IBR CONTENTS.docx

8/11/2019 IBR CONTENTS.docx

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Message From Chairman

Indian Boiler Regulations are the standards in respect of materials, design and construction, inspection andtesting of boilers and boiler components for compliance by the manufacturers and users of boilers in thecountry. These regulations are being updated regularly by amending them in line with fast changes in boiler

technology by the Central Boilers Board. With the globalisation of Indian economy and the competition it isfacing with the foreign companies, it is prudent to impart the latest information about the internationalstandards and technology without loss of time.

It gives me great pleasure to say that users across the Industry would now be able to download informationrelated to the standards for materials, design, construction as well as for registration and inspection of boilers.In fact such a move was indeed required as accessing information through hard copies is time taking and alsoinconvenient.

With the uploading of the Indian Boiler regulations - 1950, the standards would now be readily available at theclick of the mouse.

ChairmanCentral Boilers Board


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About Central Boilers Board

The Central Boilers Board, constituted under Section 27A of the Indian Boilers Act 1923 ( 5 of 1923) is

responsible for making regulations for laying down the standards for materials, design, construction as well asfor registration and inspection of boilers. The Board comprises of the represntatives of the Central and StateGovernments, Union Territories, Bureau of Indian Standards, Coal Industry, Boiler Manufacturing Industry,Boiler Ancillaries Industry, Steel Manufacturers, users of Boilers and other interests connected with the BoilerIndustry.

The Secretary, Department of Industrial Policy and Promotion is the ex-officio Chairman and Technical Adviser( Boilers) is the ex-officio Member-Secretary of the Board.

The Board deals with the problems of both the users and manufacturers and takes policy decisions for theproper growth of the boiler manufacturing units in the country. The Board formulates the Indian BoilerRegulations incorporating the latest developments taking place in the Boiler Industry all over the world.

CBB Gazette Notification
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History of Indian Boiler Regulations

Steam Boilers are of very ancient origin. The introduction of famous James Watt's improved steam engine from

1769 to 1775 onwards resulted in great improvement in steam plants.

In the year 1863, a very serious boiler explosion occurred in Calcutta which caused the loss of several lives. As aresult of this explosion, the necessity of inspection of boilers was widely recognised and a bill was introduced inthe Bengal Council to provide for the inspection of steam boilers. In the year 1864, the Bengal Act VI of 1864 waspassed which provided for the inspection of steam boilers and prime movers in the town and suburbs of Calcutta.This is the beginning of boiler legislation in India.

Following the Bengal Act of 1864, each of the other provinces framed legislation. At that time there were sevendifferent Acts and seven different sets of rules and regulations. Those Acts and rules & regulations wereinconsistent with one another. As the differences in the Acts and rules and regulations among the variousprovinces in India gave rise to many difficulties and hampered the development of industries, the CentralGovernment appointed a committee called "The Boiler Law Committee" in 1920 to examine and report on thegeneral question of boiler legislation in India.

The Boiler Laws Committee, 1920-21, the first to review the boiler laws on a national scale reported in March,1921. The report criticised the differences in the Acts, rules and regulations. The report also pointed out that inthe inspection of boilers the personal element was a weighty factor, and the difference in regulations resulted inwhat was termed as "provincial jealousy". The report stressed that all provinces should be subject to the sameregulations and work done in one province should be accepted as correct in another province. The Committeerecommended that regulations to cover the standard conditions for material, design and construction of boilersshould be framed by Government of India and make applicable to all the provinces. The report also pointed outthat regulations were entirely of technical nature and there was no reason for which these regulations would beaffected by local conditions. The Committee prepared a draft Act on the lines of which, the basic All-India Act waspassed in 1923. The Boiler Laws Committee also prepared a uniform set of technical regulations and a model setof administrative rules. A sharp distinction was drawn between the regulations and the rules. The regulationsreferred entirely to technical matters where as the rules referred to questions concerning the administration of the

Act. Indian Boiler act, 1923 provides for the safety of life and property of persons from the danger of explosion of

boilers.The Government of India Act, 1935 assigned the subject 'Boilers' to the concurrent field. The provision forconstituting Central Boilers Board having the authority to make regulations consistent with the Act was made inthe Indian Boilers (Amendment) Act, 1937. A Board called the Central Boilers Board was accordingly constitutedin the year 1937.The Central Boilers Board in exercise of the powers conferred under section 28 of the said Act, formulatedregulations on boilers. The current version of these regulations is known as the Indian Boiler Regulations, 1950with amendments up to 22nd February, 2005.


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Foreword

There has been demand for information on the Indian Boiler Regulations, 1950 both in hard copy & electronicform over the Internet. It's last reprint incorporated amendments upto 31st August, 1962.Section 13(2) of the Standards of Weights & Measures Act, 1956, came into force on the first day of

December, 1966. Under this section and the relevant State /Union Territory enactments relating to theenforcement of weights & measures, no unit of measure other than a metric unit can be used in anytransaction for the purposes of trade or commerce of any dealing or contract or any work to be done or forgoods to be sold or delivered. The standards given in thee regulations in non-metric units, therefore cannot beused for any of the above purposes with effect from aforesaid date. Work is separately underway to convert thespecifications given in these regulations in non-metric standards to metric units, and to issue an editionincorporating these, to bring this Regulation in conformity with the law with effect from December 1, 1967. Thisreprint of the old edition of these regulations is being issued for facility of reference. The mere fact, however,that in this reprint non-metric standards have been used would not absolve any person from the requirementsof compliance with the law relating to enforcement of standards of weights and measures. The standards givenin this reprint have to be converted into metric units for the purposes of trade, commerce or any dealing orcontract or for any work to be done.The latest reprint has been made available in the electronic form over the Internet for the benefit of usersacross the globe.


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CONTENTS - CHAPTER WISE

> PRELIMINARY

> CHAPTER - I

(Regulations)

> CHAPTER - II(Electric-Resistance-Welded Steel Boiler And Super-Heater Tubes For Design Metal Temperatures NotExceeding 454C (850F)

> CHAPTER - III(Boiler Tubes Subject To External Pressure)

> CHAPTER - IV(Regulations For Determining The Working Pressure To Be Allowed On Various Parts Of Boilers OtherThan Fusion Welded And Seamless Forged Drums.)

