or 2 × D whichever is greater ” (15)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAP = .625 T × Eqn. (8)
( P ] 2 D)

DOUBLE RIVETED JOINTS

DOUBLE BUTT STRAPS OF UNEQUAL WIDTH
TWO RIVETS PER PITCH

Max Pitch = 3.5 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  2.875  S1
Rivet % = ” (3)
P T  S
R = .33 + .67D ” (14)
E = 1.5 × D Reg. 165
BUTT STRAP = .75 T Eqn. (9)
(Wide)
BUTT STRAP = .625 T Eqn. (10)
(Narrow).

DOUBLE BUTT STRAPS OF UNEQUAL WIDTH

TWO RIVETS PER PITCH
Max Pitch = 3.5 × T +1.625 Eqn. (13)
100( P ] D)
Plate E = ” (2)
P
100  A  2.875  S1
Rivet % = ” (3)
P T  S
R = 2× D ” (15)
E = 1.5 × D Reg. 165
BUTT STRAP = .75 T Eqn. (9)
(Wide)
BUTT STRAP = .625 T Eqn. (10)
(Narrow).
DOUBLE BUTT STRAPS OF UNEQUAL WIDTH
THREE RIVETS PER PITCH

170
Max Pitch = 4.63 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  4.75  S1
Rivet % = ” (3)
P T  S

100( P ] 2 D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .2P + 1.15D ” (16)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAP = .75 T × Eqn. (11)
( P ] 2 D)
(Wide)
( P ] D)
BUTT STRAP = .625 × Eqn. (12)
( P ] 2 D)
(Narrow).

DOUBLE RIVETED JOINTS

DOUBLE BUTT STRAP OF UNEQUAL WIDTH
THREE RIVETS PER PITCH

Max Pitch = 4.63 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  4.75  S
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .33P + .67D ” (14)
or 2×D whichever is greater ” (15)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAP = .75 T × Eqn. (11)
( P ] 2 D)
(Wide)
( P ] D)
BUTT STRAP = .625T × Eqn. (12)
( P ] 2 D)
(Narrow).

TREBLE RIVETED JOINTS

LAP JOINT. THREE RIVETS PER PITCH

171
Max Pitch = 3.47 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  3  S
Rivet % = ” (3)
P T  S
R = .33P + .67D ” (14)
E = 1.5 × D Reg. 165

TREBLE RIVETED JOINTS

LAP JOINT. THREE RIVETS PER PITCH

Max Pitch = 3.47 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  3  S1
Rivet % = ” (3)
P T  S
R = 2×D ” (15)
E = 1.5 × D Reg. 165

LAP JOINT. THREE RIVETS PER PITCH

Max Pitch = 4.14 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  4  S1
Rivet % = ” (3)
P T  S

100( P ] D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .2P + 1.15D ” (16)
E = 1.5 × D Reg. 165

LAP JOINT. FOUR RIVETS PER PITCH

Max Pitch = 4.14 × T + 1.625 Eqn. (13)

172
 100( P ] D)
Plate E = ” (2)
P
100  A  4  S1
Rivet % = ” (3)
P T  S

100( P ] 2 D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .33P + .67D ” (14)
or 2 D whichever is greater ” (15)
E = 1.5 × D Reg. 165

TREBLE RIVETED JOINTS

DOUBLE BUTT STRAPS.THREE RIVETS PER PITCH

Max Pitch = 4.63 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  3  1.875  S1
Rivet % = ” (3)
P T  S
R = .33P + .67D ” (14)
E = 1.5 × D Reg. 165
BUTT STRAPS = .625 T Eqn. (7)

DOUBLE BUTT STRAPS RIVETED PER

Max Pitch = 4.63 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  3  1.875  S1
Rivet % = ” (3)
P T  S
R = 2× D ” (15)
E = 1.5 × D Reg. 165
BUTT STRAPS = .625T Eqn. (7)

DOUBLE BUTT STRAPS. FOUR RIVETS PER PITCH

Max Pitch = 5.52 × T + 1.625 Eqn. (13)

173
 100( P ] D)
Plate % = ” (2)
P
100  A  4  1.875  S1
Rivet % = ” (3)
P T  S

100( P ] 2 D) 100  A  1.875  S1

Combined % = + ” (4)
P P T  S
R = .2P + 1.15D ” (15)
E = 1.5 × D Reg. 165
BUTT STRAPS = .625T Eqn. (7)

TREBLE RIVETED JOINTS

DOUBLE BUTT STRAPS. FOUR RIVETS PER PITCH

Max Pitch = 5.52 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  4  1.875  S1
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  1.875  S1
Combined % = + ” (4)
P P T  S
R = .33 × .67D ” (14)
or 2 D whichever is greater ” (15)
E = 1.5 × D Reg. 165
BUTT STRAPS = .625T Eqn. (7)

DOUBLE BUTT STRAPS. FIVE RIVETS PER PITCH

Max Pitch = 6 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  5  1.875  S1
Rivet % = ” (3)
P T  S
100( P ] 2 D) 2 100  A  1.875  S1
Combined % = + ” (4)
P P T  S
R = 2P × 1.15D ” (16)
R1 = .165P × .67D ” (17)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAPS = .625T × Eqn. (8)
( P ] 2 D)

TREBLE RIVETED JOINTS

DOUBLE BUTT STRAPS. FIVE RIVETS PITCH

174
Max Pitch = 6 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  5  1.875  S1
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  1.875  S1
Combined % = + ” (4)
P P T  S
R = .33 P + .67D ” (14)
or 2 D whichever is greater ” (15)
R1 = 2×D ” (15)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAPS = .625T × Eqn. (8)
( P ] 2 D)

