% G7 Akalank’s INDIAN BOILER REGULATIONS containing INDIAN BOILERS REGULATIONS, 1950 and INDIAN BOILERS ACT, 1923 NARENDAR KUMAR JAIN AKALANK KUMAR JAIN ania fetes akalank publicationsPublished inp: Akalank Kumar Jain for Akalank Publications 3622, Mori Gate, Delhi - 110006. Email: info@akalank.com visit: www.akalank.com ISBN : 81-7639-257-X Price: Rs. 1000 US $ 300 (C&F) [outside India] Ist Edn 1985 2nd Edn. 1988 GrdEdn. —: 199 4thEdn, =: May, 1994 Sth Edn. April, 1998 6th Edn, April, 2000 7th Edo, Oct, 2003, SthEdn. —: May, 2006 9th Edn. ~: July,2007 ©All Rights Reserved with the Publishers [ee THIS BOOK CAN BE EXPORTED: ONLY BY THE PUBLISHERS. INFRINGEMENT OF THIS CONDITION | OF SALE WILL LEAD ‘TO CIVIL AND CRIMINAL PROSECUTION, oleae eee All Diagrams/Drawings/Graphs in this edition are not to scale, Printed by Atop Drinters Delhi. 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Incase of any doubt relevant act, rules, regulations, orders, etc, onthe subject from Government Department Concerned or Gazette notifications should be referred to, This Publication is sold with the understanding that the Publishers, Authors or Book Sellers are not responsible forthe result of any action taken on the basis of thisbort ne fe ‘any error or omission to any Person whether a purchaser of this publication or not. {ary effort has been made to avoid errors or omissions in this book. Inspite ofthis, errors may creep in. Any Trebek enie discrepancy noted, may be brought to the publisher's which shallbe taken core ctr next edition. jhe bockissubjectto replacement onlyif there isany binding mistake, misprintor for ‘missing pages within30 days from {he date of purchase of the book with the same edition ox the next available edition Ife Published. All expenses in this ‘connection are to be born by the purchaser AldiA Word from Publishers Patrons of our Publications have encouraged us to bring out the present revised edition of Indian Boiler Regulations. Our Ist single volume edition (5th Edition, 1998) was much appreciated by our readers. This edition of book is revised by all Gazette Notifications issued by Central Boilers Board, New Delhi published in Gazette of India till 1st June, 2007. All out, efforts have been made to make the book upto date and fool proof in all respects. All the Diagrams, Drawings and Graphs have been incorporated after the relevant Chapter(s), Regulation(s), Para(s) or Appendix for the purpose of quick reference of our valued readers. However, suggestions pertaining to improvement of the book are always welcome and shall be duly considered. We trust that the book will be of immense practical utility to all Boiler users, manufacturers, engineers and all those concerned with the subject matter. To serve the people is ‘our objective. We have already published the book on Delhi Master Plan (MPD-1962, MPD-2001, MPD-2021), Delhi Municipal Corporation Act, CPWD Specifications, New Delhi Municipal Council Act, Drugs and Cosmetics Act & Rules," Mandal Commission Report, Environment & Pollution Control Laws, Water Supply & Treatment, Civil Accounts Manual, Statutes of India and Delhi Local Laws, Central Civil Services Rules, etc. If our patrons have any suggestion or any compilation worth publishing, we shall, feel it our pleasure to discuss it with them for its publication. July 2007. The PublishersDedicated to my Mother Late Mrs. Raj Rant Jatn Akalank Kumar JainINDIAN BOILER REGULATIONS CONTENTS + REGULATIONS PRELIMINARY 1. Short Titte, Extent, Application and Commencement 2. Definitions CHAPTER I GENERAL REQUIREMENTS, APPLICATION OF STANDARD CONDITIONS AND EXCEPTIONS THERETO 3,:General requirements, application of standard conditions and exception thereto 3A. Inspection of Boiler to comply into any Foreign Code STANDARD REQUIREMENTS 4, Standard Requirements—Material, Construction, Inspecting Authority's Certificates and Maker's Stamp PROCEDURE FOR RECOGNITION OF COMPETENT AUTHORITY, INSPECTING AUTHORITY, WELL-KNOWN MATERIAL TESTING LABORATORY, WELL-KNOWN STEEL MAKER, WELL-KNOWN FOUNDRY/FORGE, WELL-KNOWN TUBE/PIPE MAKER AND WELL-KNOWN REMANENT LIFE ASSESSMENT ORGANISATION 4A. Application for Recognition 4B. Scrutiny of Applications by the Evaluation Committee AC. Recognition of a Firm as Competent Authority, Inspecting Authorities etc 4D. Validity of Certificate of Recognition 4E. Renewal of Certificate of Recognition 4F. Application for Registration of Existing Competent Authority etc. 4G. 4H. Function of Evaluation Committee 5. Modification of Formulae ;A. Material not fully identified 6. Standard specifications for materials 7. 