Indian Boiler Regulations, 1950 Bare Act

The source publishes this enactment as a single document rather than provision by provision, so the whole text is below and there are no per-section pages for it. Nothing has been shortened.

Type	Regulations
Year	1923
Jurisdiction	State of Madhya Pradesh
Status	In force as published by the source
Text	Published as one document, as the source published it

REGISTERED No. D-481 The Gazette of India EXTRAORDINARY

PART II—Section 3 PUBLISHED BY AUTHORITY No. 43 ] NEW DELHI, FRIDAY, SEPTEMBER 15, 1950 GOVERNMENT OF INDIA MINISTRY OF WORKS, MINES AND POWER CENTRAL BOILERS BOARD NOTIFICATION BOILERS New Delhi, the 15th September 1950 S.R.O. 600.—In exercise of the powers conferred by section 28 of the Indian Boilers, Act, 1923 (V of 1923), and in supersession of the Government of India Notification No. A. 470, dated Simla, the 27th October 1923, the Central Boilers Board is pleased to make the following Regulations, the same having been previously published as required by sub-section (1) of section 31 of the said Act, namely :— REGULATIONS PRELIMINARY

1. Short Title, Extent and Commencement;.—(1) These Regulations may be called the Indian Boiler Regulations, 1950.

(2) They extend to the whole of India, except Part B States.

(3) They shall come into force at once.

2. Definitions.—In these Regulations, unless the context otherwise requires,—

(a) the "Act" means the Indian Boilers Act, 1923 ;

(6) "accident" means an explosion of a boiler or steam-pipe or any damage io a boiler or steam-pipe which is calculated to weaken the strength thereof so as to render it liable to explode ;

(c) "boiler" means any closed vessel exceeding five gallons in capacity which is •used expressly for generating steam under pressure, and includes any apparatus forming an integral part of a boiler, which is wholly or partly exposed to the action of the flue gases for purpose of recovery of waste heat, and also includes any mountings or other fittings attached to such vessel which is wholly or partly under pressure when steam is shut-off but not withstanding anything contained in section 2(b) of the Act doss not include an economiser as defined in clause (cc) of section 2 thereof-

(d) "Chief Inspector" and "Inspector" mean, respectively, a person appointed to be a Chief Inspector and an Inspector under the Act;

(e) ''economiser" means any part of a feed-pipe that is wholly or partly exposed to the action of flue gases for the purpose of recovery of waste heat ;

[607] 40& TJ±hl iiA^E'LLa Ox. 1JND1A. j^AlltAOJtDlJNAxv.L LJ-ART i i (/) "feed-pipe" (i) moans any pipe or connected fitting wholly or part ly under pressure through which feed-water passes directly to a boiler.

(ii) every reference to a steam pipe or steam pipes shall be deemed to include also a feed-pipe or foed-pjpes respectively ;

(g) " Inspecting Authority " means an authority recognised by the Central Boilers Board as competent to grant n certificate in Form II* .

(h) "Inspecting Officer" means—

(i) in respect of material manufactured or boilers eonaUucled in any State an officer appointed by the Inspecting Authority in t ha t State.

(ii) in respect of material manufactured or boilers constructed outside the States an officer acting on behalf of the Inspecting Authority ;

(t) "owner" includes any person using a boiler as agent of the owner thereof and any person using a boilor ^ hich he has hired or obtained on loan from the owner thereof;

(j) "prescribed" means prescribed by regulations or rules made under the Aot ;

(k) "Steam-pipe" means any main pipe exceeding three inohes in internal diameter through which steam passos directly from a boiler to a prime-mover or other first user, and includes any connected fitting of a steam-pipe ;

(1) "State"' or ' 'States" mean a State or the States to wMch these regulations extend ; and

(m) " Structural alteration, addition or renewal" shall not T6»e deemed to include any lonowal or replacement of a petty nature when the part of fitting used for replacement is not inferior in strength, efficiency or otherwise to the replaced part of fitting.

*NOTM.—-Fot List of Inspecting Authorities reoogmsed by the Oontral Boilers Boardi see- Appendix U-

CHAPTER I GENERAL REQUIREMENTS, APPLICATION OF STANDARD CONDITIONS AND EXCEPTIONS THERETO 3 (1) A boiler shall not bo registered undor sub-section (4-) of Section 7 of the Aot and n certificate shall not be issued under sub-section (5) of that section with reference lo a boilor, unless the sttmdnrd conditions in respect of material, design and unibtruction, 'which arc specified in. the subsequent Chapters of these Regulations me natiwnod in respect of such a boilor.

(2) Notwithstanding anything contained in sub-regulation (1), the Chief Inspector may, Ruhjcrt to the provisions of Regulation 7, register a boiler and order tho issue of a certificate authorising the uso thereof, although the standard conditions are not fully satisfied in respect; of such boiler : Provided that the Chief Inspector shall not register such boiler or order the issue of such certificate, if a structural part of Hweh boilor which, is subject to piessure is made of Bessemer prpcees steel or( of cunt oi malleable cast iron. i STANDARD REQUIREMENTS ' 4. (aVM&tlWi&l.—All platwS, rivets and bars used in1 the construction of boilers shall bo tested and found to conform with the Regulations hereinafter contained, i tb) Coiistrutitibn.- Â l boilers during construction shall bo under the supervi^ eion of an Inspoctijijj Officer.

(c) Inspecting Authority's certificate,—For boilers imported into the- States a. t, certificate from an Inspecting Authority in Form II certifying that the material was tested and the boiler built under their MI|><T\ Nimi >hfill be furnished to the Chief Inspector before or with the application J'oi ic^iMiiiiion. Together •with such certificate the Inspecting AiiilH.iit \ m;'\ funii.-Ji .1 Al< n or.uidi m of Inspection book in Form I prepared in the ]II;IMIUT pu MiMicd h.v UCJMII.U ion :>M> in respect of the inspection of the boiler during construction and the hydraulic test applied on completion. In the case of steel made and tested by well-known makers in India or other countries the certificate of the makers in Form IV as prescribed in Regulation 26 may be accepted in. lieu of a certificate from an Inspecting Authority.

The Central Boilers Board shall decide whether for the purpose of this Regulation a maker is " well-known" or not.

(d) 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 should be furnished to the Chief Inspector, namely:—

(i) 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 principal 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 platep, particulars of any departure from ordinary practicein 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.

There may be included in such certificate a further declaration that samples of the angle, stay or rivet bars and rivets used in the construction of the boiler have been certified by the makers to have been tested and found to comply with the requirements of Chapter II; in which declaration the kind of material used and the limits of tensile breaking strength with which the tests-comply shall be stated with sufficient precision to obviate the risk of confusion in making nllo-w imii-. Where such further declaration is included in such certificate, the cortiii<;)1-1.- v<i\ rrc <l to in clause (iii) of this sub-regulation shall not be required.

(ii) A drawing or print to a scale, in the case of large boilers of not less than f inch to the foot and, in the case of small boilers, of not less than 1J inches to the foot, showing the principal dimensions and a longitudinal section and end -new of the boiler, and bearing the works number of the boiler and the maker's cffice stamp.

The drawing shall show details of riveting of longitudinal and circumferential sean\<- with pitch of rivets, cross spacing of rivet rows and diameters of rivet holes : the radii of curvature of dished end plates, fillets of flangep and corners of bent plates, and where gusset stays are fitted, the number and diameter of rivet holes in each gusset etay.f In the case of water tube boilers, the foregoing scales phall apply to the main boiler drums only, but in addition a general arrangement drawing of the boiler to a scale of not less than "J" to the foot shall be provided.

(iii) A certificate from the steel maker and a certificate from the maker of the plates, rivets or bars, of the nature referred to in Regulations 26 and 27 respectively.

The 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 ultimate tensile breaking strength in tons per square inch of section, th" y "r"' • "" elongation and the length on which measured, the number, kind .,. •• . • ,. '•• or other tests made and the date of tests:

Provided that whore an Inspecting Authority furnishes a certificate in Form I I together with a Memorandum of Inspection book in Form I in accordance with Bub-regulation (c), the certificates proscribed, under oluuses (i) and (iii) need not be furnished to the Chief Inspector when application is made for registiation of the boiler. But should any question arise in respect of the fitnoss of the boilers for the working pressure approved by the Inspecting Authority within a period of three years from the dato of their certificate, tho owner shall, if requested by the Chief Inspector, obtain and furnish the original documents specified in the said clauses.

(p) Maker's stamp.—The boiler shall have stamped upon its front plate in a • oonapiouous position tho following particulars :— Mtiker's nmae Year at muke Work's nurabor Toated to lbn. on IiispiK'ting Officer's or Inspecting Authority's official tttamp.

6. Modification of formulae.—(i) Under the "Regulations for determining the working pressure to be allowed on various parts of boilers, the material to which the formulae apply shall in the absoncc of express provision to the contrary be steel complying with the requirements of Chapter II .

(ii) Wheie no test certificates for shell plates and rivets are produced, the material may be treated as iron, if the Chief Inspector is satisfied that tho material is of suitable boiler quality. If in such cases the Chief Inspector is dearly satisfied that the material is of good quality, n, higher strength than that allowed for iron may be permitted but tho strength of the shell plates shall not, save for special reasons, bo assumed to be more than 20 tons. In such cases S and Sx in equations 1, 3 and 4 of Chapter IV may be respectively 20 and 21 for steel and 21 and 18 for iron.

For iron across tho grain S may be 18.

(iii) Where end plates, furnaces, flat plates, girders, gusset and other stays, etc.

are made of stool or iron for which no test certificates are produced, the working pressure as found from the formulae in which S is to be taken at tho lowest limit proscribed for the pert, reduced by lfi per cent, shall, oxcept where such material is specifically provided for m nny founulH, be tho working pressure permitted. For flat plates of copper, the working pressure fts found from the formulae, reduced by 50 per cent, shall be the working pressure permitted.

6. Standard speoifloations for materials.—-The standard specifications for steel wrought iron and copper plates and barn, and for east steel shall be those prescribed iu Chapter II, but certificates of tests of material for wrought iron (exoept for special wrought iron for screw stays) copper and cast steel shall not be required unless special allowances are required. Suoh spocial allowances shall be in the discretion of the Chief Inspector.

7. Boiler Shells not in accordance with standard conditions.—When the standard conditions are not complied with, additions to the appropriate coefficient as defined in Regulation 176 shall be made as follows :—

(a) When there are no proofs of testa of steel, 15 per cent, of the standard co- •emciant.

(b) When a boiler has not been inspected during construction by an Inspecting Officer and certified by him, 10 per cent, of the standard coefficient.

(o) When the workmanship is in any way doubtful and the Inspector is not /satisfied that any of the foregoing additions to the coefficient would be sufficient.

SEC. 3] THE GAZETTE OF INDIA EXTBAOEDINAEY 611 to meet the circumstances, such percentage of the standard co-efficient as the Chief Inspector deems fit.

Provided that nothing in this regulation shall apply to a hollow forged or a fusion welded drum if it is constructed under the supervision of an Inspecting Authority.

8. Welding-—The use of welding in the construction of boilers shall be 1 permitted only where specifically provided for in the standard conditions.

CHAPTER II MATERIALS OF CONSTRUCTION STEEL PLATES, RIVETS AND BARS

9. Process of manufacture.—Structural stool for boilers shall be mad" by the - Open Hearth or an electric process, acid or basic.

