important indian boiler regulations
TRANSCRIPT
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IndianBoilerRegulations
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TypicalQuestions
1. WhatisFormIII,FormIIIcandFormVI?
2. WhatisthedifferencebetweenIBRBoilerandnonIBRBoiler?
3. WhichcodeisusedfordesignofboilerinIndiaandothercountries?
4. Atwhatpressurecastironispermittedformanufacturingvalveandfitting?
5. WhataresequentialprocedureforstartingerectionofnewBoiler?. at n o oa sto econs ere or o erc v oun at on
7. Whatprecautionistobetakenduringcivilfoundationofboiler,fansandchimney?
8. Howwillyouprepareyourboilerforannualinspection?
. ,
ifrequired?
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1) Whatis
hogging
and
sagging?
Where
it
is
to
be
seen
in
boiler?
Hoggingandsaggingdescribetheshapeofabeamorsimilarlongobjectwhenloading
isapplied.Hoggingdescribesabeamwhichcurvesupwardsinthemiddle,andsagging
describesabeamwhichcurvesdownwards.
a) HorizontalTubes
b) Pipingbetweensupports
2)Whichtableflangeistobeusedforw.p.ofboiler30kg/cm2?
TableKofAppendixinIBR
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3)WhatisthedifferencebetweenIBRBoilerandnonIBRboilerSteamboilerasperIBR:
applicationof
heat
which
is
wholly
or
partly
under
pressure
when
steam
is
shut
off
butdoesnotincludeapressurevessel:i)withcapacitylessthan25litres (suchcapacitymeasuredfromthefeedcheckvalve
ii)withlessthanonekilogrampercentimetersquaredesigngaugepressureandworkingpressureor
.
IBRsteam
pipe
means
any
pipe
through
which
steam
passes
;such
pipes
exceeds
3.5
kg/cm2aboveatmosphericpressureorsuchpipeexceeds254mmininternal
4)WhichcodeisusedfordesignboilerinIndiaandothercountry.
India Indian
Boiler
Re ulation
IBR
ISO
Boiler
Code
ISO R
831
US AmericanSocietyofMechanicalEngineersASMESectionI
Europe EuropeanStandardforWaterTubeBoilersEuropeanNormEN12952
5)Atwhatpressurecastironispermittedformanufacturingvalveandfitting
AsperRegulation282bCastIronValvescannotbeusedabove13bargauge
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6)HowmanySafetyvalvesarerequiredtobeprovidedinaboilerasperIBR?
7)Inwhattypeofboilerfittingssuchaswatergauges,gaugecocksarenotmandatory?
9)What
are
the
IBR
requirements
of
Automated
Boiler?
10)Whatarethematerialspermittedforthemanufactureof bodiesandfittings?
11 What are limits of use of Cast Iron?
12)WhatarethelimitsofuseofCopperAlloys?
13)WhatistheIBRregulationforvalveopeningdirection?
14)What
is
the
hydraulic
test
requirement
for
chests
and
fittings
at
manufacture?
15)WhatisOrdinaryLift SafetyValve?
16)WhatisHighLiftSafetyValve?
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17)WhatisFullLiftSafetyValve?
SaturatedSteamandSuperheatedSteam?
20)
What
are
the
permissible
Pressure
Drop
in
Safety
Valves?
21)WhatarethetestscarriedoutforSpringsofaSafetyValve?
22)Whatarethespacingspecificationsof thespringcoils?
23)WhataretheIBRspecificationsforPressureGauges?
24)Whataretheminimumappliancesnecessaryforsafeboileroperation?
25)What
are
boiler
fittings?
26)Explainthedifferencebetweenareliefvalveandasafetyvalve.WhatisaSafetyRelief
Valve?
27)What
is
the
difference
between
aspring
loaded
Safety
Valve
and
aPop
Safety
Valve?
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28)Howdotherequirementsofsuperheater Safet Valvesdischargingsteamatover
eg. er
rom
e
requ remen s
o
ose
on
e
o er
rum
29)Whatismeantbythetermblowdown ofaSafetyValve?
30)Whatareaoftheboilershallbecomputedasheatingsurface?
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b.AttachmentandConstruction
.
1. SuitableSafetyValve
2. SeparatefromanyStopValve
3. Fixedascloseaspossible
4. TotheBoiler
5. SuitableStopValve
6. VisibleSteamPressureGauge distinctcolourtoindicatemaximumworkingpressure
7. WaterGauge transparent providedwithguard
8. Platebearingdistinctivenumbers easilyvisible
b.Shallbeprovidedwithmeansforattachingatestpressuregauge
c.Shall unlessexternallyfixed,beprovidedwithasuitablefusibleplugonanefficient
lowwateralarmdevice
EverypartofSteamBoiler
a)shallbeofgoodconstruction,soundmaterialandadequatestrength
b)Freefrompatentdefect
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c.Maintenance,Examinationanduse
1. BoilerandFittingsandattachmentsshallbeproperlymaintained
2. Boilershouldnotbeoperatedunlessexamined/certifiedasperprescribed bythe
3. Prescribedinstructions/proceduresafterrepairwork
4. Reportofresultofexaminationinprescribedformwithin28daysindicatingmaximum
ermissibleworkin ressureetc.si nedb theins ector re istertobemaintained
5.Boilershouldnotbetakeninusefrommanufacturerwithoutcertificatesspecifying
maximumpermissibleworkingpressureandstatingthenatureoftestsetc.
CertificatestobemadeavailableforInspection.
