Indian Boiler Regulation Book, 11th ED Akalank Publications - Ebook download as PDF File .pdf), Text File .txt) or read book online. Indian ): Qualified Boiler Welder's Certificate Issued under the lndian Boiler Requlations. Indian boiler regulations Indian boiler regulations ( Regulations For Determining The Working Pressure To Be Allowed On Various Parts Of. Indian boiler regulations. Indian boiler regulations Indian boiler regulations Contents Regulation Wise.
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The Indian Boiler Authorities strictly enforce the requirements of IBR, refusing site The latest version of the law is known as the Indian Boiler Regulation, Indian Boiler Regulations, These Regulations shall apply to all boilers including those working on principles of natural circulation, forced circulation and . Indian boiler regulation act pdf. Free Download e-Books R0 stcvsm stcvsm c windows system32 drivers stcvsm. Kernel Auto Running - C. Windows.
Structural alteration, addition or renewal shall not be deemed to include any renewal or replacement, of a petty nature when the part or fitting used for replacement is not inferior in strength, efficiency or otherwise to the replaced part or fitting Technical Adviser Boilers means Technical Adviser Boilers to the Government of India in the Ministry of Industry Department of Industrial Development. The decision of Inspecting Authorities shall be binding on all Registering authorities. Tubes and steampipes shall also be inspected at the makers works at the stages prescribed in Appendix J, and the tests conducted by the makers shall also be witnessed by the Inspecting Officer. Together with such certificate the Inspecting Authority may furnish a Memorandum of Inspection Book in Form-I prepared in the manner prescribed by Regulation in respect of the Inspection of the boiler during construction and the hydraulic test applied on completion. In case of a boiler which is to be assembled only at site, requirement of the hydraulic test on a completely assembled boiler by the Inspecting Authority shall not apply provided that the individual parts of such boiler have been hydraulically tested and certified by the Inspecting Authority separately as required under these Regulations. The drawing shall show details of riveting of longitudinal and circumferential seams with pitch of rivets, cross spacing of dished end plates, fillets and flanges and corners of bent plates, and where gusset stays are fitted the number and diameter of rivet holes in each gusset stay.
Jammu and Kashmir]. In the said Regulations, in clause 2 of Regulation 1, for the words and letter "except Part B States" the words "except the State of Jammu and Kashmir" shall be substituted. Indian Boiler Regulations. I "State" or "States" means a State or the States to which these regulations extend; m. General requirements, application of standard conditions and exception thereto 1 A boiler shall not be registered under sub-section 4 of Section 7 of the Act and a certificate shall not be issued under sub-section 5 of that section with reference to a boiler, unless the standard conditions in respect of material, design and construction, which are specified in the subsequent Chapters of these Regulations, are satisfied in respect of such a boiler.
The decision of Inspecting Authorities shall be binding on all Registering Authorities. Inspection of Boiler to comply into any Foreign Code Notwithstanding anything contained in these regulations, the Inspecting Authority may inspect any boiler meant for export during the various stages of its construction so as to comply with the requirements of any foreign code and may grant a certificate in Form IIA.
Tubes and steam-pees shall also be inspected at the makers' works at the stages prescribed in Appendix J, and the tests conducted by the makers shall also be witnessed by the Inspecting Officer.
Together with such certificate the Inspecting Authority may furnish a Memorandum of Inspection Book in Form I prepared in the manner prescribed by Regulation in respect of the Inspection of the boiler during construction and the hydraulic test applied on completion.
In case of a boiler which is to be assembled only at site, requirement of the hydraulic test on a completely assembled boiler by the Inspecting. Requirement to appear for Second class examination 1. Age — shall not be less than 20 years 2. Requirement to appear for first class examination: 1.
Age — shall not be less than 21 years 2. Procedures for making application for first class and second class examination 1. Application shall made in Form-A duly attested by the Gazetted officer 2. Service certificate in original with copy 3. Character certificate issued by employer in original with a copy. Two copies of recent bust photographs 5. Fee of Rs. Application shall be made in a Form —A duly attested by a Gazetted officer.
