Amend 1 (31-8-

AMENDMENTS TO THE INDIAN BOILER REGULATIONS, 1950 ISSUED DURINGTHE PERIOD 31-8-1962 TILL 28-2-1969.

Regulation No. 1:- Substitute the following for clause (2a) :-

“These Regulations generally apply to-

(i) all boilers, including those working on the principles of natural circulation, forcedcirculation and forced flow with no fixed steam and water line, and(ii) to steam pipes”Regulation No. 2(dd)- For he expression “Regulation 4(b)(ii)” , substitute the following :-

“Regulation 4(b)(ii) and 605” .

Regulation No. 2(k):- Delete the existing entry and substitute the following:-

‘ "Steam-pipe" means any pipe through which steam passes from a boiler to a prime-mover or other useror both, if-

(i) the pressure at which steam passes through such pipe exceeds 3.5 Kilograms per square centimeterabove atmospheric pressure; or(ii) such pipe exceeds 254 millimeters in internal diameter; and includes in either case any connectedfitting of a steam-pipe’ .

CHAPTER I

Regulation No. 4(b). - For sub-clause (i) the following clause shall be substituted:-

“ (i) All boilers during construction shall be under the supervision of an Inspecting Officer and shall beinspected at all stages of construction prescribed in Appendix J. Tubes and steampipes shall also beinspected at the makers' works at the stages prescribed in Appendix J, and the tests conducted by themakers shall also be witnessed by the Inspecting Officer.”Regulation No. 4(c) (iv). - In clause (c), in para (3) of sub-clause (iv) for the word and figure “FormIV” the following shall be substituted:-

“Form IV or Form III-B, as the case may be.”Regulation No. 4(c) (v). - Delete the following:-

“ In the case of fusion welded and seamless forged drums and headers a certificate from the manufacturerfurnishing the results of tests specified in Chapter V in regard to chemical analysis, tensile, bend andIzod impact tests.”Regulation No. 4(e) and (f). - Delete clause (e) and substitute the following clauses (e) and (f):-

“ (e) Certificates for steam pipes – A certificate of manufacture and test in Form III-A, signed by themaker and the Inspecting Authority shall be furnished.

(f) Certificates for tubes – A certificate of manufacture and test in Form III-B, signed by the maker andthe Inspecting Authority shall be furnished.”Regulation No. 4(g).- After Clause (f) add following clause (g) and the notes there under:-

“ (g) Certificates for mountings and fittings:- A certificate of Manufacture and Test in Form IIIC,

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signed by the Maker and the Inspecting Authority in respect of boiler mountings and steam-pipe fittingsduring manufacture, shall be furnished.

Note: For the purpose of this clause certificates issued by an authority empowered in this behalf by orunder the law in force or the national code in a foreign country, in respect of mountings and fittings inthat country and containing the particulars required to be specified in this certificate, may be accepted.Where, however, the material used, is in conformity with the code of the country of manufacture and iscovered by those Regulations, the permissible stress figures specified in the Code at differenttemperatures may be accepted in lieu of figures computed from the data required to be furnished underRegulation 271 in any of the following cases, namely:-

(i) Where a certificate is furnished from an Inspecting Authority to the effect that the steel complies withthe requirements of the grade steel (to be specified) and the permissible stress for the working conditionsas allowed for in the Code of the country of manufacture falls within the limit permissible under thisRegulation.(ii) Where the basis upon which these stresses have been arrived at is made available and such basis isnot found to be such as to give rise to stresses higher than those permissible under the Regulations.”

Regulation No. 5:- Substitute the following for clause (iv):-

“When the quality of material and the make of steel pipe have not been supported by certificates fromthe manufacturers in Form III-A, the pipes shall be tested in a test house and the maximum permissibleworking stress shall be such as the Chief Inspector of Boilers may in his discretion determine.”

CHAPTER I I

Regulation No. 9.- Delete the existing entry and substitute the following:-

“Process of manufacture :- Structural Steel for boilers shall be made by an Open Hearth or ElectricProcess or by any of the Oxygen Processes. Oxygen process steel shall not be used for working metaltemperaturesexceeding 427°C (800°F).”Regulation No. 10.- Substitute the following for clause (a):-

“The steel shall not contain more than 0.050 per cent of sulphur or of phosphorus and oxygen processsteel shall in addition not contain more than 0.006 per cent of nitrogen.”Regulation No. 26.- (i) For the word and figure “Form IV” , the following shall be substituted :-

“Form IV or Form III-B, as the case may be.”(ii) For the words “Open Hearth or Electric Process” , the following words shall be substituted:-

“Open Hearth or Electric Process or any of the Oxygen Processes.”Regulation No. 27.- (i) For the word and figure “Form IV” , the following shall be substituted :-

“Form IV or Form III-B, as the case may be.”Regulation No. 36 (Heading).- For existing heading above Regulation 36, the following shall besubstituted:-

“COLD DRAWN SEAMLESS STEEL BOILER AND SUPERHEATER TUBES FOR DESIGNMETAL TEMPERATURES NOT EXCEEDING 454°C (850°F).”Regulation No. 36(a).– For existing entry, following shall be substituted :-



“Material.- The tubes shall be seamless and made of steel produced by an Open Hearth or ElectricProcess or any of the Oxygen Processes. The Steel shall not contain more than 0.050 per cent of sulphuror of phosphorus and the oxygen process steel shall in addition not contain more than 0.006 per cent ofnitrogen. The manufacturer shall supply a certificate of analysis when required to do so.”Regulation No. 43 (Heading).- For existing heading above Regulation 43, the following shall besubstituted:-

“HOT FINISHED SEAMLESS CARBON STEEL BOILER AND SUPERHEATER TUBES FORDESIGN METAL TEMPERATURES NOT EXCEEDING 454°C (850°F).”

Regulation No. 43. – For clause (a), substitute the following :-

"(a) “Material.- The tubes shall be seamless and made of steel produced by an Open Hearth orElectric Process or any of the Oxygen Processes. The chemical composition of the material of the tubesshall conform to the following analysis and the steel produced by the Oxygen process shall in additionnot contain more than 0.006 percent of nitrogen:-Chemical Composition (ladle analysis).

*Carbon 0.25% maximumSilicon 0.35% maximumManganese 0.35% minimumPhosphorus 0.050% maximumSulphur 0.050% maximum

These provisions cover two quality groups of steels, namely grade 1 and grade 2, depending on theirtensile properties.*A carbon content not exceeding 0.35 per cent may be permitted subject to the approval of theInspecting Authority.

NOTE— Where the material is used for designed temperature above 399▪C (750▪F), the steel shall be ofnon-segregated or fully killed type.

Regulation No. 48.– Substitute the following for clause (b) :-

“Heat Treatment.- The tubes shall be fully annealed or normalized and tempered at a temperatureapproved by the Inspecting Authority.”Regulation No. 58. – Substitute the following for clause (a) :-

“Material Process.- The steel shall be produced by an Open Hearth or Electric Process or any of theOxygen Processes. The steel shall not contain more than 0.50 per cent of sulphur or of phosphorus andthe oxygen process steel shall in addition not contain more than 0.006 per cent of nitrogen.”Regulation No. 60. – For existing entry substitute the following :-

“Tensile test.- The tube shall conform to the following requirements:-

Kind of steel

Tensile strengthMinimum

Elongation on Lo=5do

or Lo – 5.65 Aominimum

Kg/mm2 tons/sq.inch

Type A Low Carbon Steel. . . . . . 31.5 20 25



Regulation No. 64 to 72.– Regulations 64 through 72 have since been deleted.