DOUBLE BUTT STRAPS OF UNEQUAL WIDTH

THREE RIVETS PER PITCH
Max Pitch = 4.63 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  4.75  S1
Rivet % = ” (3)
P T  S
R = .33P × .67 D ” (14)
E = 1.5 × D Reg. 165
BUTT STRAPS = .75T Eqn. (9)
(Wide)
BUTT STRAPS = .625T Eqn. (10)
(Narrow)

TREBLE RIVETED JOINTS

DOUBLE BUTT STRAPS OF UNEQUAL WIDTH
THREE RIVETS PER PITCH

Max Pitch = 4.63 × T + 1.625 Eqn. (13)

100( P ] D)
Plate % = ” (2)
P
100  A  4.75  S1
Rivet % = ” (3)
P T  S
R = 2×D ” (15)
E = 1.5 × D Reg. 165
BUTT STRAPS = .75T Eqn. (9)
(Wide)
BUTT STRAPS = .625T Eqn. (10)
(Narrow)

DOUBLE BUTT STRAPS OF UNEQUAL WIDTH

THREE RIVETS PER PITCH

175
 Max Pitch = 6 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  8.5  S1
Rivet % = ” (3)
P T  S
100( P ] 2 D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .2P × 1.15D ” (16)
R1 = .165P × .67D ” (17)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAPS = .75T × Eqn. (11)
( P ] 2 D)
(Wide)
( P ] D)
BUTT STRAPS = .625T × Eqn. (12)
( P ] 2 D)
(Narrow)

TREBLE RIVETED JOINTS

DOUBLE BUTT STRAPS OF UNEQUAL WIDTH
THREE RIVETS PER PITCH
Max Pitch = 6 × T + 1.625 Eqn. (13)
100( P ] D)
Plate % = ” (2)
P
100  A  8.5  S1
Rivet % = ” (3)
P T  S

100( P ] 2 D) 100  A  S1
Combined % = + ” (4)
P P T  S
R = .33P × .67D ” (14)
or 2 D whichever is greater ” (15)
R1 = 2×D ” (15)
E = 1.5 × D Reg. 165
( P ] D)
BUTT STRAPS = .75T × Eqn. (11)
( P ] 2 D)
(Wide)

( P ] D)
BUTT STRAPS = .625T × Eqn. (12)
( P ] 2 D)
(Narrow)

APPENDIX B
FORMS OF STANDARD TENSILE TEST PIECES

176
 BRITISH STANDARD PLATE TEST PIECES
Test Piece A.
1. Chiefly for sheets, plates, strips, flat bars, sections etc.

(i) (ii) (iii) (iv)

Nominal Thickness of test piece (see Notes 3)
⅜ in. and
Up to but not including ⅜ in.
thicker
In. in. in. in.
Width W ½ 1 1½(max.) 1½(max.)
Gauge length G........ 2 4 8 8
Parallel length (minimum) p........ 2½ 4½ 9 9
Radius at shoulder (minimum)......R 1 1 1 1
Approximate total length 8 12 18 18
When the width of the material to be tested is insufficient to permit of the preparation of the
standard tensile test piece, a piece of the full width of the material may be used.
Notes: 1. For some materials it is convenient to use straight parallel test pieces.
2. For certain non-ferrous metals it is sometimes convenient to use the standard
test piece that has a width of ½ in. and a gauge length of 2 in. for thickness
exceeding ¼ in.
3. A test piece of the dimensions given in Col. (iii) for material under ⅜ in.
nominal thickness is intended for ferrous metal only.
Test Piece A
2. In tensile tests on special sheet and strip materials (e.g. steels used for deep pressing operation)
the following alternative test piece may be used.

BRITISH STANDARD ROUND TEST PIECES

Test Piece B.

177
3. Chiefly for unmachined rods and bars not exceeding 1 in. diameter (excluding cast metals).

Gauge Length G = 8D
Length between grips p to be not less than 9 D.
All test piece of form B are strictly similar and for the same material give the same percentage
elongation. They give elongation figures nearly the same as those of standard flat test pieces 8 in.
in gauge length 1½ in. wide and ½ in thick.
Note- When tensile tests are made on unmachined square and hexagonal bars (excluding cast metal) the
gauge length shall be 8 times the distance between the flats and the length between the rips shall be
not less than 9 times the distance between the flats.

Test Piece B.
4. For rods and bars over 1 in. diameter (excluding cast metals).

Test Piece C.

178
5. Machined Round Test Piece for general purposes.

Gauge length G = 2 in
Parallel length P to be not less than 2¼ in.
Diameter D = 0.564 in.
Cross sectional area A = 1¼ in.
Radius at shoulder = ½ in. minimum for wrought metals and 2½ in. minimum for cast metals.

SUBSIDIARY STANDARD ROUND TEST PIECES

6. Machined Test Pieces for general purposes (excluding cast iron).

D
Cross sectional area A =
4

Gauge length = 4 4 = 3.54 D.