> CHAPTER - V(Fusion Welded And Seamless Forged Drums For Water Tube Boilers And Super Heaters)

> CHAPTER - VI(Requisite Mountings, Fittings and Auxiliaries)

> CHAPTER - VII(Boiler And Super Heater Tubes, Headers And Other Pressure Parts Tubes)

> CHAPTER - VIII(Steam-Pipes And Fittings)

> CHAPTER - IX(Regulations For The Registration Of Boilers And Inspection Of Boilers And Steam-Pipes)

> CHAPTER - IX A(Safety Of Persons Inside Boilers)

> CHAPTER - XElectrode Boilers (General Requirement)

> CHAPTER - XIStandard Conditions For The Design And Constgruction Of Economizer, Feed Pipes, Feed Heaters

And Other Similar Vessels (Economizers)

> CHAPTER - XII(Shell Type Boilers Of Welded Construction)

> CHAPTER - XIII(Qualification Tests For Welders Engaged In Welding Of Boilers And Steam-Pipes Under Construction,Erection And Fabrication At Site In India And In Repairing Boilers And Steam-Pipes By Welding)

> CHAPTER - XIV(Regulations made under clause (a) and (aa) of section 28 of the Act)

Small Industrial Boilers (General)

> CHAPTER - XV(Feed Water For Boiler)

> APPENDIX
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CHAPTER : I

Reg.1 Short Title, Extent, Application and Commencement

Reg.2 Definitions

Reg.3 General Requirements, Applications of Standard Conditions and Expectations thereto

Reg.3A Inspection of Boiler to comply into any foreign code

Reg.4 Standard Requirements-Material, Construction, Inspecting Authority's Certificates and Maker's

Stamp

Reg.4A Application for Recognition

Reg.4B Scrutiny of applications by the Evaluation Committee

Reg.4C Recognition of a firm as Competent Authority, Inspecting Authorities, etc.

Reg.4D Validity of Certificate of Recognition

Reg.4E Renewal of Certificate of Recognition

Reg.4F Application for registration of existing competent authority

Reg.4G Appeal

Reg.4H Function of Evaluation committee

Reg.5 Modification of Formulae

Reg.5A Material not fully identified

Reg.6 Standard Specifications for Materials

Reg.7 Boiler Shells not in Accordance with Standard Conditions

Reg.8 Use of Welding
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Reg. 1Short Title, Extent, Application and Commencement:

1) These Regulations may be called the Indian Boiler Regulations, 1950.

2) They extend to the whole of India, except the State of Jammu and Kashmir.2a) These Regulations generally apply to:-

(i) all boilers, including those working on the principles of natural circulation, forced circulation andforced flow with no fixed steam water line, and

(ii) to steam pipes.

3) They shall come into force at once

Reg. 2Definitions

In these Regulations, unless the context otherwise requires

a) the Act means the Indian Boilers Act, 1923:

b) Accident means an explosion of a boiler or steam -pipe or any damage of a boiler or steam-pipe,which is calculated to weaken the strength thereof so as to render it liable to explode:

c) Boiler means any closed vessel exceeding 22.75 litres (five gallons) in capacity which is usedexpressly for generating steam under pressure and includes any mounting or other fitting attached tosuch vessel, which is wholly or partly under pressure when steam is shut off:

cc) Calculation Pressure, in relation to a boiler, means the design pressure of any part adjusted to takeinto account the pressure drops corresponding to the most severe conditions of pressure drop andhydraulic head;

d) Chief Inspector and Inspector means, respectively, a person appointed to be a Chief Inspector andan Inspector under the Act:

dd) Competent Authority means an authority recognised by the Central Boilers Board in the manner as

laid down in regulation 4A to 4H,as competent to issue certificates to welders for the purposes ofregulation 4(b)(ii) andregulation 605;

ddd) "Design Pressure" means:-

(i) in relation to a natural or assisted circulation boiler, the maximum allowable working pressure inthe steam drum of the boiler;

(ii) in relation to a once through forced-circulation boiler, the maximum allowable working pressureat the final superheater steam outlet;

e) Economiser means any part of a feed-pipe that is wholly or partly exposed to the action of fluegases for the purpose of recovery of waste heat:

ee) Evaluation Committee means a committee constituted by the Central Government consisting of : -

(a) Technical Adviser (Boilers) : Chairman

(b) Chief Inspector (Boilers) of the State where the unit is located : Member

c) A representative of the manufacturers of boilers/ancillaries inpublic sector. : Member

f) feed-pipe (i) means any pipe or connected fitting wholly or partly under pressure through whichfeed-water passes directly to a boiler.(ii) every reference to a steam-pipe or steam-pipes shall be deemed to include also a reference tofeed-pipe or feed-pipes respectively.

g) Inspecting Authority means an authority recognised by the Central Boilers Board in the manner aslaid down inregulation 4A to 4H,as competent to grant a certificate in Form-II, II-A or II-B.

h) Inspecting Officer means :-
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(i) in respect of material manufactured or boilers constructed in any State an officer appointed bythe Inspecting Authority in that State;

(ii) in respect of material manufactured or boilers constructed outside the States an officer actingon behalf of the Inspecting Authority:

(iii) in respect of :

(a) Approval of drawings of boilers or parts thereto with minor changes, wherenecessary, except for the drawings of the first set of boilers or parts thereto;

(b) Inspection at stages of manufacture including examination of repairs;

hh) Liaison Sub-Committee means a committee constituted by the Central Boilers Board under bye -law3 (i)(e) of the Bye-Laws of the Central Boilers Board.

i) owner includes any person using a boiler as agent of the owner thereof and any person using aboiler which he has hired or obtained on loan from the owner thereof :

j) prescribed means prescribed by regulations or rules made under the Act:

k) Steam-pipe means any pipe through which steam passes from a boiler to a prime-mover or otheruser or both if :-

(i) the pressure at which steam passes through such pipe exceeds 3.5 Kilogramsper square centimetre above atmospheric pressure; or

(ii) such pipe exceeds 254 millimetres in internal diameter; and includes in eithercase any connected fitting of a steam-pipe.

l) State or States means a State or the States to which these regulations extend.

m) Structural alteration, addition or renewal shall not be deemed to include any renewal orreplacement, of a petty nature when the part or fitting used for replacement is not inferior in strength,efficiency or otherwise to the replaced part or fitting

n) Technical Adviser (Boilers) means Technical Adviser (Boilers) to the Government of India in theMinistry of Industry (Department of Industrial Development).

Reg. 3GENERAL 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 beissued under sub-section (5) of that section with reference to a boiler, unless the standard conditions in respect ofmaterial, design and construction, which are specified in the subsequent Chapters of these Regulations, aresatisfied in respect of such a boiler.

(2) Notwithstanding anything contained in sub-regulation (1), the Chief Inspector may, subject to the provisions ofregulation7 and8,register a boiler and order the issue of a certificate authorising the use thereof, under any ofthe following circumstances, namely -

(i) when the material used in the construction of a boiler, steam-pipe, economiser or superheater is not inconformity with the Indian Boiler Regulations but is known to be commonly used in other countries asbeing suitable for use in the construction of boilers and steam-pipes, provided that such material is notspecifically prohibited by the Regulation and that the methods of manufacture, fabrication and heattreatment conform to the specified Codes or Standards;

(ii) when the constructional features of a boiler, steam-pipe, economiser or superheater are not in conformitywith the Regulations but are not considered by the Chief Inspector to be inferior in strength to thoseprescribed in the Regulations and form part of the usual manufacturing practice of boilers and steam-pipes in other countries;

(iii) when a boiler, steam-pipe, economiser or superheater has obviously been built in conformity with theregulations but no certificate as required under the regulations is forthcoming.