6.Boilertobeoperatedasperanyconditionsspecifiedafterinspection7.Inspectorshouldsubmitwithin28daysofinspection maximumpermissibleworking
pressurepermitted indicatingrepairsifanyrequiredwithinaspecifiedtime
8.Falsereport/inspection/improperinspectionetc.isanoffenceand reporthastobe
submitted
9.ReinspectioncanbeorderedifChiefInspectorisnotsatisfied10.Costofreexaminationcanberecovered
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d.MannerOfExamination
1. Manner a)BeforeitisusedinaFactory
b)Beforetheexpiryofeachoftherelevantperiods
2.Boilershouldbethproughly whencoldafterinterior/exteriorhavebeenprepared
intheprescribedmanner
workingpressure onthefirstoccasion adjustsafetyvalvesettings
. ,
throughtubes,withdrawalofsampletubesfordeterminationoftubethicknessexamination,testing ultrasonic/radiographictests,steamtrial,hydraulictestingetc.
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e.IntervalsbetweenExaminations
a. Tobeexaminedifshiftedfromonepremisestoother
b. Takenintouseforthefirsttimeor14monthsafterthedatewhenitwastakentouse
c. SubjecttoRegulationsinothercases dependingonthetypeofboiler
* ApplicabletoBoilersinwhich21yearshasnotexpiredsinceitwastakenintoservice
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f.Examination AfterRepairs
Whereatanytimerepairs iscarriedouttoanysteamboilertherepairofadefect
,
Shallbeexaminedbyacompetentpersoninsuchamanneraswillenablethat
Persontosatisfyhimselfthattherepairhasbeen properlycarriedout.
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g.RestrictionsonEntry
Nopersonshallenterinanysteamboilerunless
a. Allinletsthroughwhichsteamorhotwatermightotherwiseentertheboilerfrom
anyotherpartoftherangearedisconnectedfromthatpart
. va vesortapscontro ngt eentryo steamor otwaterarec ose an secure y
lockedandwheretheboilerhasablowoffpipeincommonwithoneormoreother
boilersordeliveringintoacommonblowoffvesselorsump,theblowoffvalveortap
beremoveduntilthe valveortapisclosedandistheonlykeyinuseforthatsetofblowoffvalves.
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m.BoilerSafety
Itistheoperatorsdutytoensurethattheboilerisoperatedefficientlyandsafely.Hemust
Seethatthewaterintheboileriskeptatthecorrectlevelandthattheboilerdoesnot
Frequentobservationsofthegaugeglassisoneofthemostimportantfunctionsofthe
Boilerattendantsduties.Itisthemeansbywhichfailureofautomaticcontrolsystemscan
Bedetectedandthereforetheattendantmustensurethatthe au e lassesindicate
Correctlybyadherencetogaugeglassdrill.
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n.InsuranceRequirements
Everyboilershouldhavetwosafetyvalveseachalonecapableofdealingwiththe
Maximumrateofsteamproduction.Valvemustnotbelessthantwoinchesindiameter
Andmustbemounteddirectlyontheshellorsteamdrum.
Itisagoodpracticetoensurethatvalvesdonotbecomestuckontheirseatings by
Continuously
easingonce
per
week.
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3.DesignofFlueGasTubeBoilers
Importantfactorinthedesignoftheboilerisaboutthedrybackwetbackdesign.
Inoldertypesofdrybackdesign,hotfluegasesare900Deg.Cafterthefirstpasswere
ledtothesecondandthirdpassesthroughthedryendplate.
Thiscaused
alot
of
over
heating
of
end
plates
and
loss
of
subsequent
efficiency
also.
et ac type spre era ew eret e ot uegas romt e rstpass s e tot esecon
passthroughanendplatecompletelyimmersedinwater
ThereisalsoimproveddesignswithBackReversingChamberwherethefirstflueendsin
secondpass
completely
immersed
in
water.
Certain
additional
radiation
tubes
are
also
Incorporatedinthechamberincreasingtheefficiency.Thissystemreducestheoverheating
.
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ImportantRegulations
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RegulationNo.281
very o ers a eprov e a eas w e o ow ng
twosafetyvalvesoneofwhichmaybeahighsteamandlowwatertypesafetyvalve
innocaseshouldbetheboreoftheseatofthevalvebelessthan19mm(3/4)
,
fittedattheendofthesuperheateroutletheader
in
case
of
boilers
with
no
fixed
steam
and
waterline,
the
fittings
of
such
accessories
that
,
maynotbeinsistedupon
twoindependentfeedapparatusinwhichpowerissuppliedfromtwoindependent
fromacommonsteammainfedbytwoormoreactiveboilersincaseofsingleboilerbelowheatingsurfacedoesnotexceed sq.ft.twoindependent
sourcestothetwofeeda aratusisnotnecessar
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RegulationNo.281A
AdditionalRequirementsforAutomaticBoilers
1.General
boilerswithwaterlevelandfiringcontrols
b. Whencontrolsarehousedexternaltoboiler
i)provisionforisolationofwaterandsteamconnections..capableofbeinglocked
ino en osition
watersideconnectionsshouldbewithspindlehorizontaltoavoidairlock
ii)meansprovidedtotesttheoperationofthecontroloralarmandforblowing
topreventaccumulationof deposits
iii)
drain
system
should
have
visual
indication
of
flowc.Electricalbasedcontrolsystemanyfaultinthecircuitshouldcutoffuelandsirsupplies
..manualresettingsystem.electricalconductorsandequipmentconnectedshouldbe
properlyinsulatedand adequateprotectionagainstingressofmoistureandeffects
ofhightemperature
d.Whereevaporatingcapacityis>than3700Kg/hour,controlsmusthavefacilityfortestingregularlywithoutalteringthelevelofwater.fullyredundantsystemforfullyautomatic
systems..