Regulation No. 74(a) – For existing entry, following shall be substituted:-

“Process of manufacture.- Steel for castings shall be made by an Open Hearth or Electric Process orany of the Oxygen Processes. Oxygen process steel shall not be used for temperatures exceeding 427°C(800°F).”Regulation No. 74(b).- For the words “The steel shall contain” , substitute the following:-

" The steel shall comply with the chemical composition specified in the table below and the OxygenProcess Steel shall in addition not contain more than 0.006 per cent of nitrogen.”Regulation No. 81.- (i) For clause (a) substitute the following:-

“ (a) Process of manufacture- Steel for forgings shall be made by an Open Hearth or Electric Processor any of the Oxygen Processes. Oxygen process steel shall not be used for temperature exceeding 427°C (800°F).”(ii) For clause (b) substitute the following:-

“ (b) Chemical analysis.- The steel shall not contain more than 0.050 per cent of sulphur or ofphosphorus and Oxygen Process steel shall in addition not contain more than 0.006 per cent ofnitrogen.”

CHAPTER I I I

Regulation No. 100.- For existing entry, following shall be substituted:-

“Normalising of certain Steel Plates- All steel plates which are dished, flanged or locally heatedshall be afterwards normalised unless they have been heated during the operation within the normalisingrange.”

Regulation No. 107.- For clauses (a) to (d) substitute the following:-

“The requirements of welded shells shall be covered by the provisions made in Regulations in Chapter Vor Chapter XII, as the case may be.”Regulation No. 122..- For clause (1) substitute the following:-

“As an alternative to Adamson flanges, furnaces which are partly fitted with corrugated sections shall bestrengthened by means of suitable stiffening rings adequately welded to the furnaces. The moment ofinertia of the stiffener shall not be less than that required by Regulation 592(b) In no case shall a flatstiffener be less than 63 mm x 13 mm. (2½'' x ½'').”Regulation No. 127.- For clause (a) substitute the following :-

“ (a) Cross tubes shall be made from weldless steel pipes or from plate or strip rolled and electricresistance or fusion butt welded pipes by electric arc process. The fusion welding shall conform to therequirements of chapter XII. Tolerances on these pipes shall conform to the requirements of Regulation345. Where welded pipes are used, the longitudinal welds shall be so situated that they are not exposedto the direct impact of flame.”Regulation No. 128.- For clause (a) substitute the following :-

Type C Medium CarbonSteel . . . . . 42 27 21"



“ (a) The uptakes shall be formed from weldless steel pipes or from plate or strip rolled and electricresistance welded or fusion butt welded pipes by electric arc process. The tolerances on these pipes shallcomply with the requirements of Regulation 345.”Regulation No. 151(d).- Delete the words:-

“and stress relieved”Regulation No. 151(e).- Delete the words:-

“and the welds shall be suitably heat treated”Regulation No. 151(f).- For existing entry, following shall be substituted:-

“For design metal temperature over 454°C (850°F) material to be used shall be in accordance with theRegulations 48, 53 and 56A.”Regulation No. 151(h).- After clause (g), insert the following new clause (h):-

“ (h) All butt welds of tubes shall be tested as required hereunder:-

(i) Components greater than 178 mm (7 inch) bore- All welds shall be non-destructively tested byradiographic or other approved methods. (ii) Tubes greater than 102 mm (4 inch) bore and upto and including 178 mm (7.inch) bore- 10per cent of the welds by each welder, selected at random with a minimum of 2 welds per welder, shall besubjected to non-destructive examination by radiographic or other approved method.

(iii) Tubes 102mm(4 inch) bore and under- Sample welds simulating the production welds shall beprovided for mechanical testing either at a rate of 2 per cent or after each 150 welding hours with aminimum of one sample weld per welder.

Alternatively, 5 per cent of the welds made by each welder selected at random, with a minimumof one weld per welder, shall be subjected to non-destructive examination by radiographic or otherapproved method. This rate may be reduced to 2 per cent by arrangement with the Inspecting Authorityafter initial satisfactory results have been produced.

In the event of any non-destructive test not meeting the requirements, defects in the weldsrepresented by that test shall be rectified and the Inspecting Authority may call for an increase in thenumber of non-destructive tests until such time as a satisfactory standard is achieved.”Regulation No. 152.- For clause (e), substitute the following:-

“ (e) Where tubes are strength welded direct to the tube plates, the technique followed shall be approvedby the Inspecting Authority and all welds shall be suitably heat treated. In the case of plates below 22mm thickness, the requirement of stress relieving by heat treatment after welding of the tubes may bewaived provided the weld satisfies the requirements of the maximum hardness and also the requirementsconcerning the impact values of the weld metal. The welding procedure adopted and the weld sequenceselected shall also be subject to the approval of the Inspecting Authority. This provision is applicable toonly shop welding of tubes at the Manufacturers' Works.”Regulation No. 154.- For clause (a) substitute the following:-

“ (a) (i) Headers and mud boxes etc of Water Tube Boiler may be of seamless or welded steel, or of caststeel

complying with the requirements of the provisions contained in Regulations 73 to 80. Where welded,the

welding shall be stress relieved, radiographed and in all respects shall be to the satisfaction of theInspecting



Authority.

(ii) Open ends of seamless steel tube headers may be closed by forging or the ends may be secured by bolting, screwing or welding in an approved manner. Bolting shall not be used where the bolts are

exposed to or are swept by gases of combustion.(iii) The method of attachment of the ends shall be subject to the approval of the Inspecting Authority.”

Regulation No. 166.- Add the following at the end of clause (c):-

“Where the door of a mudhole cleaning hole or sight hole is fabricated by welding for boilers notexceedinga working pressure of 8.8 kg/cm2. (125 lbs. per sq. inch), the stud shall pass through the plate and besecured to it by strength-welding on the inside and fillet-welding on the outside to the satisfaction of theInspecting Authority. The door shall be stress relieved by heat-treatment after welding.”

CHAPTER V

Regulation No. 235. – For Regulation 235, substitute the following: -

“Process of Manufacture. - Carbon steel for seamless shall drums shall be made by an Open Hearthor Electric Process, or any of the Oxygen processes. Oxygen Process steel shall not be used for workingtemperatures exceeding 427°C(800°F)".

Regulation N o. 236. – For Regulation 236, substitute the following: -

“Chemical Analysis. – The steel shall not contain more than 0.050 per cent of sulphur or ofphosphorus and Oxygen Process steel shall in addition not contain more than 0.006 per cent o fnitrogen.”Regulation No. 244. – At the end of clause (b), the following shall be added: -

"Tests on butt welds on pipes shall be required under Regulation 151(h)

Regulation No.252. – For Regulation 252, the following shall be substituted: -

"Method of Making Welded Joints- Provided the requisite quality of welding is achieved, the seamsmay by welded from both sides of the plate or from one side of the plate with or without a backing strip.If a backing strip is used, it shall be removed and the surface so exposed shall be dressed.

Additional runs of metal shall be deposited at the surface of the welded seams so that the welded metalat the level of the surfaces of the plate is refined as far as possible. The surfaces of the weld shallthereafter be machined or ground so as to provide smooth contours and to be flush with the respectivesurfaces of the plate. There shall be no undercutting at the junctions.

When affixing standpipes, branch pipes, seatings, compensating plates, doubling plates or manholeframes, not less than two runs of metal shall be deposited at each weld. Each run of weld shall bethoroughly cleaned and freed from slag that may adversely affect the quality of the succeeding runs.Welds shall be marked permanently to facilitate their location.”Regulation No.254. – For the words “shall not fall in line” substitute the following: -

“Shall not fall in line except where the rings of the drum are in two halves of unequal thickness” .



Regulation No.255. – For existing entry, substitute the following: -

“Position of the Tube holes- Tube holes in welded seams should be avoided. Where they areunavoidable they may be machined through welded seams after these seams have been radiographed,and stress relieved. The efficiency of the ligament in the direction of weld shall be multiplied by a weldfactor not exceeding 0.95 except where the distance from the edge of the tube hole to the edge of theweld is greater than 13 mm (1/2"). The edge of the weld shall be considered to be the edge of the weldgroove as machined in the plate prior to welding".

