Important Indian boiler regulations

7/22/2019 Important Indian boiler regulations

1/87

IndianBoilerRegulations


2/87

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?


3/87

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


4/87

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


5/87

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?


6/87

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?


7/87

28)Howdotherequirementsofsuperheater Safet Valvesdischargingsteamatover

eg. er

rom

e

requ remen s

o

ose

on

e

o er

rum

29)Whatismeantbythetermblowdown ofaSafetyValve?

30)Whatareaoftheboilershallbecomputedasheatingsurface?


8/87

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


9/87

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.


11/87

e.IntervalsbetweenExaminations

a. Tobeexaminedifshiftedfromonepremisestoother

b. Takenintouseforthefirsttimeor14monthsafterthedatewhenitwastakentouse

c. SubjecttoRegulationsinothercases dependingonthetypeofboiler

* ApplicabletoBoilersinwhich21yearshasnotexpiredsinceitwastakenintoservice


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f.Examination AfterRepairs

Whereatanytimerepairs iscarriedouttoanysteamboilertherepairofadefect

,

Shallbeexaminedbyacompetentpersoninsuchamanneraswillenablethat

Persontosatisfyhimselfthattherepairhasbeen properlycarriedout.


13/87

g.RestrictionsonEntry

Nopersonshallenterinanysteamboilerunless

a. Allinletsthroughwhichsteamorhotwatermightotherwiseentertheboilerfrom

anyotherpartoftherangearedisconnectedfromthatpart

. va vesortapscontro ngt eentryo steamor otwaterarec ose an secure y

lockedandwheretheboilerhasablowoffpipeincommonwithoneormoreother

boilersordeliveringintoacommonblowoffvesselorsump,theblowoffvalveortap

beremoveduntilthe valveortapisclosedandistheonlykeyinuseforthatsetofblowoffvalves.


14/87

m.BoilerSafety

Itistheoperatorsdutytoensurethattheboilerisoperatedefficientlyandsafely.Hemust

Seethatthewaterintheboileriskeptatthecorrectlevelandthattheboilerdoesnot

Frequentobservationsofthegaugeglassisoneofthemostimportantfunctionsofthe

Boilerattendantsduties.Itisthemeansbywhichfailureofautomaticcontrolsystemscan

Bedetectedandthereforetheattendantmustensurethatthe au e lassesindicate

Correctlybyadherencetogaugeglassdrill.


15/87

n.InsuranceRequirements

Everyboilershouldhavetwosafetyvalveseachalonecapableofdealingwiththe

Maximumrateofsteamproduction.Valvemustnotbelessthantwoinchesindiameter

Andmustbemounteddirectlyontheshellorsteamdrum.

Itisagoodpracticetoensurethatvalvesdonotbecomestuckontheirseatings by

Continuously

easingonce

per

week.


16/87

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

.


17/87

ImportantRegulations


18/87

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


19/87

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


20/87

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


21/87

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


22/87

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


23/87

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


24/87

RegulationNo.284

Packin ofCocks

Thebodiesofallcocksexceptthoseforpressuregaugesshallbepackedwithasbestos

Orotherheatresistingmaterialandshall beofsubstantialdesign thoseoverone

Inchboreshallhavespecialprovisionotherthantheglandforsecuringtheplug.

Watergaugecolumncocksmaybeeitherasbestospackedorsolidplugtype.


25/87

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


26/87

RegulationNo.286

Directionof

Operation

Valvesshallbeclearlymarkedtoindicatethedirectionofflow.Valvesdirectlyconnected

Toboilersshallbefittedwithindicatorstoshowclearlywhetherthevalveisclosedor

Openandallvalvesshallopenbyanticlockwiserotation.

l i


27/87

RegulationNo.287

Thevalvesandspindlesshallbeefficientlyguidedandmeansshallbeprovidedin

Everycasetopreventthemleavingtheirguides.Theworkingpartsshallhavesufficient

Clearancetoensurefreedomofmovementunderallconditionsofservice.