(3) No structural part of a boiler, which is subject to pressure, shall be made of Bessemer process steel or of Castor Malleable Cast Iron.
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(4) Where no specific provision is made in these regulations for design or manufacture of any pressure part, theInspecting Authority may permit the design, manufacture, stage inspections and certification of such pressureparts including the valves, mountings and fittings conforming to the Codes or Standards like BS, ASME Boilerand pressure vessels code, TEMA, TRD, GOST and JIS which are known to be commonly used in industriallyadvanced countries. The decision of Inspecting Authorities shall be binding on all Registering authorities.

(4A) The tubes of boilers and heat exchangers made of Titanium and other exotic metals may be approvedas per international codes, including ASME, BS, DIN, TEMA with the minimum thickness specified in thosecodes of manufacture.

Reg. 3AInspection of boiler to comply into any foreign code:

Notwithstanding anything contained in these regulations, the Inspecting Authority may inspect any boiler meantfor export during the various stages of its construction so as to comply with the requirements of any foreign codeand may grant a certificate in Form-II-A.

Reg. 4STANDARD REQUIREMENTS

(a) Material.-All plates, rivets and bars used in the construction of boilers shall be tested and found to conformwith the Regulations hereinafter contained.

(b) Construction.-

(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.

(ii) Welders engaged in site welding of boilers, steam-pipes, economisers and superheaters shall possessand produce to the satisfaction of the Chief Inspector the Welders Performance Qualification Certificateissued by a Competent Authority.

(c)Certificates, etc. under section 14(1)(c) of the Act.-In advance of or along with an application for registration ofa boiler the following certificates and drawings or specifications shall be furnished to the Chief Inspector, namely:-

(i) A certificate in Form-II.- from an Inspecting Authority certifying that the material was tested and the boilerwas built under their supervision. Together with such certificate the Inspecting Authority may furnish aMemorandum of Inspection Book in Form-I prepared in the manner prescribed by Regulation 386 inrespect of the Inspection of the boiler during construction and the hydraulic test applied on completion. Incase of a boiler which is to be assembled only at site, requirement of the hydraulic test on a completelyassembled boiler by the Inspecting Authority shall not apply provided that the individual parts of suchboiler have been hydraulically tested and certified by the Inspecting Authority separately as requiredunder these Regulations.

NOTE.-In lieu of Form-II, a certificate in Form-II-B may be granted by the Inspecting Authority for boilersfor which variations from the standard conditions in respect of material, design and construction featureshave been permitted by the Board or the Inspection Authority under sub-regulation (5) or sub-regulation(6) of regulation3.

(ii) A certificate in Form-III of manufacture and test signed by the maker or by a responsible representative ofthe maker of the boiler containing a description of the boiler, its principle dimensions, particulars of thekind of material used in its construction, the thickness of all plates, the diameter of and method of formingthe rivet holes in the shell plates, particulars of any departure from ordinary practice in making the shellsuch as solid rolling or welding, the hydraulic test to which the boiler was subjected, the intended working

pressure, the area of heating surface, the maximum continuous evaporative capacity, the year and placeof make, and the works number of the boiler.


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NOTE.-The Chief Inspector may, however, approve a modified form of certificate wherein items which donot pertain to a particular boiler may be omitted.

(iii) A drawing or print to a scale, in the case of large boilers of not less than inch to the foot and, in thecase of small boilers of not less than 1 inches to the foot, showing the principal dimensions and a

longitudinal section and end view of the boiler, and bearing the works number of the boiler and Makersoffice stamp. The drawing shall show details of riveting of longitudinal and circumferential seams withpitch of rivets, cross spacing of dished end plates, fillets and flanges and corners of bent plates, andwhere gusset stays are fitted the number and diameter of rivet holes in each gusset stay.

In the case of water tube boilers, the foregoing scales shall apply to the main boiler drums only, but inaddition a general arrangement drawing of the boiler to a scale of not less than inch to the foot shall beprovided.

(iv) A certificate in Form-IV from the steel maker and a certificate from the maker of the plates, rivets or bars,shall show the charge numbers, the plate or bar numbers and the number and dimensions of the variousplates etc. tested, their chemical analysis, their ultimate tensile breaking strength in tons per square inchof section, the percentage of elongation and the length on which measured, the number, kind and resultof bend or other tests made and the date of tests:

Provided that where an Inspecting Authority furnished a certificate in Form-II together with a Memorandum ofInspection Book in Form-I in accordance with sub-regulation (c)(i) the certificates prescribed under clauses (ii)and (iv) need not be furnished to the Chief Inspector when application is made for registration of the boiler. Butshould any question arise in respect of the fitness of the boilers for the working pressure approved by theInspecting Authority within a period of three years from the date of their registration, the owner shall if requestedby the Chief Inspector obtain and furnish the original documents specified in the said clauses.

Provided further that in respect of the steel made and tested by Well-known Steel Makers recognised by theCentral Boilers Board in the manner laid down in regulations 4A to 4H, a certificate of Well-known Steel Maker inForm-IV-A shall be accepted in lieu of a certificate from an Inspecting Authority:

Provided also that in respect of the tubes/pipes made and tested by Well-known tube/pipe maker recognised bythe Central Boilers Board in the manner as laid down in regulations 4A to 4H, a certificate of manufacture and

test of Well-known tube/pipe maker in Form-III-D or III-E, as the case may be, shall be accepted in lieu of acertificate from an Inspecting Authority.

In case where certificate in Form-IV is not producible owing to such certificate containing details of plates usedfor other purpose, also, all the relevant information in respect of the boiler furnished in Form IV-A duly signed bythe Makers of the boiler and countersigned by the Inspecting Authority, shall be acceptable in lieu of thecertificate in Form-IV. Original steel makers certificate or manufacture and results of tests shall be produced tothe Chief Inspector on demand.

In the case of fusion welded drums the diagram of welded repairs and temperature charts of heat-treatment shallalso be furnished.

In addition, certificates in respect of yield point at service temperature (0.2 per cent proof stress), the averagestress to produce elongation of 1 per cent (creep) in 100,000 hours and the average and the lowest stresses toproduce rupture in 100,000 hours in the material, wherever is applicable, are to be furnished.

(vi) For tubes and pipes subjected to internal pressure, a certificate giving results of tests regarding chemicalanalysis, warm yield point (0.2 per cent proof stress), the average stress to produce an elongation of 1per cent (creep) in 100,000 hours and the average and the lowest stresses to produce rupture in 100,000hours in the material wherever applicable, shall be furnished.