D; Register of registration and inspection fees in Form NO. Treasury or the Reserve Bank of India in the state of Karnataka under the following prescribed Head of account through challan. Alteration or renewal of boiler component Duty of owner at examination Production of certificates. Part II. See Gazette of lndia. Section 3. Definitions In these Regulations. Short Title. All DiagramslDawings in this book are not to scale.
In the said Regulations. I f "feed-pipe3'- i: Indian Boiler Regulations c signing and issue of certificates in the relevant. I "State" or "States" means a State or the States to which these regulations extend.
ASME Boiler and pressure vessel code. Inspection of Boiler to comply into any Foreign Code Notwithstanding anything contained in these regulations. TEMA with the minimum thickness specified in those codes of manufacture. The decision of lnspecting Authorities shall be binding on all Registering Authorities.
General requirements. Tubes and steam-pipes shall also be inspected at the makers' works at the stages prescribed in Appendix J. In case of Waste Heat Boilers. In case of a boiler which is to be assembled only at site. The Chief lnspector may. Together with such certificate the lnspecting Authority may furnish a Memorandum of lnspection Book in Form I prepared in the manner prescribed by Regulation in respect of the lnspection of the boiler during construction and the hydraulic test applied on completion.
IOOfor General Assembly drawing. I I In case where the original certificate from well-known steel makers in Form IV is not produceable. In the case of water tube boilers. I 6 Indian Boiler Regulations iii A drawing or print to a scale. The drawing shall show details of riveting of longitudinal and circumferential seams with pitch of rivets.
Provided further that in respect of the steel made and tested by Well-known Steel Makers recognised by the Central Boilers Board in the manner laid down in regulations 4A to 4H.
The certificate from the 3 maker of the plates. Provided that where an lnspecting Authority furnished a certificate in Form II together with a Memorandum of Inspection Book in Form I in accordance with sub-regulation c i the certificates prescribed under clauses ii and iv need not be furnished to the Chief Inspector when application is made for registration of the boiler. For pressure parts. But should any question arise in respect of the fitness of the boilers for the working pressure approved by the lnspecting Authority within a period of three years from the date of their registration.
Provided also that in respect of the tubeslpipes made and tested by well-known tubelpipe maker recognised by the Central Boilers Board in the manner as laid down in regulations 4A to 4H. I iv A certificate in Form IVfrom the steel maker and a certificate from the maker of the plates.
Until In addition. Ill the short-term stress-rupture tests for hours as described below are carried out by NMUSteel Plants for the purpose of checking whether the steel is up to the specification and also to ensure that the Steel is capable of meeting the long-term rupture stress valueslmaximum allowable stress values given in ASME or BS or EN Code. Both the samples should pass hour tests at the above stress and temperature.
The samples could be in the form of semi-finished products. These samples may be selected at random by the Chief Inspector of Boilers of the respective State. At this stress. I a certificate is furnished by the producer of the steel to the effect that the steel has been manufacturedstrictly in accordance with the technical requirements of the ASME or BS or EN Code to assure that the creep rupture requirements are complied with. Work's Number I tests may be carried out by them and the particulars regarding testing of material including mechanical tests as certified by them shall be noted in the appropriate column or paragraphs in the certificate inForm Ill-B Tested to In case All boilers of capacity less than 20 Tons per hour shall carry all the mountings or fittings certificates in respective forms with details mentioned in Form Ill.
New Delhi. Central Boilers Board. Central Boilers Board shall send a questionnaire in any of the Forms Forms XV-A to XV-G applicable to the area of activity to the applicant who shall send the same after duly completed. Well-known Steel Maker.
Well-known Material Testing Laboratory. Well-known FoundrylForge. Two Thousand US Dollars per additional unit shall be deposited. Application for Recognition 1 An application for recognition as Competent Authority. Ministry of Industry Department of Industrial Development. Well-known Foundry or Forge. The certificate of recognition shall be from the date of the visit of the plant by the Evaluation Cornmittee and shall be for a period of five years.
Central Boilers Board and in case the Liaison Sub-committee decides to refuse recognition. Central Boilers Board shall send all the applications received under subregulation 1 of regulation 4A. Recognition of a Firm as Competent Authority. In the case of renewal of the recognition. Function of Evaluation Committee The Evaluation Committee shall evaluate the performance of a firm applying for recognition in accordance with the provisions of these regulations.