Controlrequirements i)cutofffuelandairwithsuitablealarms
oc ou ypew manua rese requ remen
iii)itsownentirelyindependentelectricalcontrolcircuit
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e.Wheremountedexternallytotheboiler,theoverridingcontrolshall
eprov e w sownc a m er
ii)complywiththerequirementsofclause(b)
.
a)Floatordisplaceroperatedor
b)
operated
by
electrical
probe
or
thermostat
or
3.AutomaticFirin Controls
a)should
control
air
and
fuel
effectivelyb)Cutofffuelandairasrequired
i)flamefailure lockouttypemanualreset
ii)failuretoignitewithincertaintime
iii)waterlevelloworhigh
iv)increaseinboilerpressurebeyondlimtsv)failureofFD/IDfans/dampers
vi)steamtemperatureinforcedflowoncethroughboilerincreases
NOTE: Theaboveprovisionsdonotapplytooncethroughforcedcirculationboiler
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RegulationNo.282
Materials,Tem eratureandPressureLimits
(a)Materials: Thematerialsusedinthemanufactureofthebodiesofthefittings
Shallcomplywiththefollowingrequirements:
(i) SteelCastingsshallcomplywith28tonsgrade1(Regulations73to80)
(ii) SteelforgingsshallcomplywithRegulations81to85Ironcast ngss a comp yw t t eRegu at ons86to93
(iv) BronzecastingsshallcomplywiththerequirementsunderRegulation282
(v) Theseatsanddiscsofvalvesshallbemadeofnocorrosivemetal
(b)Limits
of
cast
Iron
: CastIronshallnotbeusedfor
(a) Temperatureabove220Deg.C
(b) Pressureexceeding13bargauge
(c) Valvesexceeding200mmnominalborewhichareconnected
directly
to
the
boiler e geor ou e scgateva vesw c areconnecte rect y
totheboiler
(e)BoilerBlowdownfittings
Explanation: The
expression
connected
directly
to
the
boilers
covers
and
valves
which
Cannotitselfbeisolatedfromtheboiler
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NOTE
: Spheroidal Ironmay
be
used
for
temperature
not
exceeding
282
Deg.C and
Pressurenotexceeding17.58kg/cm2provideditcomplieswiththefollowing
Requirementsinrespectofthephysicalproperties
(a) 0.2%proff stress250kg/mm2
n mume onga onpercen
(c) LimitsofCopperalloy:Copperalloyshallnotbeusedfortemperatures
. .
Inthecaseofvalvesnotconnecteddirectlytotheboiler,thistemperaturelimitationmaybeincreasedto200Deg.C
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RegulationNo.283
(a) Allcastingsshallbesmooth,soundandfreefromflawsorotherinjuriousdefects
Variationsinthicknessatanypartshallbegradualandsubstantialfilletsshallbe
provided.
T e o yo a o ermount ngs a econnecte tot e o er ange yastrong
andstiffneck.Innocaseshallthethicknessoftheneckofbronzemountingbeless
than3/16inchforsizesuptoandincludinginchboreorinchforsizesover
nc ore
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RegulationNo.284
Packin ofCocks
Thebodiesofallcocksexceptthoseforpressuregaugesshallbepackedwithasbestos
Orotherheatresistingmaterialandshall beofsubstantialdesign thoseoverone
Inchboreshallhavespecialprovisionotherthantheglandforsecuringtheplug.
Watergaugecolumncocksmaybeeitherasbestospackedorsolidplugtype.
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RegulationNo.285
CoversandS indles
(a) Valvesofinchboreandoverdirectlyconnectedtoboilersandothervalvesof2
orstudsandthescrewedportionofthespindleshallbeoutsidethestuffingbox.
Allvalves
for
superheated
steam
shall
be
fitted
with
an
external
screwed
spindle
(b)Wherethecoversofvalvesaresecuredbystudsshallbescrewedintothebodywithfull
threadforalengthofatleastonediameter.Thestudholesshallnotpenetrateintothe
c Valves with screwed covers shall be fitted with suitable lockin device to revent the
rotationofthecover
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RegulationNo.286
Directionof
Operation
Valvesshallbeclearlymarkedtoindicatethedirectionofflow.Valvesdirectlyconnected
Toboilersshallbefittedwithindicatorstoshowclearlywhetherthevalveisclosedor
Openandallvalvesshallopenbyanticlockwiserotation.
l i
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RegulationNo.287
Thevalvesandspindlesshallbeefficientlyguidedandmeansshallbeprovidedin
Everycasetopreventthemleavingtheirguides.Theworkingpartsshallhavesufficient
Clearancetoensurefreedomofmovementunderallconditionsofservice.
R l i N 288
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RegulationNo.288
Flan es
(a) Flangesshallbeinaccordancewiththetablesfortheappropriatepressure
(b)
In
the
case
of
safety
valves
the
drilling,
thickness
and
bolting
of
inlet
flanges
shall
be
diameterofflangeadopted.Inthecaseofoutletflangesthepressuretakenshallbethe
pressureontheoutletsideofthevalve
(c)Forthepurposeofdeterminingparticularsofflangesforblowdownandscumpipefittings,thedesignpressureofthefittingsshallbeassumedtobeworkingpressureof
the boiler
(d)Allflangesshallbemachinedontheface,spotfacedormachinedatthebackandthe
boltholesshallbedrilled
R l ti N 289
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RegulationNo.289
ValveSeatin s
, .
Providedineverycasetopreventthevalvesleavingtheirguides
Regulation No 290
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RegulationNo.290
Chestsetc.inGeneral
(a) Allchestsandfittings shallbesmooth,soundandfreefromflaws,cracksortootherinjuriousdefects. Aftercompletion,thechestsshallbetestedhydraulically atthe
areintended.