10. Chemical Analysis.—(a) The steel shall contain not more than 0-06 per cent, of sulphur or of phosphorus.

(b) A sulphur print test shall be taken from the material of each charge used for rivet bars for the purpose of ensuring that sulphur segregates are not concentrated in the core. The stage in manufacture at which this test is made shall be at the option of the Steel Maker.

11. Freedom from Defects, etc.—The finished material shall be sound and free from cracks, surface flaws and laminations. Hammer dressing, patching or welding is prohibited but this does not prevent the removal of slight scale or shell by the use of chisel, file or buff, providing the material is not reduced to under the specified thickness.

12. Rolling Margin—No plate or rolled section shall be under the specified thickness at any part, nor more than 5 per cent, over the calculated weight, except that in the case of thin plates and wide plates the weight tolerances shall be as set out in the table below.

Schtiule of pnrsenttjz Billinj anight tolerances for boiler plates.

Thickness in.

1/4 to under 5/16 5/16 to under 3/8 3/8 to under 7/16 7/16 to under 1/2 1/2 to under 5/8 5'8 to under 3/4 3/4 to under 1 .

1 to under 2 . .

Under 48 % 5 5 5 •~> ,> .5 5 •"> 48 to under 60 % 5 o 5 5 •̂ 5 5 o Width m 60 to under 72 % 5 5 5 5 5 5 .

72 fro under 84 0/ la 7 6 6 5 o o n i inches 84 to under 93 % 9 7-5 6 6 6 5 96 to under 108 % 12 10 8 7-5 6 5 5 5 108 to under 120 % 12 9 8 7-5 7 6 5 120 to under o/ /o 12 11 9 9 7 132 and over 0/ /o 15 12 10 9 8 7 All the above margins will be taken over nett theoretical weight.

18. Testing and Inspecting.—The following tests and inspections shall be made at the place of manufacture prior to despatch ; but, in the event of any of the material [1«12 THE 0iM5?fi3BPtfffl ffl3?SA EXTKAOBDINARY [£A»T II proving unsatisfactory in. t,lxe opqrfie of, being worker! into boilers, suoh material nh.aH be rejected, notwithstanding any previous certificate of satisfactory testing, «nd suoh further tests of the material from the same charge shall bo made as the Trtwpsiotitig1 Qffieef in- attendkhice1 may f-onsider desirable, j ' f i | i ' i

14. Selection oi test pieces.—All ttst pieces shall bo seleotod by tho Inspecting Offioor and tested in his presence, and he shfill satisfy himself that the conditions 'flWiii described are fulfilled. '

16. (a) Tensile test pieces.—The tensile strength and ductility shall be determined from standard test pieces (see App. "R) cut lengthwise or crosswise from tho rolled material. When material is annoaled or otherwise treated before despatch, tho test pieces shall be similarly and simultimeously tieatod with the material before testing.

(b) (I) Plates, Angles and Tees.—Wherev^t practicable, the rolled surface shall be retained on two opposite sides of tho test piece. Tho tensile stress and elongation shall bo determined on standard test piece A (see App. B).

(ii) Bound Ban.- -Round bars may be tested fall size tm rolled or they may be turned down to a convenient size If tested 1 inch djamettjr or under, test piece B (see App. B) shall be used. The sectional area of the tosi piece shall not be less than J squaro inch.

Where fhe te,a,t piece is over 1 inch diameter, test piece Bx (see App. B) may b» usod.

Any straightening of the test pieces which may be required shall be done oold.

, J6r Tensile Testff.^-The ultimate tensile stress and elongation of the various ojasmos qf ,ma;terials phall be between tho limits shown in the table below but a range , of not mppo t h w 4 tons in'each olass of material shall be permitted.

Should a tensile tost piece break outside the middle half of the test gauge length the test may be discarded and another test be made of tho same plate or bar.

1 i J)nH(Tiption Pluten for shells butt utrrtp^, PltitfV) for IlanKiiip or woklinK Flutes for fiii'iiacoH Sttty anftlfi nnd ten bftjN Rivot burn Ulhnidto toilflllo t̂roRn in 26—:t(l 24—.10 2(1—Ifl 11—.10 Minimum elonKotion per oeut.

Tre t̂ piono A 23 iur 2fl- 30 20 for 28 -32 20 for 3 2 - 36 23 for 2 4 ^ 3 0 20 for 28—32 23 23 for 2fi- 30 20 for 28—32 20 for 32—3fi TOHL pinw R 23 for 26—10 20 for 28—32 20 for 32 --30 25 for 24^-2.S 23 for 26—30 Tost piHOfi f 28 for 20- -30 24 for 28- - 32 24 for 32—38 30 for 2<1—2S 28 for 20- 30

17. Number of Tensile Tests.—(a) Plates.—For sholl platca, butt straps and gusset plates one tensile tost pieoo shall bo cut from oach end of every plato as rolled.

(b) For other plates such as end plates, furnace and flanging plates etc., on« tensile tost pieco shall bo cut from one ond of every plate as rolled.

(c) Angle, tee, rivet and stay bars.-—One tensile test shall be made from oaoh 15 or part of 15 bars rolled of oach seotion or diameter from tho same oharge, but not lesa than two tensile tests shall be made unloss the total number of bars rolled from tho ^arae charg-e is1 8 or less than 8 and the bars are of the same section or diameter, in J ^hfeh! odm brie tensile teat shall suffice. For round bars of 1} inches diameter and 13H0. 8] 1. .jn WA^UWLI-EJ U.E J.JNLUA iiijl.1.

under, the numbers 50 and 20 shall be substituted for 15 and 8 respectively for determining the numbm of tests required.

18. Dump Testa.—Short lengths equal to twine, thoir diameter out from tho rivet bars shall, when rold, withstand -without fraoture being compressed to half their length. A dump test shall be made for eaoh Tensile Test.

19. Bend. Testa.—(a) Cold Bends.—Test pieces shall bo sheared lengthwise or crosswise from plates or bnrs, and shall not be less than 1 | inches wide, but for small bars the whole soetion may be used. For rivet bars bend tests aro Hot required,

(b) In all cold bend tests, on samples 0" 5 inch in thickness and above., tho rough edge or arris caused by shearing may be removed by filing or grinding, and samples 1 inch in thiokness and above, may have the edges maohinod, but the test pieces shall receive no other preparation. The test pieoos shall not be annoaled unless the material from which they are out is similarly annealed in which case tho test piece shall be Similarly and simultaneously treated with tho material boforo testing.

(o) For oold bend tests the test pieoe shall withstand, without fracture, being doubled over until tho internal radius is equal to 1£ times the thickness of the test pieoe and the sides are parallel.

(d) For small sectional material these bond tests nmy be made from the flattened bar.

(e) Bond tests may be made either by pressure or by blows.

20. Number of Bend Teats.—(a) Plates.—A bend test shall bo taken from eaah plnio aw rolled. Vor plates exceedins; 2J- tons in weight one bend test shall bo taken from eacli end. The bend tests from shell plates, butt straps and other platen which have not to be flanged or •« ork<-d in the fire or Avhiob when in use are not to be exposed to flame shall be oold bend tests.

(b) Angle Bars.—A oold bend lest shall be mado from eaoh angle bar rolled.

21. Manufactured Rivets.—(a) Quality of Material.—Rivets shall bo manufactured from steel complying with the aforementioned requirements of this Chapter in respect of iivot bais.

(b) Tests. —(i) Tho rivet shanks shall bo bend cold, and hammered until two parts of the shank touch, without fractuie on Ibe outsirlo of the bend.

(ii) Tho rivet heads shall be 6attenod while hot, without craoking at the edges, until their diameter is 2J times the diameter of the shank.

(o) Number of Tests. —"Op to half per cont oi rivets of eaoh size shall bo selected by the Inspector or Inspecting Officer from bulk for the above tests.

22. Additional tests before rejection.—Should the test pieces first rjelootod by the Inspeotor or Inspecting Officer not fulfil the test requirements, two further tests of the sanio kind may bo made, but should either of these fail, the plates or bars from which test pieces wore out shall be Telected. In all such oases further tests shall be made before any material from tbo same charge can bo accepted.

28. Branding.—Every plate and bar shall be clearly and distinotly marked by the maker in two plaoes with .in approved quality hi and indicating that the material has complied with the lequired tests ; and alno with the number or identification marks by which they can be traced to tho charge from winch the material was made.

24. Defacing of rejected material.—In the event of the matorial failing in any case to withstand the prescribed tests, the Inbpectnr or Inspecting Officer shall see that the quality brand stamped on the matorin.1 has been defaced by punch marks xtending bevond the brand in the form of a cross, denoting that the material has e«ec rejected.

J.. .ih (j&A* l i JU Ox 1JNLM.A J B A I . IAUHJ , A.i.\k. u.. [ £ A B T H

26. Facilities tor inspection.—The maker shall adopt a system of marking tHe' inpotH, billets, slabs, plates, bars, e tc , which will enable all finished material to bo traced to the original charge, and the Inspector or Inspecting Officer shall be given every facility for tracing all platen and bars to then* respective charges, and for witnessing the required testa. When ho is satisfied with the material and with the results of the tents, tie shall be furnished with two copies of the advice notes of the' material for his signature.

26. Steel not produced where rolled.—Where steel is not produced in the work* at which it is rolled, a certificate in Form IV shall be supplied to the Inspecting Officer deputed to witness the testing of the material, stating the Open Hearth or Electric Process by which it was made, the name'of the Steel Maker who supplied it, also the numbers of the charges for reference to the books of the Steel Maker. The number of the charge shall be marked on each plate or bar for the purpose of identification,

27. Maker's certificate.- -Before tho mill sheets are signed, the maker shall furnish the Inspecting Officer with a certificate in Form IV guaranteeing that tha material ha.s been made by the Open Hearth or an Electric Process acid or basio and that it has been subjected to, and has withstood satisfactorily the test above described in the presence of the Inspecting Officer.

WEOUOT IRON STAY AND HIVET BARS

28. Rivet Bars.--The tensile breaking strength shall bo between 21 nnd 2fl tor* with HU elongation of not less, than 25 per cent, measured on tho standard Tost Pieoe B (as rolled) or 30 per cont. measured on the Standard Test Pieoe Bx (as rolled).

29. Manufactured Rivets Tests.—To oomply with Regulation 21.

30. Stay Bars. —Tho tensile breaking strength Fhall be between 21 and 25 tonff with an elongation of not less than 22 per cent, measured on the Standard Tost Pieoa B or 27 per cent, measured on the Standard Test Piece B r

3X. Stay Bars—Bend Tests.—To comply with Regulation 19

32. Special Iron for Screw Stays for Fireboxes and Combustion Chambers.—I» order that iron screw wi ays may be approved of the same size an would be required for mild steel, the iron must withstand the following tebts:—

(a) Tensile Tests.- -The tensile breaking strength.shall not bo less than 211 ton* per square inch, with an elongation of not less than 25 per cent, measured on the Standard Test Piece B or 30 por cent, measured on the Standard Test Piece Bx.

(b) Bend Tests. —Tost pioces oither of tho bar as rolled, or turned down to 1 inch diameter, ^hall stand bending cold until the sides ate parallel and the space between the two sides is not greater than tho diameter of the test pieoe,

(o) Number of Tensile Tests.—The bare us rollod shall bo placed in batohes of twenfcv, nnd one tensile test shall be t aken from each batoh, If this is unsatisfactory two other bars shall be selected for test, and should either of these fail tho batch shall be rejected.