Regulation No.270. – Delete the following expression appearing at the end of clause (a): -

“and f = permissible stress on butt weld from the table in Regulation 271, Column B.”Regulation No.271 (i) – For Sub-Regulation 271 (i) substitute the following and delete the ‘Note’appearing there under: -

For temperature at or below 454°C(850° F), the smaller of the two values: -

Regulation No.271 (ii) – (a) Substitute the following for Sub-Regulation 271(ii):-

For temperatures above 454▪C(850▪ F) the lower of the following two values: -

(b) Below the connotation for SR, the following sub-Para shall be inserted: -

"Such deduction need not be made provided the minimum specified values of R and E at any part ofthe section of the steel plate used in the manufacture of the Boiler drum are guaranteed by a "Wellknown Steel Maker" or certified by an Inspecting Authority.

Regulation No.279 (Heading). – Substitute the following for heading above Regulation 279:

“STANDPIPES AND NOZZLES”Regulation No.279. – For existing entry, following shall be substituted: -

"(a) Standpipes and Nozzles Welded to Shell-Where standpipes or nozzles are secured by welding,adequate compensation for the hole cut shall be provided. Compensation shall be considered adequatewhen the sectional area 'X' to be compensated measured through the axis of the shell is less than thecompensating area 'Y' given in Figure 25-B. (click here to view the Figure(F25-B)

Sectional area X = (d n x es )

Sectional area Y= 2 (t n- e n) b x fn / fs + 2tnx b x fn / fs + 2(t s - e s) C1 + C2

Wheredn = internal diameter of the standpipe or nozzle;ts = actual thickness of shell;



tn = actual thickness of standpipe or nozzle;es = equivalent thickness of shell i.e., thickness of a seamless shell of similar material unpierced bytube holes and is designed for the same conditions of pressure and temperature as the shell in questione n = equivalent thickness of the standpipe calculated similarly as for e plus any thickness if requiredto withstand any external load on the standpipe or nozzle;b = the least of the values of

2.5 times t;2.5 times tn;

or if the length of the standpipe or nozzle outside or inside the shell is less than this value; ' b' shall belimited to the actual length in each case.C w = the aggregate cross-sectional area of the fillet welds;C i = ts+ 76 mm (3 in.) or dn/2, whichever is greater;f s = the permissible stress for the material of the shell at the working metal temperature;f n = the permissible stress for the material of the standpipe or nozzle at the working metal

temperature.

In case where 'y' is less than 'X' a compensating plate shall be fitted to the shell at the standpipeand secured by fillet welds as in figure 25-B.

The area of cross section of this compensation plate shall be governed by the ratio between thepermissible stress at the working metal temperature for the materials of the shell and the compensatingplate.

(b) Standpipe and nozzles welded to dished end plates- Where the standpipe or nozzles are weldedto dished end plates, the compensation shall be considered adequate if calculated on the same basis as in(a) above. But the cross sectional area of the end plate to be compensated shall be calculated on the basisof equation 74 and the height of standpipe above the outer surface or within the inner surface of the endplate shall be measured along the radial line passing through the center of the opening.

(c) Minimum thickness of Flange- The minimum thickness of the flanges and the body of standpipesshall be in accordance with the table under Regulation 156.

CHAPTER VI

Regulation No.281 – (a) For the first item in Regulation 281, namely, “Two Safety Valves (minimumdiameter ¾”)” , the following shall be substituted: -

"Two safety valves, one of which may be a high steam and low water type safety valve. In no caseshould the bore of the seat of the valve be less than 19 mm (¾").(b) The following shall be inserted at the end of the fourth paragraph: -

"In the case of a single boiler of the Shell Type and not connected in a battery with other boilers, theheating surface of which does not exceed 1022 (1,100 sq. ft.) two independent source of power supply tothe two feed apparatus will not be necessary".

Regulation No.282(a).– for paragraph (iv), the following shall be substituted; -

(iv) Bronze casting shall comply with the following requirements namely: -



Regulation No.290(b).- For the first sentence in the second paragraph of clause (b), the followingsentence shall be substituted: -

"The working pressure of the chests shall be determined by equation 91or 91A, whichever is applicable,where the term '2 Se' shall be substituted by the term '1.8 x S'.

Regulation No.290(v).- For clause (c), the following shall be substituted: -

“The working pressure and the thickness of the chests shall be determined by the following formulae,subject

to minimum thickness as specified in regulation 283(b)

Where S is the specified minimum tensile strength for the grade of material.

D- is the external diameter of the chest.t - is the minimum thickness of the chest, excluding tolerance, andC - is the minimum positive tolerance as specified here under:-

For Bronze Chests C = 1.5mm or 0.06 in. For Cast Iron Chests C = 5mm or 0.20 in.

For Cast Steel Chests C = 5mm or 0.20 in.”Regulation No.290 (d).- Insert the following as clause (d), after clause (c) :" For chests made of cast steel, for service temperature exceeding 290°C (554°F), the working pressure

Chemical composition Grade A Grade BTin 5.5 to 8% 4.0 to 6.0%Lead 1.0 to 3.0% 4.0 to 6.0%Zinc 3.0 to 6.0% 4.0 to 6.0%Total of all elements other than set outabove and excluding copper and incidentalnickel

0.50% 0.50%

Copper plus Incidental nickel Balance Balance

Physical Properties

Sand Cost(cast on)

Sand Cast(separatelycast)

Ultimate Tensile strength

Elongation percent minimumon standard test piece C

Ultimate tensile strength

22kg/mm2 (14.5 tons/sq.in) 8%

23kg/mm2 (14Tons/sq.in)

20.5kg/mm2 (13 tons/sq.in) 15%

20.5kg/mm2 (13Tons/sq.in)

Elongation percent minimumon standard test piece C.

12% 15%



as calculated by equation 76, shall be multiplied by a factor given below: -

Intermediate values may be interpolated.”

Regulation No.307(a).- For existing entry following shall be substituted:-

" The springs shall be manufactured from steel made by the Acid Open Hearth or Electric Process andthe Chemical composition shall be within the following limits:

Carbon Steel

Silicon Manganese Steel

The manufacturers shall supply an analysis of each cast when required by the Inspecting Authority to doso. Should independent analysis be required, these shall be made at the rate of one per cast.

All springs shall be formed hot and suitably hardened and tempered."

Regulation No.307 (b) - The following NOTE shall be inserted at the end of the Regulation :-

"NOTE - Special steels developed by individual Manufacturers may be accepted by the Chief Inspectorof Boilers at their discretion."

Regulation No.308 - For existing entry ,the following shall be substituted:-

315°C (600°F) 0.90345°C (653°F) 0.80375°C (707°F) 0.75405°C (761°F) 0.71435°C (815°F) 0.66454°C (850°F) 0.63

Element Per centMin Max

Carbon 0.90 1.20Silicon 0.30

Manganese 0.45 0.80Sulphur 0.050

Phosphorus 0.050

Element Per centMin Max

Carbon 0.50 0.65Silicon 1.50 2.00

Manganese 0.70 1.00Sulphur 0.050

Phosphorus 0.050



"Dimensions- For ordinary lift valves, the compression or extension of safety valve springs requiredto load the valves to the set pressure shall not be less than one quarter of the diameter of the valve dueconsideration being given in the case of spring loaded lever safety valves to the ratio of leverage. Theproportion of unloaded length to external diameter of the spring shall not exceed 4.1.

These requirements do not apply to full lift and high lift safety valves."

Regulation No.309 - (i) In sub-Regulation (1) after the words following formulae". the followingheading shall be inserted :-

"For Spring in Extension."

(ii) After Equation 82, the following shall be inserted:-

"For Springs in Compression- The working pressurecalculated by the above equation may be increasedby 25 per cent.

(iii) For the 'NOTE' the following shall be substituted:-

Note (1) The above formulae are based on the maximum allowable safe stress of 5.624 kg/crn2 (80,000lbs. per square inch) on the sections of the springs under extension and 7,030 kg/cm2 (100,000 lbs. persquare inch), where they are in compression.

(2) The above values of 'C' apply only to the case of 'full-lift' Safety Valves, where L2 is equal to D/4. Incase of "high-lift" and "ordinary lift" Safety Valves", respective values of "C" may be worked out byusing appropriate values of L2".