Provided that the firm which has been granted recognition and has not completed a period of three years. Renewal of Certificate of Recognition a A firm desiring renewal of the certificate of recognition shall apply for such renewal at least three months before the expiry of the validity of the certificate to the Secretary.
Appeal 1 Any firm not satisfied with the reasons given by the Liaison Sub-committee for refusing to accord recognition may file an appeal in writing to the Chairman.
Inspecting Authority. Indian Boiler Regulations 4D. Certificate of Recognition A certificite of recognition issued under regulation 4C. Well-known FoundryIForge. Central Boilers Board who after following the procedure laid down in these regulations may renew the certificate of recognition and such renewal shall be valid for a further period of five years.
Provided further that if an application is not made in time. Application for Registration o f Existing Competent Authority etc. All the existing firms recognised as Competent Authority.
Validity of. If in such cases the Chief Inspector is clearly satisfied that the material is of good quality. Modification o f Formulae i Under the Regulations for determining the working pressure to be allowed on various parts of boilers.
For iron across the grain the tensile strength may be 18 tons per square inch. Indian Boiler Regulations iv Documentation a lnspection and test procedures. In such cases the values of tensile and shear strength shall not be more than 26 and 21 tons per square inch for steel.
Material not fully identified Where the material as for example plate. Standard specifications for materials The standard specifications for steel wrought iron and copper plates and bars. Registratioh 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.
Indian Boiler Regulations 13 iii For flat plates of copper. Age of boiler from the date of first use in years Reduction in working pressure percent 25 5 35 10 45 15 50 20 60 30 70 40 80 50 90 60 70 8. Welding a The use of welding in the construction of boilers shall be permitted only where specifically provided for in the standard conditions. Process of Manufacture a 'steel for plates shall be made by the open hearth.
Chemical Analysis a The Steel shall not contain more than 0. For plates having thickness more than 12 mm. The boiler manufacturer may. Testing and lnspecting The following tests and inspections shall be made at the place of manufacture prior to despatch.
Schedule of Percentage of Rolling Weight Tolerances for Boiler Plates All the above margins will be taken over nett theoretical weight. Surface defects may be repaired by welding. Rolling Margin No plate or rolled section shall be under the specified thickness at any part. Minor surface defects of the plates may be removed by mechanical means to achieve a smooth level surface provided that the minimum specified thickness is maintained.
Freedom from defects. Where a steel plant is not able to designate steel as IS: If a certificate of test is furnished by the steel makers in respect of tests carried out by them and another certificate is furnished in respect of remaining tests conducted by any one of the independent testing laboratories or the Bharat Heavy Electrical Limited.
Such remaining tests may also be conducted at the Bharat Heavy Electricals Limited. Tiruchirapally in respect of plates intended for their use. Tensile test pieces a The tensile strength and percentage elongation shall be determined from test pieces of gauge See regulation Durgapur or the National Test House.
Alipur or Sewri. Central Mechanical Engineering Research Institute. National Metallurgical Laboratory. Testing and certification of semi-skilled steel for which all tests not carried out in a steel plant Where a steel plant has not been able to carry out all the tests required under the regulations for testing the semi-skilled steel.
If the certificate of tests from steel makers and the National Metallurgical Laboratory. Alipur or Sewri for conducting the remaining test provided that samples are drawn in the presence of the lnspecting Authority. Selection of test pieces All test pieces shall be selected by the lnspecting Officer and tested in his presence. Tiruchirapally in the presence of the lnspecting Authority in respect of plates intended for their use. It is open to the manufacturer to take such steel which has the required potentialities of IS: Indian Boiler Regulations 17 tests which it has not been possible for them to conduct in order to get the steel certified as IS: Wherever practicable.
Tensile test a The tensile strength of different grades of material shall be within the limits specified in regulation 9 d. Table Minimum values for the ratio of the stress at proof limit 0. For plate thickness exceeding 60 mm test pieces shall be taken from the exterior third of the plate cross-section. I I I d The minimum values of the stress at proof limit 0. Tensile strength kg. The test pieces shall not be annealed unless the material from which they are cut is similarly annealed in which case the test piece shall be similarly and simultaneousljl treated with the material before testing.