(d) Number of Bend Tests.—One ordinary bond tost shall bo taken from eaoh batch, and a similar test piece from each batch shall be lightly and evenly nicked on one side with a sharp cutting tool and bent back at this point through an anglo of 180 degrees by piossure or by a succession of light blows. The fraoture must be clean, fibrous, free fiom slag or dirt or any coarse crystalline structure, If cither of these is unsatisfactory, two other bars shall be selected for test, and should either of these fail the batoh shall be rejected.

(e) In all cases the selection of tho test pieces shall be made by the Inspector or the Inspecting Officer.

'^atiV &) THfe'G-AZETEE QE1 INDIA EXTEA.U IL. IA. .J.

COPPER PLATEvS, STAY AND RTVET BARS AND TUBES

33. Plates—(a) Process.—Tho oox>por shall be nre-refinod or electrolytic, and hot-rolled from suitable nakes.

(b) Chemical Composition.—The platan shall contain not loss than 99 per oent.

of coppor, and between -3 % and -5 % of arsenic.

(o) Freedom from defects.—Tho plates shall be cloan, smooth and froe from defects and shall have u workmanlike finish They shall be thoroughly annealed.

(d) Boiling Margin.—No plat a shall bo under the specified thickness at any part, nor more than 5% over tho calculated weight. The scrap margin, partly sheared and left attached, shall be no1 lean than 3 inches tit the ends and 1J inches tiit each Hide.

(e) Tensile Tests.—One tensile tusl shall bo taken from eaoh plato as rolled.

The tensile breaking strength, fi oin Standard Test Piece A, shall not be leas than 14 tons per sq. in. "with an elongation of not loss than 35%.

(f) Hot and Cold Bend teats. -Ono hot (temperature between 1200°T\ and 1400oI\) and ono cold bend test shall bo taken from each plate as rolled.

Tor either hot or cold bend 1estH the test piece •ahall withstand being doubled.

ovei without fraci uro uniil the sides are touching and parallel.

34. Stay and Rivet Bars—(a) Process.—To comply with Regulation 33 (a).

(b) Chemical Composition—To comply wilh Regulation 33 (b).

(d) Rolling Margin.—The bars in any part shall not be more than 1% over or more than 1/2 % under the specified diametci

(e) Tensile Tests.—The tonsile broaking-sttength shall not ho less than 14 tona per sq. in. with an elongation of noi IOHH than 40% on the Standard Test Pieoe B.

(f) Bend Teats. -To comply wilh Regulation 33(f).

(g) Dump Tests. -Apiece of tod 1 in. long shall be placed on end and hammered or crushed down cold to a thick nebs of 3/8in. without showing either crack or flaw on tho circumference of the resulting dine.

(h) Number of Tests.—One bar, from wliioh the required test specimens shall be taken, shall be solei ted at rnndom from each batch of 50 (or part thereof) bars of eaoh size from each melt. From each bar selected one tensile test, one cold bend test, ono hot bend test, and ono dump test shall bo made.

35. Tubes—(a) Process.—The copper shall bt fire-rofined or olootrolytio and shall bo made into tubes eithei by tho hot rolling or cold drawing piocess. The tubes shall be finished by cold drawing.

(b) Chemical Composition.—To comply with Regulation 33(b).

(c) Freedom from Detects.—The finished 1ubof», both externally and internally shall be sound, clean, smooth well finished and free from surface defects and longitudinal grooving, and the ends must bo clean and square.

(d) Tolerance.—Tho actual weight of oaoh tube ahall not be more than 6% above the calculated weight. Unions, otherwise specified, they shall be straight cylindrical, of uniform tki<knoas and external diameter throughout.

(e) Treatment o! Test Specimens.—All teat material, if not already hi an annealed condition, shall be annealed before testing and shall comply with the mechanical tests without further heat or mechanical treatment.

16 X. _U GAZETTE OP INDIA EXTRAORDINARY [PABT II OOLD DRAWN SEAMLESS STEEL BOILER AND SUPERHEATER TUBES— FOR DESIGNED STEAM TEMPERATURE NOT EXCEEDING 850°F (454°0)

36. (ft) Material.—The tubes shall be seamless and made of steel produoed by an Open Hoarth or Electric ProoesB, acid or basic, and shall be certified as such by the makers of the steel and tubes. The material of the tubes shall show on analysis not more than 0 • 045 por cent .of sulphur and 0 • 04 per oent. phosphorus and the manufacturer shall supply a certificate of the analysis when required to do so.

Note.—Where the material i*» Uhed for designed stoam tern features above 750°F (399°0) and not exceeding 85O°P (454°0) the steel shall be of non-segregated of fully killed type.

(b) Annealing.—The tubes shall be oarefaUy annealed throughout their length flfter the operation of drawing and the ends shall be carefully annealed after the process of swelling or reduoing the diameter.

(o) Freedom from Defects.—The tubes both internally and externally shall be -sound, clean, smooth, well finished and free froni surface defects, rust, longitudinal Beaming and grooving. The ends shall bo clean and wquare.

(d) Tolerances.—(i) ThlokneSB,—Tho tolerance in thickness shall be 5 por oent.

toelow and 10 per oent. above the specified thickness.

(ii) Swelled or Reduced Ends.—Where tho ends of tubes are swelled or reduced, the thickness at the ends may be reduced, or increased under or over, the actual thickness of the tubes by an amount strictly in proportion to the percentage of suoh swelling or reduoing and in addition to this allowance tho tolerances specified in paragraph (i) of this sub-regulation shall also apply.

(iii) Diameter.—The external diamoter of the tubes, measured at any point shall be not greater than that specified, but may be loss by not more than 1 per oent,

(iv) Length.—The length of the tubes shall be not loss than that epeoifiod and not more than 1/8 inch greater.

37. Selection of Tabes for Test.—Two per oont. of the tubes of oaoh thickness and diameter and only one for every 100 or part thereof above 400 tubes of suoh •similar size shall be made available to the Inspocting Officer for testing to the -extent of such numbers.

38. Tensile Test.—Test pieces out from the endft of the selected tubes shall comply with the following requirements :— .Strip out from tubes imd tested in thon' curved conditions.

"Test lengths taken from finiahod tuboa (ends to be plugged for gripa).

Ultimate tennde stre.ifl.

Tons por Hq. m.

Not lesd than 20 20 IS ot moro than 28 38 Minimum i>loiigntion per cout.

On i £ in. think and ovor 20 25 i in.

LOHO fclitin i" thick.

18 23 On 2 in.

£ in. thioli and over 30 Letw than i" thiok.

28 flue. 81 THE GAZETTE OF INDTA HXTBAORDINAEY ttlT

39. Flattening Test.—A ring not leas than 2 inohe* in length out from one end of each selected tube shall be flattened between two parallel flat surfaces, the width ofwhioh shall be not less than 1£ times tho diameter of the tube. When the pressure is released, the interior surfaces of tho lent piece (at the middle) shall remain at the following distances apart and the tent piece shall then show no sign of oraok or flaw.

Tuboa over 10 3.W.G. in thieknrww TuboB up to and including 10 S.W.C1. in thickness.

N't it THoro than twice the thicknem of the tube.

Until the interior surfaces meet, at th» middle

40. Expanding Tests.—-The tubes shall withstand expanding by a drift expander having a total included angle of between 40° and 60° (20° to 30° per side) to the following increases in external diameter without showing crack or flaw.

Thickness of tube 8 S.W.O. and thinner Thinner than S S.W.G. upto anil including 3 S.W.G-.

Thicknrthnn 3 S.W.U.

Increase in diameter per cent.

16 12 9-5

41. Additional test before rejection.—(a) Should a tube seleoted for testing purposes show definile signs of failure in any one or moro of the testa speoified in Regulations 38, 39 and 40, two further tests of the same kind may be made at the option of the manufacturer from two additional tubes selooted from tho same batch.

(b) If the ropeat tests tire satisfactory the tubes shall be accepted provided that in all other respects they fulfil the conditions of this Standard. Should either of tho tubes fail in any test, the biitch of tubes represented may be re-heat-treated in accordance with. Rogulation 36(b) and then retested in accordance with Regulations 38,31) and 40 but employing twico the number of tost pieces. If these seoond repeat tests are satisfactory, the tubes shall be accepted provided that in all other respects they fulfil the conditions of this Standard; but if definite defects are again shown, the batch of tubes which tho test pieces represent shall be rejocted.

42. Hydraulic Test.—Each tube shall be tested at the makers works by hydraulic pressure in accordance with the following table governing the rolation between the test pressuro and tho design pressure to which tho tube will bo subjected in aei-vioe.

Design pressure lb/nq. in.

Up to and including 500 .

Abovo COO upto tind including 1000 .

Abovo 1000 Hydraulic toat prosHUro lb/sq. ni.

minimum inoo Twice tho design pressure:

1000 ubove the design pressure.

-#18 THE GAZETTE OF INDIA EXTRAORDINARY [PART U In all i-nses the tensile strews (S) on the material when under these tests shall DP not exceed 10 tons, per sq. in. as doterminod by the formula S «= -5— Where D =aoutsido diameter of tho tube in inches P a tea t pressure in tons per sq. in.

t =inominal thickness of tube wall in inches.

HOT FINISHED SEAMLESS STEEL BOILER AND SUPERHEATER.

TUBES FOR DESIGNED TEMPERATURES NOT EXCEEDING 850nF (454°C)

43. (a) Material.—To comply with Regulation 36(a).

(b) Annealing.—The ondt- of all tubon shall be carefully annoaled to a length not less than 0" if they have been submitted 1o a process of swelling or reducing the end dimensions.

(d) Tolerances.—The tubes shall be of the dimensions spooifiod, straight, cylindrical, of uniform thickness and edema 1 diamol er i hroughout, subject to the working" margins piveti in the table below:—

(i) Diameter.—The external diameter of the tubetj measured at any point shall be within the following tolerances of diameter specified :•—- OntmtU) d [lUnoter of tiibns.

Up to tirid including 2J in.

O v e r 24 i n . . . .

T o l e r a n c e .

^ 1 /04" — 1 / 3 2 " H 1 % -

(ii) Thickness.—Tho thickness of the tubes shall be within the following toleranoen •- — Outsido rlinintjter of tubes.

Up to ami moluding 2J in.

O^er 2} m Tolerance J 17*% - 71% ^ io% — 0% Whero the ends of the tubes are swelled or reduced the thickness at the enda may be decreased below or increased above the nominal thiokness of the tubes by an amount in proportion to the percentage of aueh swelling or reduction and, in addition to this allowance, the tolerances relating to thickness shall also apply.

(Jii) Length.—The tubos shall be not less than the nominal length but may «xcccrl it by the amount given below :— Up to and including 30 it.

Over 30 ft 1/8 in.

iH in.

(e) Selection of tubes for test.—To comply with Regulation 37.

44. (a) Tensile Test Tost pieces out from the ends of tho annealed portions removed from tho ends of the selected tubes shall comply with tho folio-wing requirements :•— — • Strips cut from tubes und tested in thoir curvod condition.

Test lengths) tuken from fliiishod tubas («nda ul tubtiH to be plugged from gripa).

Ultimate tunsile utroHH ul tona por HCJ. in.