Parallel length P = 9|8 G. minimum = 3.98 D. minimum
Radius at shoulder for wrought metals = G|4 minimum
(0.88 D. minimum).
Radius at shoulder for cast metals = 5G|4 minimum.
(4.40 D. minimum).
All test pieces confirming to the above dimensions are similar to Standard Test Piece C with
corresponding shoulder radius and give the same percentage elongation as Test Piece C. for the
same material.
Recommended dimensions for subsidiary Standard Round Test Pieces are tabulated below.
Standard Test Piece C. (0.564 in diameter) is included for comparison. Any test piece, however in

179
which the diameter is not less than 0.125 in. and the dimensions of which conform to the
subsidiary form, is recognised as a subsidiary standard test piece.
Diameter D Cross Gauge length Parallel Radius
sectional G length P
area A (minimum)
Wrought Cast metal
material
inch Square inch inch inch inch inch
1.128 1.0000 4.00 4.50 1.00 5.00
0.977 0.7500 3.46 3.89 0.88 4.30
0.798 0.5000 2.82 3.18 0.70 3.50
0.564 0.2500 2.00 2.25 0.50 2.50
0.424 0.1412 1.50 1.69 0.37 1.85
0.399 0.1250 1.41 1.58 0.35 1.75
0.357 0.1000 1.26 1.42 0.31 1.55
0.282 0.0625 1.00 1.12 0.25 1.25
0.226 0.0400 0.80 0.90 0.20 1.00
0.159 0.0200 0.56 0.63 0.14 0.70
0.125 0.0122 0.44 0.50 0.11

CHAPTER XI
STANDARD CONDITIONS FOR THE DESIGN AND CONSTRUCTION
OF ECONOMISERS AND FEED PIPES
Economisers
500. (a) An economiser shall not be registered under sub-section (4) section 7 of the Act and a
certificate shall not be issued under sub-section (5) of that section with reference to an
economiser, unless the standard conditions in respect of materials, design and
construction, which are specified in this Chapter are satisfied in respect of such
economiser.
Provided that an economiser in use at the time Chapter XI of these Regulations came
into force may be so registered and such Certificate may be issued in respect thereof
notwithstanding that such standard condition and not satisfied in respect of such
economiser.
(b) Notwithstanding anything contained in sub-regulation (a) the Chief Inspector may
subject to the provisions of Regulation 502, register an economiser and order the issue
of certificate authorising the use there although the standard conditions are not fully
satisfied in respect of such economiser.

180
 General Requirements
501. (a) All cast iron and steel headers and the parts used in the resembly of an economiser
shall conform with the requirements of this chapter in respect of material specification
and test, workmanship and structural requirement.
(b) All economiser under construction shall be under the supervision of an Inspecting
Authority and must be so certified by that Authority.
(c) For economiser imported into all the provinces and the Capital of the Federation, a
certification from the Inspecting Authority in Form VII certifying that the material was
tested and the economiser built under its supervision shall be furnished to the Chief
Inspector before or with the first application for registration.
(d) In advance of or along with an application for registration the following shall be
furnished:
(i) A certificate in Form VIII of manufacture and test signed by the Maker or by a
responsible representative of the maker, containing the description of the
economiser, particulars of the material used in its construction and the dimensions
of the several parts with the declaration that the limits of tensile breaking strength
and tests comply with the standard conditions.
(ii) A certificate from the maker of the material stating the tensile breaking strength
and the elongation provided that if the Maker and manufacturer be the same, the
Manufacturer’s precise statement showing the above information shall be accepted.
502. Where no certificates are produced, the working pressure as and by formula will be
reduced by 10 percent. When the workmanship is however in any way doubtful and the
Chief Inspector is not satisfied that any of the foregoing conditions would be sufficient to
meet circumstances, he may at his discretion reduce the working pressure such percentage
as he deems fit.
503. Maker’s Certificate for steel Economisers- The maker shall finish the Inspecting
Officer with a certificate in the following form :
“We hereby certify that the material described below has been made by the Open Hearth
or an Electric process acid|basic and has been satisfactorily tested in the presence of the
Inspecting Offier|our Test House Manager in accordance with the Standard Tests.”
504. For all new Economisers the hydraulic test must be applied as shown below:
On components before assembly Hydraulic test Pressure
Cast Iron Tubes, headers and bends and steel Twice working pressure minimum test pressure
headers. 500 lbs. per square inch.
Steel Tubes Twice the working pressure, minimum test
pressure of 1000 lbs per square inch.

The above test pressures shall be held for a minimum period of ten minutes.

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505. Material of construction- Workmanship and manufacture-All material used in the
construction of pressure parts shall be tested and shall conform with the following
requirements.
(a) The workmanship throughout shall be of the highest possible standard. All castings
shall be well finished, free from external defects, porous places and blow holes, and
true to dimensions without warping. Where chaplets are used, there must be
satisfactory fusion with the metal. Chaplets must be properly timed with metal free
from lead.
(b) The screw threads of bolts must be of British Standard Whitworth form.
(c) All component parts shall be manufactured to limit gauges to secure inter-
changeability throughout.

Cast Iron Tubes and Headers

506. Process of Manufacture- The minimum tensile strength based on a test bar 1.2˝ diameter
as cast and machined to .798˝ diameter gauge shall not be less than 13 tons for cast iron
tubes and 15 tons for cast iron headers and shall not show on analysis a Sulphur and
Phosphorous content exceeding the amount specified below:
Maximum
Sulphur Phosphorous
Tubes ... .... .... .... .... .... .... .... .... .12% 1.2%
Headers ... .... .... .... .... .... .... .... .... .1% 1.0%

507. Test bars-

(a) When the test bars are cast separately, they shall be poured at the same time and
from the same ladle of metal as the casting or castings they represent. The number
of test bars specified in Regulation 508 shall be applicable to all castings of each
melt.
(b) When the bars are cast on the mould for the casting and the mould for the test piece
shall be joined together in such a manner that the liquid metal fills both moulds at
the same operation.
(c) All test shall be cast in green sand or dry sand moulds according as to whether the
casting or castings they represent are moulded in green sand or in loam or dry sand
respectively.
(d) The test bars shall not be subjected to any heat treatment after leaving the moulds
except where the castings are heat treated.