Hydraulictestshallbemadewithwaterwhichmaycontainacorrosioninhibitor,with
keroseneorwithothersuitableli uid rovideditsviscosit isnot reaterthanthatofwater
atatesttemperaturenotabove52Deg.C
(b) Valvesmaybefabricatedfromseamlesssteelpipesof pressuresnotexceeding250pounds
persquareinchandtemperaturesnotexceeding800Deg.F.Theweldingshouldconformto
Regulation 125andvalvechestshouldbestressreleived afterfabrication.Valvesmeant
foruseinpipeworkmayalsobefabricatedbyweldingfromseamlesssteelpipesbutno
restrictionasaboveregardingpressureandtemperatureshallapplytothemprovided
theweldingcomplieswithalltherelevantrequirements offusionweldingsuchasstress
releivingandradiographicinspectionoftheweldand thelikedprescribedinChapterV
of
these
Regulations
Theworkingpressureofthechestsshallbedeterminedby equation21or91Awhichever
isapplicablewheretheterm2Seshallbesubstitutedbytheterm1.8XS
( c) The working pressure and the thickness of the Bronze and Cast iron Valve chests shall be
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(c)TheworkingpressureandthethicknessoftheBronzeandCastironValvechestsshallbe
determinedbythefollowingformulaesubjecttotheminimumthicknessasspecified
inRegulation283(b)
(d)Theworkingpressureandthethicknessofthesteelvalvechestsofcircularcrosssection
shallbedeterminedbytheformulaenamely
(e)Theworkingpressureandtheminimumthicknessofthesteel valvechestofspherical
crosssectionshallbedeterminedbythefollowingformula,namely
(f)ThenumberofvalvesandfittingswhichshallbemadeavailabletotheInspecting
Officer(excludingmechanicaltests)shallbeasfollows:
Uptoandincluding51mm10percentover51mmanduptoandincluding76mmofthenumberofchests15percent
..
over114mm100percent
Testingandinspectionofvalvesintendedforservicepressureexceeding10.5kg/cm2or
Temperatureexceeding204Deg.Candactuallytestseachfittingathisworks,theinspecting
SPECIAL REQUIREMENTS OF SAFETY VALAVES
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SPECIALREQUIREMENTSOFSAFETYVALAVES
Re ulationNo.291
GeneralSafetyvalves,ordinary,highliftandfullliftshallbesoconstructedthatbreakageofany
Partwillnotobstructthefreeandfulldischargeofsteamfromtheboiler
Regulation 292
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Regulation292
AsafetyvalveinwhichthevalveheadliftsautomaticallyadistanceofatleastD/24with
anoverpressurenotexceeding 10%ofthesetpressure.Thereshallnotbeany
atleastD/8.
Distheminimumboreofthebodyseat.
(b)HighLiftSafetyValve
AsafetyvalveinwhichthevalveheadliftsautomaticallyadistanceofatleastD/12with
.
Mechanicalstopwhichwouldpreventthevalveheadfrombeinglifted adistanceofAtleastD/6
Distheminimumboreofthebod seat.
(c)FullLiftSafetyValve
ASafety
Valve
in
which
the
valve
head
lifts
automatically
a
distance
such
that
the
area
ofdischargewhichlimitstheflowthroughthevalveisbetween100%and80%ofthe
minimumareaatanysectionatorbelowthebodyseat.Thisliftisachievedbyarapid
.
Regulation 293
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Regulation293
MinimumAggregateArea
Dischargecapacity
of
safety
Valve
Therateddischargecapacityofasafetyvalvewhichdischargesaturatedsteamshallbe
calculatedusingthefollowing equation:
E=CAP
Where,
E=istherateddischar eca acit ofsaturatedsteam k h
P=isthehighestpressureofanysafetyvalvemountedontheboiler(barabsolute)
A=isthearea(mm2)
Cisaconstant OrdinaryLift 0.05
HighLift 0.01
.
(b)SuperheatedSteam
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( ) p
Therateddischargecapacityofasafetyvalvewhichdischargessuperheatedsteam
Es = E/ (1+2.7Ts /10000)
where ES istherateddischargecapacityofsuperheatedSteam(Kg/h)
Eistherateddischargecapacityofsaturatedsteamcalculatedusing
Ts isthedegreeofsuperheatDeg.C
Theaboveequationmaybeusedtodeterminetherateddischargecapapcityof
.
temperatureof
the
steam
shall
be
taken
as
375
Deg.c
c Thetotal eakloadeva orationofaboilershallbecalculatedonthebasisofeva oration
notlessthan30 kg/hr/m2ofheatingsurface(exclusiveofsuperheaterandnonsteaming
economiser).
Inthe
case
of
Waste
Heat
Boilers,
however,
when
the
evaporation
per
squaremeteroftheheatingsurfaceiscertifiedbythemanufacturertobelessthan30kg.
theminimumnumberofsafetyvalvesrequiredmaybecalculatedonthebasisof
theactual maximumevaporationoftheboiler
Regulation 294
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Regulation294
OverPressureofSafetyValves
TheSafetyvalvesshallbesodesignedthattheyattainrateddischargecapacitywiththe
Overpressurenotgreaterthanthatgivenintheregulation292 providedthatthe
Safetyvalveswhichhaveadischargearealessthan80%oftheflowarea,theoverpressure
atwhichthedesignliftisattainedshallnotexceed10%ofthesetpressure.
Forsafetyvalveshavingdischargearea80% ormoreoftheflowarea,theoverressureatw c t e es gn t satta ne s a notexcee percento setpressure.
Regulation 295
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Regulation295
PressureDrop
TheSafetyvalvesshallresetatapressureatleast2.5%belowbutnotmorethan5%below
.
seatborelessthan32mmandhavingasetpressureof2bargaugeorless.