Not loss than 20 20 Not more than 28 Minimum nlongution ptir rent.

on 8 1/4 in.

thick and over 20 25 in.

Lena than 1 /4 in.

thick 18 23 on '2 in.

1/4 in.

thick and over ,-JO Leni thn,ii 1/4 in.

think 28

(b) Flattening Test-—A ring not less than 2 inches in length cut from the annealed portions removed from tin1 ends of the selected tuboH Hhn.ll be flattened between two parallel flat surfaces, (he width of which shall be not less than ] J times tho diameter of the tube. When the pressure is released, the interior surfaces of the test piec,c at the middle shall remain at a distance apart of not more than three times tho thickness of tho tube and 1 he test piece shall then show no sign of crack or flaw.

(o) Expanding Tests.- -The annealed tube ends shall wilhstand expanding by a drift expander having a total included angle of between 40° and 60° (20° to 30° per side) to the following increase in external diameter without showing truck or flaw:— Thieknoas ol Tube °. S.W.O. mid thinner Thinner than 5 S.W.G. und up to and including 3 8.W.G.

Thicker thun 3 S.W.O.

Increune in Diameter peT o«)it.

IB 12 0-fi

45. (a) Additional tests before rejection.— Should tube suleettd for testing purposes show definite signs of failure in any one OJ more of 1he tests specified in Bogulations 44(a), 44(b) and 44(c) 1 wo further tests of the same kind may be made at the option of the manufacturer from tw o additional tubeH selected fi om the same batch.

(b) If the repeat tests are satisfactory the tubes shall be aooepted provided that in all other respeots they fulfil the condition* of this Standard. Should eiiher of the tubes fail in any test, the batch of tubes represented may bo re-heat-treated in aooordanoe with Regulation 43(b) and then re-tested in aocordanoe with Regulations 44(a), 44(b) and44(c) but employing twice the number of test pieces. If these second repeat tests are satisfactory, the tubes shall bo aooepted provided that in all other respects they fulfil the conditions of this Standard; but if definite defeots are again shown, the batch of tubes which the tests pieoes represent shall be rejeoted.

46. Hydraulic Teit.—Each tube shall be tested at tho makers' works by hydraulic pressure in accordance with the following table governing the relation between the test pressure and the design pressure to which, the tube will be subjeoted in service.

Deugn pretmur* lb/»q. iu.

Up to and including 500 Above fiOO up to »nd including 1000 Above 1000 . - Hydrnuho test pressure Ib./sq. in.

minimum 1000 Twice the danign pressure 1000 above the design preaauro.

In all cases the tensile stress (S) on. the material when under these terti eh all not exceed 10 tons per sq. in. as determined by tho formula :— DP S ~ — 2t Whore D =* outside diameter of tubo in inches.

P = test pressure in Ions per sq. in.

t =• Nominal thk'knesN ot tube wall in inches.

SEAMLESS HALF-PER CENT. MOLYBDENUM STEEL BOILER AND' SUPERHEATER TUBES EOR DESIGN STEAM TEMPERATURES NOT EXCEEDING 950cr (51()°O)

47. General.—Those Regulations (over both hot finishod and oold drawn seamless boiler and superhoatei tubcR which Hhall conform in all respects with the requirements herein specified.

48. (a) Material.—The 1ubos whaJl bo manufactured from steel produoed by the Open Hearth or Elootrio processes and shall conform to the following limits of chemieal compositions:— I'arbon . . . . . . . . 0 15% maximum Mmnganemi . . . . 0 4 0 to 0-70% Silioon . . . - 0 1 0 toO -38% Sulphur . • • • . 00.1% maximum TUoaphorua . . . . . 0 0 6 % Molyodouum 0-4"> to !• 63% The steelmaker shall supply a certificate of the normality of the steel.

(b) Heat Treatment.—The tubes shall be normalised at a temperature bet-ween 1688°F (920° C) and 1760° F (960° C).

(o) Workmanship and toleranoe.—The tubes shall be well finished, 'olean and free from harmful defects. They shall bo reasonably straight, smooth, cylindrical, and subject to the following tolerances before bending :—

(t) Diameter.—The external diameter of the tubes measured at any point shall be within the following tolerances of the diamoter specified :•— Type of Tube Hot finished .

Cold drawn Ontsidn Diameter of Tube "Up to and including '2^ in.

Over 21 in A l l 4 1 / l t N . . . . . .

Tolerance -i 1/04 in.

— 1/32 in.

± 1% + 0 - 1 %

(ii) Thiokne«S.~The thickness of the tubes shall be within the following toleranoea:— T y p e of T u b e Hot . finished .

Oold d r a w n Outsiclo D i a m e t e r of T u b e U p to tincl inc lud ing 2J in. . . .

Ovor 2-J in.

A l l H i / e ^ . . . . . .

Toleranue + Mt% - 7 i% H 115% - 5 % H 10% - «% Where the ends of the tubes are swelled or reduced the thicknopis at the ends may be decreased below or increased, nbove the nominal thickness of the tubes by an amount in proportion to the pereontage of such swelling or reduction and, in addition to thi'i allowimee. the 1oVrane.es relating to thickness shall also apply.

Swelling or reduction sha.il \m carried out before the heat treatment specified in Regulation 48(b).

(iii) Length.—The tubes shall bo no1 less than the nominal longth but raay exceed it by the amount given below :•— "Up to imd inclnrhng 30 it £>vpr !J0 ft. , . .

1/8 in.

1/4 in.

x. .. UAZ,. ±1JS On J.NDIA -TJAi-JtAU. JJ1 . A. „,. [..AfitFiX

(d) Seleotion oi tubes for testing—After heat treatment, tho tubes shall bo presented foi1 mechanical teHting in accordance with Regulations 49(a), 49(b) ami 49(c) in batches of not more than 100 of the same nominal diameter and thickness.

Tho manufacturer shall provide at his own expense extra tubes at, the rate of 2 per cent, of each diameter and thickness of tube specified and thi-> ]nsi~»oetiiig Offioer shall select for 1 est such of the tubes as he may think proper to the extent of the percentage mentioned. Should the number of tubes ouleied of any one nominal size exceed 400 then, for every 100 tubes or part thereof above that number, one additional tube shall be provided. The .samples for testing shall not bo heat-treated after selection.

49. (a) Tensile Test—Test pieces out from the ends of tho selected tubon shall comply with tho following requirements:— — Strips flit from tubes tind timtod in their curvnd condition.

Testi LoiigtliH tuknn from fniwhod tubes (en<ln oftnboH to be plugged for gripw).

Ultimuto T«mile Htrima in tonn p«r sq. in Not lorn than 27 2r, Not more thtin 33 33 Minimum elonfjution per oont. on M mches 1/4* tdk'k ami ovor 10 23 LOHH than 1/4" thick 17 21

(b) Flattening Test.—A ring not less than 2 inches in length out from one ond of each selected tube shall be flattened between two parallel flat surfaces, the width of which shall be not less than 1J times the diameter of the tubo. When the pTessure is released, tho interior surfaces of the test piece (at the middle) shall remain at a distance apart of not more than three timos the specified thickness of the tube and the test piece ahaII then show no sign of crack or flaw.

(e) Expanding Tests.—Tho tubes shall withniaml expanding by a drift expander having a total included angle of between 40" and 60° (20° to 30" each sido) to the following increases in external diameter without showing crack or flaw :—7 Thk'kiiHHH of tube ]0 S.W.G. ftnd thinner Thinner than 9 S.W.G-. up to un<l mcluriiup: 0 S.W.U. .

Thinker than fl S.W.Q Inert a«iH in rlitimetor pur i-ent.

12J «i

60. Additional tests before rejection.—Should a tube selected for tost ing purposes show definite ei^ns of failure in any one or more of the tests specified in Regulations 49 (a), 49(b) and 49(c), two further tests of the same kind may be made at the option of the manufacturer from two additional tubes selected from the same batch. If the repeat tests are satisfactory the tubes shall be aooepted provided that in all other respects they fulfil the conditions of this Standard. Should either of the tubes fail in any teat, the batch of tubes represented may be ro-heat-treated in accordance with Regulation 4-8 (b) and thon retosted in accordance with Regulation*!

49 (a), 49(b) and 49(c) but employing twice the number of test pieces. If these second repeat teats are satisfactory, the tubes shall bo accepted provided that in all other respects they fulfil the conditions of this Standard ; but if dofinite defects are again shown, the batch of tubos which the test pieoes represent shall bo rejected.

51. Hydraulic Test.—Each tube shall bo to, ted at the maker's -works by hydraulio pressure in accordanco with the following table governing the rolation between the test pressure and the design pressure to whioh the tube will bo subjected in •ervice.

Design pressure lb 'aq. in.

C p to and inoluding 600 . . . . .

Above 500 up to and including 1000 .

Above 1000 Hydraulio test pressure lb/sq. in.

minimum 1000 Twioo the dosign pressure.

1000 above the doaign presaur*.

In all cases the tensile stress (S) onjtho material when under these tests oball not oxoeed 10 tons por sq. in. as determined by the formula :— 2t Whoro D =• outside diameter of tube in inches.

P —test pressure in tons per sq. in.

t ^nominal thickness of tube wall in inohes.

SEAMLESS CHROME-MOLYBDENUM STEEL BOILER AND SUPER- HEATER TUBES POR DESIGN STEAM TEMPEEATURES NOT EXCEEDING 1000°F (538°C)

52. General.—The se Regulations oovor both Hot finished and Cold Drawn Seamless Boiler and Superheater Tubos which shall conform in all respeots with the requirom nts heroin spocifWl.

53. (a) Material.—Th> tub^s hall be manufactured from stool produoed by the open Hearth o.' Electri proi-os ,es and shall conform to the following limits of chemical composition- - Carbon , . . . . . . 0 -12% maximum, MmiRHiioflB 0 - 3 5 t o O - 8 G % Silicon 0'10 to 0 •60'% Sulphur . . . . . . . 0 -05% mnjimum PhoBphorufi . . . . . . . 0-05% maximum Molybdonum O'fiOtoO'70% Chromium 0-75 to 1-25% The sL^olmakor shall supply a certificate of the normality of the steel.

(b) Heat Treatment.—Tho tubos shall bo fully annealed, or normalised at a -temperature between 16S8°F (920° C) and 1760°F (960°C).

(o) Workmanship and tolerance.—The tubes shall bo well finished, olean and free from harmful defects. They RHU.11 bo reasonably straight, smooth, cylindrical and subject to the following tolerances before bending :•—• (») Diameter. -Tho external diameter of tlw tubes measured at any point shall b» within tho following tolerances of the diameter specified :•— Typo of Tubs Hot, finished Cold drawn Outside Diameter of Tube Up to and including 2J in. .

Ovor 2 | in.

A l l M i z e H . . . . .

Tolerance h 1/64* ~ 1/32' + '% - 1% -1 0 1 or («) Thickness.- Tho thickness of tho tubes shall be within the following tolerances :— Typo of Tube Hot finished .

Cold drawn Oulsido Diumoter of tube Up to mid including 2$ in.

Over 2$ in .

All sizes . . . . . . .

Toloranoe + iH% - 7*% + ' 6% — o% + 100/ - fi% Where the ends of the tubes are swelled or reduced, the thickness at tho ends may bo deoieased below or increased itbovo the nominal thiekne-w of the tubes by an amount in proportion to tho percentage of such swelling or reduotion and, in addition to this allowance, tho tolerances relating to thickness shall aho apply.