R l i N 288


28/87

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


29/87

RegulationNo.289

ValveSeatin s

, .

Providedineverycasetopreventthevalvesleavingtheirguides

Regulation No 290


30/87

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


31/87

(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


32/87

SPECIALREQUIREMENTSOFSAFETYVALAVES

Re ulationNo.291

GeneralSafetyvalves,ordinary,highliftandfullliftshallbesoconstructedthatbreakageofany

Partwillnotobstructthefreeandfulldischargeofsteamfromtheboiler

Regulation 292


33/87

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


34/87

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


35/87

( ) 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


36/87

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


37/87

Regulation295

PressureDrop

TheSafetyvalvesshallresetatapressureatleast2.5%belowbutnotmorethan5%below

.

seatborelessthan32mmandhavingasetpressureof2bargaugeorless.

Regulation296


38/87

g

MountingsofSafetyValves

(a) Safetyvalvesshallbemountedwithoutanyinterveningvalveonpadsorbranchesused

fornootherpurpose.Theaxisofthevalveshallbevertical.Thecrosssectionalareaof

theboreofeachpadorbranchshallbeatleasttotheareaoftheboreattheinletof

thesafetyvalveorwheretwoormoresafetyvalvesaremountedonthesamepador

branch,atleastequalto thesumoftheareasoftheinletboresofallthesafetyvalves

(b)Branchesshallbeasshortaspossiblesoasnottoimpairtheproperactionofthesafety

valvesorimposeanyunduestressonthebranchesattheirpointofattachmentto

. . ,

whenfullliftsafetyvalvesaremountedonthem shouldbereducedattheinlet.Theinletandoutletflangesshallbedrilledinaccordancewiththeapproximate

.

Regulation297


39/87

g

Openingsin

Shell

Openingsintheboilershell.Dischargingsteam shall havedirectaccesstothesafety

valvewithoutflowingthroughinternalpipes.

Regulation298


40/87

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


41/87

oreac enc ose sa e yva vec es ameanso ra n ngs a eprov e .

Thedrainpipeshallbelaidwithacontinuousdownwardgradientclearof the

Boilertoaplacewherethedischargeisvisibleandcannotdoinjurytoanyperson

Regulation300


42/87

Movin Parts

Thevalvesandspindlesshallbeefficientlyguidedandmeansshallbeprovidedineverycase

.

Toensurefreedomofmovementunderallconditionsofservice.

Thespindleshallnotbefittedwithastuffingbox.

Thebearingsoftheleversoflevervalveshallbesodesignedastoallowfreeworkingofthe

Valveunderallconditionsofservice.Wheretheleverismountedonpinbearings,theholes

Metal.

Regulation301


43/87

Thebearin softheleversoflevervalveshallbesodesi nedastoallowfreeworkin ofthe

Bearingsfor

Levers

Valveunderallconditionsofservice.Wheretheleverismountedonpinbearings,theholes

Inthelevershallbebushedwithnoncorrodiblemetalorthepinsshallbeofnoncorrodible

Metal.

Regulation302


44/87

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


45/87

Easin Gear

Safetyvalvesshallbesoarrangedthattheycanbeeasedofftheirseatswhenunder

pressureandtheeasinglevershallpositivelyliftthevalve.

Regulation304


46/87

Lift

Safetyvalvesshallbecapableofbeingliftedadistancesuchthattheareaofthe

dischargeedgeshallnotbelessthantheminimumaggregateareaAinRegulation293

Regulation305


47/87

Hi handLowwaterAlarms

HighandLowwateralarmsshallbeadjustedsothatthealarmissoundedwiththewater

levelvisibleinthegauges

Regulation306


48/87

Thespecifiedpressure.

Regulation306A

The

set

pressure

of

a

safety

valve

may

be

adjusted

using

air

or

other

gas

as

the

test

Mediumprovidedthatthesafetyvalvehasbeensubjectedpreviouslytohydraulic

Regulation307


49/87

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

Important Indian boiler regulations

Documents

Transcript of Important Indian boiler regulations