8. g Registration of second-hand boilers not in accordance with the standard conditions Welding CHAPTER II MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS, SECTION AND BARS IN CARBON STEEL 9. Process of manufacture -* 10, Chemical analysis 11. Freedom from defects, etc. 12. Rolling margin 13. Testing and inspecting 13A. Designate steel 13B. Testing and certification of semi-skilled steel for which all tests not carried out ina steel plant 14, Selection of test pieces 15. Tensile test pieces 16. Tensile test 17. Number of tensile tests 18, Dump test 19, Bend tests—Cold bends 20. Number of bend tests 21. Manufactured rivets Beowowe 10 10 10 i 12 12 12 12(viii) Indian Boiler Regulations 22. Additional test before rejection 18 23. Branding 18 24. Defacing of rejected material w 25. Facilities for Inspection 18 26. Steel not produced where rolled 5 19 27. Maker's certificate 19 WROUGHT IRON STAY AND RIVET BARS 28, Rivet bars 19 29. Manufactured rivet tests 19 30. Stay bars v 31. Stay bars-bend tests 9 32. Special iron for screw stays for fire-boxes and combustion chambers » COPPER PLATES, STAY AND RIVET BARS 33. Plates 20 34. Stay and Rivet Bars a COPPER, BRASS AND STEEL TUBES 35. (1) Copper tubes— a 35. (2) Brass Tubes— 2 35. (3) Carbon Steel Tubes a ‘COLD DRAWN SEAMLESS CARBON STEEL BOILER, SUPERHEATER AND HEAT EX-CHANGER TUBES FOR DESIGN METAL TEMPERATURES NOT EXCEEDING 454°C (850°F) - 36. Material process 37. Selection of Tubes for Test ~ 38, Tensile and Hardness tests 39, Flattening test 40. Expanding or Flaring test 41. Additional test before rejection 42, Hydraulic test SEAMLESS CARBON STEEL PIPES FOR HIGH TEMPERATURE SERVICE FOR DESIGN METAL TEMPERATURES NOT EXCEEDING 454°C (850°F) 43. Material 44, Tensile, Bend and Flattening tests 45. Additional tests before rejection 31 46. Hydraulic test 31 SEAMLESS FERRITIC AND AUSTENITIC ALLOY STEEL BOILER, SUPERHEATER AND HEAT EXCHANGER TUBES RUNRRRE 8B 47. General 31 48. Material 32 49. Tests % 50. Additional tests before rejection 36 51. Hydraulic test 36 SEAMLESS FERRITIC PIPES FOR HIGH TEMPERATURE SERVICE 52, General 9 53A. Material 40 53B. Heat treatment 40 53C. Workmanship and tolerance 40 53D. Selection of Tubes for testing rt 54, Test 2 55, Additional tests before rejection 42Indian Boiler Regulations (ix) 56. Hydraulic test 42 586A. Seamless Chromium-Molybdenum Steel Boiler and Superheater Tubes for design metal temperatures not exceeding 577°C (1070°F) “4 ELEGTRIC-RESISTANCE-WELDED STEEL BOILER AND SUPERHEATER TUBES FOR DESIGN METAL TEMPERATURES NOT EXCEEDING 454°C (850°F) 57. General 47 58, Material 7 59. Flattening & Flaring test 48 60. Tensile test 49 61. Hydraulic test 49 62. Test specimens 50 63. Number of fests 50 COLD DRAWN-RESISTANCE-WELDED STEEL BOILER AND SUPER-HEATER TUBES FOR DESIGN METAL TEMPERATURE NOT EXCEEDING 484°C (850°F) 63A. Material 50 STEEL CASTING 73. Scope $1 74. Process of manufacture 51 75. Freedom from and rectification of defects 52 76. Number of test provision of test samples 52 77. Tensile test * 53 78. Bend tests i 53 79. Additional ests before rejection 33 80. Procedure for welding 54 FORGED OR ROLLED PRESSURE PARTS OTHER THAN SEAMLESS DRUMS OR CARBON STEEL 81. Forged or rolled pressure parts 85 82. Selection of test pieces 55 83. Tensile strength 56 84. Bend tests 56 85. Additional tests before rejection 57 GENERAL GREY IRON CASTINGS (GRADE A) 86. General grey iron casting (Grade A) 37 87. Provision of test bars 37 88. Dimension of test bars 58 89. Mechanical test 58 90. Transverse test 59 91. Tensile test 59 92. Number of transverse and tensile tests 60 93. Additional tests 60 COVERED ELECTRODES FOR METAL ARC WELDING OR MILD STEEL 94. Central requirements 61 95, Requirements for normal penetration electrodes—Initial tests 62 96. Requirements for deep penetration butt-welding, electrodes initial test 63 97. Requirements for deep penetration fillet welding electrodes initial test 64 98. Periodic check test 64 APPENDIX H-1 (1) Parent metal for test plates 6 Q) All-weld metal test 6