Swelling or reduotion shall be carried out befoie the heat treatment specified in Regulation 53(6).

(Hi) Length.—Tho tubes bhall be not less than t KB nominal length but may be 1/8 in. greater.

(d) Salection of tubes for testing.—Ait or he»t treatment, tho tubes shall be presented for mechanical testing in accordance, with Regulations 54(a), *>4(b) wnd fi4(e) in batches of not more th in 100 of the same nominal diamelei and thickti"RH. The man'ifact mvr whall urovide at his own expense exirji luhfi nt the m,re of 2 per c-ent.

of each diameter and thickness of tube apneifi'wl and Ihc Inspecting Officer shall select for. t o^ such ot the tnbo as he may think proper to the extent of the percentage mentioned. Should tho number of tubes specified of any one nomina1 size e\eeed 400 then, for every 100 tubes or part th >reof above that numbei, ono additional tube shall be provided. The samples for touting shall not be heat treated after jSelee/fcion.

54. (a) Tensile Test.—Tost pieces cut from the ends of the seleoted .tubos shall comply with the following requirements :-- Stripe cut from tubes and tasted in their curved oonditjon .

Tost IengthH taken from finiBher) tubim (ends of tubea to be plugged for gripe).

ITU untile Tonsilo Hire™ in tonH per HCJ. in.

Not lobM than 27 26 Not moi'o Lhan 33 33 Minimum Elongation per cunt, on S mobos j " thick & over 10 23 Le«n tlian J" thick 17 21

(b) Flattening Test,—A ring not less 1han 2 iiichos in length cut from ono end of each selected tube shall be flattened between two parallel fiat surfaces, the width «>f which shall be not lews thttn 1J times the diameter of the lube. When the pressuro in released, the interior surfaces of the test pieces (at the middle) shall remain at a distance apart of not moie than three times the specified thickness of the tube and tho test piece shall then shew no sign of crack oi flaw,

(o) Expanding Tests. - The tubes shall withstand expanding by a drift expander having a total included angle of between 40" and 60° (20° and 30° per side) to the following increases in external diameter without showing ci ack or flaw :— Thickness of Tubo 10 H.W.G. and thinner .

Tlurmor than t> S.W.G. up to and including fi 9 T h i c k e r t h a n 6 . . . . .

. W . G .

Iucroaup m Diamoter per oont.

65. Additional tests before rejection-- -KUoukl a tubo selected for u sling purposes show defuiite signs of failure m any one or more of the tests specified in Regulations 54(u), 54(b) and 54(e), two further tests of the same kind may be made at the option of the manufacturer from two additional selected tubes. If the repeat tests arc satisfaotory the tubes shall bo accepted provided that in all other leapcuts they fulfil the conditions of this standard. (Should either of tho tubes fail in tmy teat, the liatoh of tubes represented may be re-hoat-lreated in aecordimee with Regulation 53(b) and thon retestedin accordance with Regulations 54(a), 54(b) and 54(o), but employing twice the number of test pieces.

If these second repeat tests are satisfactory, the tubes shall be accepted provided that in all othor respects they fulfil the conditions of this standard ; but if definite defects are again shown, the batch of tubes which the test pieces represent shall be rejected.

T _ l i l iS liAZ. 1J.JS Ux I N U I A jcjAlBAUJttJDl. A. ... E*A*f -11

56. Hydraulic Test.—Eaoh tube shall bo tested at the maker's works by hydraulic pressure in accordance with the following table governing the relation between the test pressure and the design pressure 1O which the tubes will be subjected in service.

ltoaitfn pressure Ib./»q. in.

000 or 1P88 Above 800 but not exceeding 1000 Above 1000 . . . .

Hydraulic test pressure lb/sq. in. minimum.

1000 Twioe the design preaauro.

1000 above the design pressure.

In all oases the tensile stress (S) on the material when under these tests shall not exceed 10 tons per sq, in. as determined by the formula :— DP 2t Where D = outside diameter of tube in inches.

P =tost pressure in tons per sq. in.

t ^nominal thickness of tube wall in inob.es.

ELECTRIC-RESISTANCE-WELDE!) STEEL BOILER TUBES FOR TEM- PERATURES UPTO 750" F, AND PRESSURES UPTO 840 Lba./SQ. IN.

(FOR EXTERNAL PRESSURE).

57. General.—These Regulations cover eleotrio-resistanee-welded tuboa made of steel and intended for boiler tubes.

58. (a) Material -Process.-—The material shall bo made either or both of the following processes : Open-hearth or electric-furnace.

(b) Manufacture.—Tubes shall be made by oleotrio-resistanc -welding and shall be normalised at a temperature above the upper critical temperature.

(c) Chemical Composition.—Tho steel shall conform to the requirements as to chemical composition prescribed in Table below:— TABLE—Chemical requirements.

Carbon, per cent Manganpue, per cent Phosphorus, max., yxir oont.

Sulphur, mm., per oent. .

Type A T-.OW Carbon Stool 0-08 to 0-18 0 30 to 0-60 0-04 0-045 Type O Medium Carbon Steel 0-36 max.

0-80 max.

0'04 0'04S

59. (a) Flattening Test.—(i) A section ot the tube not let« than 2^ in. in length shall be flattened cold between parallel plates until the opposite walls of the tube S B O , 8 1 • T H E G A Z E T T E O F I N D I A E X T B A O R t > I N A B Y ' 8 2 7 meet. No oracke or breaks in the metal shall occur until tho distance between the platea is less than the calculated value of 'H' by the following formula :— (l+e)t JJ __ c+t/1) Where H «•» distance befrwocn flattening }jluics in inches, t = nominal wall thickness of tube in inches, D = aotual outside diamotor of tube in inches, an<l c = deformation per unit length (constant for iv given grade of steel, 0-08 for types A, 0"07 for type C).

Evidenoe of laminations or burnt material, or incomplete penotration of the weld, shall not develop during tho entire flattening process

(ii) The weld shall be placed 90 deg. from the line of direction of the applied force.

(Hi) Superficial ruptures as a result of minor surface imperfeotione shall not bo cause for rejection.

" (b) Flange Test.— (i) A section of tho tubo not less than 4 in. in length shall be capable of having a flange turned over at a right angle to the body of the tubo without oracking or showing flaws This flange, as measured from the outside of the tube, shall not be less than 1/8 in, nor more than ^ in. Within these limitu, the width of the flange shall be not less than the following :— Outs ide D iame te r of Tubo , in.

£$• a n d u n d e r . . . . . .

Over H t o 3-3/4 . . . . . .

Over 3-3/4 t o 5 W i d t h of F l a n g e T y p e A 1 5 % of outs ide d i a n i t e r 3/8 in .

1 0 % of outs ide d i ame te r T>po C w 75 per nont of that required for (type A.

(ii) In making the flange test, it is recommended that tho flaring tool und die block shown in ~Ei«. bfTow be u°pd.

A-OOOT TUBE LESS i" B*OO OF TUBE LtSS J* P-ARJNG TOOL ^ i^OOOFTUBEPLVS^ . txe BUOCW.

(c) Crush Test.—When inquired by tho Inipoctinii Autliority^orushingFtestB shall be made on sections of tubo 2^in. in length whioh Hhall stand crushing longitudinally, without oracking, splitting, or opening at tho weld, as follows :— W a l l t h i c k n e s s o f t u b e s , i n .

0 - 1 3 5 M i d u n d e r . . . . .

O T O T O - 1 8 5 Height of Crushed Section, in.

Type A TuboB 3/4, or until outside folds are in contact Ii Type C Tubes Crush te»t» not required.

Slight rarfftoe checks shall not be cause for rejection.

628 THE GAZETTE Of INDTA EXTRAORDINARY [PART I I

(d) Reverse Band Test. A motion 4 in. in 1 jjgih shall be taken evory 1Q00 ft. of flnishoil welded tubing to bo split longitudinally 180 deg. from tho weld and the sample opened n,n<J flattened with tho weld lit tho point of max. bend. There shall be no evidence of cracks or lack of penetration or overlaps resulting from flaeh.

removal in the weld.

60. Tensile Properties.—Type (1 tubei-' shall conform to the reqtiirnnents u& to tensile properties prescribed in Tablo below :— Tensile Requirements T e n s i l e H t r o n g I h , i n i i i , , £ jov « q . i n . . . . . . .

Y i o l d p o i n t , m m . , . . . . . . . . .

E l o n g a t i o n i n 2 i n . , m i n . , p e r u e n t , . . . . . . .

t f o r l o n g i t u d i n a l H t r i p t e a l w a, d e d u o t i o n f o r o a c l i 1 / 3 2 i n . d o o r o a f l f i i n w a l l t h i o k n e s n b e l o w , 1 / 1 0 i n . f r o m t h o u u ^ i u m i n . e l o n g a t i o n o f t h e f o l l o w - i n g p o r c e n t a g o . . . . . . . . . . .

fiOOOO lbs.

37000 lbs.

30 1-50

61. Hydraulic Test- -(a) Each tube shall b^ tosti-d at the milker's works and shall withstand for a minimum of 10 seconds a hydraulic test pressure which shall imposo a minimum fibre stress of 16,000 lbs/aq. inch and not oxoeoding 24,000**" lbs/«q. inch, for type A arid not exceeding 26,000 lbs/sq. inch, for typo C as determined by the following for/nula:— 2tS P -= I) Whore P — Hydraulic test pressure in lbs/eq. in, 8 — fibre stress.

I) — Outside diameter of tubo in inches, and T — thioknoss of tube wall in inches.

(b) Tube shall bo struck near both ends whilo under tlje tost pressure with a 2-lb. stool hammer or its equivalent.

62. Test Specimons.- (a) 'IVt spiciinfiia roqnimi for tho flattening and flange tests spocified in Eegulitions 59(a) and »9(b) MII.HII bo tiiken from the ends of finished tubes prior to ui^-setting, swaging, expanding, or other forming operations, or being out to length. They ahull be smooth on the ends and free from burrs und flaws.o

(b) If dosirable and praufcieable, tension tests may be made on full sections of the tubes up to tho capacity of the testing machine. For larger size tubes, tho tension test specimen shall consist of a striji cut longitudinally from the tube and not flattened between gauge marks. Tho sides of the specimen shall be parallels betwoon gauge marks ; the width, irrespective of the thickness, shall be 1 in., the gaugo length shall be 3 in.

(o) All specimens shajl be tested at room temperatures.

83. Number of Teste.— (a) .For type A, one of- tho tests specified in Regulations 69(i»), 59(b) and 5()(c) sball be made from each lot of 250 tubes or fraction thereof and from eaoh 2,000 ft. or fraction thereof safe end material. For typo C, one of each of the tests specified in Regulations fi9(a), 59(b), 5!)(o) and 60 shall bo inado from eaoh lot of 250 tubes or fraction thereof. A reverse bend test specified in Regulation 69(d) shall be uia.de on each 1600 ft. of finished tubing.

(b) ff any test specimen shows dofectivo machining or develops flaws, it may be discarded and another specimen substituted. j

(o) If the percentage of elongation of any tension tost specimen is less than that specified in Regulation 60 and any part of the fracture is more than 3/4 in. from the oontre of tho gauge longth, as indicated by scribe scratohos marked on the specimen beforo testing, a re-test shall bo allowed.

(d) Eaoh tube shall be subjected to tho hydraulic test speoifled in Regulation

61.