Regulation296
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g
MountingsofSafetyValves
(a) Safetyvalvesshallbemountedwithoutanyinterveningvalveonpadsorbranchesused
fornootherpurpose.Theaxisofthevalveshallbevertical.Thecrosssectionalareaof
theboreofeachpadorbranchshallbeatleasttotheareaoftheboreattheinletof
thesafetyvalveorwheretwoormoresafetyvalvesaremountedonthesamepador
branch,atleastequalto thesumoftheareasoftheinletboresofallthesafetyvalves
(b)Branchesshallbeasshortaspossiblesoasnottoimpairtheproperactionofthesafety
valvesorimposeanyunduestressonthebranchesattheirpointofattachmentto
. . ,
whenfullliftsafetyvalvesaremountedonthem shouldbereducedattheinlet.Theinletandoutletflangesshallbedrilledinaccordancewiththeapproximate
.
Regulation297
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g
Openingsin
Shell
Openingsintheboilershell.Dischargingsteam shall havedirectaccesstothesafety
valvewithoutflowingthroughinternalpipes.
Regulation298
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g
Dischar ePassa e
Thesafetyvalvedischargepipesshallcomplywiththerequirementsofclauses(a)and(b)
ofthisregulation.Thedischargepipeshallbeasshortandstraightaspossibleandbe
.
shallbeprovidedinthedischargepipesystemsothatthedischargecanreadilybe
heardbytheBoilerAttendant.
(a) SteamsafetyValve:
(i)OrdinaryandHighliftvalves:Whereawastesteampipeisfitted,thepipeandthe
passageleadingtoitshallhaveacrosssectionalareanotlessthantheminimum
combinedareaofthesafetyvalvesrequiredbyRegulation293
(ii)FullLift
valves
:Forfullliftvalvestheareaofwastesteampipeandpassages
leadingtoitshallhaveacrosssectionalareanotlessthantwiceAorsucharea
a ove sm n mumasmay erequ re orva ves av nga g erapprove
constant,whereA,EandPareasdefinedin Regulation293
(b)EconomiserSafetyValve:Theareaofthedischargepipefromaneconomisersafety
.Wherethedischargefromseveraleconomisersafetyvalveisconnectedtothe
maindischargepipe,thediameterofthemaindischargepipeshallbedesignedto
particularconditionsoftemperatureandpressurewhichmaybeapplicable
Regulation299
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oreac enc ose sa e yva vec es ameanso ra n ngs a eprov e .
Thedrainpipeshallbelaidwithacontinuousdownwardgradientclearof the
Boilertoaplacewherethedischargeisvisibleandcannotdoinjurytoanyperson
Regulation300
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Movin Parts
Thevalvesandspindlesshallbeefficientlyguidedandmeansshallbeprovidedineverycase
.
Toensurefreedomofmovementunderallconditionsofservice.
Thespindleshallnotbefittedwithastuffingbox.
Thebearingsoftheleversoflevervalveshallbesodesignedastoallowfreeworkingofthe
Valveunderallconditionsofservice.Wheretheleverismountedonpinbearings,theholes
Metal.
Regulation301
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Thebearin softheleversoflevervalveshallbesodesi nedastoallowfreeworkin ofthe
Bearingsfor
Levers
Valveunderallconditionsofservice.Wheretheleverismountedonpinbearings,theholes
Inthelevershallbebushedwithnoncorrodiblemetalorthepinsshallbeofnoncorrodible
Metal.
Regulation302
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Attac mento We g tsan Spr ngs
a na everan we g sa e yva ve, ewe g s a e nonep ecean a a c e o e
leverinsuchawaythatthesafetyvalvecannotbeoverloaded
,
adjustingscrewssothatthevalvescannotbeoverloadedwhenunderthesteam.
Interferencewithloadonthespring,afterthesafetyvalvehasbeenadjusted,shallbe
nut
on
the
adjusting
screw
which
shall
be
further
safe
guarded
by
means
of
a
padlock
orothersuitabledevice.Wherespringsareintension,linksorothersuitablestopsshallbe
fitted to revent the s rin bein extended a reater amount than that corres ondin
toavalveliftofD/4
Where
D=diameterofvalveseating
Regulation303
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Easin Gear
Safetyvalvesshallbesoarrangedthattheycanbeeasedofftheirseatswhenunder
pressureandtheeasinglevershallpositivelyliftthevalve.
Regulation304
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Lift
Safetyvalvesshallbecapableofbeingliftedadistancesuchthattheareaofthe
dischargeedgeshallnotbelessthantheminimumaggregateareaAinRegulation293
Regulation305
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Hi handLowwaterAlarms
HighandLowwateralarmsshallbeadjustedsothatthealarmissoundedwiththewater
levelvisibleinthegauges
Regulation306
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Thespecifiedpressure.
Regulation306A
The
set
pressure
of
a
safety
valve
may
be
adjusted
using
air
or
other
gas
as
the
test
Mediumprovidedthatthesafetyvalvehasbeensubjectedpreviouslytohydraulic
Regulation307
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Materials
(a) Springs ThespringsshallbemanufacturedfromsteelmadebytheAcidOpenHearth
orElectricProcessandtheChemicalcompositionshallbewithinthefollowing
limits
(Page
206)
ThemanufacturersshallsupplyananalysisofeachcastwhenrequiredbytheInspecting
Authoritytodoso.Shouldindependentanalysisberequired,theseshallbemadeatthe
.
Allspringsshallbeformedhotandsuitablyhardenedandtempered
Allthespringsabove10mmbardiametershallbeformedhotandthespringsbelow16mm
Bardiametershallbeformedhotorcold.Thespringsshallbesuitablyhardenedand
Regulation308
Di i
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Dimensions
Forordinaryliftvalves,thecompressionorextensionofsafetyvalvespringsrequired
toloadthevalvestothesetpressureshallnotbelessthanonequarterofthediameter
ofthevalvedueconsiderationbeinggiveninthecaseofspringloadedleversafetyvalve
totheratioofleverage.Theproportionofunloadedlengthtoexternaldiameterofthe
spring
shall
not
exceed
4:1
Theserequirementsdonotapplytofullliftandhighliftsafetyvalves.