182
508. Number of tensile tests-
(a) The number of tests required for each batch of castings shall be in accordance with
the following table the various classes of castings being divided into a
representative group-
Group Weight of Castings Test Requirements
1. Up to 38 lbs. ... ... ... ... ... One test for each 30 cwts. of
castings or part thereof.
2. Over 28 lbs. and up to 1 cwt ... ... ... ... ... One test for each 2 tons of
castings or part thereof.
3. Over 1 cwt. and up to 1 on.. ... ... ... ... ... One test for each 4 tons of
castings or part thereof.

In the above Groups 1, 2 and 3 all castings represented by one test must be poured
from the same ladle of same heat as the bar or bars provided for the test.
Group Weight of Castings Test Requirements
4. Over 1 ton and important castings One test for each 4 tons of
castings or part thereof or for
each casting weighing 4 tons or
more.

(b) The additional tests to be carried out before a casting or batch of castings is rejected
shall be in accordance with the following table-
1st test piece If this fail The second test piece shall the tested
2nd test piece If this passes The batch or separate castings represented shall be
accepted.
If this fails The batch or separate castings represented may be
rejected.
(c) Provided always that in the case of failure of both test pieces if either show
obviously defects a third test piece may be taken from a broken casting or a piece
may be cut from a usable casting for further testing as follows:
3rd test piece If this passes The batch or separate castings represented shall
be accepted.
If this fails The batch or separate castings represented may
be rejected.
509. Standard test piece- The tensile test bar shall conform to the dimension shown in the
following. Bars may be tested with either plain or screwed ends.

Dimensions of Test Bars

183
Diameter Gauge Area Min. Min. Min. Screwed ends Approximate Main cross
as cast Diameter parallel Radius length minimum over- sectional
length of all length thickness
plain of casting
ends represented
Size Min plain Screwed
length ends ends
B D A P R C E F Lp Ls. In.
in. in. Sqin. in. in. in. in. in. in. in. in.
12 0.798 0.50 2 3½ 2 1⅛ 1⅛ 8¼ 5⅞ Over ¾
B.S.F and not
exceeding
1⅛
1⅛
B.S.W

The test bar shall be cast as parallel bars of the Diameter given in column B and then
machined to the Dimension D and P in the above table.

Constructional Requirement
Cast Iron Economisers.
510. (a) Economisers with pressed socket joints not reinforced:
Area of socket in contact
W.P. = × friction Factor
(Width inside Header) (Pitch of tubes in Header)
W.P = working pressure in lbs. per sq. in... ... .... ..... .... Eqn. (122)
Friction Factor = 525
(b) Header for above Economisers- The maximum working pressure shall be
determined by the following formula:
27(t ] 3) 2
W.P. ] .... .... ... ..... .... .... .... .... .. ... ... .... Eqn. (123)
b2
t = Thickness at flat sides in thirty seconds of an inch.
b = Depth in inches of the inner side exposed to pressure.
511. (a) Economisers with pressed socket joints reinforced:
Area of socket in contact
W.P. = × friction
(Width inside Header) (Pitch of tubes in Header)

No. of stays per header

Factor × × P.... .... .... .... ... Eqn. (124)
(No of sockets per header)
Friction Factor = 525.
P = 600 for approved design of reinforced stay.
(b) Tubes for above Economisers- The working pressure shall be governed by the
governed following formula:
280(t ] 6)
W.P. = .... ... ... .... ... ... ... ... .... ... ... ... .... Eqn. (125)
d
t = Thickness in thirty seconds of an inch.

184
 d = External diameter in inches.
512. (a) Header for Economisers with reinforced sockets joints- These headers shall be of
circular section throughout without flat surfaces exposed to internal pressure.
250(t ] 9)
W.P. = .... .... ... ... .... .... .... ... ... ... ... .. Eqn. (126)
d
t = Thickness in thirty seconds of an inch.
d = External diameter in inches.
(b) Manifold pipes for above Economisers- These pipes shall be of circular section and
the working pressure shall be determined by the following formula:
250(t ] 7)
W.P. = .... .... .... .... ... ..... ... ... ... ... ... .Eqn. (127)
d
t = Thickness in thirty seconds of an inch.
d = External diameter in inches.
513. (a) Cast iron Economiser with gills or other extended surface Tubes- The working
pressure shall conform to the following formula:
380(t ] c)
W.P. = ... .... ..... ..... ..... ..... .... ... .... Eqn. (128)
d
t = Thickness in thirty seconds of an inch.
c = 8 for portion where gills act as reinforcement.
10 for portion not reinforced.
d = External diameter in inches.
(b) Bends and manifold pipes for above Economisers- The working pressure shall be
governed by the following formula:
250(t ]10)
W.P. = .... ... .... .... ... .... ... .... ... .... ...Eqn. (129)
d
t = Thickness in thirty seconds of an inch.
d = External diameter in inches.
514. Joints bolts for cast iron Economisers-
(a) The maximum working pressure for the bolts shall be calculated by Regulation 517.
(b) The use of studs tapped in to cast iron is not permitted for pressure parts.
515. Use of cast iron- Where the water temperature is expected to exceed 425º F the use of
cast iron for pressure parts is prohibited.
516. Steel tube Economisers with cast iron sleeves-
(a) Tubes- Where tubes are protected from external corrosion by cast iron sleeves shrunk
in position and property spigotted and socketted, the working pressure shall be
determined by the following formula:
170(t ] 5)
W.P. = .... .... .... ..... .... .... .... .... .... ... Eqn. (130)
d
t = Thickness in one-hundredths of an inch.
d = External diameter in inches.