NOTE:- Until 33,000 hours tests are carried out by National Metallurgical Laboratory or CorporateResearch and Development Laboratory of Bharat Heavy Electricals Limited for collecting elevatedtemperature data of alloy steel produced indigenously against ASME or BS or EN Code, these grades ofsteel may be accepted and long time elevated temperature properties/maximum allowable stress valuesgiven in ASME or BS or EN Code, as the case may be, may be used for the purpose of design. Providedthat

(I) a certificate is furnished by the producer of the steel to the effect that the steel has beenmanufactured strictly in accordance with the technical requirements of the ASME or BS or EN Code to


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assure that the creep rupture requirements are complied with.

(II) the Steel maker furnishes the necessary certificate that the steel conforms to the chemical analysis,room and elevated temperature mechanical properties given in ASME or BS or EN Code as the casemay be.

(III) the short-term stress-rupture tests for 1000 hours as described below are carried out by NML/SteelPlants for the purpose of checking whether the steel is up to the specification and also to ensure that theSteel is capable of meeting the long-term rupture stress values/ maximum allowable stress values givenin ASME or BS or EN Code, as the case may be, and a certificate is given by NML/Steel plant to thiseffect.

(IV) two numbers of 1000 hour creep rupture tests shall be carried out at a temperature 50C above theservice temperature for each grade of steel for tubing or piping or castings or plates grades; when infurnace and/or in superheater zone. However, the forging to be used in valves should be tested at 550Cfor 1000 hours. The stress to cause rupture in 1000 hours at above temperatures may be taken from themaster curve corresponding to 20% line. At this stress, a minimum rupture life of 1000 hours isexpected. Both the samples should pass 1000 hour tests at the above stress and temperature. Thesesamples may be selected at random by the Chief Inspector of Boilers of the respective State. The

samples could be in the form of semi-finished products, say, forged bars of about 25mm

2

which willundergo heat treatment as prescribed by the relevant specifications.

(d) Makers Stamp.- The boiler shall have stamped upon its front plate in a conspicuous position the followingparticulars:-

MAKERS NAME

Works Number_____________________________________ Year of make__________________ Tested to__________________________ Lbs.________________________ on _______________W.P.________________________________________________ Lbs._____________

Inspecting Officers orInspecting Authoritys Official

Stamp___________________________________

(e) Certificates for steam-pipesA certificate of manufacture and test in Form III-A, signed by the maker andthe Inspecting Authority shall be furnished.

(f) Certificates for tubesA certificate of manufacture and test in Form III-B, signed by the maker and theInspecting Authority shall be furnished.

Note: In case of tubes made by Well-known Tube Makers recognised by the Central Boilers Board in the manneras laid down in regulations 4A to 4H in India or other countries, material testing including mechanical tests maybe carried out by them and the particulars regarding testing of material including mechanical tests as certified bythem shall be noted in the appropriate column or paragraphs in the certificate in Form III-B. In case, certificatefrom the Well-known Tube Makers as aforesaid, is produced, such certificate may be accepted in lieu of the

certificate from the Inspecting Authority in so far as it relates to testing of material including mechanical testsspecified in this form.

(g) Certificates for mountings and fittings:- A certificate of Manufacture and Test in Form III-C signed by theMaker and the Inspecting Authority in respect of boiler mountings and steam-pipe fittings during manufacture,shall be furnished.

Note-1: For the purpose of this clause certificates issued by an authority empowered in this behalf by or underthe law in force or the national code in a foreign country, in respect of mountings and fittings in that country andcontaining the particulars required to be specified in this certificate, may be accepted. Where, however, thematerial used, is in conformity with the code of the country of manufacture and is covered by those Regulations,the permissible stress figures specified in the Code at different temperatures may be accepted in lieu of figurescomputed 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 with the

requirements of the grade steel (to be specified) and the permissible stress for the working conditions asallowed for in the Code of the country of manufacture falls within the limit permissible under this
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Regulation.

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

Note-2: For the purpose of clause (c), (e), (f) and (g) of this regulation, certificates issued by an authority

empowered in this behalf by or under the law in force or national Code or Standard of any foreign country inrespect of plates, bars, tubes, pipes, forgings and castings manufactured in that country and containing theparticulars required to be specified in the steel makers certificates referred to in the above mentioned clauses ofregulation 4 may be accepted provided such certificates contain a statement duly signed by the Inspecting

Authority to the effect that these materials comply with the requirements of the law or the Code or Standard of theforeign country.

Note-3: Photostat copy of the certificate in Form III-C shall be accepted provided it is endorsed by themanufacturer or the Inspecting Authority.

(h) Certificates of inspection during construction of pipes for which variation from standard conditionshave been permitted.- A certificate of manufacture and test in Form III-A(I), signed by the maker and theInspecting Authority shall be furnished.

(i) Certificate of Inspection during construction of tubes for which variation from standard conditionshave been permitted.- A certificate of manufacture and test in Form III-B(i), signed by the maker and theInspecting Authority shall be furnished.

Reg. 4 A

PROCEDURE FOR RECOGNITION OF COMPETENT AUTHORITY,INSPECTING AUTHORITY, WELL-KNOWN MATERIAL TESTINGLABORATORY, WELL-KNOWN STEEL MAKER, WELL-KNOWNFOUNDRY/FORGE AND WELL-KNOWN TUBE/PIPE MAKER AND WELL-KNOWN REMNANT LIFE ASSESSMENT ORGANISATION:-

Application for recognition:-

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

(2) On receipt of applications under sub-regulation (1), the Secretary, Central Boilers Board shall send aquestionnaire in any of the Form (Form XV-A to XV-G) applicable to the area of activity to the applicantwho shall send the same after duly completed, to the Secretary, Central Boilers Board.

(3) Any firm applying for recognition under sub-regulation (1) shall have a minimum experience of two yearsin the area of activity for which recognition is applied for.

(4) In case of firms in foreign countries seeking recognition as Well known Steel Maker, Well knownPipe/Tube maker, Well known Foundry or Well known Forge, a fee of US$ 10,000/ - (Ten ThousandUS Dollars) to meet the expenses of the visit of the Evaluation Committee shall be deposited along with

the completed Questionnaire form.

Provided that where the firm has more than one manufacturing unit in the same country, an additionalfee at the rate of US$ 2000/- (Two Thousand US Dollars) per additional unit shall be deposited.

The Evaluation Committee shall carry out the evaluation of the manufacturing works of the firm within120 days of receipt of the fees.


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Reg. 4 BScrutiny of applications by the Evaluation:-

(1) The Secretary, Central Boilers Board shall send all the applications received under sub-regulation (1) ofregulation 4A,along-with replies to the questionnaire under sub-regulation (2) ofregulation 4A,to the

Evaluation Committee.