Regulation No.313 - For the existing entry the following shall be substituted:-

"Spacing of Coils- The space between the coils when the valve is lifted to 1/4th of its diameter, shallbe not less than 1.6 mm (1/16 inch) for full lift valves and 0.8 mm (1/32 inch) for ordinary and high liftvalves.

Regulation No.316(c) - Regulation 316(c) has been deleted.

CHAPTER-VI I

Regulation No.337- For the existing entry following shall be substituted:-

" Material and Construction- (a) All tubes which are subject to internal pressure of water or steamshall be cold drawn or hot finished seamless or electric resistance welded in accordance withRegulations 36 to 63. Except as provided for in clause (b) below they shall be without joint.

(b) Tubes having an external diameter not exceeding 5 inches may be jointed and such joints may beflashed welded, machine forge welded arc or gas welded. Tubes have 5 inches diameter may also bewelded provided they are located outside the furnace. Such welds must conform to the requirements ofChapter VIII.

(c) Flash welding shall be undertaken on a welding machine of a type approved by the InspectionOfficer and the external fin caused by welding shall be completely removed. The internal fin caused bywelding shall also be removed subject to a maximum height of 20 percent of the wall thickness of thetube.



(d) Arc welded butt joints shall be made by the metallic shielded arc process and stress relieved.

(e) When gas welding is implied the technique followed shall be approved by an Inspecting Officer andall welds shall be suitably heat treated.

(f) For design metal temperature over 454°C (850°F) material to be used shall be in accordance withRegulations 48, 53 and 56A.

(g) The technique employed in all field welding of tubes shall be subject to the approval of the ChiefInspector of Boilers.

Where, however, material used is in conformity with the Code of the country of manufacture and it iscovered by these Regulations, the permissible stress figures specified in the Code at differenttemperatures may be accepted in lieu of figures computed from the data required to the furnished underRegulations 338 and 340 in any of the following cases:-

(i) Where a certificate is furnished from the Inspecting Authority to the effect that the steel complieswith requirements of the grade steel (to be specified) and that the permissible stress for the workingconditions as allowed for in the code of the country of manufacture falls within the limits permissibleunder the Regulations.

(ii) Where the basis upon which these stresses have been arrived at is made available and such basis isnot found to be such as to give rise to stresses higher than those permissible under the Regulation"

Regulation No.338(a)- (i) For the portion beginning with the words "Permissible Working Stress fortubes:-" and ending with words "which ever is the lowest " the following shall be substituted:-

"Permissible Working Stress for tubes:-

For temperature at or below 454 ▪C (850▪F)

Whichever is lower

For temperature above 4540 C (8500 F---------

Whichever is lower"

(ii) In clause (a) for the equation and the values

of C given under it the following shall respectively be substituted :-



C=1mm (0.04")"

(iii) For clause (d) the following shall be substituted :-

(d) "For radiant superheater tubes the maximum steam temperature for which the part of the element isdesigned plus 50°C (90°F )".

Regulation No.338(c) - Delete the following words :-

"(c) Where tubes are bent resulting thickness of the tubes at the thinnest part shall be not less than thatrequired for the plain tubes."

Regulation No.339- For existing entry following shall be substituted :-

" Materials and Construction- The materials and construction shall comply with Regulations 154and 245."

Regulation No.340 (c) - In the Table under Regulation 340,for the entries under the column "Carbonand Alloy Steel ".the following shall be substituted :-

"The lower value obtained in each case at the specified temperature calculated on the following basis:-

For temperature at or below 454°C (850° F )

For temperatures above 454°C(850° F )

Regulation No. 340(f) - After clause (e) the following shall be inserted :-

"(f) End Attachments- The ends of rectangular headers may be formed integral with the header orattached by welding.

The working pressure for the flat ends shall be calculated by the following formula:-

where,



W.P. = Working Pressure,

f = permissible stress for the material at the working metal temperature,

t = thickness of the plate at the weakest part,

d = the least width between the walls of the rectangular header,

C = 1 mm (0.04"),

K = 0.32 for ends integral with or flanged and butt welded to the header,

= 0.40 for ends directly strength welded to the header in an approved manner.

Regulation No.342 - For existing entry the following shall be substituted :-

"(a) Cylindrical Headers:- Where cylindrical headers are provided their working pressure shall bedetermined by Equation 72.

(b) End Attachments- The attachment of ends and the method of calculating the working pressureshall be in accordance with clause (f) of Regulation 340.

Subject to the following modification:-

K = 0.19 for ends integral with or flanged and butt welded to the header.

= 0.28 for ends directly strength welded to the header in an approved manner.

and d = internal diameter of the header".

CHAPTER VI I I

Regulation No.343(1)- Re-number Regulation 343 as 343 (1) and omit the words "lap welded".

Regulation No.343(2)- The following shall be added after Regulation 343 (1) as 343 (2) :-

"(2) Where, however, material used is in conformity with the code of the country of manufacture and itis covered by these Regulations, the permissible stress figures specified in the code at differenttemperatures may be accepted in lieu of figures computed from the data required to be furnished underRegulation 350 in any of the following cases:-

(i) Where a certificate is furnished from the Inspecting Authority to the effect that the Steel complieswith requirements of the grade steel (to be specified) and that the permissible stress for the workingcondition as allowed for in the code of the country of manufacture falls within the limits permissibleunder the Regulations.

(ii) Where the basis upon which these stresses have been arrived at is made available and such basis isnot found to be such as to give rise to stresses higher than those permissible under the Regulations.

Where pipes have to be fabricated by longitudinal fusion butt electric arc welding of plates rolled toshape, the limits prescribed for butt welded pipes in Table 2 under Regulation 349 shall not apply. The



requirements other than those relating to the minimum thickness of shell for fusion butt weldingprescribed in Chapter XII shall be applicable to such pipes".

Regulation No.344(a)- For existing entry, following shall be substituted :-

"(a) The pipes shall be made from steel made by an Open Hearth of Electric Process or by any of theOxygen Processes. Oxygen process Steel shall not be used for working metal temperatures exceeding427°C(800°F). Hot finished seamless pipes may, however, be made of Bessemer Steel. Bessemer Steelshall not be used for pressures exceeding 21 kg/cm2 (300 lbs.in.2) or temperatures exceeding 260°C(500°F). If the Bessemer Process is used, the steel shall be made by a manufacturer approved by theInspecting Authority.

When used for temperatures exceeding 399°C (750°F) the steel shall be of non-segregated or fullyskilled type".

Regulation No.344(d).- The following words shall be omitted :-

"roll lap welded, hydraulic lap welded and "

Regulation No.344(e).- After sub-Regulation (d) the following shall be inserted :-

"Not withstanding anything contained in sub-Regulation (a) the material specifications given in thisChapter shall not apply to steam-pipes and fittings used for conveying steam at a pressure not exceeding1 kg cm2 the approval in regard to the quality of the material being left to the discretion of the ChiefInspector of Boiler."

Regulation No.345- In Regulation 345 the existing clause shall be lettered as clause (a) thereof, andafter clause (a) as so lettered ,the following shall be inserted :-

"(b)- The pipes shall be made within the limits of tolerances given below:-

Regulation No.346.- In the last sentence for the entry "427° C (800° F)" the following shall besubstituted :-

"454° C (850° F)."

Regulation No.347(a). - In clause (a) the following shall be added at the end :-

"(i) For cold drawn seamless construction -Regulation 39.

Class Tolerance onOutside diameter Nominal thicknessUp to and including Over 51 mm .

51 mm (2” ) (2” )SeamlessE.R.W

+0.4 mm (1/64”)

-0.8mm.-(1/32”)

+ no limitation

-12.5%

Butt welded 1% 1% + no limitation-12.5%



(ii) For hot finished seamless construction -Regulation 44 (b).