185
 (b) If these tubes are screwed at the ends the thickness given by the above formula shall
be taken as the minimum thickness at the root of the thread.
(c) When the connections between the tube ends are made by bends formed from steel
tubes, the resulting thickness of the bends at the thinnest point shall not be less than
that required by the formula above.
(d) Suitable provision must be made for supporting horizontal tubes at one or more
intervals in their length to relieve bending stresses and these supports as well as the
end connections must permit free expansion.
(e) The standard conditions for material and test shall conform to Regulations 520 to 524.

517. Joint bolts- The maximum working pressure for the bolts shall be determined by the
following formula:
2
N C  1.28 
P= D ]  ... .... ... .... ..... .... .... ... ... ..Eqn. (131)
A  n 

N = No of bolts securing the parts.

n = No. of screw threads per inch.
D = Bolt diameter in inches measured over the threads.
A = The area exposed to pressure which is assumed to be bounded by a line midway
between the pitch line of the bolts and the inner edge of the flange where flat joints
are used with joint rings. Where conical joint faces are used with joint rings of
curvilinear cross section, the area exposed to pressure shall be assumed to extend to
the root of the thread where the tube ends are screwed or to a corresponding
boundary if the flanges are attached by other means.
C = 4700 for steel bolts of 28|32 tons tensile material where the diameter over thread is
less than 3|4 inch.
= 5600 for steel bolts of 35|40 tons tensile material where the diameter over threads is
less than 3|4 inch.
= 5600 for steel bolts of 38|32 tons tensile material where the diameter over threads is
not less than 3|4 inch and not greater than 7|8 inch.
518. Headers for above Economisers-
(a) The main collecting or disturbing headers shall be fabricated from solid drawn
seamless steel tubing of tensile strength not more than 35 tons per sq. in. the working
pressure being determined by the following formula:
325(t ] 4)
W.P. = .... .... .... ..... ..... ...... .... ... Eqn. (132)
d
t = Thickness in thirty seconds of an inch.
d = External diameter in inches.
(b) Branches below 2˝ bore shall be screwed and welded into headers. Larger branches
shall be expanded and welded or secured by some means addition to simple welding.

186
 Suitable provision for expansion must be made in the connection between headers and
tubes.
(c) The Standard conditions for material and test shall conform to Regulation 520 to 524.
Steel Economisers
519. Rectangular Headers- The material of construction and other requirements for headers
shall comply with Regulation 320 to 322.
520. Tubes- Material- All tubes forming part of steel Economisers which are subject to internal
pressure shall be solid drawn and made of steel produced by an acid or basic open hearth
or an electric process and shall show on analysis not more than .05% of Sulphur or
phosphorus.
521. Tensile Test- Longitudinal strips or lengths cut from the ends of the selected pipes shall
comply with the following requirements-
Ultimate tensile Minimum elongation percent
stress in tons per sq.
in.
on 8 in. on 2 in.
Not less Not more ¼ʺ thick Less than ¼ʺ thick Less than
than than and over ¼ʺ thick and over ¼ʺ thick
Strips cut from the 23 30 20 18 32 30
pipes and tested in their
condition
Test length taken from 23 30 25 23 .... ....
finished pipes ends of
pipes to the plugged for
grips

522. Flattening test (for pipes up to and including 4˝ nominal bore)- A ring not less than 2˝
in length cut from one end of each selected pipe shall when cold withstand, without
showing either crack or flaw, being flattered between two parallel flat surfaces until the
pressure is released the interior surfaces of the test piece remain at the middle a distance
apart equal to four times the thickness of the pipe.
523. Cold Bend test (for pipes over 4˝ nominal bore)- A strip 1½ wide cut circumferentially
from one end of each selected pipe shall when cold withstand, without showing either
crack or flaw, being doubled over in the direction of original curvature round a bar, the
diameter of the bar being:
For pipes up to and including ⅜ʺ thick .......... 3 times the thickness.
Or pipes over ⅜ʺ thick ................................... 4 times the thickness.
524. Additional tests before rejection- Should a pipe selected fro testing purposes fail in any
one or more of the tests specified, two further tests of the same kind may be made from
two additional selected pipes. If the repeat tests are satisfactory the pipes shall be
accepted provided that in other respects they comply with the requirements of these
Regulations but if failure again occurs the pipes which the test pipes represent shall be
rejected.
525. Constructional requirements- Tubes of pipes-
(a) The maximum working pressure shall be-

187
  t 
220 9
W.P. = 1.125  .... ...... .... ... ..... ..... ... ... Eqn. (133)
D
t = Thickness of tubes in one hundredths of an inch.
D = Outside diameter in inches.
(b) No tubes 1½˝ or more in diameter shall be less than 10 S.W.G.
(c) The tubes shall be screwed, expanded or welded to the headers.

Valves and Mountings

526. (a) Thermometers- All Economisers shall be provided with Thermometers or measuring
water temperature adjacent to the inlet and outlet connections.
(b) Safety Valves- A valve which shall prevent increase of pressure beyond a
predetermined limit shall be fitted to every economiser and the design shall provide
against unauthorized interference with the loading. Economisers with pressure parts of
cast iron and arranged in groups of tiers connected by circulating piping shall have a
safety valve fixed on each group of tier. Safety valves should have a minimum diameter
of 2˝.
(c) Pressure Gauge- Means for indicating the pressure gauge in the economiser shall be
provided by a pressure Gauge constructed on the lines of Regulation 308.
(d) Air Release Valve- Means must be provided for the release of air at all points where
air accumulation may occur.
(e) Blow of Drain Valves- Means must be provided for draining the economiser
completely of water.
(f) Non-return valves- Economisers provided with means for heating the incoming feed
by mixing it with hot water from the economiser outlet must have a non-returns valve in
the hot water return line.