(2) The Evaluation Committee shall examine all the applications and replies to the Questionnaire under sub-regulation (1) and

(i) where the application is for recognition as Competent Authority or Inspecting Authority, theEvaluation Committee may, (a) call any of the applicants if it considers necessary, to appear beforeit to give clarification or additional information that may be required by the said Committee; (b) visitany of the applicant firms on a specific request in writing from such firm to evaluate the performanceof the said firm:

(ii) where the applicants are for recognition as Well-known Material Testing Laboratory, Well-knownSteel Maker, Well-known Foundry or Forge, Well-known tube / pipe maker and Well-knownRemnant Life Assessment Organisation, the Evaluation Committee shall inspect the laboratories ofsuch Material Testing Laboratory and Remnant Life Assessment Organisation or the factories of

such steel makers, foundry or forge and tube or pipe makers, where the testing or manufacturingactivities are being carried out in order to evaluate the performance quality of the tests conductedand product manufactured.

(3) The Evaluation Committee after satisfying itself that the requirements specified in sub-regulations (1) and(2) are fulfilled, shall submit a report along with its recommendations to the Liaison Sub-Committee.

Reg. 4 CRecognition of a firm as Competent Authority, Inspecting Authorities etc.:

(1) The Liaison Sub-Committee shall consider the reports and the recommendations of the EvaluationCommittee submitted under sub-regulation (3) ofregulation 4Band after examining all the aspects ofsuch report, shall either accord recognition to a firm or refuse recognition to such firm.

(2) In case the Liaison Sub-Committee decides to accord recognition to a firm a certificate of recognition inone of the Forms (Form XVI-A to XVI -I) applicable to the area of activity shall be issued by the Secretary,Central Boilers Board and in case the Liaison Sub-Committee decides to refuse recognition, it shall informthe applicant in writing giving reasons therefore.

Reg. 4 DValidity of certificate of recognition:

A certificate of recognition issued underregulation 4C,shall be valid for a period of three years.

Reg. 4 ERenewal of certificate of recognition:

(a) A firm desiring renewal of the certificate of recognition shall apply for such renewal at least three monthsbefore the expiry of the validity of the certificate to the Secretary, Central Boilers Board who after followingthe procedure laid down in these regulations may renew the certificate of recognition and such renewalshall be valid for a further period of five years:

(b) Notwithstanding anything contained in sub-regulation (a), the period of validity shall be deemed to havebeen extended till such time the decision on the renewal is communicated to the firm.

Reg. 4 FApplication for registration of existing Competent Authority etc.:

All the existing firms recognised as Competent Authority, Inspecting Authority, Well-known Steel maker, Well-known Foundry/Forge and Well-known Tube and Pipe Maker and Well-known Remnant Life Assessment
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Organisation, shall make an application to the Secretary, Central Boilers Board, within one year from thecommencement of the Indian Boiler (4

thamendment) Regulations, 1988, and in case no application is made

within the time specified the recognition of such firm shall be deemed to have been withdrawn:

Provided that the firm which has been granted recognition and has not completed a period of three years, shallcontinue to be so recognized as such till the expiry of the period of three years:

Provided further that if an application is not made in time, the same may be entertained by the said authority if theapplicant satisfies the authority that there was sufficient cause for not making application in time.

In regulation 4F, in the opening sentence, after the words Inspecting Authority, the words Well -known MaterialTesting Laboratory shall be inserted.

Reg. 4 GAppeal.:

(1) Any firm not satisfied with the reasons given by the Liaison Sub-Committee for refusing to accordrecognition may file an appeal in writing to the Chairman, Central Boilers Board, for reconsidering itsapplication.

(2) All applications received by Chairman, Central Boilers Board, under sub-regulation (1), shall be decided inthe meeting of the Central Boilers Board and the decision of the Board thereon shall be final.

Reg. 5Modification of Formulae

(i) Under the Regulations for determining the working pressure to be allowed on various parts of boilers, thematerial to which the formulae apply shall in the absence of express provision to the contrary be steelcomplying with the requirements ofChapter II.

(ii) Where no test certificate for plates and rivets are produced, the material may be treated as iron, if the ChiefInspector is satisfied that the material is of suitable boiler quality. If in such cases the Chief Inspector isclearly satisfied that the material is of good quality, a higher strength than that allowed for iron may be

permitted but the strength of the plates shall not, save for special reasons, be assumed to be more than 26tons per square inch. In such cases the values of tensile and shear strength shall not be more than 26 and21 tons per square inch for steel, and 21 and 18 tons per square inch for iron. For iron across the grain thetensile strength may be 18 tons per square inch.

(iii) For flat plates of copper, the working pressure as found from the formulae, reduced by 50 per cent shall bethe working pressure permitted.

Reg. 5 AMaterial not fully identified:

Where the material as for example plate, bar, billet, pipes and tubes are not covered by mill test certificate eitherdue to misplacement or late receipt of the same but otherwise there are reasons to believe that the materials are

genuine and of standard specifications registering authority or Chief Inspector of Boilers may permit the use ofsuch materials as a special case after thorough verification test in a Test house to his satisfaction at the rate notless than 25% subject to the following conditions:-

(a) In respect of Plates-

(i) The plates shall have a steel makers stamp.

(ii) Use of such uncertified plates, however, will not be allowed for manufacture of Shell or Drum of theboilers.

(iii) Shipping documents/order documents shall be made available to establish the specifications of themanufacture for inspection and testing of plates.

(b) For Billets, bars, pipes and tubes-Shipping documents shall be made available to establish the specifications for manufacture for inspection and

testing.
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Reg. 6Standard specifications for materials.

The standard specifications for steel wrought iron and copper plates and bar, and for cast steel shall be thoseprescribed inChapter II.

Reg. 7Registration of second hand boilers not in accordance with the standard conditions:-

If a second hand boiler is not conforming to the requirements of these regulations for its registration, then thesame shall not be registered except in the following cases, namely:-

(i) Water Tube boilers- Where the documents required under its code of manufacture for its registration arefurnished and its workmanship is not in any way doubtful, the second hand Water Tube Boiler may beregistered by reducing the working pressure of the parts of the boiler as calculated from these regulationsby ten percent.

Provided that a higher working pressure, being not more than the working pressure allowed by the code ofmanufacture, may be allowed on the recommendation of the Board made by it on the basis of lifeassessment tests carried out on the boiler.

(ii) Shell Type Boilers- Where the documents required under its code of manufacture, for its registration arefurnished, the second hand Shell Type Boiler may be registered by reducing the working pressure of theparts of the boiler as calculated under these regulations as per the table given below:-

Age of boiler (from the date of first use)in years. 25 35 45 50 60 70 80 90 100

Reduction in working pressure(percent) 5 10 15 20 30 40 50 60 70

Reg. 8Welding:-

(a) The use of welding in the construction of boilers shall be permitted only where specifically provided for inthe standard conditions.
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CHAPTER : II

Reg.9 Process of manufacture

Reg.10 Chemical Analysis

Reg.11 Freedom from defects, etc

Reg.12 Rolling Margin

Reg.13 Testing and Inspecting.

