sure they are certified to the Indian Boiler Regulations. (IBR). The Indian Boiler Authorities strictly enforce the requirements of IBR, refusing site installation or. Indian boiler regulation act pdf. Free Download e-Books R0 stcvsm stcvsm c windows system32 drivers stcvsm. Kernel Auto Running - C. Windows. This Act may be called the Indian Boilers Act, (2). It extends to the whole "prescribed" means prescribed by regulations or rules made under this Act;. (f).
|Language:||English, Arabic, Dutch|
|Genre:||Business & Career|
|ePub File Size:||23.70 MB|
|PDF File Size:||16.54 MB|
|Distribution:||Free* [*Register to download]|
Central Boilers Board Examination, Result · Application Form for Competent Person Authorisation Card · Instructions to submit the application for. destined for installation in India must comply with the Indian. Boiler Regulation ( IBR) The IBR is a construction code that includes requirements for design, . Indian Boiler Regulations, These Regulations shall apply to all boilers including those working on principles of natural circulation, forced circulation and .
II the Steel maker furnishes the necessary certificate that the steel conforms to the chemical analysis, room and elevated temperature mechanical properties given in ASME or BS or EN Code as the case may be. NMUSteel plant to this effect. At this stress, a minimum rupture life of hours is expected. Both the samples should pass hour tests at the above stress and temperature. These samples may be selected at random by the Chief Inspector of Boilers of the respective State.
The samples could be in the form of semi-finished products, say, forged bars of about 25 mm2 which will undergo heat treatment as prescribed by the relevant specifications. All boilers of capacity less than P Tested to Lbs ,.. Form III-B. Notes: 1 For the purpose of this clause certificates issued by an authority empowered in this behalf by or under the law in force or the national code in a foreign country, in respect of mountings and fittings ln that.
Indian Boiler Regulations, These Regulations shall apply to all boilers including those working on principles of natural circulation, forced circulation and forced flow with no fixed steam and water line. Indian Boiler Regulations, deals with the following: General and standard requirement of boiler. Materials for construction of boiler. Construction and workmanship of boiler.
Working pressure to be allowed for various pressure part of boiler. Requisite mountings and fittings of boiler.
Steam pipes and fittings. 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.
Indian Boiler Regulations, 1950
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.
Indian Boiler Regulation Book-2010, 11th ED Akalank Publications
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. The samples shall be stamped by the lnspecting Officer so as to identify the castings to which they relate. Some of the test samples shall be taken from as near the top and others near from the bottom of the casting as is practicable. Indian Boiler Regulations b If the test samples are attached to the castings. The test samples shall be cast in moulds of the same material as is used for the castings and shall be made at the same time as the castings.
Such test samples shall not be detached from the castings until heat-treatment of the castings has been completed and they have been stamped by the lnspecting Officer. Bend tests may be made by pressure or by blows. Should either of the re-tests fail. All the castings shall be fully machined to such an extent that all critical sections are exposed for full thickness. The test pieces shall be bent over the thinner section.
If repairs by welding are carried out the castings shall be. Castings found to be unsound may be treated in accordance with Regulation Inspecting Officer may call for hardness testing of c Non-destructive tests-The lnspechng Officer may call for radiographic examination or other non-destructive testing of the castings. If the welding repairs are sanctioned by the Inspecting Officer. Bend tests Cold bend tests shall be made upon test pieces having rectangular section of one inch wide by inch thick.
Where this further heat treatment is applied. U or V will be governed by i the thickness of the casting. Pre-heating-Variations in composition. The electrode manufacturer's recommendations for the use of the electrode should be strictly followed. When the later is used. In double preparation. Procedure for welding In order to maintain a high standard of workmanship in the practice of arc-welding to steel castings.
Electrodes for Grades B and C castings should be agreed between the manufacturer and the lnspecting Officer. Where cracks extend through the section of the casting. Repaired areas of castings shall be reexamined by the lnspecting Officer in accordance with sub-clause i and shall be shown to be free from harmful defects. Surface condition-The surfaces of the steel. The preparation for the welding of cracks should be of the U or V types. U or V the root of the U or V should be sufficiently open to ensure complete penetration.
Castings found to be unsound may be treated in accordance with regulation Stress-relieving treatment-When the welding is carried out after the casting has received its normal heat treatment. When afIer consideration of each casting in the iight of the above variables it is deemed necessary to pre-heat. Electrodes-The electrodes shall comply with Regulations 94 to 98 for Grade A castings.