(iii) For molybdenum seamless construction -Regulation 49(b)

(iv) For chrome molybdenum seamless construction - Regulation 54(b)

(v) For electric-resistance welded tubes - Regulation 59 (a)

(vi) For copper steam pipes Regulation 35

For pipes where the ratio between the wall thickness and the diameter would not permit the maintenanceof the distance between the flat surfaces specified in the above regulation, this shall be limited to 2/3rdthe bore of the pipe".

Regulation No.347(c) - In clause (c) the following clause shall be added at the end :-

" In cases where the outside diameter of the pipe is less than 8 times the wall thickness, the diameter ofthe former shall be equal to 4 or 2/3rd of the nominal bore of the pipe, whichever is less".

Regulation No.347-Table 1.- In the main heading the words and bracket "Roll Lap Welded and "and"Hydraulic (Water gas )Lap welded pipes " shall be omitted.

Regulation No.348- Delete clause (a).

Regulation No. 349 -(1) In Table 2-

(a) the method of manufacture specified in the second column as "Hydraulic lap welded" and the entriesrelating thereto shall be omitted;(b) In the second column the words "Roll lap Welded." shall be omitted ;(2) In Table 2, against the entry "Carbon Steel ":- (1) In column 2, the expression "Max, nominal O.D 114 mm (4 1/2 in)" shall be deleted. (2) in column 5, for the word "Straight "occurring for the second time the abbreviation "Do " shall besubstituted.

Regulation No. 350- (1) For existing entry the following shall be substituted :-

"350" Steel Pipes- The maximum working pressure allowed on steel pipes shall be determined by thefollowing formula:-

Where t = nominal thickness less permissible negative tolerance.W.P = Maximum working pressureS = allowable stress as specified in table 3 or Regulation 343D = Outside diameter of pipe.e = Efflciency factor. = I for seamless and electric resistance welded Steel pipes .



= .9 for welded steel pipes for valves of t upto and including 22 mm ( 7 /8° ) = .85 for welded steel pipes for valves of t over 22 mm(7/8" )and upto and including 29 mm(1/1/8").c = 0.1 cm (0.04 in)(2) In Table 3 , for the entries in the first column headed "Material and method of manufacture thefollowing shall be substituted :-

CARBON STEELA Butt welded and Bessemer hot finished seamless .B Casting(3) In Table 3 for the entries:-"Carbon steelSeamless hydraulic lap welded and The lowest value obtained on the followingElectric resistance welded basis fromMolybdenum steel Seamless For temperatures upto and including 350° C (662°F )

Chromium Molybdenum Steel Seamless For temperatures above 350° C (662° F)

Where T.S = Minimum Tensile strength at 20°C (68°F). Et = Yield point ( 0.2% proof stress ) at temperature 't'. Sr = The average stress to produce rupture in 100,000 hours and in no case more than 1.33 timethe lowest stress to produce rupture. Sc = The average stress to produce an elongation of 1%(creep) in 100,000 hours"

the following entries shall be substituted :-

"Carbon steel The lowest value obtained on the following basis fromSeamless and Electric resistance welded For temperatures upto and including 554° C (850° F )

Molybdenum steel Seamless For temperatures aboveChromium Molybdenum Steel 454° C (850° F) Seamless

Where , T.S = Minimum Tensile strength at 20° C (68°F).Et = Yield point (0.2% proof stress )at temperature .Sr = The average stress to produce rupture in 100,000 hours and in no case more than 1.33time the lowest stress to produce rupture.



Sc = The average stress to produce an elongation of 1% (creep) in 100,000 hours"

Regulation No. 351(b)- For the letter ,symbol ,words and figure "S = Allowable Working stress asspecified in tale 4". the following shall be substituted :-

" S = Allowable working stress as specified in Table 4 or Regulation 343"

Regulation No. 351 (Table )- For Table 4 ,the following table shall be substituted :-TABLE 4

Maximum Permissible Working Stress for Carbon and Alloy Cast SteelPipes

(See Regulation 351 )Lower value obtained in each case at the specified temperature calculated on the following basis:-

For service temperature at or below 454° C (850° F)

For service temperature at or above 454°C(850°F)

Regulation No. 353- For regulation 353,the following regulation shall be substituted :-

(a) Flanges of Carbon Steel Pipe- The material for carbon steel flanges, where forged, cast or cutfrom the plates (excluding branches forged integral with the pipes) shall be made of steel produced byan Open Hearth or Electric process or any of the Oxygen processes.

Carbon steel flanges shall not be used for temperatures exceeding 454▪C (850▪F). Flanges shall be madewithout a weld and shall be free from lamination or other defects, they may be secured by screwing1riveting or welding.

Blank flanges shall be of mild steel of cast steel and shall be not less in thickness than the flanges towhich they are attached. The material shall comply with the requirements specified in relevantregulations of Chapter II or Chapter V of these Regulations.

(b) Flanges of Alloy Steel Pipes- The material for alloy steel flanges, where forged, cast or cut fromplates (excluding branches forged integral with the pipes), shall be made from the steel produced by anOpen Hearth or Electric process. Flanges should be made without a weld and shall be free fromlamination or other defects. The material of alloy steel flanges shall comply in all respects with therequirements of Regulation 234. The material for flanges shall be similar to that of the pipes to whichthey are to be attached. The flanges are to be so designed that the total stress induced in them does notexceed the maximum permissible stress as may be determined by the criteria laid down underRegulation 271.

Blank flanges of alloy steel shall be not less in thickness than the flanges to which they are to beattached. The material shall be similar to that of the flanges.

(c) Non-ferrous Flanges- The material for non-ferrous flanges shall be of bronze. The chemicalcomposition shall comply with the requirements of sub-clause (iv) of Regulation 282 (a). when flanges



are attached to copper pipes by brazing, they shall be secured in such additional way (i.e. by riveting orforming a conical bore in the flange) so that the resistance to withdrawal from the flange does notdepend wholly on the brazing".

Regulation No. 360 (b)- For the words, figures, letters and brackets "Where pipe having a wallthickness exceeding 13 mm (1/2 in) are butt-welded together they shall be effectively stress relieved inaccordance with the following :- " the following shall be substituted :-

"Where pipes are butt-welded together, such weld shall be effectively stress relieved when the wallthickness exceeds 13 mm (1/2 inch ) or carbon content of the steel exceeds 0.25% or pipes are made ofalloy steel in accordance with the following :-

Regulation No. 360 (d) - After clause (c) the following new clause shall be inserted :-

"(d) - TESTS ON COMPLETED WELDS ON PIPELINE "

(I) Classification

For the purpose of tests, pipelines shall be divided into two classes:-

Class I - Pipelines for service condition in which any one of the foregoing limits is exceeded:-

Design temperature . 218°C(425°F) Design Pressure . 17.6 Kg/cm2 (250 lbs/sq in ) Feed water . 24.6 Kg/cm2 (350 lbs/sq in )

Class I I - Pipelines for service condition in which none of the foregoing limits is exceeded.

(2) Identification of Welds

The welder's identification mark shall be stamped without indentation, or stenciled adjacent to eachcompleted weld.

(3) Tests for Class I pipelines

(i) Where the completed pipeline are not subjected to hydraulic test:

Where the completed pipelines are not tested by the application of hydraulic pressure, the weldsshall be subjected to the following inspection

Piping over 102 mm (4 in ) bore - All butt-welds shall be subjected to non-destructive examinationby radiographic or other approved methods. the entire circumference of the first five welds made byeach welders shall be non-destructively examined .If these are found to be satisfactory and theInspecting officer or Inspector is in other respects satisfied with the welding technique methods ofcontrol and supervision employed relaxation in the extent of non-destructive examination may beconsidered but this relaxation shall in no case permit the non-destructive examination of less than one -third of the circumference of each of the remaining welds made by the welder concerned.

Piping 102 mm (4 in ) bore and under ,but not less than 38 mm (1 1/2 in ) bore - Five percent ofthe butt-welds made by each welders with a minimum of two welds per welder ,selected at random shallbe subjected to non-destructive examination by either radiographic or other approved methods or may becut out for visual examination and bend tests.