Regulation309
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(1)
(2)
Regulation310
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(1) CompressionSpringsshallnotshowanypermanentsetafterbeingcompressedcoiltocoil
.
permanentsetafterbeingtested25%inexcessoftheload
necessaryunderworkingconditionstoliftthevalve
(2)TorsionBarsshallnotshowapermanentdistortionafterbeingtwistedtoananglefifty
percentinexcessoftheworkingangle
(
Regulation311
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Extensionspringsshallbemadefromroundsectionwire
Regulation312
N b f Eff i C il
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Numberof EffectiveCoils
Thenumberofeffectiveorfreecoilstoacompressionorextension4 springshallbe
determinedfromthefollowingformulae:
(i) ForRoundorSquareWire
N=KCd4 / SD3
ii ForRectan ularWire
N = 66B3 H3 K / (B 2 + H2 )SD2
Where N=NumberofEffectiveCoils
K=Compressionortensionininchesatsetpressure
C=22forround,30forsquaresteel
d =diameterorsideofsquaresteelin16th ofaninch
D =meandiameterofcoilininches
B=Breadthofwirein16t ofaninch
H
=
Depth
of
wire
in
16
th
of
an
inch
Regulation313
S i Of C il
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S acin OfCoils.
Thespacebetweenthecoildwhenthevalveisliftedto1/4th ofitsdiametershallbenot
Lessthan1.6mm(1/16inch)forfullliftvalvesand0.8mm(1/32inch)forordinary
andhighliftvalves
Regulation314
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Finishing
of
ends..
Compressionspringsshallhavetheirendsgroundedflatandsmoothandatrightangles
Totheaxisofthespringsoverthefullcircumferencesothatwhenplacedonendona
.
STOPVALVES
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Regulation315
LeverValves
Wherethe
valve
is
operated
by
means
of
a
lever,
whether
hand
or
mechanically
controlledThelevershallbeofamplestrengthandthebearingsshallbesodesignedastoallowfree
Workingofthevalveunderallconditionsofservice.
Steam Sto Valve
Regulation316
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SteamSto Valve
(a) Thestopvalvecommencingtheboilerorsuperheatertothesteamdeliverypipeshall
practicableorincaseofboilerswithoutsuperheatersascloseaspracticabletothedrum.
Wheretwoormoreboilersareconnectedwithasteamreceiveroranyothervessel,
a steam sto valve shall be fitted between the boiler and such receiver or vessel.
(b)Steamstopvalvesshallbeattacheddirecttotheboilershellortosuitablepadsor
standblocksandtheneckorthevalvechestshallbereasonabl shortandofstron
construction.Thesteamstopvalvemayalsobeattachedtoastandpipe,aconnecting
pipeorthesuperheaterheader.Theattachmentmaybemadebyboltedflangesorbutt
weldedjoints.Suchbuttweldedjointsshallbesuitablystressreleivedwherenecessary.
Providedthatinthecaseoflargerboilerinwhichitisproposedforthepurposeofdrainage
Orowingtoobstructiontoconnectthesteampipestothesteamstopvalveatahigherlevel
thanwouldbeobtainedunderthisRegulation,averticalstandpipenotexceeding5
diametersinheightwillbepermittedbetweenthestopvalveandtheboiler.Suchstandpipe
shallbeofstrongconstructionandofwroughtiron,mildsteelorcaststeel.Theflangesof
Wroug tironormi dstee pipess a erivetedorwe dedtot epipesandt eres a
Benobranchonthestandpipeforanyotherconnection.
Providedalsothatinthecaseoflargeboilerinwhichitisdesiredtofitateepieceforthe
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purposeo prov nga ranc connec on e ween es opva vean e o er,suc a ee
Piecemaybesofitted.Theteepieceshallbeofstrongconstructionofwroughtiron,mildSteelorcaststeelandshallnotexceed2diametersinheight.Astopvalveshallbe
.
(d)Whentwoormoreboilersareconnectedtoacommonsteammainandthereareno
,compulsory.Inthecaseofboilersfittedwithweldedpipes,fittingofanindependent
automaticisolatingvalveshallbecompulsory.
BLOWDOWNCOCKORVALVEANDPIPES
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Regulation317General
.
Tothecockorvalveshallnotbeboundfastinarchorbrickworkandshalldischargeata
Pointwherethereisnodangerofinjurytoanyperson.Thesepipesshallnotbeconnected
To a i e common to another boiler. The continuous blowdown ma however be connectedtoacommonheaderdischargingfreelytoanadequatelyventedtankorsump.Theheaders
Shallbeofsufficientlylargecrosssectionandtheblowoffcockshallbeprovidedwithvent
Pi efreefromvalvesandofsufficientsizeto reventaccumulationof ressure.Ifhowever
Thetankisintendedforcollectingflashsteam,asafetyvalveofadequatecapacityshallbe
Provided.Thetankshallbesolocatedthatallpartswillbeaccessibleforinspection.
Regulation318
BlowdownMountings
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g
(a) Eachboilershallbefittedwithasuitableblowdownvalveorcockplacedatorasnear
(b)Forlocomotive,verticalandmarinetypeboilersthevalveorcockshallbeattacheddirect
totheboilerortoasuitable adorstand i e.Forwatertubeboilersthevalveorcockshallbeoutsidethebrickworkwithasubstantialsteelpipebetweenitandthemud
box.
