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Reg. 4
Standard Requirements

(a) Material.-All plates, rivets and bars used in the construction of boilers shall be tested and found to conform with the Regulations hereinafter contained.

(b) Construction.-

(i) All boilers during construction shall be under the supervision of an Inspecting Officer and shall be inspected at all stages of construction prescribed in Appendix J. Tubes and steampipes shall also be inspected at the makers’ works at the stages prescribed in Appendix J,  and the tests conducted by the makers shall also be witnessed by the Inspecting Officer.
(ii) Welders engaged in site welding of boilers, steam-pipes, economisers and superheaters shall possess and produce to the satisfaction of the Chief Inspector the Welders Performance Qualification Certificate issued by a Competent Authority.

(c) Certificates, etc. under section 14(1)(c) of the Act.-In advance of or along with an application for registration of a boiler the following certificates and drawings or specifications shall be furnished to the Chief Inspector, namely:-

(i) A certificate in Form-II.- from an Inspecting Authority certifying that the material was tested and the boiler was built under their supervision. Together with such certificate the Inspecting Authority may furnish a Memorandum of Inspection Book in Form-I prepared in the manner prescribed by Regulation 386 in respect of the Inspection of the boiler during construction and the hydraulic test applied on completion. In case of a boiler which is to be assembled only at site, requirement of the hydraulic test on a completely assembled boiler by the Inspecting Authority shall not apply provided that the individual parts of such boiler have been hydraulically tested and certified by the Inspecting Authority separately as required under these Regulations.

NOTE.-In lieu of Form-II, a certificate in Form-II-B may be granted by the Inspecting Authority for boilers for which variations from the standard conditions in respect of material, design and construction features have been permitted by the Board or the Inspection Authority under sub-regulation (5) or sub-regulation (6) of regulation 3.
(ii)

A certificate in Form-III of manufacture and test signed by the maker or by a responsible representative of the maker of the boiler containing a description of the boiler, its principle dimensions, particulars of the kind of material used in its construction, the thickness of all plates, the diameter of and method of forming the rivet holes in the shell plates, particulars of any departure from ordinary practice in making the shell such as solid rolling or welding, the hydraulic test to which the boiler was subjected, the intended working pressure, the area of heating surface, the maximum continuous evaporative capacity, the year and place of make, and the works number of the boiler.

NOTE.-The Chief Inspector may, however, approve a modified form of certificate wherein items which do not pertain to a particular boiler may be omitted.

(iii)

A drawing or print to a scale, in the case of large boilers of not less than ¾ inch to the foot and, in the case of small boilers of not less than 1 ½ inches to the foot, showing the principal dimensions and a longitudinal section and end view of the boiler, and bearing the works number of the boiler and Maker’s office stamp. The drawing shall show details of riveting of longitudinal and circumferential seams with pitch of rivets, cross spacing of dished end plates, fillets and flanges and corners of bent plates, and where gusset stays are fitted the number and diameter of rivet holes in each gusset stay.

In the case of water tube boilers, the foregoing scales shall apply to the main boiler drums only, but in addition a general arrangement drawing of the boiler to a scale of not less than ¼ inch to the foot shall be provided.
(iv)

A certificate in Form-IV from the steel maker and a certificate from the maker of the plates, rivets or bars, shall show the charge numbers, the plate or bar numbers and the number and dimensions of the various plates etc. tested, their chemical analysis, their ultimate tensile breaking strength in tons per square inch of section, the percentage of elongation and the length on which measured, the number, kind and result of bend or other tests made and the date of tests:

Provided that where an Inspecting Authority furnished a certificate in Form-II together with a Memorandum of Inspection Book in Form-I in accordance with sub-regulation (c)(i) the certificates prescribed under clauses (ii) and (iv) need not be furnished to the Chief Inspector when application is made for registration of the boiler. But should any question arise in respect of the fitness of the boilers for the working pressure approved by the Inspecting Authority within a period of three years from the date of their registration, the owner shall if requested by the Chief Inspector obtain and furnish the original documents specified in the said clauses.

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, a certificate of Well-known Steel Maker in Form-IV-A shall be accepted in lieu of a certificate from an Inspecting Authority:

Provided also that in respect of the tubes/pipes made and tested by Well-known tube/pipe maker recognised by the Central Boilers Board in the manner as laid down in regulations 4A to 4H, a certificate of manufacture and test of Well-known tube/pipe maker in Form-III-D or III-E, as the case may be, shall be accepted in lieu of a certificate from an Inspecting Authority.

In case where certificate in Form-IV is not producible owing to such certificate containing details of plates used for other purpose, also, all the relevant information in respect of the boiler furnished in Form IV-A duly signed by the Makers of the boiler and countersigned by the Inspecting Authority, shall be acceptable in lieu of the certificate in Form-IV. Original steel maker’s certificate or manufacture and results of tests shall be produced to the Chief Inspector on demand.

In the case of fusion welded drums the diagram of welded repairs and temperature charts of heat-treatment shall also be furnished.

In addition, certificates in respect of yield point at service temperature (0.2 per cent proof stress), the average stress to produce elongation of 1 per cent (creep) in 100,000 hours and the average and the lowest stresses to produce rupture in 100,000 hours in the material, wherever is applicable, are to be furnished.