Reg.13A Designate steel

Reg.14 Selection of test pieces

Reg.15 Tensile Test pieces

Reg.16 Tensile tests

Reg.17 Number of Tensile Tests

Reg.18 Dump Tests

Reg.19 Bend Tests

Reg.20 Number of Bend Tests

Reg.21 Manufactured Rivets

Reg.22 Additional tests before rejection

Reg.23 Branding

Reg.24 Defacing of rejected material

Reg.25 Facilities for inspection

Reg.26 Steel not produced where rolled

Reg.27 Makers Certificate

Reg.28 Rivet Bars

Reg.29 Manufactured Rivets Tests

Reg.30 Stay Bars

Reg.31 Stay Bars - Bend Tests

Reg.32 Special Iron for Screw Stays for Fire-boxes and Combustion Chambers

Reg.33 Plates

Reg.34 Stay and Rivet bars

Reg.35-1 Copper Tubes

Reg.35-2 Brass Tubes

Reg.35-3 Carbon steel tubes

Reg.36 Material process

Reg.37 Selection of Tubes for Test

Reg.38 Tensile strength

Reg.39 Flattening Test

Reg.40 Flanging and drift expanding test

Reg.41 Additional test before rejection
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Reg.42 Hydraulic Test

Reg.43 Material




Reg.47 General

Reg.48 Material

Reg.49 Tensile Test

Reg.49B Flattering Test

Reg.49C Expanding Test


Reg.51 Hydraulic test.

Reg.52 General

Reg.53 a Material

Reg.53 b Heat treatment

Reg.53 c Workmanship and tolerance

Reg.53 d Selection of Tubes for testing

Reg.54 a Tensile Test

Reg.54 b Flattening Test

Reg.54 c Expanding Tests



Reg.56A Seamless Chromium

Reg.57 General

Reg.58 Material

Reg.59 Flattening test

Reg.60 Tensile Test

Reg.61 Hydraulic test

Reg.62 Test specimens

Reg.63 Number of tests

Reg.63A Cold Drawon Electric

Reg.73 Scope

Reg.74 Process of manufacture

Reg.75 Freedom from all rectification of defects

Reg.76 Number of tests

Reg.77 Tensile Test

Reg.78 Bend tests

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Reg.80 Procedure for Welding

Reg.81 Forged or rolled pressure parts

Reg.82 Selection of test pieces


Reg.84 Bend Tests


Reg.86 General grey iron casting (Grade A)

Reg.87 Provision of test bars

Reg.88 Dimension of test bars

Reg.89Mechanical test

Reg.90 Transverse test

Reg.91 Tensile test

Reg.92 Number of transverse and tensile tests

Reg.93 Additional Tests

Reg.94 General requirements

Reg.95 Requirements for Normal Penetration Electrodes

Reg.96 Requirements for Deep Penetration Butt-Welding Electrodes

Reg.97 Requirements for Deep Penetration Fillet Welding Electrodes

Reg.98 Periodic Check Test

Reg.98A Filler rods for gas welding of steel
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Reg. 9MATERIALS OF CONSTRUCTION

STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL

Process of manufacture

(a) Steel for plates shall be made by the open hearth, electric furnace or basic oxygen process or any otherprocess which gives steel having equivalent specified properties.

(b) General deoxidation practice shall be appropriate to the type of steel used, particularly where the deoxidationpractice influences the level of the elevated temperature properties of steel.

(c) Rimmed steels may be permitted only for riveted drums or shells made of plates having a nominal thicknessupto 20 mm.

(d) Plates of carbon steel shall conform to one of the following four grades of tensile strength:-

(i) 37 to 45 kgf/mm2

(ii) 42 to 50 kgf/mm2

(iii) 47 to 56 kgf/mm2

(iv) 52 to 62 kgf/mm2

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

Reg. 10

MATERIALS OF CONSTRUCTION


Chemical Analysis

(a) The steel shall not contain more than 0.05 per cent of sulphur or phosphorus.

(b) A sulphur print test shall be taken from the material of each charge used for rivet bars for the purpose ofensuring that sulphur segregates are not concentrated in the core. The stage in manufacture at which this test ismade shall be at the option of the Steel-Maker.

(c) When the material is required for flame cutting and/or welding, the carbon content shall not exceed 0.30% andspecial precautions shall be taken when the carbon content exceeds 0.26%.

When steels are intended for service temperatures over 700F the silicon content shall be not less than 0.10% oralternatively, the material shall pass the proof test for creep quality of carbon steel plates of boiler quality.

(d) Plates having thickness of 12 mm and less than that, not intended for hot forming, can be supplied inunnormalized or as rolled condition subject to the condition that the code of manufacture provides for the same.For plates having thickness more than 12mm, not intended for hot forming, shall be supplied in the normalizedconditions:

Provided that the normalizing may be exempted if it is demonstrated by the manufacturer that equivalentproperties can be produced by the rolling subsequent cooling.

NOTE:- The boiler manufacturer may, if he so wishes order a check analysis.


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Freedom from defects, etc.

Minor surface defects of the plates may be removed by mechanical means to achieve a smooth level surfaceprovided that the minimum specified thickness is maintained. Surface defects may be repaired by welding, onlywith approval of the Inspecting Authority provided that the plate is stress relieved after welding where necessary.



Rolling Margin

No plate or rolled section shall be under the specified thickness at any part, nor more than 5 per cent over thecalculated weight, except that in the case of thin plates and wide plates the weight tolerances shall be as set outin the table below:

Schedule of percentage of Rolling weight tolerances for boiler plates

Thickness Width in inches

Under48

48 tounder 60

60 tounder 72

72 tounder

84

84 tounder96

96 tounder108

108 tounder120

120 tounder132

132 and over

In % % % % % % % % %

to under5/16

5 5 5 7 9 12 - - -

5/16 tounder 3/8

5 5 5 6 7.5 10 11 12 -

3/8 tounder 7/16

5 5 5 6 6 8 9 11 15

7/16 tounder

5 5 5 5 6 7.5 8 9 12

to under5/8

5 5 5 5 6 6 7.5 9 10

5/8 tounder

5 5 5 5 5 5 7 8 9

to under1

5 5 5 5 5 5 6 7 8

1 to under2

5 5 5 5 5 5 5 9 7

All the above margins will be taken over nett theoretical weight.