(c)ForCornishandLancashireboilersthecockorvalvemaybeattachedtoacaststeel
elbowpipeofsubstantialsectionboltedtoasuitablestandpipeorpadrivetedtotheboiler.Butcastironelbowpipeshallnotbepermitted.
Regulation310
BlowDown Valve or Cock
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Blow DownValveorCock
(a) Eachvalveorcockshallbefittedwithadevicewhichshallindicateclearlyitsopenand
suchthatitcannotberemovedunlessthevalveorcockisfullyclosed.
(c)Cocksfittedwithtaperplugsshallbeoftheboltedcovertypewithseparatepacking
WATERGAUGES
Re ulation 320
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Re ulation320
(a) Everyboilershallhavetwomeansofindicatingthewaterlevelinitandhavemarkedonitwhenapplicableinacontiguouspositioneasilyseenthelevelofthehighestpartof
,
Providedthatinthecaseofboilerdrumsbelow3feetdiameterwherethereisdifficulty
infittingtwowatergauges,twotestcocksandaglasswatergaugemaybefitted.
(b)Forboilershavingevaporatingcapacitygreaterthan10,000lb.mofwaterperhour,one
ofthewatergaugemaybeoftheremotewaterlevelindicatortype.
(c)Thelowestvisiblepartoftheglassofthewatergaugeandlowertestcockshallbefixed
atsafeworkinglevel.Forlocomotiveboilerthisshallnotbelessthan2inchesabove
thehi hest artofthefireboxroof late.
(d)Glasswatergaugesshallbesoplacedastoeasilyseenandreachedbytheboilerattendant.
Thefittingsofglasswatergaugesandtestcocksshallbeofsubstantialmakewithlarge
passagewaysthroughthemtofacilitatecleaning.Thegaugecockswhenopenshallhave
theirhandlesinaverticaldirectionandeachhandleatitsjunctionwiththeplugshall
beplainlymarkedwithadeeplinetoindicatethedirectionofthepassagewaythrough
theplug.Whendetachablehandleareprovidedarrangementshallbemadetoprevent
incorrect
fitting
of
the
handle.
Regulation321
Drains
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Adraincockorvalvewithasuitabledischargepipeshallbefittedtoeachwater
.
Regulation322
Protectors
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Wheretubularglasswatergaugesarefitted,substantialprotectorsshallbe
.
Regulation323
GlassSize
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Tubularwatergaugeglassshallbenotlessthaninchandnotmorethan
.
Regulation324
Safet Devices
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Watergaugeglassmountingsshallbefittedwithselfcleaningdevicesinthebottom
.
Regulation325
Gau eColumns
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Wherethegaugesaremountedonacolumnthereshallbenoconnectingpassage
Betweenthecolumnsandtheboiler.
Regulation326
Isolatin Cocks
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Whereisolatingcocksorvalvesconnectingwatergaugepipestotheboilerarefitted.
Packinggland.
PRESSUREGAUGES
Regulation327
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(a)Forpressureuptoandincluding35kg/cm2,pressuregaugedialsshallbegraduatedin
Kg/cm2from Zerototwicethepressureasnearlyasmaybepracticable.
(b)Forpressureexceeding35kg/cm2,therangeofthegraduationshallbefromZerotoone
and
a
half
times
the
maximum
permissible
working
pressure
as
nearly
as
may
bepracticablebutinnocaseshallthemaximumgraduationonthegaugebelessthan
70kg/cm2
(c)Thescaleonthedialshallbeclearlyandpermanentlymarkedinkg/cm2.
(d)Thedialofeachpressuregaugeshallhavetobemarkeduponitinred. themaximum
wor ngpressure
(e)Wherethegaugesiscompensatedforaheadofwaterbetweenthegaugeandtheboiler
, .gaugesshallbecalibratedwithinanaccuracyof+1percent.Boilerpressuregaugesshall
notbelessthan150mmindiameter
(f)Thetravelofthepointerofthedialgaugeshallnotexceed 3259???
Regulation328
Connections
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Connections
adjacenttothegaugeinsuchamannerthatthegaugemaybeshutoffandremoved
Whilsttheboilerisundersteam.
Regulation329
Gauge Cocks
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GaugeCocks
All handlesofthe au ecocks shallbe aralleltothe i esinwhichthe are
locatedwith whenthecocksareopenandmarksshallbecutonthe shankofthe
Cockindicatingopenposition.
Regulation330
Test Connections Inspectors Pressure Gauge Attachment
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TestConnectionsInspector sPressureGaugeAttachment
Everyboilershallbefittedwithavalveorcockcarryinginaverticalpositionareceiving
ScrewforattachmentoftheInspectorspressuregauge.Thereceivingsocketshallbe
TappedforM/20x1.5metricthreadsandshallbefittedwithaneasilyremovablecap.
FUSIBLEPLUGS
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Regulation331
General
Fusibleplugsshallbeofsufficientheightandfittedinsuchapositionastogiveearly
Protectionto
all
parts
of
the
boiler
liable
to
damage
by
the
direct
application
of
furnaceHeatintheeventofshortageofwater
thefurnacefrom12inchesto18inchesinfrontofthebrickworkfirebridge
Regulation332
Type
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yp
Fusible lu sshallconsistofanouterbod withacentralconical assa ethesmallest
Parttobenotgreaterthaninchforplugssuitableforpressureupto100lbspersq.in.
Andnotgreaterthan3/8inchforplugsforpressuresexceeding100lbs.persq.in.
The
passage
shall
be
closed
by
a
plug
secured
by
an
annual
lining
of
fusible
alloy
so
thatTheplugmaydropcleariftheliningmelts.
Theportionofthebodycarryingthefusiblemetalshould preferablybedetachablefrom
Thebasetoallowofeasyreplacementwithoutremovingthewholefittingfromtheboiler.