Piping less than 38 mm (1 1/2 in) bore - Special tests are not normally required but two per cent ofthe welds by each welder on a pipeline may be cut out from the pipeline for visual examination and bendtests. (ii) Where the completed pipeline are subjected to hydraulic test-

Where the completed pipeline are tested by the application of hydraulic pressure the welds shall besubjected to the following inspection procedure:-

Piping over102 mm (4 in) bore-Ten per cent of the welds made by each welder on a pipeline with aminimum of two welds per welder,selected at random ,shall be subjected to non-destructive examination by radiographic or other approvedmethods.

Piping 102 mm. (4 in.) bore and under, but not less than 38 mm. (1 1/2 in.) bore-Two per cent ofthe welds made by each welder on a pipeline with a minimum of one weld per welder, selected atrandom, shall be subjected to non-destructive examination by radiographic or other approved methods ormay be cut out for visual examination and bend tests.

Piping less than 38 mm. (1½ in.) bore- Special tests are not normally required but two per cent of thewelds by each welder on a pipeline may be cut from the pipeline for visual examination and bend tests.

(4) Tests For Class I I Pipelines

(i) All pipelines under this classification shall be subjected to hydraulic test on completion of erection.

(ii) On completion of the first ten production welds made by each welder, one of the welds shall be cutout for test purposes or alternatively, the welder shall prepare a test specimen made up of two similarlengths of piping welded in a position as closely representative of a selected production weld as ispracticable. The test specimen shall be subjected to visual examination and bend tests.

(iii) Two per cent of the remainder of the welds made by each welder shall be selected at randomand cut out for test purposes, or, alternatively the welders shall prepare a test specimen made up of twosimilar lengths of piping welded in a position as closely representative of a selected production weld asis practicable. The test specimen shall be subjected to visual examination and bend tests.

(5) Re- tests- If any test specimen is unsatisfactory, two further weld specimen for re-tests shall beselected from the production welds and subjected to tests. In the event of failure of any of the re-testspecimens, the production welds carried out by this welder subsequent to the previous test shall besubject of special consideration.

Regulation No. 362(c) - (i) For Equation (91-A),the following equation shall be substituted:-

and the connotation for "tm " 'and ' "c'" shall be amended to read as follows :-

tm = nominal thickness of the branch less the permissible negative tolerance.



C = 1.0 mm (0.4 inch)."

(ii) Equation (91-E ) shall be substituted by following equation:-

Regulation No. 365 (1) In clause (2) of sub-regulation (f) for the portion beginning with the word andfigure

'Class I ' and ending with the words and figure "specified for class I" the following shall besubstituted :-

"Class I ---- No limit to scantlings

Class II ---- When none of the following limits is exceeded :-

(i) Working Pressure -35 kg / sq cm. (500 lbs sq in)

(ii) Product of working Pressure and internal diameter -3750 (21,000)

(iii) Design temperature -343° C (340°F).

Class III -- When none of the following limit is exceeded :-

(i) Working Pressure -7.4 kg / sq cm. (105 lbs sq si)

(ii) Product of working Pressure and internal diameter -940(5250)

(iii) Design temperature -171° C (340°F).

(2) For the last sub-paragraph beginning with the words "All shells shall "and ending with the word andfigures "Chapter XII" the following shall be substituted :-

"Tests for class III fusion welded seams shall comply with the requirement of those of Chapter XIII

Class I and Class II shells shall be stress relieved by heat -treatment after completion of all welding andbefore hydraulic test. The heat-treatment shall conform to the requirement of Chapter XIII"

Regulation No. 366 (I ) - In sub-regulation (a)-

(1) in "f" below the below the equation for determining the maximum working pressure of shells, for thewords "Permissible working stress " the words and shells for the words and figures "maximumpermissible working stress as prescribed in Regulation 271 or 350 whichever is applicable" shall besubstituted :

(2) for the first Table the following Table shall be substituted :-



(3) in the second Table prescribing the minimum thickness of shells, in the first column after the wordsand figure "Fusion welded Class II" the word and figure "and Class III" shall be inserted :

(4) the third table and the the sentence above and below that table for determining the maximumpermissible stress for cylindrical parts of seamless fusion welded and riveted shells shall be omitted.

(5) the fourth table and the sentence above and below that table for determining the maximumpermissible stress for shells made form welded less pipes shall be omitted;

(6) the paragraph dealing with suitability of circumferential seams of riveted shells shall be omitted :

(II) In sub-regulation (b) (1) for the paragraph containing the formula regarding the valve of E thefollowing shall be substituted:-

"The valve of E may be taken as unity when the diameteral cross sectional area of the compensatingframe and/or ring is equal to or greater than the diameteral cross-sectional area of the opening in the endplate to be compensated "

(III) In clause (2) of sub -regulation (b) for "f" below the equation for determining the maximumworking pressure for welded -in flat end plates the following shall be substituted:-

"Maximum permissible working stress in pounds per sq inch at working metal temperature asprescribed in regulation 271 " and the table and the sentence below the table for determining the valveof "f" shall be omitted".

Regulation No. 367 - For existing entry the following shall be substituted :-

"steel screwed and socketed Joints and ,Mountings of steel: steel couplings or sockets may be used on pipes within the limits

Class Efficiency factor EI 0.90II 0.75 if welded from both sides

0.50 if welded from one side only.III 0.45

Nominal bore

Maximum permissiblepressure

Maximum permissibletemperature

Lbs /Sq. in.

Kg /Cm2

▪C ▪F

Up to and including 25 mm(1in.) 175 12.25 260 500

Over 25 mm (1” ) up to andincluding 38mm (1 ½ ”) 150 10.5 260 500

Over 38 mm (1 ½”) up to andincluding 76 mm (3 ”) 125 8.75 260 500

Over 76 mm (3” ) up to andincluding 102 mm (4 ”)

100120

78.5

260177

500350

Over 102 mm (4” ) up to and 100 7 171 340



Where tapered threads are employed and the diameter of the pipe does not exceed 38 mm (1 1/2 ). theuse of such sockets and mounting may be permitted upto the limits of 31.6 kg/cm2 (450 lbs/sq.in)".

Regulation No. 368 - For existing entry the following shall be substituted -

Bronze Screwed and Socketed Joints and Mountings and Fittings of Bronze:- Mountings andfittings of bronze upto 76 mm (3") diameter may be attached directly to steel pipes by screwing whenthe pressures and temperatures do not exceed 8.5 kg/cm2 (120 lbs. sq. in.) and 225°C (435°F)respectively; where tapered threads are employed, such joints may be used for pressures not exceeding17.6 kg/cm2 (250 lbs. sq. in.) Bronze fittings above 76 mm (3") diameter shall be of flangedconstruction.

CHAPTER IX

Chapter IX (Heading ): For HEADING of chapter IX substituted the following :-

"REGULATIONS FOR THE REGULATION OF BOILERS AND INSPECTION OF BOILERSAND STEAM-PIPES"

Regulation No. 376 - For clause (d) the following shall be substituted:-

(d) Provision shall be made for the effective disconnection of all steam and hot water communicationwith another boiler under steam as required in Chapter IX -A of these Regulation"

Regulation No. 377. - The words 'For Inspecting Officer's shall be omitted.

Regulation No. 378. - The following proviso shall be added at the end of clause (e):-

"Provided that the Inspector may, at his discretion, allow the lagging and brick work to remain in situ,in case of boilers where the covered parts have been fabricate and tested before erection in position".

Regulation No. 379. - In clause 'k' for the words "Except in the case of small portable and vehicularboiler " substituted the following :-

" Except in the case of vertical boilers heating surface of which is less than 18.50 sq. m. (200 sq. ft.)portable and vehicular boilers".

Regulation No. 381. (a) - & (b) - In clause (a) and (b) for the words and figure "Chapter IV and V " thewords "relevant chapter shall be substituted.