Feed Pipes
527. General- Feed pipes may be made of steel, cast iron or copper but no cast iron pipes will
be accepted for a working pressure over 200 lbs. per sq. in. or 425ºF. Copper feed pipes
shall be solid drawn and not exceed 8˝ external diameter and may be used for a working
pressure not exceeding 350 lbs. or 300ºF.
528. Steel feed pipes-
(a) The standard conditions for material of construction and tests for steel pipes shall
comply with Regulations 520 to 524.
(b) The maximum working pressure shall be determined by Equation (133) in Regulation
525.
529. Cast iron feed pipes-
(a) The standard conditions for material of construction and tests for cast iron pipes shall
comply with Regulations 505 to 509.
(b) The maximum working pressure shall be determined by the following formula:

188
 130(t ] 6)
W.P. = ..... ..... .... ..... ..... ..... ...... ..... ....Eqn. (134)
d
t = thickness in thirty seconds of an inch.
d = the external diameter of the pipe in inches.
530. Copper feed pipes-
(a) The standard conditions for material of construction and tests for coppper pipes shall
comply with Regulations 35.
(b) The maximum working pressure shall be determined by the following formula:
 t 
60 3
1.125 
W.P. =  ..... .... ..... ..... .... .... ....... ... Eqn. (135)
d
t = thickness in hundredths of an inch.
d = external diameter of the pipe in inch.

Regulations for Registration and Inspection of Economisers

531. Preparation for Inspection- At each inspection the economiser shall be empty and
thoroughly cleaned internally and externally. At least 25% of the caps should be opened
in scattered positions and others will be removed in the inspections presence to ensure
that thorough internal scaling has been carried out prior to his examination.
532. Procedure for registration-
(a) On receipt of an application for registration the Inspector shall after the economiser
has been prepared for examination, take full particulars of the design and ascertain the
working pressure allowed by the Regulations.
(b) If no formula or co-efficient applicable to any part is contained in the Regulations the
Chief Inspector shall at his discretion determine the fitness of the part. The Inspector
shall enter full particulars of the economiser together with calculations of the various
parts in a Memorandum of Inspection Book (Form. No. IX) and submit it to the Chief
Inspector.
(c) After Inspecting the economiser and ascertaining by the prescribed calculations the
maximum pressure to which it may be worked, the Inspector shall witness the
hydraulic test in accordance with Regulation 534 and may issue a Provisional Order in
Form X.
533. Procedure at subsequent inspection-
(a) After the economiser has been cleaned the Inspector shall make a thorough
examination so far as its construction permits. The external condition of the tubes
should be carefully noted for wasting especially at the feed inlet end and all accessible
tubes should be callipered. The internal surfaces of cast iron tubes should be closely
observed for graphitic wasting as far as it is possible and in the event of any tube
failure these should be broken up for scrutiny so that the general internal condition of
the other tubes may be estimated.
(b) Where tubes or other parts are wasted the strength should be re-calculated.
(c) The scraper gear should be examined to note if any parts are missing if the length of
travel is adequate and if the scrapers are correctly adjusted.

189
 (d) All cap bolts are to be inspected also the condition and position of the chamber and
baffles.
(e) The record of each inspection and calculations will be entered in the Memo Book.

534. Procedure for Hydraulic test- Every economiser for registration shall be hydraulically
tested in the presence of an Inspector to 1½ times the working pressure. Subsequent
hydraulic test may be carried out after repairs or when the Inspector considers it
necessary.
During the test all parts externally and in the flues shall be noted for leakage.
535. Memorandum of Inspection Book- In this book the Inspector shall enter all particulars
and dimension of the economiser with calculations for the various parts together with
details of hydraulic test. At subsequent inspection the Inspector shall enter all notes
pertaining to the condition of the various parts.
536. Registration books will be maintained on the lines of Regulation 367.
537. Grant of certificate- A certificate for the use of an economiser shall be granted in
Form XI.
538. Casual visits –
(a) The Inspector shall note if the economiser is working satisfactorily and if the safety
valves are correctly adjusted, if the scraper gear is operating and if the external
brickwork is free from cracks. He shall also ascertain if the by-pass flue is used when
water is not passing through the economiser tubes i.e. when raising steam etc.
(b) The Maker’s instructions for working should be strictly followed by the owner.
Note- It is recommended that the feed inlet temperature to the economiser should not be
less than 100ºF. to prevent sweating and consequential external corrosion of the
tube and bottom headers.
539. Economiser rating- The rating shall be equivalent to the area of the heating surface in
square feet.
540. Registration Fee- An application for registration fee shall be accompanied by the
appropriate fee.
Tk.
For Economiser rating not exceeding 500 50
For Economiser rating exceeding 500 but not exceeding 1000 60
For Economiser rating exceeding 1000 but not exceeding 1500 70
For Economiser rating exceeding 1500 but not exceeding 2000 80
For Economiser rating exceeding 2000 but not exceeding 2500 90
For Economiser rating exceeding 2500 but not exceeding 3000 100
For Economiser rating exceeding 3000 but not exceeding 3500 110
For Economiser rating exceeding 3500 but not exceeding 4000 120
For Economiser rating exceeding 4000 but not exceeding 4500 130
For Economiser rating exceeding 4500 but not exceeding 5000 140
For Economiser rating exceeding 5000 150
541. Engraving of Registry Number-
(a) Each section, branch pipe or detachable part subject to the working pressure shall be
marked for identification with a Registry Number and also the appropriate device as
shown in Regulation 362.
(b) In the case of the ordinary vertical type of cast iron Economisers the device and
number shall be stamped on the header flange connected to the top branch pipe. In

190
 each case the stamping shall be on some conspicuous part not affected by the gases or
other corroding influence.

