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Reg. 392, Reg. 392 a, Reg.392 b

Repairs to boilers and steam pipes

(1) Major repairs such as fusion welded or riveted patches to shells, fire boxes and end plates of boilers and extensive building up of wasted parts of boilers permitted under these regulations, the renewal of furnaces and end plates, parts of shell, fire boxes, girders and steam-pipes, etc. shall only be entrusted to a firm who is recognised as a repairer under these regulations. 

(2) Any firm seeking recognition shall apply to Chief Inspector of Boilers of the State in which the recognition is sought.  

(3) A firm seeking recognition as a repairer shall meet the following requirements depending upon the class of boilers, namely:-

(i)                Class I boiler repairer- The owner of the firm himself shall have a degree in mechanical or electrical engineering or the firm shall have on its rolls a permanently employed engineer having a degree in mechanical or electrical engineering with the firm having at least five years' experience in fabrication, erection, repair or maintenance and quality control of boilers, and qualified and permanently employed welders as per the provisions of these regulations;

(ii)               Class II boiler repairer- The owner of the firm himself shall have a diploma in mechanical or electrical engineering or the firm shall have on its rolls a permanently employed engineer having a diploma in mechanical or electrical engineering with the firm having at least three years' experience in fabrication, repair and maintenance of boilers;

(iii)             Class III boiler repairer - The firm shall have the experience of five years in repair, maintenance, operation, erection or inspection of boiler.

(iv)             (a) Where the power stations, fertilizer plants, chemical and petrochemical plants or refineries apply for repair of their own boilers, they shall have all the facilities in-house and may apply to the Chief Inspector of Boilers of the State for permission to repair their own boilers in accordance with these regulations. 

(b) On receipt of the application for permission to repair to a boiler, the Chief Inspector of Boilers of the State shall reply to the request within a period of fifteen days of the receipt of the application.

(4) On receipt of the application under sub-regulation (3), the Chief Inspector shall send a questionnaire in ‘Form XVIII’ to the applicant.

(5) The Chief Inspector will scrutinize and evaluate the application along with the replies to the questionnaire and after satisfying himself that the following requirements are fulfilled, shall recognise the firm as a repairer in the category applied for, namely:-

(i)                that the firm possesses rectifier or generator, grinder, general tools and tackles, dye-penetrant kit, expander and measuring instruments; 

(ii)               that the electric arc or oxy-acetylene welding sets and all other tools and plant in his possession for carrying out repairs are suitable for the work undertaken;

(iii)              that the quality of material used conforms to the specifications prescribed in these regulations;

(iv)              that the supervisory and operational staff employed by the firm possesses the necessary training and experience for the work undertaken;

(v)               that all welders employed by the firm possess certificates issued as required under Chapter XIII of these regulations;

(vi)              standard of work should be of high order and comply with all the requirements and test that may be prescribed by the Chief Inspector.

(6) The recognition of the firm as a repairer shall be for a period of two years.  Thereafter they shall apply for renewal of their recognition at least two months before the expiry of said period.

(7) In case the repairer is found indulging in violating the provisions of the Act/Regulations knowingly or unknowingly, the firm shall be blacklisted under intimation to Chief Inspector or Director of Boilers of all the States/Union territories and renewal shall not be done in any case.


(a) Procedure for repairs

(1) The repair work shall be carried out under the supervision of Inspector, and when the fireboxes and smoke tubes of locomotive tube boilers are withdrawn, the internal parts, which are otherwise inaccessible to close inspection, shall be inspected by the Inspector. 

(2) Repair to boiler shells shall be carried out by patching or by removing a strip of worn or damaged plate and inserting the new strip with covering straps over the longitudinal butt ends, the strength of the riveted joints to be not less than that of the longitudinal joints of the shell. 

(3) (a) Patches for fire exposed plates shall be fitted metal to metal without joint of any description. 

(b) The affected part shall be cut out, leaving the corners of the hole well-rounded. 

(c) Patches shall be secured, wherever possible, properly spaced rivets with a width of plate at least equal to the diameter of rivet between the edge of the rivet hole and the edge of the plate. 

(d) Where riveting is impracticable, the plate shall be secured by welt fitting countersunk headed screw pins. 

(4) The thickness of a patch plate shall not be less than the original thickness of the plate which it is used to patch.

                (5) Bulged or distorted furnaces or circular section may, if the bulge or distortion is not too great, be pressed back to shape. 

 (6) Circular furnaces of horizontal boilers that have become distorted may be suitably reinforced. 

(7) (a) Anti-collapse rings shall be of substantial section either of single or double angles bolted back to back with screw stays not less than 22mm in diameter and about 178mm in pitch passed through flat of angle and screwed into the furnace, the ends being either rounded or riveted over on the fire side and fitted with nuts at the other. 

(b) The stay bolts shall be fitted with ferrules not less than 1 inch in depth between furnace and angle ring. 

(8) Welding shall not be accepted for the repair of any part of a boiler for which welding is forbidden for a new boiler under these regulations and boiler shells shall not be repaired by welding beyond the filling up of a small isolated corroded or pitted part or the making up of wasted edges of openings. 

(9) Cracks or grooving in dished or flat end plates of cylindrical shells or in the bends of furnace flanges in a circumferential direction may be weed out and welded. 

(10) Wasted parts of circular furnaces and fire-boxes and fire exposed flat plates as in rectangular fire-boxes and combustion chambers may be cut out and be replaced by new pieces welded in or they may be built up by welding.  

(11) Longitudinal cracks in circular furnaces and fireboxes and cracks in rectangular fireboxes and combustion chambers may be welded. 

(12) No stay bar shall be welded. 

(13) Smoke tubes may be butt welded either by fusion welding, flush welding or oxy-acetylene welding, and these may be tested hydraulically at the discretion of the Chief Inspector.


(b) Welding

The Repairer shall satisfy the Chief Inspector,-

(i) that the electric arc or oxy-acetylene welding sets and all other tools and plant in his possession for carrying out repairs are suitable for the work undertaken.
(ii) that the quality of material used conforms to the specifications that are prescribed.
(iii) that the supervisory and operational staff employed by him possess the necessary training and experience for the work undertaken.
(iv) that all welders employed by him possess certificates issued as required under Chapter XIII of these Regulations.
(v) Standard of work should be of high order and comply with all the requirements and test that may be prescribed by the Chief Inspector.
 
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