Regulation No. 381. (e) - For clause (e) the following clause shall be substituted :-

" Where a certificate in Form II and a Memorandum of Inspection Book in Form I are furnished by anInspecting Authority in accordance with sub-regulation (c) of Regulation 4 the Inspector shall, onreceipt of an application for registration under sub-section (1) of Section 7 of the Act, proceed to makesuch examination and measurement of boiler as will satisfy him that the boiler is the one certified by theInspecting Authority and carry out a thorough examination and check the measurements to ensure the

including 127 mm (5 ”)



correctness of the Inspecting Authority's certificate and that no damage has been caused in transit.

The Inspector shall, if he is satisfied with the condition of the Boiler, the correctness of the particularsand approved working pressure entered in Form I by the Inspecting Authority subject the boiler tohydraulic test in accordance with Regulation 379.

When the Inspector is satisfied that the boiler has satisfactorily with stood the test, he shall issue aprovisional order to enable the boilers to be worked".

Regulation No. 382. - For clause ( a ) and (b) the following clauses shall be substituted :-

Regulation No. 382. -* Engraving of registry number :

"(a) The registry number of every boiler shall, within a period of one month from the date of receiptthereof be cut in the front plate or any such position as shall be pointed out by the Inspector. The devicefor each State Union Territory shall be distinguished by the following letters: (Click here to view theTable)

The distinguishing letters shall be engraved above a number and separated there from by a horizontalline 64 mm (two and a haif inches) in length. The letters and figures shall be 25 mm (one inch) in heightand of suitable breadth, provided that in the case of small boilers the letters and figures of the devicemay, in the discretion of the Chief Inspector, be reduced to 10 mm (3/8") in height. The whole shall beenclosed in a rectangle, the upper and lower sides of which shall be 76 mm (three inches) apart and 6mm (one quarter inch) clear of the top of the letters and the bottom of the figures respectively asindicated below:-

The side lines shall be at equal distance clear from the figures. The engraving shall not be less than 0.4mm (1/64 inch ) in depth.

(b) The engraving shall be complete and ready for verification within one month from the date ofreceipt of registry number, and the fact shall be reported to the Chief Inspector of Boiler within thisperiod".

Regulation No. 389. - For the words "as safeguard against over loading the date and pressure of the lasthydraulic test of the boiler and when applicable of the main steam-pipes prescribed substituted thefollowing :-

"as safeguard against over loading and the date and pressure of the last hydraulic test of the boiler"

Regulation No. 392. - Substitute sub-clause (iv) of clause (b) by the following :-

"(iv) that all welders employed by him possess certificates issued as required under Chapter XIII ofthese Regulation"

Regulation No. 394. (a) - For clause (a) the following clause shall be sub-stituted:-

"(a) Steam pipes shall be inspected and hydraulically tested before erection in place, in test pressure to



be that prescribed in the standard conditions for steam pipes. A certificate from the Inspecting Authorityin Form Ill A, stating that this has been done by him may be accepted. If the Inspector is satisfied withthe test, the pipes may be erected in position. The Chief Inspector shall intimate his approval to theowner regarding the suitability of the pipe line for use at the pressure and temperature to be specified.

Regulation No. 394. (b) - In clause (b) for the words "The test pressure at such hydraulic test shall benot less than twice the working pressure of the boiler "the following words shall be substituted :-

"The test pressure at such hydraulic test shall be not less than one and half times, the working pressureof the boiler of the intended working pressure of pipe as the case may be".

Regulation No. 394. (c) - For clause (c) the following clause shall be substituted :-

"(c) A memorandum of Inspection Book shall be prepared in respect of steam-pipe and fittings in formNo. XIV. In this book, the Inspector shall enter in ink all particulars and dimensions of the steam pipeand fitting with calculations for the various parts in detail, particulars of hydraulic test and his inspectionnotes.

At subsequent inspection, the Inspector shall enter the date of the inspection and hydraulic test togetherwith notes thereon.

The Inspector shall also enter in the Memorandum of Inspection Book remarks regarding the generalcondition of the steam-pipes and fittings, and repairs, replacements of alterations, if any, and the extentto which the steam pipes have been cleaned of lagging and covering so that the book provides a usefulrecord of the steam-pipes and fittings for the information and guidance of Inspectors at subsequentinspection.

In the event of an accident to a pipe line or its fittings, necessary remarks shall also be entered in thebook.

The Memorandum Book shall be submitted to the Chief Inspector, who will check all particulars andcalculations and approve the working pressure and temperatures that are to be permitted for the variousparts of the pipe line and fittings. The pressure and temperature once approved for the particular steampipe line shall not be altered except on a written authority from the Chief Inspector.

CHAPTER IX -A

Regulation No. 396. - After clause (c) the following new clause (d) shall be inserted :-

"(d) When electric light is used for work inside a Boiler shell or drum or any confined space within aboiler, the voltage shall not exceed 24 volts and the owner of the boiler shall provide a hand lamp withlamp-guard, keyless socket, insulated handle and extension cord of approved type.

Where power is used for working any equipment inside a boiler the metallic portion of the equipmentshall be effectively earthed."

CHAPTER XI

Regulation No. 501.- For clause (c ) ,the following clause shall be substituted:-



“ A certificate from the Inspecting Authority in Form VII certifying that the material was tested and theeconomisers built under its supervision shall be furnished to the Chief Inspector before or with the firstapplication for registration.”

Regulation No. 519.- In clause (g), after the word ‘economiser ‘ the following words shall be inserted:-

“where it is not integral with the boiler.”Regulation No. 525.- In sub-clause (vi) of clause (b) ,for the words and figures “ In no case,however ,shall the thickness of a connector bend be less than 13 thirty-seconds of an inch” , thefollowing shall be substituted:-

“ In no case, however, shall the thickness of a connector bend be less than 10.3 mm(13 thirty-seconds ofan inch) for 18.75 kg/cm2 (12.0 tons/ sq.in.) and 22.00 kg/cm2, (14.0 tons/ sq.in.) grade irons and 9.0mm(11 thirty-seconds of an inch), for 26.00kg/cm2 (16.5 tons /sq.in.) grade iron.”

CHAPTER XI I

Regulation No. 537.- For paragraph 1, the following paragraph shall be substituted: -“Materials of Construction- Plates, sections and bars used in the construction of these boilers shall

comply in all respect with the requirements of chapter II and V.”

Regulation No. 546(f).- For clause (f) the following shall be substituted:-“ (f) Flanged circumferential seams shall be arranged so that they do not fall in line with those of theadjacent flue or with the circumferential seams of the shell.”

Regulation No. 546(j).- For clause (j) the following shall be substituted:-

“ (j) Forms of flue connections to end plates are shown in Figures XII / 13, XII / 14, XII / 15 , XII / 16or subject to the approval of the Inspecting Authority, be in any other form of welding groove.”

Regulation No. 548.- For the first sentence starting with “The uptakes shall" and ending” with “FigureXII/3 or XII/4” the following shall be substituted:-

“The uptakes shall be formed from seamless or electric resistance welded or fusion buff welded pipes byelectric arc process. The tolerances on these pipes shall comply with the requirements of Regulation345. The uptakes shall be fusion buff welded to the upward flange of the opening of the furnace crownplate in accordance with Figures XII / 3 and XII / 4.”

Regulation No. 549.- For the first sentence starting with “Cross tubes shall” and ending “steel tubes”the following shall be substituted:-

“Cross tubes shall be made from weldless steel pipes or from plate or strip rolled and electric resistancewelded or fusion butt welded pipes by electric arc process. The fusion welding shall conform to therequirements of Chapter XII. Tolerances on these pipes shall conform to the requirements ofRegulation 345.”

Regulation No. 554.- After the words “stud forge solid with the door.” at the end of third paragraph, thefollowing shall be added:-

“Where the door of a mudhole, cleaning hole or sight hole is fabricated by welding for boilers not



exceeding a working pressure of 8.8 kg./cm (125 lbs. per sq. inch), the stud shall pass through the plateand be secured to it by strength welding on the inside and fillet-welding on the outside to the satisfactionof the Inspecting Authority. The door shall be stress relieved by heat treatment after welding.”