FORM VII

Inspecting Authority’s Certificate of Inspection Construction

Designation of Inspecting Authority

We hereby certify that type, Economiser, consisting of sections and tubes to each section
was constructed for a working pressure of ................lbs. by Messrs...................... under our
supervision and inspected at various stages of construction and workmanship were satisfactory
and in accordance with the standard conditions for the design and construction of Economiser
laid down in Chapter XI of the Boiler Regulations 1947.
Identification mark on each section,
Branch Pipe or other pressure part,
Position of same.
The section on completion were subjected to a water pressure of ........lbs. per sq. in. ten
minutes in the presence of the Inspecting Officer on .......... and satisfactorily withstood the test.
Samples of the material used in the constructions of the Economiser were tested in the
presence of the Inspecting Officer and were found to comply with the tests prescribed in Chapter
XI of the Boilers Regulations 1947.
We have satisfied ourselves that the construction and dimensions of the Economiser are as
shown in the makers drawing No. ...................Signed by us and that the particulars entered in the
Maker’s certificate of manufacture in Form VIII countersigned by us are correct to the best of
our knowledge and belief. e

Dated at this day Signature

of
Inspecting Authority

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 FORM VIII
Works Address
CONSTRUCTOR’S CERTIFICATE OF MANUFACTURE AND TEST
Description............ Type of Economiser
No. of Sections
No. of tubes Intended
Working Pressure lbs.
Year of Manufacture
Total heating surface of tubes
Description
2. Inspecting Authority............ Economiser constructed under supervision of section hydraulically
tested for.............minutes and inspected after test by
3. Construction and Details are in Drawing No.
Workmanship All castings are well finished, free from external defects, porous
places and blow-holes and true to dimensions without warping.
Where chaplets are used, there is satisfactory fusion with the metal.
Chaplets are properly tinned with metal free form lead.
All screw threads are of British Standard Whitworth form.
All component parts are manufactured to limit gauges to secure
interchangeability throughout.
4. Economiser parts and fittings material Maker Inspecting Officer Remarks
particulars of material used. Header
Tubes and/or
pipes
Valve Chests
Bolts

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 THICKNESS OF PARTS AND TENSILE LIMITS
5. Part of Thickness Tensile Elongation Gauge Brand and
Economiser in 32nds strength limits to % length No.
limits to tons

Headers

Tubes

Bolts

Certified that the particulars entered herein are correct and that the parts and fitting mentioned
above have been used in the construction and fittings of the Economiser.
The particulars shown against the various parts used are in accordance with the maker’s
certificate in our possession.
The design of the economiser in section and end view with principle parts fully dimensioned
is that shown in drawing No...
The Economiser has been designed and constructed to comply with the Boiler Regulations for
a working pressure of...............lbs. per sq. in. at our Works above-mentioned and the sections
satisfactorily withstood a water test of............lbs. per sq. in. for .............. minutes on................
day of ...........in the presence of our .................... responsible representative whose signature is
appended hereunder.

Designation of Maker
Signature of Engineer who
Witness the test.

Dated at this day of

Signature of the Inspecting Authority

Note- The drawing of the Economiser and Maker’s certificate of manufacture showing results
of test for tensile strength and elongation must accompany this certificate and if the
economiser has been built under the supervision of an Inspecting Authority their
certificate in Form VII must accompany.

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 FORM IX
(REGULATION 535)
BOILER ACT, 1923
BOILER INSPECTION DEPARTMENT
ECONOMISER
REGISTRY NUMBER

MEMORANDUM OF INSPECTION
OR
REGISTRATION BOOK
MISCELLANEOUS
District
Owners
ADDRESS OF FACTORY

Nearest Railway Station

ECONOMISER REGISTERED AT ON
REGISTER BOOK NO. PAGE
REGISTRY NUMBER VARIFIED ON
APPROVED WORKING PRESSURE LBS.
ECONOMISER RATING INSPECTING FEE
REGISTRATION BOOK FILLED AT ON
REMARKS ON TRANSFERS, ETC.

194
 PROVISIONAL ORDER AND CERTIFICATE RECORD
Fee Date of Date of Certificate Period of Working Economiser Remarks
payment Inspection No. & Certificate Pressure Rating and
date Inspector’s
initial

Type of eeconomiser:
MAKER
INTENDED WORKING PRESSURE
PLACE AND YEAR OF MAKE
MAKER’S No.
DESCRIPTION OF ECONOMISER
No. OF TUBES LENGTH DIA.
THICKNESS
INTERNAL DIAMENSIONS
No. OF HEADERS
THICKNESS OF HEADERS
LENGTH OF TOP BRANCH PIPE THICKNESS
LENGTH OF BOTTOM BRANCH PIPE THICKNESS
DIMENSIONS OF CAP OPENNINGS
DIAMETER OF CAP BOLTS

MOUNTINGS
No. Diameter Type Position Material
SAFETY VALVE
STOP VALVE
BLOW DOWN
THERMOMETER
PRESSURE GAUGE

195
 ADDITIONAL FITTINGS
MAKER’S CERTIFICATE
NAME OF MAKER
MAKER’S HYDRAULIC TEST PRESSURE
MAKER’S DRAWING NO
NAME OF INSPECTING AUTHORITY
NAME OF MAKER OF MATERIAL

TUBES
PROCESS HEADERS
BOLTS

TEST RESULT
TUBES T E
HEADERS T E
PIPES T E
BOLTS T E

% Sulphur.
% Phosphorus.
Maker’s Identification Marks.
Position.