(vi)

For tubes and pipes subjected to internal pressure, a certificate giving results of tests regarding chemical analysis, warm yield point (0.2 per cent proof stress), the average stress to produce an elongation of 1 per cent (creep) in 100,000 hours and the average and the lowest stresses to produce rupture in 100,000 hours in the material wherever applicable, shall be furnished.

NOTE:- Until 33,000 hours tests are carried out by National Metallurgical Laboratory or Corporate Research and Development Laboratory of Bharat Heavy Electricals Limited for collecting elevated temperature data of alloy steel produced indigenously against ASME or BS or EN Code, these grades of steel may be accepted and long time elevated temperature properties/maximum allowable stress values given in ASME or BS or EN Code, as the case may be, may be used for the purpose of design. Provided that

(I)  a certificate is furnished by the producer of the steel to the effect that the steel has been manufactured strictly in accordance with the technical requirements of the ASME or BS or EN Code to assure that the creep rupture requirements are complied with.

(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.

(III)  the short-term stress-rupture tests for 1000 hours as described below are carried out by NML/Steel Plants for the purpose of checking whether the steel is up to the specification and also to ensure that the Steel is capable of meeting the long-term rupture stress values/ maximum allowable stress values given in ASME or BS or EN Code, as the case may be, and a certificate is given by NML/Steel plant to this effect.

(IV)  two numbers of 1000 hour creep rupture tests shall be carried out at a temperature 50C above the service temperature for each grade of steel for tubing or piping or castings or plates grades; when in furnace and/or in superheater zone.  However, the forging to be used in valves should be tested at 550C for 1000 hours.  The stress to cause rupture in 1000 hours at above temperatures may be taken from the master curve corresponding to 20% line.  At this stress, a minimum rupture life of 1000 hours is expected.  Both the samples should pass 1000 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 25mm2 which will undergo heat treatment as prescribed by the relevant specifications.

(d) Maker’s Stamp.- The boiler shall have stamped upon its front plate in a conspicuous position the following particulars:-

MAKER’S NAME

Works’ Number_____________________________________ Year of make__________________ Tested to __________________________ Lbs.________________________ on _______________ W.P.________________________________________________ Lbs._____________

Inspecting Officer’s or
Inspecting Authority’s Official
Stamp
___________________________________


(e) Certificates for steam-pipes – A certificate of manufacture and test in Form III-A, signed by the maker and the Inspecting Authority shall be furnished.

(f) Certificates for tubes – A certificate of manufacture and test in Form III-B, signed by the maker and the Inspecting Authority shall be furnished.

Note: In case of tubes made by Well-known Tube Makers recognised by the Central Boilers Board in the manner as laid down in regulations 4A to 4H in India or other countries, material testing including mechanical tests may be carried out by them and the particulars regarding testing of material including mechanical tests as certified by them shall be noted in the appropriate column or paragraphs in the certificate in Form III-B. In case, certificate from the “Well-known Tube Makers” as aforesaid, is produced, such certificate may be accepted in lieu of the certificate from the Inspecting Authority in so far as it relates to testing of material including mechanical tests specified in this form.

(g) Certificates for mountings and fittings:- A certificate of Manufacture and Test in Form III-C signed by the Maker and the Inspecting Authority in respect of boiler mountings and steam-pipe fittings during manufacture, shall be furnished.

Note-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 in that country and containing the particulars required to be specified in this certificate, may be accepted. Where, however, the material used, is in conformity with the code of the country of manufacture and is covered by those Regulations, the permissible stress figures specified in the Code at different temperatures may be accepted in lieu of figures computed from the data required to be furnished under Regulation 271 in any of the following cases, namely:-
(i) Where a certificate is furnished from an Inspecting Authority to the effect that the steel complies with the requirements of the grade steel (to be specified) and the permissible stress for the working conditions as allowed for in the Code of the country of manufacture falls within the limit permissible under this Regulation.
(ii) Where the basis upon which these stresses have been arrived at is made available and such basis is not found to be such as to give rise to stresses higher than those permissible under the Regulations.

Note-2: For the purpose of clause (c), (e), (f) and (g) of this regulation, certificates issued by an authority empowered in this behalf by or under the law in force or national Code or Standard of any foreign country in respect of plates, bars, tubes, pipes, forgings and castings manufactured in that country and containing the particulars required to be specified in the steel makers certificates referred to in the above mentioned clauses of regulation 4 may be accepted provided such certificates contain a statement duly signed by the Inspecting Authority to the effect that these materials comply with the requirements of the law or the Code or Standard of the foreign country.

Note-3: Photostat copy of the certificate in Form III-C shall be accepted provided it is endorsed by the manufacturer or the Inspecting Authority.

(h) Certificates of inspection during construction of pipes for which variation from standard conditions have been permitted.- A certificate of manufacture and test in Form III-A(I), signed by the maker and the Inspecting Authority shall be furnished.

(i) Certificate of Inspection during construction of tubes for which variation from standard conditions have been permitted.- A certificate of manufacture and test in Form III-B(i), signed by the maker and the Inspecting Authority shall be furnished.

 
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