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Testing and Inspecting

The following tests and inspections shall be made at the place of manufacture prior to despatch; but in the eventof any of the material proving unsatisfactory in the course of being worked into boilers, such material shall berejected, notwithstanding any previous certificate of satisfactory testing, and such further tests of the materialfrom the same charge shall be made as the Inspecting Officer in attendance may consider desirable.

Reg. 13AMATERIALS OF CONSTRUCTION


Where a steel plant is not able to designate steel as IS: 2002 because of the fact that they have not been able tocarry out all the tests required as per IS 2002, the steel plant may supply steel with a certificate in respect of suchof these tests as it has been possible, for them to carry out indicating the tests which it has not been possible forthem to conduct in order to get the steel certified as IS: 2002. It is open to the manufacturer to take such steelwhich has the required potentialities of IS: 2002, provided he can arrange the remaining tests to be conducted atany of the independent testing laboratories, namely, the National Metallurgical Laboratory, Jamshedpur; TheCentral Mechanical Engineering Research Institute, Durgapur; and the National Test House, Alipur or Sewri,provided that samples be drawn in the presence of the Inspecting Authority. Such remaining tests may also beconducted at the Bharat Heavy Electricals Limited, Tiruchirapalli in the presence of the Inspecting Authority inrespect of plates intended for their use.If the certificate of tests from steel makers and the National Metallurgical Laboratory, Jamshedpur, or the CentralMechanical Engineering Research Institute, Durgapur or the National Test House, Alipur or Sewri or BharatHeavy Electricals Limited, Tiruchirapalli be furnished in the manner mentioned above, the boiler quality platesshall be accepted by the Inspecting Authority/Chief Inspector of Boilers of the State.

Reg. 14MATERIALS OF CONSTRUCTIONSTEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEELSelection of test pieces

All test pieces shall be selected by the Inspecting Officer and tested in his presence, and he shall satisfyhimself that the conditions herein described are fulfilled.

Reg. 15MATERIALS OF CONSTRUCTIONSTEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEELTensile Test pieces

(a) The tensile strength and percentage elongation shall be determined from test pieces of gauge lengthspreferably equal to Lo=5.6(Ao)

1/2(see regulation 16).Alternatively, other gauge lengths may be used, provided the

elongation is expressed as the equivalent value on a gauge length of 5.65(A o)1/2

.(b) In arbitration cases, a test piece of gauge length equal to 5.65(Ao)

1/2for rectangular test piece or 5 dofor round

test pieces shall be used. For plate thickness exceeding 60mm, test pieces shall be taken from the exterior third ofthe plate cross section. Wherever practicable, the rolled surface shall be retained on two opposite sides of the testpiece.


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Reg. 16MATERIALS OF CONSTRUCTIONSTEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEELTensile tests

(a) The tensile strength of different grades of material shall be within the limits specified in regulation 9 (d).

(b)The upper yield point at room temperature shall be not less than 50% of the specified minimum tensilestrength at room temperature.(c)The breaking elongation in percentage shall be not less than ( N-Rm)/C

Where Rm = Tensile strength at room temperature in kgf/mm2

N = a quality index of 100 for plate thickness upto 50 mm or 95 for platethickness over 50mm.

C = 2.2 for only gauge lengths of L=5 d oor L=5.65/ A

Where L= gauge length

A= original cross section of the rectangular test piece.

d= original diameter of the round test piece.

NOTE: C= 1.9 for gauge lengths of 4 Afor test piece of Appendix-B.(d)The minimum values of the stress at proof limit 0.2% at elevated temperature (Et) may be calculated bymultiplying the minimum specified tensile strength at room temperature (R20) by the value of the ratio (Et/R20) givenin the table below:

TABLE

Minimum values for the ratio of the stress at proof limit 0.2% at elevated temperature (Et) to the minimum specifiedtensile strength at room temperature (R20) of carbon steel boiler plates.

Temperature 250C *275C 300C 325C 350C 375C

Et/R20 0.40 0.38 0.36 0.34 0.33 0.32

Temperature 400C 425C

Et/R20 0.31 0.30

*For temperatures lower than 300C any test required for acceptance purposes (in the absence of records ofprevious tests at these temperatures) shall be made at 300C, in which case the proof stress shall be not less thanvalue obtained by calculation from the specified minimum tensile strength at room temperature and the aboveproof-ratio of 0.36 for 300C.



Number of Tensile Tests

(a) PlatesFor shell plates, butt straps and plates, gusset plates, end plates, furnace plates and flangingplates one tensile test piece shall be cut from each plate as rolled.

(b) Angle, tee, rivet, and stay bars.- One tensile test shall be made from each 15 or part of 15 bars rolled ofeach section or diameter from the same charge, but not less than two tensile tests shall be made unless thetotal number of bars rolled from the same charge is 8 or less than 8 and the bars of the same section ordiameter, in which case one tensile test shall suffice. For round bars of 1 inches diameter and under, thenumbers 50 and 20 shall be substituted for 15 and 8 respectively for determining the number of tests required.
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Dump Tests

Short lengths equal to twice their diameter cut from the rivet bars shall, when cold, withstand without fracturebeing compressed to half their length. A dump test shall be made for each Tensile Test.



Bend Tests

Cold Bends.-(a) Test pieces shall be sheared lengthwise or crosswise from plates or bars, and shall not beless than 1 inches wide, but for small bars the whole section may be used. For rivet bars bend tests are notrequired.

b) In all cold bend tests, on samples 0.5 inch in thickness and above, the rough edge or arris caused byshearing may be removed by filing or grinding, and samples 1 inch in thickness and above may have theedges machined, but the test pieces shall receive no other preparation. The test pieces shall not be annealedunless the material from which they are cut is similarly annealed in which case the test piece shall be similarlyand simultaneously treated with the material before testing.

(c) (i) For bend test of plates of all grades of steel, the test piece shall withstands, without fracture, being bentcold through 180

oaround a mandrel, the radius of which shall have a relationship to the plate thickness as

given below:

Tensile strength Mandrel Radius

36 - 49 kg./mm2 1 T

41 - 57 kg./mm2 1 T

45 - 64 kg./mm2 1.5 T

where T = Plate thickness

(ii) For cold bend test of sections and bars, the test piece shall withstand, without fracture,being doubled over until the internal radius is equal to that shown in Table under regulation 16and the limbs 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.


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Number of Bend Tests

(a) Plates.- A bend test shall be taken from each plate as rolled. The bend test from shell plates, butt straps andother plates which have not to be flanged or worked in the fire or which when in use are not to be exposed toflame shall be cold bend test.

(b) Angle Bars.- A cold bend test shall be made from each angle bar rolled, provided that the cold bend testneed not be carried out if basic material specification does not call for it.

(c) Stay Bars.- A cold bend test shall be made from every 15 stay bars as rolled from each charge.



Manufactured Rivets

(a) Quality of Material.- Rivets shall be manufactured from steel complying with the aforementionedrequirements 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 sank 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 2times the diameter of the shank.