This treatment need be applied only in cases where welding has been such as to induce either internal stresses which would be detrimental to the casting. In the case of headers for example. For headers with outside diameter less than mm longitudinal test pieces may be allowed.
In the case of headers which are closed by special covers. At least one test piece shall be made from each group. The test may be performed also on the semi-finished material for example a bar or a billet. For headers with closed ends. Surface defects may also be repaired. Selection of test pieces a For testing.
In the case of flanges swaged in dies. Indian Boiler Regulations 61 When considering the advisability of applying this further treatment. Similar procedures shall be followed for test pieces of other forgings. Provided that the minimum required thickness is maintained. If the treatment.
In the case of headers. Tensile strength Indian Boiler Regulations a The tensile strength of the material shall conform to one of the following four grades: Ultimate tensile stress Tonslsq. Upto 32 Above 32 and upto 36 Above 36 and upto 38 Internal radius of bend inch I Bend tests may be made by pressure or by blows. When the bars are cast-on. The test bars shall not be subjected to any heat treatment after leaving the moulds..
All test bars shall be cast in green sand or dry sand or in loam moulds according as to whether the casting or castings they represent are moulded in green sand. Provision of test bars The lnspecting Authority shall state at the time of enquiry whether he requires tensile or transverse tests.
Additional tests before rejection 63 Should either a tensile or a bend test fail. When the test bars are cast separately they shall be poured at the same time and from the same ladle.
If the results obtained from these retests are satisfactory. Dimension of test bars a Transverse Test Bars-The transverse test bars of the diameter specified by the lnspecting Authority according to the main cross-sectional thickness of the casting represented. The number of test bars specified in Regulation 92 shall be applicable to all castings of each melt.
INDIAN BOILER REGULATIONS
If these retests do not give satisfactory results the forgings represented may be re-heattreated together with the remainder of the test blocks and presented for further testings. In all cases where final retests do not give satisfactory results. Freedom from defects-The castings shall be sound. They shall be well dressed or fettled and shall be machinable by normal methods. Transverse test A transverse test bar cast in accordance with Regulation 88 a must when placed on suppolts set at the distance shown in column 2 of the following table sustain a load applied at the centre of not less than that shown in column 3 and must show before rupture a deflection not less than that shown in column 4.
Bars cast within these limits of diameter may also be machined before the transverse test is made. For diagram and table see under clause b of this Regulation. Mechanicaltest The casting must comply with the transverse and tensile tests specified in Regulation 90 and Regulation Bars may be tested with either plain or screwed ends.
All test pieces shall be selected by the Inspector and tested in his presence and to his satisfaction. Minimum deflection Grade A in. Distance between support in. Grade A Tons per sq.
Tensile test A tensile test bar machined to the dimensions shown in Regulation 88 b and tested with either plain or screwed ends must show a breaking strength of not less than that shown in the following table: Diameter of test bar in. If the diameter of a transverse test bar as cast varies within the limits specified in Regulation 88 a the equivalent breaking load for the factors given in Appendix F. Minimum breaking loadGrade A lbs. Size E in.
Self-aligning grips to ensure axial loading are recommended. One test for each 4 tons of castings or part thereof. Over 1 cwt. Provided always that in the case of failure of both test pieces if either show obvious defects a thih test piece may be taken from a broken casting or a piece may be cut from a usable casting for furthc 1 testing as follows: The batch or separate casting represented shall be accepted.
C 2nd I The batch or separate casting represented may be rejected. Number of transverse and tensile tests J The number of tests required for each batch of castings shall be in accordance with the followinq I table. Group Weiqht of castinas Upto 28 lbs.
G and. One test shall refer I to one transverse and one tensile test. One test for each 2 tons of castings or part thereof. One test for each 4 tons of castings or part thereof or fc each casting weighing 4 tons or more. I The electrodes shall comply with the requirements of physical tests prescribed for each class. In the above groups 1.
The batch or separate casting represented may be rejected. Over 1 ton and important castings where mutually agreed upon.. Over 28 lbs. Provision shall be made for end or centre gripping. I a normal electrodes for use in one or more welding positions. The tolerance on the specified diameter of the core wire of the electrodes shall be plus or minus 0.
The variation in the thickness shall not exceed 3 percent. Trade name of the Electrodes. I I a a relative ease in the control of the slag and weld metal during welding. Name of the Manufacturer.. When stored. For electrodes recommended for all positions.