SEC. 3] THE GAZETTE OF INDIA EXTB AOEDINAEY 629 LAPWELDED STEEL BOILER TUBES (FOR EXTERNAL PRESSURE)

64. (a) Material.—The tubes shall bd ,nade from steel which shall show on ana lysis not more than O'()5 per cent, of ^ulphur or phosphorus. The manufacturer shall supply a certificate of the analysis AH hen required to do so.

(b) Annealing.—The ends of all tubes shall be carefully annealed .

(cl) Tolerances. — The t ibes shall be of the dimensions specified, straight, cylin drical, of uniform thickness and external diameter throughout, subject to the work ing margines given in table below :— Outside diameter of lube Under 2 | inch .

2-| inch and over On diameter Plus Inch 1 64 Per cent.

1 Minus Inch 1 32 Per cent.

1 On thickness Plus Per cent.

"1 t 10 Minus Per cent.

10 on length Plus Inch 1/8 Minus Inch 0

(e) Selection of tubes for test.—To comply with Regulation 37.

65. Tensile test.—(a) To comply with Reg. 44(a).

(b) Flattening test.—To comply with Reg. 44(b), the weld being placed 45° from the horizontal.

t,c) Expanding test.—r-The selected tubes shall, when cold, withstand being expanded by a drift or a roller expander to the following increases in diameter without showing crack or flaw :— Thickness of tube 8.W.G.

Up to 10 Above 10 to 6 Above 6 . . . . . . . . . . .

Increase in diameter per cent.

9-5 7-5 5

66. Additional Tects.—Shrukl a tub<. !-elected for testing purpose, in accordance with Regulation 37 fail to satisfy the requirements of any one or more of the tests (specified in Regulations 65(a) (b) (c), if so desired by the manufacturer, the tubes represented shall be re-annealed and then retested in accordance with these Regulations and if the repeat tests are satisfactory, the tubes shall be accepted provided that in other respects, they fulfil the conditions of these Regulations, but if the tube again fails to satisfy the requirements, the tubes which the test pieces represent shall, be rejected.

67. Hydraulic test.—Every tube shall be tested at the Maker's works by hydraulic pressure to not less than 1,000 lbs. per sq. in. Any tubes failing to withstand this test shall be rejected.

^u*U 1-tLj U A Z i j j l l l i Ui . I N l J l A .bjivliJAUxvLU.iNA.Rj. [ l !UlJ- xl WROUGHT IRON LAPWELDED BOILER TUBES (FOR EXTERNAL PRESSURE)

68. (a) Material.—The tubes shall b<? made from wrought iron which shall show on analysis not more than 0*10% manganese and 0"03% sulphur.

(b) Annealing.—The end of all tubes shall bn carefully annealed.

(d) Tolerance.—Tho tubes shall be of tho dimensions specified subject to working margins given below. They shall be straight and cylindrical, of unifoim thickness, concentric and unless otherwise specified, of uniform external diameter through* out.

The working margin shall be as follows :— On thickness—plus or minus 10%.

On external dia. for tubes under 2\"—plus 1/64* and minus 1/32".

„ ,, for tubes 2" and larger—plus or minus 1 per cent.

(e) Selection of tufces for test.—To comply with Regulation 37.

69. (a) Tensile Test.—Lengths or strips cut from the selected tubes shall comply with the following requirements :— Strips cut from the tubes clear of the welds and tested in their curved condition Tested longths taken from finished tubes (ends of tubes to be plugged for grips) Ultimate Tensile Strength in tons/ sq. in.

Not less than 20 20 Not more than 24 Elongation per cent, on 8 in.

10 12*

(b) Flattening Test.—To comply with Regulation 39.

70. Expanding Test.—The selected tubos shall, when cold, withstand being expanded by a drift or roller expander to the following increases in diameter without showing crack or flaw:— Thickness of Tube SWG Up to 6 Above 6 . . . . . . . .

Increase in Diamoter per cent.

71. Crushing Test.—A ring 2 in. in length cut from one end of each selected tube shall withstand, without showing crack or flaw, being crushed on end by hammering or pressure when cold, until the length is reduced to 1-5/8 in.

72. Hydraulic Test.—Every tube shall be tested by internal hydraulic pressure to not less than 1,000 lbs./sq. in. Any tube failing to withstand this test shall be rejected.

STEEEL CASTINGS

73. Scope.—Steel castings shall be of the following grades, according to the purpose for which they are to be used and as may be specified :— Grade I . . . . . . . 28 to 35 tons per sq. ia.

e»de II 35 to 40 „ , J 1.H..CJ h'ii l i f t L . lnVi-A. . . i . U.

74. (ft) Process of manufacture.—Steel for oastings shall bo made by the Open Hearth or an Electric Process, acid or basic

(b) Ohemlcal Analysis.—Sto;>l usod for gradoa I and I I castings shall not show <>u analysis more than 0.06 per cent, of sulphur or phosphorus as determined from the test samples, and tho manufacturer shall supply an analysis of each oast when requested.

(c) Heat treatment.—All castings flhall be hoat treated to refine the crystalline structure throughout tho oasting by heating to a uniform temperature not loss than the normalising temperature and allowing to cool slowly from the maxirmun temperature in a praetioally uniform manner: or alternatively normalised by heating in.

a similar manner and allowing to cool in still air.

(d) Freedom from defects.—All castings shall be free from twists, craoks. flaws and similar defects.

75. Repairs to defective castings.—Casting* shall not bo repaired or weldod with out the speoino sanction of the Inspecting Officer, If required the castings shall be suitably re-heattreatod to remove- internal stresses. Should a defect impair the strength of the castings, ropair by welding or otherwiao shall not bo permitted.

76. Number of tests.—At least one tensile- and one bend test shall be made from the oaating from each charge, and when more than one casting is made from one ohargo, at least one tensile and one bend tost stall be made from the castings run from ono oommon pouring head ; but separate tests shall be made from each oasting or set of castings run from each soparate pouring head.

Test pieces shall riot be cut off until they have been stamped by the Inspecting Officer after the annealing has been completed.

77. Temile tests. -The ultimate tonsils stress, yield point and elongation for grades I and I I eastings shall bo not less than shown in table below:— Tensile Tests on Steel Castings Omde I . . . .

II . . . .

Minimum ultimate Tonsilo Hti'ongth Tons per aq. in.

28 35 Minimum yiold point JJI tonnB of Tonailu strength por cent.

SO 50 Minimum Elongation on test piouo 'C (figure 5 to Appx, B) per oent.

20 15 Should a tensile test pieoe break outside the middle half of its gauge length, the test may at the manufacturer's option be discarded and another test be made of the same oaating.

78. Bend teats.—Cold bend tests shall bo made upon test pieoos having a rectangular seotion of one inch Wide by 3/4 inch thick. The test pieces shall be maohined and the odgea rounded to a radius of 1/16 inoh. The test pieces shall be bent over th» thinner section.

632 THE GAZETTE OF TNDTA EXTRAORDINARY [PART II Bond teats may be made by pj essnni 01 by blows, and tho tost piecesshall without fraituro withstand being bent lound R forjm r having ft radius of 1 inch through an angle not Jess thim that given m the following table .— Braiio orCtiHtuiK 4.ugle of Bund I . . . . . 00° II . . . . . l20r

79. Additional teats before rejection. —Should a test pr>er- fir«t wlectod by Hie luspeotor not fulfil the test roquiremonts, two additional tests of the namo kind from the sumc easting or group of cawlingfi shall bo made. Should one of the additional teat pieces fail to fulfil the specified tost requirements, the castings .shall bo rejected.

80. Waiving of tests.—No tests shall be mado from unimportant steel casting or from Hteol ('listings which aie used lor articles usually made ot cast iron, if the scantlings are not materially reduced below what would be required if oast iron were used.

OARRON STEEL TORGINGS (OTHER THAN 4WAIMLESS DRUMS)

81. (a) Process ot manufacture.—(Jarbon . 1eel for forgings shall be mado by the Open Hearth or an Electric Process, acid or basic.

(b) Chemical analysis.—Tho steel shall <ontain not more than 0-05 par eeul. ot sulphur or of phosphorus.

(c) Fresdom from detects. -Til** forpingH shall be froo from defects ot any kind and shall bo finished to the prescribed dimensions. Defects m forgings, shall not be repaired without the previous .sanction of tho Inspecting Officer,

(d) Heat treatment.—Kadi forging shall bo efficiently h'vit-tioated unless during the last stage of mauiifactute it has been finished at such n temperature as to ensure that tho mateiial ot tho foigmg •will have satisfactory meehunical properties.

82. Selection of teat pieces.—Hiiftu iont material shrill be left on oa< h forging for test pieces. In the case of a number of small forgings, not less (linn two per cent, of (he total or not lesR than 2 forgings from each cast.

83. (a) Tensile tests. —The ultimate tenmlo wtroHs and elongation shall bo between the limits of 26 and 32 Tons per sq. in and 28% and 22% respectively determined on.

Butmh Standard Test Piece 0, or subsidiary Standard Round Test Piece (See Appendix B.)

In no case shall the sum of the ultimate tensile Htrows and corresponding < longation be loss than 54.

(b) Should a tonailr) t'»st pieoe break outside tho middl i half of the test gauge length the test may, at the maufacturor's option, bo discarded and anothei test be made of tho name forging.

84. Bend tests.- (a) Bond test pieces shall ba rectangular section I in. wide by 3/4 in. thick. The edges shall be rounded to a radius of 1/16 in. The tost pieoos shall bf> bont over the thinner seotion.

Sao. 3] THE GAZETTE OF INDIA EXTRAORDINARY 633

(b) The test pieces shall, \ 'Jnn t old, be capable of being bent, without fracture through >in angle of 1K01", the internal radius of the bend not greater than \" inch Bend tests may bo inudo by uiessure or by blows.

85. Additional teats before rejection.- Should cither a tensile or a bend te^t fail, two fnrtliei tests of the type which failed may be made on tost piectfl cut fiom the same foiging. If the results obtained Jfiom those retests aro satisfactory, the forgings shall bo accepted, provided that in other respects they fulfil the conditions laid down above for steel forgingh. If these letests do not give satisfactory results the forgings represented may Lc re-heat-treatcd together with the remainder of the tost blocks and presented for furthei testings.

in all cases whore final retests do not give satisfactory results, the forgings represented by the test pieces which fail shall be rejected GRNERAL GREY TRON CASTINGS (GRADtt A)

86. (a) Process Oi manufacture.—Tho eastings shall be cast from metal melted or refmed in any metallurgical plant other than an iron ore smelting furnace, for the use of which furnace permission m writing must bo received from the Inspecting Authority.

(b) Chemical composition. The composition of the iron as cast shall be left to tho discretion of the manufacturer but the maximum percentage of phosphorus may be specified by the Inspecting Authority if In- MO dosnes.

(c) Moulding.—(i) The castings shall be ucourai-ely moulded in accordance with tho pattern oi working drawings supplied by the Inspecting Authority, with tho addition of such lettering as may bo specified.

(ii) The casting shall be sound, clean, out of t \uu t and free fioin blow holes distortion and all siutac and other defects. They shall be well dressed or fettled and Mhu.ll bo machinable by normal methods PROVISION OF TEST BARS

87. The Inspecting Authority shall stato at the t̂ mo of enquiry whether ho requires tensile or transverse tests, or both, and ho may also specify cast-on bars where the design oi (he cas1 ing and method oi lunning permit.