A dump test shall be made for each Tensile Test. Dump Tests Short lengths equal to twice their diameter cut from the rivet bars shall. Number of Tensile Tests a Plates-For shell plates. For rivets bars bend tests are not required. Bend Tests-Cold bends a Test pieces shall be sheared lengthwise or crosswise from plates or bars. If the unsatisfactory result of a test is obviously due to technical conditions of the testing methor' or to a closely limited defect of a test piece.
Number of Bend Tests a Plates-A bend test shall be taken from each plate as rolled. Following this. Additional test before rejection I 1! I Should the test pieces first selected by the Inspector or lnspecting Officer not fulfil the tesf requirements. The bend tests from shell plates. Branding I. In all such cases further tests shall be madC before any material from the same charge can be accepted. As an alternative the rivet bars may be bundle and tabbed to enable the material to be traced to the cast of steel from which they are made.
Manufactured Rivets a Quality of Material-Rivets shall be manufactured from steel complying with the aforementioned requirements of this Chapter in respect of rivet bars.
I i Every plate. If the unsatisfactory result of test is due to an unfavourable heat treatment the plate and the test strip may bL heat treated again. Name of the manufacturer.
Steel not produced where rolled Where steel is not produced in the works at which it is rolled.. When he is satisfied with the material and with the results of the tests.
Maker's Certificate Before the mill sheets are singed. Facilities for Inspection The maker shall adopt a system of making the ingots. Heat No. Defacing of rejected material In the event to the material failing in any case to withstand the prescribed tests.
Indian Boiler Regulations 21 ii Every plate shall also be stamped by the steel maker as provided in IS: Plate No.
Rivet Bars The tensile breaking strength shall be between 21 and 25 tons with an elongation of not less than 25 per cent measured on the Standard Test Piece B as rolled or 30 per cent measured on the Standard Test Piece B. The following information shall necessarily be provided: The number of the charge shall be marked on each plate or bar for the purpose of identification.
If either of these is unsatisfactory. The fracture must be clean. E To comply with Regulation F I[ 8 To comply with Regulation 19 Ntimber of Tensile Tests-The bars as rolled shall be placed in batches of twenty.
Stay Bars. If this is unsatisfactory. Stay Bars-Bend Tests. The tensile breaking strength. Minimum tensile strength lb.
The scrap margin. They shall be thoroughly annealed. If the tensile test is made on a piece of tube. The tubes shall be finished by cold drawing. A batch shall not consist of more than tubes. The results obtained from a batch shall be uniform. From each bar selected.
If the tensile test is made on strip cut from the tube. Not less than Not less than 70 per cent of copper and not more than a total of 0. The test piece shall be flattened down until the interior surfaces of the tube meet and then be double over on itself.
Indian Boiler Regulations g Flanging Test-The test piece shall stand flanging cold see Diagram 3 without showing either crack or flaw until the diameter of the flange measures not less than 40 per cent more than the original diameter of the tube.
The tubes shall withstand the test without showing any signs of weeping of evidence of defects.
The tubes shall be straight and unless otherwise ordered they shall be uniform diameter throughout. Indian Boiler Regulations The manufacturer shall supply when required free of charge. On external diameter k 0.
The working margins shall be as follows: The test piece shall be flattened down until the interior surfaces of the tube meet and then be doubled over on itself. The steel shall be fully killed. The tubes shall withstand the test without showing any signs of weeping.
Indian Boiler Regulations 27 iii Flattening and Doubling over Test-The test piece shall stand the following test when cold without showing either crack or flaw. The outside diameter at the point of grinding may be reduced by the amount so removed. Over Finished tubes shall be reasonably straight and have smooth ends free of burrs. They shall have a workmanlike finish. Cold finished seamless tubes Under Surface imperfections like any discontinuity or irregularity found in the tube may be removed by grinding.
Outside Diameter mm Hot finished seamless tubes They shall be reasonably straight. These permissible variations in lengths apply to cut lengths up to and including 7. They shall be smooth on the ends and free from burrs and flaws. Over Under Over 3. For large size tubes. For lengths over 7. Over Over 4.