Regulation333
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Thenonfusibleportionsoftheplugshallbeofbronzeexceptwherethenatureofthe
Boilerwaterprecludestheuseofnonferrousmaterial.Thefusiblemetalshallbeanalloy
meltingreadilyatatemperaturenotlessthan150Def.Finexcess ofthesaturatedsteam
Temperatureatthemaximumpermissibleworkingpressureoftheboiler
Regulation334
Attac menttoBo er
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Wherever racticablefusible lu sshallbescrewedintotheboiler latesfromthe
Waterside.ThescrewedportionshallhavethreadsofWhitworthformnotmorethan
11perinch
FEEDVALVES
Regu at on335
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General
(a) Feedcheckvalvesshallbeofthenonreturntype
(b) Wherethevalveisnotofscrewdownnonreturntypeaseparatescrewdownvalve
shallbeprovided
c e sc arge romt e ee c ec va veor romt e nterna ee p pe prov e s a
beabovelowwaterlevelandinthecaseofLancashireandCornishBoilersshallbeatleast
5ft.beyondthefirebridge.Providedthattherestrictionaforesaidregardingthe
(d)Thedischargeendoffeedpipeshallbesolocatedthatitisnotclosetoanyrivetedjoint
Regulation336
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Feedcheckvalvesorregulatingvalvesshallbesoarrangedastoenablethemto
Satisfactorilyoperatedfromtheboilerfloor
Inthecaseofabatter ofboilersconnectedtoacommonfeedran e,there uirement
Of Regulation281inrespectofthenumberoffeedapparatusshallbeconsidered
TohavebeenfulfilledprovidedatotalsupplyoffeedwaternotlessthanthecombinedMaximumcontinuousratingofallactiveboilerscanbemaintainedevenifanyoneof
Thesourcesofpowersupplyshouldfail
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FORMS
FORMI MEMORANDUMOFINSPECTION
OR
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REGISTRATIONBOOK(Regulation386&487)
FORMII INSPECTIONAUTHORITIESCERTIFICATEOF
INSPECTIONDURINGCONSTRUCTION
DURINGCONSTRUCTIONINRESPECTOFABOILER
MADETOFOREIGNCODEFOREXPORT
FORMIIB INSPECTIONAUTHORITIESCERTIFICATEOFINSPECTION
DURINGCONSTRUCTIONINRESPECTOF BOILERSFORWHICHVARIATIONFROMSTANDARDCONDITIONS
HAVEBEENPERMITTED
Regu at on 4 c Note
FORMIII WORKSADDRESS
CONTRACTORSCERTIFICATEOFMANUFACTURERANDTEST
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( Regulation4(c). )
FORMIIIB CERTIFICATEOFMANUFACTUREANDTEST
(
Regulation
(f)
)
MOUNTINGSANDFITTING
(Regulation269)
FORMIV STEELMAKERSCERTIFICATEOFMANUFACTUREAND
RESULTSOFTESTS
FORMV PROVISIONALORDERUNDERSECTION9OF
THEINDIANBOILERSACTOF1923
(Regulation381(c)
FORMVI BOILERINSPECTIONDEPARTMENT
CERTIFICATEFORUSEOFABOILER
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(Regulation389)
CONDITIONS
(ReverseofFormVI)
FORMVII INSPECTINGAUTORITYSCERTIFICATEOFINSPECTIONUNDER
CONSTRUCTION
DESIGNATIONOFINSPECTIONAUTHORITY(Regulation501(e))
CONSTRUCTORS CERTIFICATEOFMANUFACTUREANDTEST
(Regulation501(d))
OR
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REGISTRATIONBOOK
Re ulation 528
FORMX Regulation525(e))
FORMXI CertificateforuseofanEconomiser
(Regulation530)
REVERSEOFFORMX!
Conditions
FORMXII
RecordofWeldersQualifications/RequalificationsTest
(IndianBoilerRegulation1950)
(Regulation613)
FORMXIII QualifiedBoilerWeldersCertificate
IssuedUnder
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TheIndianBoilerRegulation,1960
FORMXIV MemorandumofInspectionBook
(Regulation394(c) )
egu a on
Questionaire tobeansweredbyfirmsseekingrecognitionbythe
CentralBoilersBoardtobecomeanInspecting Authorityunder
,
FORMXV
B
Regulation4A(2)
Questionaire forelicitinginformationregardingthecompetencyofa
firmtoberecognisedasCompetentAuthorityunderRegulation4A(2)
ofTheIndianBoilerRegulations,1950
Questionaire tobeansweredby SteelMakersseekingrecognitionbythe
CentralBoilersBoardtobenotifiedasawellknownSteelMaker
FORMXVD Regulation4A(2)
CentralBoilersBoardtobenotifiedaswellknownFoundry/Forge under
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Regulation4A(2)
of
The
Indian
Boiler
Regulations,
1950
FORMXVE Regulation4A(2)
Questionaire tobeansweredbyTube/Pipemakerseekingrecognitionbythe
Regulation4A(2)ofTheIndianBoilerRegulations,1950
CentralBoilerBoard
Certificateof
Approval
for
Inspecting
Authority
FORMXVIB Regulation4C(2)
CentralBoilerBoard
CertificateofApprovalfor CompetentAuthority
FORMXVIC Regulation4C(2)
CertificateofApprovalforWellKnownSteelMaker
FORMXVID Re ulation4C 2
CentralBoilerBoard
f f l f ll d
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Certificateof
Approval
for
Well
Known
Foundry
FORMXVIE Regulation4C(2)
CertificateofApprovalforWellKnownForge
FORMXVIF Regulation4C(2)
Central
Boiler
BoardCertificateofApprovalforWellKnownTubeMaker
FORMXVIG Regulation4C(2)
CertificateofApprovalforIwellKnownPipeMaker