When tho teat bars aro ea.s1 separately tJif \ shall be pound at tho same time and from the same ladle ot metal as I he anting oi castings they reprosmt The number of tost bars spenned in Regulation 92 shall be applicable to all castings of oach melt.

When the bais are last-on, the mould for tho casting and the mould foi the tost piece shall be joined together in such u. inannei that the liquid m'otul fills both moulds at the same operation All tost ba,is shall be east in green sand or dry sand moulds according as to whether the casting or castings they lepresent are moulded in groen sand, or in loam or dry sand respectively.

The test bars shall not be subjected to any heat treatment after leaving the moulds.

.LiLtS liA.. juJ.JL.ci Us? INDIA J L A I B A O B - U I M A E T {PAB* l l DIMENSIONS OP TEST BARS

88. (a) Transverse Test Bars.—Tho tmnsverae tost bars of the diametor specified by the Inspecting Authority according to the main cross sectional thickness of the casting represented, shall oonform to the following dimensions :

Diiimoter of toat Bar in.

0-6-fc 0-87S± l-2± l-6± 2-l± Limits on dLimotor in.

0 -045 0 -06fl 0 090 0-10 0-10 Overall length in.

10 ie 21 21 27 Main crosa-ueotional thickness of casting represented in.

Not evcooillng 3/8 Over 3/8 and not exceeding 3/4 Over 3/1 Hiir] not exoeoding 1,1/8 Over, 1,1/H urui not exrooding 1, 5/8 Over 1,5/8 Bars east to iv si/.e in excess of the limits given above may be mar-hiuerl to a diameter within the specified limits. Bars cast within these limits of diameter may also be machined before the transverso test io made, providing tha t the finished diameter falls within thche limits.

DIAGRAM L ,-J.

JU .

L .A , H iU t .

1JN U 1A ffiA J -^ A U i TABLE Diameter as cast B in.

0-6 0-875 1-2 1-6 2-1 Gauge diameter D in.

0-309 0-564 0-798 1-128 1-696 Area A sq. in.

0-125 0-25 0-50 1-00 2-00 Miu.

parallel length P in.

1 2 2 2 2 Min.

radius R in.

u 3i 31 Min.

length of plain C in.

H 2 21 3i Screwed ends Size E in.

i B.S.P.

9/16B.S.F.

9/16 B.S.W.

3/4 B.S.F.

7/8 B.S.W.

1,1/8 B.S.F.

1,1/8 B.S.W.

H B.S.P.

11 B.S.W.

2 B.S.P.

Min.

length F in.

9/16 3/4 i-i /a 2 Approximate minimum ov^all length Plain ends • L P in.

41 7-1/16 8-1/32 1 1- 1/8 Screwed ends LS in.

3 4-13/16 5-7/8 Main cross-3e«tional thickness of casting represented in.

Not exceeding 3/8 Over 3/8 and not exceeding 3/4 Over 3/4 and not exceeding 1-1/8 Over 1,1/8 and not exceeding 1-5/8 O-T-ST 1-5/8.

Th» test bars shall be cut as paralfel bars of the diameter given in Column X and than maohin»d to th» dimension* D and P in the above tabW. |

(b) Tensile Test Bars.—Tho tonsils ton! bturs of tho diameter specified by the Inspecting Authority, according to the main croSH-wectional thickness of the oasting" represented, shall conform to the dimensions shown in tho following table. Bars may bo tested with either plain or bercwod ends.

(c) For castingn over 2 inches in lb.ieU.neHH a test bar of larger diameter than 2-1 inches mu.y be used by agreement bolween the manufacturer and the Inspecting Authority. For diagram and table- wee pp. 28 to 29 MECHANICAL TEST

89. The canting must comply with the transverse and tensile teats spooiflod in Regulations 90 and 91. All tent pieces shall be selected by the inspector and tested in hid presence and to hin satisfaction.

TRANSVERSE TEST

90. A transverse test bar cast in accordance with Regulation 88(a) must, whon placed on supports wet at the distance shown in column 2 of the following table sustain a load applied at the centre of not loss than that shown in column 3 and must show before luptme a deflect ion not lent) than that shown in column 4.

The suppoitH and the point of application of the load shall he rounded to iv radiuft of not less than 1/8 inch.

Diamotor of tent bar 1 m.

0-0 0-875 1-2 1 0 2 - 1 Distance between HlippOliH 2 i n .

» J2 18 18 24 Minimum breaking load—Grade A 3 lb .

«30 1,185 1,050

4.2H0 0,600 Minimum dufloction—Grude A 4 in.

0'07 0 10 0-15 0-12 0 lfl If the diameter of a trsinsvorne test bur in cuflt varies within the limits specified in Regulation 88 (a) I he equivalent bunking load for the 1 >ut bar of nhindurd diameter shall be calculated in uccord.iine with the factors given in Appendix F.

TENSTLE TEST

91. A tensile tesh bin machinal to the1 dimensions shown in Regulation 88 (b) and tested with either plain or screwed endH must show a bieaking strength of not less than that shown m tho following ttible.

Diamoter ot tost btu" i n .

0-0 0-875 1 -2 ] -fi 2-1 J\Tmuni3m Tjltiinatt) tonHilo Htroflê —^Oi'ado A TOIIB por sq, in.

12 .5 12 11 10-fi 10 NOTD.—Solf-aligning grips to onsure axial loading ai'o rucoraroeudod.

NUMBER OF TRANSVERSE AND TENSTLE TESTS

92. The nurabi'i of U«nts rnquiicd for each batch of cufitiiijrs hhull ho in aicotdance with the following table, the various clas-fccf-. oi' uislings being divided into four repiesonttitiv-' gioiipr. One test shall refer to one transverse and ono tensile test, whethei taken i'lom otic or two lest bain at c .">-!..

Group 1 2 3 Woij/ht of cuHiniKH Up to 28 lb Over 2M lb, iind upto ] owl.

Over 1 owt. and upto orin Lou T«Ht roquiremontu Ono test for ouch 30 cwt. of pnutm^B or part rlioinof.

Ono tent for oaL'li 2 toils of castings or Xiait thmoof.

One tost lor 'Jacli 4 tons of OftstingB or part t Unroof.

In (ho above (Jroups, I, 3 und 3, all castings represented by one test must ho poured from tho same ludle or same heut as the bur nr barn provided for the test.

4 OVOT 1 ton and important castings whoro mutiinlly agrcod upon.

One tost for enoh 4 tonfl of oustingB or part thereof or for eooh caatinp; weighing 4 tonn ur more.

93. Additional Tests.—The additional tests to be carried out. before a e&Btini!;

or butch of castings in rejected H1IH.11 be in. accordance with tho following tiT lo :— Tent pieoi) l n t 2 n d Evont If this fails . . . .

If this paRHOn If this CHIIH . . . .

Oonditions The noooiid toHt pinco nlitill be tented.

Tho batoh or sop&rnto cutting ropre^ontod ahtiH bo noeoptod.

Thn bulch or stipareto casting represented rauy be rejootcd

Provided tihvayn that in the cane of failure of both test pieces if either show obvious defoel* a thiul test piece may be taken from a broken easting or a piece may bo cut from a usable uasling for further testing aw followtt :— 3 r d I t thin paBHos If thin failH . . . .

The batoh or miparate oastiug r(«proHOnted shall bo accepted, The biitoh or Hfijjarato casting ''eyirewentod may be rejected.

COVERED ELECTRODES FOR MKTAL ARC WEUMNG (Î OB flA.Nn OrWBATIOH)

94. Construction.— Tho motal olootioilcs shall be provided with a Mnx co^ring applied eKtcnuilly by painting, wpraying, dipping, wrapping or other method.

9^. Application.—The covered ol.inirodeR shall b> wuitable for motal are welding of mild wtoel having a tensile strength not exceedig 33 tons per sq inch.

ltLV L.A2. Lin Ux 1WU1A JVAI. AU. ,LI1HA. ... „ i±

96. Quality.—The electrodes shall bo uniform in quality and when used in ac- •oordanoe with the appropriate instructions of the Manufacturer shall be capable of flowing freely and smoothly without producing an undue amount of " under cutting " in the parent metal adjacent to the weld.

97. Covering— (a) Strength.—Tho c ovoring shall be mifficiently robust to withstand without damage the normal conditions of transport, storage, handling and use to which the electrodes are to be subjected.

(b) Uniformity.—The oovering shall be substantially unifojm in out ido diarnoter throughout its length and shall fuse evenly.

(c) Stability.—The stability of the covering shall be such that if the electrodes are stored they shall, after a period of thrco months, be oapablc of giving results similar to those at the date of despatch from the supplier,

(d) Storage.—The requirements of paragraph (c) abovo shall apply only if the electrodes have been kept in their original packages in an enclosed dry storeroom.

98. Mechanical properties of All-weld Metal test pieces.—The mechanical properties shall be determined on all-weld-metal test specimens as follows :•—

(a) Tensile Test.—The tensile test shall be made on a specimen having ft gauge length of 3-54 times the diameter of the test piece. The ultimate tensile stress, elongation and reduction of area of tho deposited metal shall be not less than the figures given in the table.

(b) Impact Test.—Impaot tests shall be made on a three notoh specimen. At least two of the three values obtained shall be not less than that given in the tablo.

Ultimate Tonsil* •tread (tone per sq. in-) ruin.

IS Elongation on 3 • 54D (per cent.)

20 Reduction of Area (per cent.)

min.

38 Impact Vftluo 30 ft. Ib.

CHAPTER HI CONSTRUCTION AND WORKMANSHIP GENEBAL

99. Preparation of Plates.—With ihe exception of gusset plates, which may be sheared, tho edges of all plates and butt fltiaps shall bo planned or machine gafl out to an angle of approximately 80° with the surface of tho plate.

100. Annealing after working in fire.—All steel plates which are welded, dished, flanged or locally heatod shall be afterwards efficiently annealed.

101. Minimum thickness of Plates.—No boiler plate shall be lens thnn £ inch in thickness.

SHELLS, ANGLE RINGS, BUTT STRAPS, ETC.

102. Cylindrical Shells.—Eaoh ring shall be bent while cold to cylindrical form to the extreme ends of tho plate. Tho bonding shall be done entirely by machine and "heating or hammering is prohibited.

108. Position ol Longlttiainal Seam* Each rin£ of plate fotming "the shell, barrel or drum shell, where practicable, be in one piooe and have its longitudinal seam well out of line with those of the adjoining rings. In Lancashire, Cornish, and other types of boilers, -where p;utn <>f tho HIVII aie exposed to flame, the longitudinal yearns* î hull, whoio practicable, be in the steam »paie, arranged alternately on each wide of the crown and clear of tho buck work.

104. CireumSeiential ana End Seams.—(a) The s-trcngih of the search joining the end platen of flat end Lancanhi]e and Cornish boilers with the eylindi ical shells shall be not lew than S8 per cent, of the strength of the calculated thickness of the plat" JR found by Equation (1), The str ength of the int ormediate ?w»mR of flat ended bmlet'H and all scam a of diRh ended boilers shall be 50 per cent of that of the longitudinal seams but in no rust less than 42 per tent of the strength of tho calculated thickness of the plate.