Outside diameter mm 2. Length tolerances on the positive side other than specified may be mutually agreed. Tensile and Hardness Tests The test specimen shall comply with the following requirements. For longitudinal strip tests a deduction in percentage elongation 1. The hardness test may be carried out on the wall cross section or on a flat on the outside surface of the tube sample.
Evidence of laminated or unsound material. If any failure in the tests should occur. Hydraulic test i Each tube shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure subject to a minimum of 1.
OO kg. If any of these tests fails. Additional test before rejection i If any one or more tests specified in these regulations fail. Expanding or Flaring test A section of the tube approximately mm in length shall stand being flared with a tool having a 60 degree included angle until the tube at the mouth of the flare has been expanded to the percentages given below.
Indian Boiler Regulations 5 When low D-to-t ratio tubular products are tested because the strain imposed due to geometry is unreasonably high on the inside surface at the six and twelve 0' clock location. Grade PA 0. Pipes manufacturer shall explore a sufficient number of visual inspections to provide reasonable assurance that they have been properly evaluated.
Cold drawn pipes shall be given a sub-critical anneal. The pipes shall conform in all respects with the requirements herein specified. For large size pipes. They shall be smooth on ends and free from burrs and flaws. The minimum wall thickness at any point shall not be more than Seamless Hot finished and Cold finished pipes can be ordered in specified length or in random length.
If ordered in specified length. Indian Boiler Regulations i Permissible variations in outside diameter: Hot finished and cold finished seamless pipes - Outside diameter mm Permissible variations mm Over Under The tensile test may be carried out on the test pieces cut out from tl. If the area thus calculated is more than 4FA. If the calculated area is less than mm2then t I use the actual area thus obtained. Grade Weld Strength MPa kglmm?
As an alternative. Indian Boiler Regulations a Tensile test-Test pieces cut from the ends of the selected pipes shall comply with the following requirements.
Indian Boiler Regulations ii For pipe whose diameter equals or exceeds mm. General i These regulations cover both hot finished and cold drawn seamless boiler. Substitution of the bend test for the flattening test shall be subject to the approval of downloadr. If any failure in the tests should occur the entire batch of the pipes shall be rejected. These shall conform in all respects with the requirements herein specified.
Additional tests before rejection If any one or more tests specified in these regulations fail. The bend test specimens shall be bent at room temperature through degree without cracking on the outside of the bent portion. If the repeat tests are satisfactory the pipe shall be accepted. The inside diameter of the bend shall be 25 mm. Hydraulic test i Each pipe shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure.
Grade Temperature T9 and T22 shall be Degree C. T2 and TI2 either hot finished or cold drawn.
If furnished in the normalised and tempered condition. The heat treatment procedure. Over Under Hot finished Seamless tubes Cold finished Seamless tubes Under If the P grade is hot rolled. Indian Boiler Regulations 37 - iv Grade 12xIM4 shall be normalised at degree C and tempered at degree C for a period of 1 to 3 hours.
If cold working is involved in processing. Indian Boiler Regulatir. Over 3. For grade 12 x IMI 0. Over 4.
These permissible variations in length apply to cut length up to and including 7. O iv 'All specimens shall be tested at room temperature. They shall be smooth on tbends and free from burrs flaws. Indian Boiler Regulatior-. I ii If desirable and practicable. Indian Boiler Regulations Contd. T22 41 0. Indian Boiler Regulations a Tensile and hardness tests-The test specimen shall comply with the requirements as given in Table 3. Table 3: Additional tests before rejection i If any one or more tests specified in these regulations fail.
Indian Boiler Regulations b Flattening test-A section of the tube not less than 63 mm in length shall be flattened cold between two parallel flat surfaces to a distance between the plates H as calculated by the formula given below.
If any failure in the tests should occur the entire batch of the tubes shall be rejected. Hydraulic test i Each tube shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and a half time the design pressure subject to a minimum of 1.
Indian Boiler Regulations Table 4: P2 and PI2 either hot finished or cold drawn may be given a final heat treatment at degree C to degree C. If furnished in the norrnalised and tempered condition.