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CALCULATIONS

HEADERS

TUBES

197
 BRANCH PIPES

BOLTS

HEATING SURFACE

TOTAL HEATING SURFACE

ECONOMISER RATING

CALCULATION MADE BY SUBMITTED ON

CALCULATIONS CHECKED BY ON
LEAST PRESSURE: THAT FOR LBS.
APPROVED WORKING PRESSURE LBS.
CHIEF INSPECTOR’S REMARKS AND SIGNATURE

198
 INSPECTOR’S NOTES

COUNTERFOIL No.
No. FORM No.
[Regulation 532 (c)]
Name of person or firm to which provisional PROVISIONAL ORDER UNDER THE
order is granted. BOILERS ACT, 1923
Description of Economiser
..............................................................................
Maker no. .............................................................................
are hereby permitted to use.......................... the
Rating Economiser (RY) No.................................. and
Economiser Rating..................................... made
Pressure permitted by............................ and bearing Maker’s
No................. at a maximum pressure of...........
Period lbs. per sq. in/maximum temperature of
...........ºF. pending the issue or refusal of a
Date certificate within six months from the date hereof
after which period this order will become void.

Dated at this day of

Inspector
Inspector

199
 FORM XI

...............................................................Boiler Inspection Department.

CERTIFICATE FOR THE USE OF AN ECONOMISER
Regulation (537)
Registry Number of Economiser Type
No. of Tubes
Number of Headers
Place and year of
Economiser Rating
manufacture
Name of Owner
Situation of Economiser
Repair
Remarks
I/We hereby certify that use the above described Economiser is permitted by me/Chief
Inspector under the provisions of Section.
...............of the Boilers Act, 1923 (V of 1923), to be worked at a maximum pressure of
................lbs. per sq. in./maximum temperature of .............ºF. for the period from to..........
The loading of the safety valve is not to exceed ..........................lbs.
Fee Tk. .............paid on............................. Dated at....................... this ...................day of

Countersigned,
Inspector

200
 (Reverse of Form XI)
Conditions
1. No structural alteration, addition or renewal shall be made to the Economiser without
written permission from the Chief Inspector.
2. This certificate shall cease to be in force:
(a) On the expiry of the period for which it was granted, or
(b) When any accident occurs to the Economiser, or
(c) When any structural alteration, addition or renewal is made in or to the
Economisers, or
(d) If the Chief Inspector in any particular case so directs when any structural
alteration, addition or renewal is made in or to the Economiser, or
(e) On the communication to the owner of the Economiser of an order of the Chief
Inspector in Inspecting prohibiting its use on the ground that it is in a dangerous
condition.
3. The Economiser shall not be used at a pressure greater than the pressure temperature
entered in the certificate as maximum pressure temperature entered in the certificate as
maximum pressure temperature nor with the safety valve set to pressure temperature
exceeding such maximum pressure temperature.
4. The Economiser shall not be used otherwise than in a condition which the owner
reasonably believes to the compatible with safe working.
Note- Details regarding Economiser are recorded in a Registration boolt No.............. of
which a copy may be obtained on payment of an application to the Chief
Inspector.

201
 FORM-XII
Certificate of Manufacture and Test for Small Industrial Boilers
(Manufactured Under Chapter- XII)

1. Maker’s Name............................................................ Year of Make.................................

2. Manufactured for................................................................................................................
3. Location of Installation......................................................................................................
4. Boiler Identification...........................Inspecting officer’s stamp......................................
5. Drawing No.......................... Alteration No......................................................................
6. Design Code............................ Working Pressure (kg/cm2)..............................................
7. Size of Boiler
Length (Meters) Width (Meters) Height (Meters) Diameter (Meters)

8. Shell/Furnace/Tube Plates/Flange Details

Material Specification CHEMICAL COMPOSITION MECHANICAL PROPERTIES
C Si Mn P S Y S U.T.S %EL
Tube...................................................................................................................................
Furnace...............................................................................................................................
Tube Plates.........................................................................................................................
Flange.................................................................................................................................
Boiler Tubes/Pipe/Pads Details..........................................................................................

Diameter Thickness Material CHEMICAL COMPOSITION MECHANICAL PROPERTIES

Specification
C Si Mn P S Y S U.T.S %EL

Tube...................................................................................................................................
Pipes...................................................................................................................................
Pads....................................................................................................................................
9. Volumetric Capacity.........................................................................................................
10. Heating Surface..................................................................................................................
11. Nozzle connection.
(a) Steam Outlet............................................................................................................
(No. Size Type of Nozzles)

(b) Safety Valve............................................................................................................

(No. Size Type of Nozzles)

(c) Auxiliary.................................................................................................................
(No. Size Type of Nozzles)

(d) Blow off Valve........................................................................................................

(No. Size Type of Nozzles)

(e) Feed Water Valve....................................................................................................

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 (No. Size Type of Nozzles)

12. Shop Hydro Test Pressure...........

........................... (Signature of Manufacturer) Date.............................

We certify that the above boiler constructed under our supervision and inspected at a
various stages of construction by the inspecting officer and that the construction,
workmanship were satisfactory as per Bangladesh Boiler Regulations.

Inspecting Officer Signature of Inspecting Authority

Dated..........................This.............................Day of...................................20...........................

203
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