Regulation No. 558.-(1) For the first paragraph the following paragraph shall be substituted:-

“Provided the requisite quality of welding is achieved the seams, may be welded from both sides of theplates or from one side of the plate. Before the second side of the plate is welded, the metal at thebottom of the first side shall be removed by grinding, chipping, machining or other approved method.”

(2) For paragraph 2, the following paragraph shall be substituted:-

“Additional runs of metal shall be deposited at both surfaces of the welded seams to ensure that the weldmetal at the level of the surfaces of the plate is refined as far as possible. The surfaces of the weldswhich are to be subsequently radiographed shall thereafter be machined or ground so as to providesmooth contours and to be flush with the respective surfaces of the plate. In the case of circumferentialshell seams welded by submerged arc or any other approved automatic process producing a similarsurface finish, such circumferential welds, need not be flush dressed, subject to their surface finish andshape being acceptable to the Inspecting Authority. There shall be no under-cutting of the junctions.”

Regulation No. 567-A.- After Regulation 567, the following new Regulation shall be inserted:-

“567-A. Nothing in Regulation 567 shall preclude the use of dished ends in compliance withRegulations 275 to 278, where not fitted with an uptake.”

Regulation No. 573.- For the portion beginning with the words

“The thickness and bolting of all flanges” and ending with the words “D is the external diameter ofstandpipe in inches” , the following shall be substituted:-

“The thickness of flanges, and the bolting of all flanges joining mounting shall be in accordance withAppendix E-“Tables of Pipe Flanges” . In no case however shall the thickness of flanges be less than13mm(½ inch)

(a) For pressure up to 25.5 Kg/sq.cm. (360 lbs./sq.in.) the thickness of standpipe fabricated fromseamless tubes with flanges welded on shell be determined by equation:-

where, t is the thickness of standpipe.

D is the internal diameter of standpipe.

C is 5mm(3/16in.)”

Regulation No. 591.- The following shall be substituted as first paragraph of the Regulation:-



“Gusset Link, Brace and similar Stays.-For welded Lancashire Cornish and Cylindrical HorizontalMulti-tubular type boilers, all-welded gusset stays shall not be used. To ensure flexibility, link stays, barstays, brace stays and other similar stays or suitably designed gusset stays other than the all-welded typeshall be used. All welded gusset stays, however, may be used in cylindrical horizontal waste heat andcylindrical vertical multitubular boilers.”

Regulation No. 592(b).- For the connotation ‘E’ , the following shall be substituted:-

“E” is the modulus of elasticity in pounds per square inch which may be taken as 27.8 x106” .

(II) The following shall be added at the end of clause (b):-

“Where stiffening rings are made in sections from bar or plate , the abutting ends should be so preparedas to ensure to ensure that full penetration welds are made.

The thickness of the ring should be kept to the minimum required. The thickness of the ring should notexceed 1½ times the thickness of the furnace plate. The throat thickness of the fillet welds attaching thering to the furnace plates must not be less than 10mm(3/8inch) i.e., the leg length of the weld should beat least 13mm(½inch).”

Figure XII/21 and Figure XII/22.-For Figures XII/21 and XII/22 the following Figures shall besubstituted:-

Figure XII/67 Figure XII/68 and Figure XII/69-The values of 'C' given below the respectiveXII67,XII/68 and XII/69 shall be omitted.

CHAPTER XI I I Heading chapter XI I I - Heading of this chapter is to read as follows:-

“QUALIFICATION TESTS FOR WELDERS ENGAGED IN WELDING OF BOILERS ANDSTEAM-PIPES UNDER CONSTRUCTION, ERECTION AND FABRICATION AT SITE ININDIA AND IN REPAIRING BOILERS AND STEAM-PIPES BY WELDING”

Regulation No. 602.- For existing entry, the following shall be substituted:-

“602.Scope- These regulations shall apply to testing of welders engaged in the manufacture and sitewelding connected with erection and fabrication and repair of boilers and steam-pipes of ferrousmaterial.”


Engaging of Certified Welders- No welder shall be engaged on welding of boilers or steam-pipesunder construction, erection or fabrication at site or in the repair of boilers or steam-pipes, unless hepossesses a certificate as required under the Regulations hereinafter contained.”

Regulation No. 605.- For the expression “Form XII/ Form XII” the expression “Form XIII” shall beSubstituted.


“Production of Certificate- The holder of such certificate shall be bound to produce it when calledupon to do by the Inspecting Authority, Inspecting Officer or Inspector, as the case may be.”



Regulation No. 609(B)-(2)(c).- For clause (c) under item 2 entitled “ Test Welds for qualification(Electric or Gas)” , the following clause substituted;-

“ (c) For Tube Welding- A butt welded joint of two pieces of boiler tubes with the axis in a verticalposition and tubes of same size fixed in adjoining positions. This test shall be in addition to the test forpipe welding under clause (b).”

Regulation No. 610.- For clause (c) the following clause shall be substituted:-

“ (c) Tube Welding- A butt welded Joint of two pieces boiler tubes with the axis in a vertical position,and tubes of same size fixed in adjoining positions. This test shall be in addition to the test for pipewelding under clause (b).”

Regulation No. 611 (a).- (I) For the words “ No heat treatment shall be carried out after completion ofthe welding” , The test specimen shall be similarly treated as required for the actual production weld”shall be substituted.

(II) After the words and figures “as per Regulation 261 and 262” , the following shall be added at theend:-“ In the case of alloy steel specimen, the angle of the bend is to be decided by the competent authority,provided that the angle shall, in no case, be less than 120°.”

Regulation No. 611 (e).- The following shall be added at the end of clause (e):-“ If any test piece does not reach the required standard two further welds shall be made and the procedurein the above sub-regulation repeated. If any of these welds does not reach the required standard, thewelder-shall be deemed not to have qualified for a certificate.”

Regulation No. 612 (I ).- The clause (c), following shall be added at the end:-“ or 611(d), as the case may be.”

(II) After (c), the following new clause (d) shall be inserted:-

“ (d) Additional Test Before Rejection- Should any of the test pieces tested in accordance with theabove sub-regulations fail to meet the specified requirements, one further weld may be cut from thespecimen and subjected to the same test.If any test piece does not reach the required standard, two further welds shall be made and the procedurein the above repeated. If any of these welds does not reach the required standard the welder shall bedeemed not to have qualified for a certificate.”

Regulation No. 613(i).- For the word and figure “Form XIII” , the word and figure “Form XII” shall besubstituted:-

“Should a candidate fail in the oral or written examination but pass in the practical test, he may be re-examined in oral or written examination within a period of twelve weeks from the date of examinationof practical test, and if he obtains not less than 60 per cent marks in the re-examination, he shall bedeemed to have qualified for a certificate.”

Regulation No. 614.- The following paragraph shall be added at the end of para of the regulation:-

“Any certificate issued for any purpose under the rules made by the State Government in this behalf



shall be deemed to have been issued for that purpose under this Chapter and any action taken under thesaid rules, shall be deemed to have been taken under this Chapter.”

Regulation No. 615.- For existing entry the following shall be substituted:-

"Maintenance of Records- Every manufacturer or repairer of boilers and steam-pipes shall maintaina record of all welding personnel engaged on welding and repairing of boilers and steam-pipes,particulars of each welder and the work handled by hi. Such record shall be produced to the InspectingAuthority, Inspecting Officer or an Inspector on demand.In the case of welders who undertake welding under their own responsibility, the record as aforesaidshall be maintained by themselves.

CHAPTER XV

Regulation No.623.- The words, figures and abbreviations “where the gauge pressure exceeds1Kg/cm2.” Shall be added at the end.

Regulation No.626.- For the words and figures “ or Chapter XI” the words and figures “and / orChapter V” shall be substituted.

Regulation No.630-b(i).- In clause (i) of sub-regulation (b) for the word and figure “Equation 72” theword, figure, brackets and letter “Regulation 366 (a)” shall be substituted.



Amend 1 (31-8-

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Transcript of Amend 1 (31-8-