(c)Number of Tests.- Upto half per cent of rivets of each size shall be selected by the Inspector or InspectingOfficer from bulk for the above tests.



Additional tests before rejection

Should the test pieces first selected by the Inspector or Inspecting Officer not fulfil the test requirements, twofurther tests of the same kind may be made, but should either of these fail, the plates or bars from which testpieces were cut shall be rejected. In all such cases further tests shall be made before any material from the samecharge can be accepted.

If the unsatisfactory result of a test is obviously due to technical conditions of the testing method or to a closelylimited defects of a test piece, then the failure can be left out of consideration in the decision on the fulfilment ofthe requirement and another test piece may be substituted. If the unsatisfactory result of test is due to anunfavourable heat treatment the plate and the test strip may be heat treated again. Following this, the entire testshall be repeated.


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Branding

(i) Every plate, section and bar shall be clearly and distinctly marked by the maker in two places with thenumber of identification mark by which they can be traced to the charge from which the material wasmade. As an alternative the rivet bars may be bundle and tabbed to enable the material to be traced tothe cast of steel from which they are made.

(ii) Every plate shall also be stamped by the steel maker as provided in IS: 2002. The following informationshall necessarily be provided:-

1. Name of the manufacturer;

2. Specification:

3. Heat No.;

4. Plate No.; and

5. Stamp.



Defacing of rejected material

In the event of the material failing in any case to withstand the prescribed tests, the identification mark of theInspecting officer which has been stamped on the material, shall be defaced by punch marks extending beyondthe identification mark, in the form of a cross, thus denoting that the material has failed.



Facilities for inspection

The maker shall adopt a system of making the ingots, billets, slabs, plates, bars, etc. which will enable all finishedmaterial to be traced to the original charge, and the Inspector or Inspecting Officer shall be given every facility fortracing all plates and bars to their respective charges, and for witnessing the required tests. When he is satisfiedwith the material and with the results of the tests, he shall be furnished with two copies of the advice notes of thematerial for his signature.



Steel not produced where rolled

Where steel is not produced in the works at which it is rolled, a certificate in Form IV or Form III-B, as the casemay be, shall be supplied to the Inspecting Officer deputed to witness the testing of the material, stating the Open


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Hearth or Electric Process or any of the Oxygen Processes by which it was made, the name of the Steel-Makerwho supplied it, also the numbers of the charges for reference to the books of the Steel-Maker. The number ofthe charge shall be marked on each plate or bar for the purpose of identification.



Makers Certificate

Before the mill sheets are signed, the maker shall furnish the Inspecting Officer with a certificate in Form IV orForm III-B, as the case may be, guaranteeing that the material has been made by the Open Hearth or an ElectricProcess, acid or basic, and that it has been subjected to, and has withstood satisfactorily the test abovedescribed in the presence of the Inspecting Officer.


WROUGHT IRON STAY AND RIVET BARS

Rivet Bars

The tensile breaking strength shall be between 21 and 25 tons with an elongation of not less than 25 per centmeasured on the standard Test Piece B (as rolled) or 30 per cent measured on the Standard Test Piece B1 (asrolled).



Manufactured Rivets Tests

To comply with Regulation 21.



Stay Bars

The tensile breaking strength shall be between 21 and 25 tons with an elongation of not less than 22 per centmeasured on the Standard Test Piece B or 27 per cent measured on the Standard Test Piece B1.


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Stay Bars - Bend Tests

To comply with Regulation 19.



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 ironmust withstand the following tests:-

(a)Tensile Tests.- The tensile breaking strength shall not be less than 21 tons per square inch, with anelongation of not less than 25 per cent measured on the Standard Test Piece B or 30 per cent measured on theStandard Test Piece B1.

(b) Bend Tests.- Test pieces either of the bar as rolled, or turned down to 1 inch diameter, shall stand bendingcold until the sides are parallel and the space between the two sides is not greater than the diameter of the testpiece.

(c) Number of Tensile Tests.- The bars as rolled shall be placed in batches of twenty, and one tensile test shallbe taken from each batch. If this is unsatisfactory two other bars shall be selected for test, and should either ofthese 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 piecefrom each batch shall be lightly and evenly nicked on one side with a sharp cutting tool and bent back at thispoint 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, two other barsshall 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 Officer.


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COPPER PLATES, STAY AND RIVET BARS

Plates

(a) Process.- The copper shall be fire-refined or electrolytic and hot-rolled from suitable cakes.

(b) Chemical Composition.- The chemical composition of the plates shall be as follows:-

Per cent.

Copper 99.2 minimum

Arsenic .30 to .50

Antimony 0.05 maximum

Bismuth 0.05 maximumOxygen 0.10 maximum

(c) Freedom from defects.- The plates shall be clean, smooth and free from defects and shall have aworkmanlike finish. They shall be thoroughly annealed.

(d) Rolling Margin.- No plate shall be under the specified thickness at any part, not more than 5% over thecalculated weight. The scrap margin, partly sheared and left attached, shall be not less than 3 inches at theends and 1 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. inch with anelongation of not less than 35%.

(f) Hot and Cold Bend tests.- One hot (temperature between 1200F and 1400F) and one cold bend testshall 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 thesides are touching and parallel.


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COPPER PLATES, STAY AND RIVET BARS

Stay and Rivet bars

(a) Process.- To comply with Regulation 33 (a).

(b) Chemical Composition.- To comply with Regulation 33 (b).

(c) Freedom from 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 % under the specifieddiameter.

(e) Tensile Tests.- The materials shall have the tensile properties shown in the following table:-

Tensile properties

Unturned rods (rods upto1 inches dia.)

Turned rods (rod above 1inches dia.)

Minimum tensile strength lb. per sq.

inch.32,400 32,400

Elongation, minimum per cent in 2

inches gauge length.40 45

f) Bend Tests.- To comply with Regulation 33(f).

(g) Dump Tests.- a piece of rod 1 inch long shall be placed on end and hammered or crushed down cold to athickness of 3/8 inch 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 atrandom from each batch of 50 (or part thereof) bars of each size from each melt. From each bar selected, onetensile test, one cold bend test, one hot bend test and one dump test shall be made.
http://dipp.nic.in/boiler_rules_updated/reg33.htm#ahttp://dipp.nic.in/boiler_rules_updated/reg33.htm#ahttp://dipp.nic.in/boiler_rules_updated/reg33.htm#bhttp://dipp.nic.in/boiler_rules_updated/reg33.htm#chttp://dipp.nic.in/boiler_rules_updated/reg33.htm#chttp://dipp.nic.in/boiler_rules_updated/reg33.htm#chttp://dipp.nic.in/boiler_rules_updated/reg33.htm#bhttp://dipp.nic.in/boiler_rules_updated/reg33.htm#a

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