P9 and P22shall be degreeC. Over iii Permissible variation in length: Over ii Permissible variations in wall thickness: For all grades. For large size pipes the tensile test specimen shall consist of strip cut longitudinally from the pipe and which is not straightened within the gauge length and further heat treated. I Table 5: Hydraulic test i Each pipe shall be tested by the manufacturer and shall withstand a hydraulic pressure to one and half times the design pressure but not greater than pressure calculated by the following formula given below.
A sufficient length of pipe shall stand being bent cold through 90 around a cylindrical mandrel. Indian Boiler Regulations b Bend test-For pipes of outside diameter The bend test specimens shall be bent at room temperaiure through degree C without cracking on the outside of the bent portion. A section of the pipe not less than 63 mm is length shall be flattened cold between two parallel flat surfaces to a distance between the plates H as calculated by the formula given below.
Substitution of the bend test for the flattening test shall be subject to the approval of the downloadr. Indian Boiler Regulations where. Over 9 meters 30 ft.
Upto and including 9 meters 30 ft. Swelling or reduction shall be carried out before the heat-treatment specified in Regulation 56A iii. Should the number of tubes specified of any one nominal size exceed The samples for testing shall not be heat treated after selection.
Thickness of Tube 3 mm. If the second repeat tests are satisfactory. Flattening test carried out in accordance with any other standard code may be accepted in which case. Should either of the tubes fail in any test. Indian Boiler Regulations 51 vii Flattening test-A ring not less than 51 mm 2 inches in length cut from one end of each selected tube shall be flattened between two parallel flat surfaces.
When the pressure is released. If the repeat tests are satisfactory. In case of cold finished tubes the heat treatment shall be done after the' final cold finishing process. Material c. Provided that ifthe tubes are not hydraulically tested at the pressure required under this regulations. WC1 grade may be fully killed.
General a These regulations cover electrically welded tubes made of steel and intended for boiler. C to Deg. The internal weld upset shall be trimmed throughout the length of the tube so that the maximum height shall not exceed 0.
Note 2: For rimmed or semi-killed steel. The tube shall be well finished and free from harmful defects. The external weld flash shall be removed completely.
If rimming steel is used. C either rimming. C shall be of fully killed type. Where the length is specified as exact length or cut length. No cracks or breaks in the metal shall occur unit the distance between the plates is less than the given by the following formula. Hz- 1te t t etD Where. For every 3 metre increase in length above 6 metres.
Evidence of lamination or burnt material or incomplete penetration of the weld shall not develop during the testing. The steel used for design steam temperature above Deg.
When Ladle analysis is not available the analysis of sample tube selected at random may be used. Allowable permissible stress as per the. Hydraulic test I I a Each tube shall be hydraulically tested at the makers' works and shall withstand a hydraulic pressure to one and half times. The sides of the specimen shall be parallel between gauge marks. If the repeat tests are satisfactory the tubes shall be accepted. Test Specimens a Test specimens required for the flattening and flaring test specified in regulations 59 a and 59 b shall be taken from the ends of finished tubes prior to up setting.
Number of tests a The test specified in regulations 59 and 60 shall be made on minimum 2 tubes for first and 1 per or part thereof for tubes over number. Temperature range Deg. Scope I I a This regulation shall cover carbon steel castings used in the construction of boilers and steam pipes including their fittings. Thickness Outside diameter Plus 7. Tolerance on length shall be in accordance with Regulation 58 f. I vi Hydraulic test-This shall comply with the provision of Regulation WC 3 above.
Defects may be repaired by welding only. If the lnspecting Officer does not make such an agreement with the manufacturer. The specified permissible variations in size or thickness shall not be exceeded. Process of manufacture The steel used for castings shall be made by the Open Hearth or Electric Furnace or any other process which gives steel having equivalent properties.
The heat-treatment shall consist of annealing and normalising. Indian Boiler Regulations 57 b For all types of steel castings conforming to these regulations only the minimum values for tensile strength are fixed. Number of test provision of test samples Tensile and bend test pieces shall be prepared from test samples representative of each melt or heat-treatment batch as follows: Freedom from and rectification of defects The steel castings shall have clean surfaces and shall be free from injurious defects.
The discretion of the manufacturer shall not. The steel shall comply with the chemical composition specified in the table above. The agreement for attached test samples shall include the precise location and method of attachment. Test samples shall be stamped by the lnspecting Officer after that heat-treatment process.