Recommended current range. The ultimate tensile stress shall be not less than 28 tons square inch. Requirements for normal penetration electrodes-Initial tests i. The electrodes shall be deemed to be satisfactory provided no hot cracking occurs under the conditions of test.
Greater cracks may be neglected provided they do not run into the full Section of the weld.. The following initial tests on each brand of electrodes shall be carried out: Where any test specimen fails to satisfy the requirements of any particular test.
Indian Boiler Regulations, 18th Edition, Reprint 2019
The elongation shall be not less than 25 per cent and the minimum reduction of area shall be not less than 35 per cent. Electrodes intended for use with more than one type of current or polarity shall be tested using each type of current and polarity. Periodic check tests and Production control to ensure that the requirements of these Regulations are fulfilled. The batch of electrodes shall be accepted as having passed the test provided that the tests of both the additional specimens are satisfactory.
Batch Number. The ultimate tensile stress of each test specimen shall be not less than 26 tons per square inch and yield stress not less than 20 tons per square inch. The method of preparation of the test pieces is specified in Appendix H-I. Classification as per Indian Boiler Regulation. Requirements for deep penetration butt-weldinglelectrodes Initial test-For electrodes recommended for deep penetration butt-welding.
The method of preparation of the test and of carrying out the tests shall be as specified in Appendix H Of each pair of specimens. Indian Boiler Regulations 69 I d Transverse bend test-Two bend tests one with the face and the other with the root in tension shall be carried out for each welding position for which the electrode is recommended by the manufacturer.
The average of the three impact values for each test specimen shall be not less than 30 ft. Premature failures at corners of the test specimen shall not be considered a cause for rejection. The ultimate tensile stress of each specimen shall be not less than 28 tons per square inch.
These test pieces shall be capable of withstanding an ultimate tensile load of not less than Premature failure at corners shall not be considered cause for rejection.
C shall be taken as 0. The electrode shall be deemed to be satisfactory provided that on completion of the test. The method of preparation and carrying out the test shall be in accordance with Appendix H-I. Length of horizontal leg of fillet weld shall not vary more than 1. Each specimen shall withstand an ultimate tensile load of not less than Note 3: Fillet weld size.
Requirements for deep penetration fillet welding electrodes initial test The following initial tests on each brand of electrodes shall be carried out: I MAX. For the purpose of calculating the test load. All-weld test pieces shall be prepared as shown in Figure 1 by depositing weld metal between the chamfered edges of two plates. APPENDIX H-1 See Regulation 95 1 Parent metal for test plates The parent metal used in preparing test pieces and test specimen shall be mild steel of welding quality in the normalised condition this condition is optional in the case of all-weld metal tests with an ultimate tensile stress of not less than 28 and not more than 32 tons per square inch and in elongation of not less than 20 per cent on standard test pieces A 1 Appendix B 2 All-weld metal test Method of preparation of test pieces.
The test specimen shall not be subjected to any mechanical or thermal treatment other than that required herein. The two plates shall be 7 inches long and the dimension B from square edge to root edge of each side plate shall be between: The welding current used shall be within the appropriate range given by the manufacturer. The weld metal shall be deposled in single or multi-run layers and the direction of deposition of each layer shall be alternatively from each end of the specimen.
The assembly shall not be quenched between the deposition of individual runs. Each run of weld metal shall not be less than inch and not more than inch thick. The welding position for the assembly shall be Rat. I 2 " l i 3 inches minimum and 4 inches maximum when testing 10 S. The time interval between the completion of one run and the commencement of deposition of the succeeding run shall be not less than 5 minutes.
The assembly shall be welded together with these plates pre-set so that the gap at the top between the chamfered edges of the plates is 1 inch and the plates may be approximately level when the butt-weld is completed.. The portion including the weld shall then be removed by cutting away the excess plates at the places indicated in Figure 1. TO 1 IN. On completion of the weld the specimen shall be allowed to cool in still air.Such remaining tests may also be conducted at the Bharat Heavy Electricals Limited.
The rotation of weld is the angle formed between the upper portion of vertical reference plane which passes through the line of the weld root and a line drawn from the line of the weld root which intersects the weld surface at a right angle and a point equidistant from either edge of the weld see Fig. Forms of Standard Tensile Test Pieces: The depth of the crown plate opening from the commencement of the curvature of the flanging radius shall be not less than twice the plate thickness with a minimum of 1 inch.
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.