(b) In boilers of other types the strength of the circumferential and transverse Beanie shall be not loss than 38 per cent, of that of calculated thickness of the plate as found bv Equation (1) and not less than fi() peT cent of that of the longitudinal seams whichever is the greater.

(o) When tho shell plate thickness exceeds ]l/lfi inch the intermediate circumferential seams shall be double riveted.

(d) In tho ca^e of the electrode boileis where the diameter of the shell does not exceed 18", the end platen may be attached to the fiholl by means of Electric Arc fillet w« ldin.2 provided the welds are stress relieved and the cubical capacity and working pressure do not exceed 30 gallons and 120 lbs. respectively.

105. Angle Rings.—Angle rings for the attachment of end pint OR to shell plates and 'ii flue sections shall be rolled or machined HO that they fit closely to the flat and cylindrical surfaces to bo connected, and shall be machined or machine gas out on tin. caulking edges.

106. Thickness ot Shell Angle Rings.—Where shell plukb find end plates are, connected by means of an external angle ring, the angle ringw s~.liall be not Ws in thii-ktiesq Ihnn as follows:—

(1)

(2)

(3) For nhnll phitoa up to and unlading S/H ineh in thirknom For shell plntM nxo^odinc 5/fi mi h in thick- IWB^ nml upto and including 1 iiw-'h m thick- Fo\ HIH'II plutfp ov«r 1 inch in thiekiKmn 10 p« r cent in OXCRHB of the thickness of tha shell platxi.

00 por cent of the thieltiiesm but not lens thnii 11/16 inch.

Miiriu from dnglo bar havnif; a sflction thiokneaa of 1 inch.

107. Welded Shell Plates.—(a) Except as provided for in Chapter V end in Regulation 112, where longitudinal seam1; arc welded the wold shall bo entirely co\oied by a butt strap or butt Htraps securely riveted to the shell.

(b) Foi small steam domes when the welding is clone by hammer and the plates do not exceed £ inch in thickness butt straps may be omitted.

(e) The strength of the weld covered by butt straps shall bo assumed to bo 50 pei mi t of that of the solid plate. The thickneHs of a single strap or combined thu knews- of double straps shall be not leas than tho thioknesr of the shell plate.

, =a wil .

108. Longitadinal Seam*.—The longitudinal seams shall be butt-jointed with double straps when the diameter or Working Pressure exoeeds the limits stated below:— T y p n of Boi le r L o c o T y p e s . . . . . . .

V e r t i c a l T y p e s . . . . . .

O t h e r T y p o W h e n d i a m e t e r exceeds F e e t .

2 ' -6" 8 6 W h e n W o r k i n g P r e s s u r e oxoeeas L b s .

200 125 HO

109. Bntt Straps.—Butt straps shall bo out from the shtll plaUb or, alternatively, all the butt straps of each required thickness slip 11 be out from one plate.

The lengths of the straps wherever practicable shall be transverse to the diicction of rolling of the plate. Straps shall be pressed or bent in rolls to the shell curvature.

110. Thinning ol Butt Straps.—Thinning of tho cnds of butt Rtisps which tuck under shell rings, shall be done oold by machine and not by heating or hammering.

'The shell plate shall be notched out to reoeivo the thinned end of the butt strap, -so that there shall be no undue thinning of the butt strap.

111. Alternative Construction.—(a) As an alternative lothe tucking of but1- *trap ends under the shell rings, tho ends may be terminated at the edge c f the shell rings or ends and electrically welded thereto.

112. Local Welding of Butt Seama.—(a) The ends of longitudinal butt soains of «hell rings may be welded for a lenjjth not exoeeding three times the overlap at the •circumferential seam, providod the butt straps are run as clorSely as practicable to the circumferential soam.

(b) Only metal arc welding of the butt seams of shell rings shall be permitted.

113. Flat End Plates.—(a) The end plates of boilers shall preferably be in one piece made from one rolled plate. Alternatively, the end plates shall be built up by butt-welding two pieces. In the latter case the line of welding shall be parallel to the horizontal axis of the boiler and shall run through the centre line of furnace or furnaces of Lancashire boilers and between two rown of stays of marine type boilers.

In tho ease of flat end plates the fusion welding, shall comply with stress relieving (requirements and in the ease of dished end plates the fusion welding shall be aubjeotcd to both stress relieving and radiographio examination.

(b) The peripheral flanging of end plates shall be done by machine. Such flanging shall preferably be dono in ono operation, but whore this is impracticable sectional or creep machine flanging may be permitted, pro\ ided that the plate in worked at a suitable temperature, and the plate is heated to an adequate distance beyond the portion under immediate treatment.

(c) Care must be taken to see that the flanges arc circular and of good surface, free from local irregularities, and that they are parallel a ad square with the flat part of the plate. For the purpose of relieving internal stresses, all plates which have been Hanged or locally heated shall afterwards be efficiently annealed unless during the laat utage of manufacture they have been uniformly heated throughout.

(d) Flat portions of end plates, on completion of all flanging and machining operations, shall be flat and free from set or distortion.

r I I . I I I in m m i n . m t . - . . - • . . . , „ • — . ; , • „ . . i f - - f i r , B B _ _

114. Strengthening of Flat End Plate at Manhole.—(a) In the End Plates of Lancashire Boiler type the raudhole in the lower part of the front end plate shall be fitted with a flanged rivetod strengthening ring, the thickness of the flat portion of which shall be not less than (1-5 T X1/8 in.) where T equals the thickness of the end plate in inches.

(b) In boilers 7 ft. 6 in. diameter and above, the mudhole frame shall be fitted "with a peak to reinforce the portion of tho end plate between and below the furnaoeB, and this peak shall be .securely riveted thereto with rivets of similar pitch to the remainder of the frame.

(c) In all cases the front end plate gussot stays below tho furnaoes shall be placod a,s closely as possible to tho mudhole frame.

(d) Where flat end plates are flanged for connection to the shell, the inside Tadius of flanging shall bo not. less than ) -75 times the plate thickness, with a minimum of 1 | m.

115. End Plates in steam spaces.—When the end-plates of boilers situated in tho steam space are liable to contact with hot gasos the ond plates shall be efficiently shielded from such contact.

118. Hemispherical Crowns.—(a) All segments shall be pressed in one heat to 'correct curvature. The adjacent plates shall bed closely at the seams and wherever possible at the junction of two seams tho plates shall be maohined down to provide •a fair surface to tho joint, [f the thinning is dono by hoa+ing and hammoring the plate shall bo subsequently annealed.

(b) The cylindrical portion of the crown shall be tangential to the hemispherical portion and fit truly to the shell.

(c) Where hemispherical shell crowns are pressed from one plate they shall be pressed to form by machine in progressive stages without thinning and on com- •plction shall be annealed.

117. Dished End and Crown Plates.—(a) The inside radius to which a plate is dished shall not be greater than the external diameter of the shell to which it is attached, except in the case of Lancashire and Cornish boilers when the radius shall mot exceed 1^ timos the diameter of the sh 11.

(b) Tho inside radius of curvature of the flanges tt the shell or firebox shall not be loss than four timos the thickness of the crown or end plato and in no case loss •than 2\ inches.

(o) The inside radius of curvature to uptakes shall be not less than twice the thickness of the crown plate and in no case less than 1 inch.

(d) Bunged mouth-pieces may be welded on to end plates in place of the ortho- •dox flanging for the attachment of furnace tubes. Such welding shall comply •with provisions of Regulation 125.

(e) Manhole frames may be similarly welded on the front end plates, and will 'be subject to piovisionn of Regulation 125.

118. Tube Plates.—Smokebox tube plates ahull bo flanged for attachment to the 'barrel or shall be flat and connected thereto by an external riveted angle ring.

119. Parts ot the Smoke Tube Plates within the tube nests.—(a) Where the total urea of all tho 1 nbc no-.ts exceeds 7 sq. ft. stay tubes shall bo fitted within the nosts.

"Whoi e Htay tubes Arc not fitted th» ends of tho tubes shall be beaded or boll mouthed.

(b) The parts of tube plates which lio outside the nests of tubes shall bo stayed or supported wherever tho size of the area of plato subject to steam pre^u^e necessitates staying or support, either by marginal stay tubes or other means.

120. Flanging o4 End Plates.—All flanges shall bo a good fit to the shell and flues. Flogging and'or hammering in the fitting of these parts is prohibited. The.

-caulking edges of all flanged plates shall be nmhined or machine gas cut.

FURNACES

121. Furnaces in general.—(a) No furnaoo or firebox top, -whether plain or corrugated, shall exceed 7/8 inch in thickness, and all oircular sectioned furnaces •when new shall be as near the tiuJy circular foim as the type of joint •will permit.

(b) The use of Z angle rings for furnace foundation seams shall be prohibited.

122. Furnaces of Horizontal Boilers.—(a) The &ection* of Hie, internal flues snail each be in one plate and Bhall be bent while cold to circular form and shall b» welded longitudinally.

(b) The maximum permissible variation in diameter at any cross section shall not exceed the thickness of the plate.

(c) The welds shall be placed at tho lower part of the flues, and shall break joint in successive sections by at least 12 inches.

(d) Each flange for the circular seams shall be formed at one heat by suitable machinery.

(e) The sections shall be allowed to cool gradually to avoid internal stresses.

(f) The caulking edges of all fluo flanges shall be maohined or machine gas cut.

(g) The circular seams shall be arranged so that they do not fall in line with those of the adjacent flue or with the circumferential seams of the shell and are at least 6 inches apart,

(h) When flues ate flanged for attachment to both end plates tho total length of each completed flue thall not exceed the length of the shell measured from the inner surface ot tho back end plate to the inner surface of the front end plate, both adjacent to the shell.

(i) Where the flues are flanged for attachment to tho end plates, tho end sections sball be 1/16 inch thicker than the remaining sections, except in cases where the calculated thickness is over 13/16 inch, when the end-sections shall be 7/8 inch in thickness.

(j) Tho flanged portion of furnace rings shall have a radius of curvative of not less than 1 inch on water side.

(k) Seotions of corrugated flues may be fusion butt welded oiroumferontially and afterwards stress relieved by heat treatment.

123. Furnaces of Vertical Boilers.—(a) The vertical portion shall be in one plate and shall be bent to oircular form in a similar manner to the shell plates.

(b) Circular furnaces shall preferably be tappered, a taper of 1J in. in diameter per 1 foot of height being recommended. The minimum water spaco at the bottom between the furnaces and the shell shall not be less than 2 in. for boilers up to 2 ft.

6 in. in diameter and shall be not less than 2J in. for boilers over 2 ft. 6in. in diameter.

(o) Where hemispherical furnace crowns are pressed from one plate they shall be pressed to form by machine in progressive stages without thinning and on oompletion shall be annealed.

(d) Ogee flanging where integral with the firebox or in a separate ring shall preferably be formed at one heat by suitable machinery and shall be allowed to cool gradually to avoid internal stresses,

(e) Furnaces of vertical type boilers may be attached to the shell at the fire" hole by a solid rectangular section steel ring riveted together or by a circular ring of substantial section fusion welded to shell and firebox. Where the latter construction is employed the opening in the shell for fireholc shall be substantially compensated by a i ing welded on the outside of the shell plate.

(f) At the firehole the firebox plate and the shell plate may be flanged and fusion welded together.

SEC. 8] THE GAZETTE OF INDIA EXTBAOBDINAIU 64»

184. Longitudinal Seams.—The longitudinal seams of furnaces may be either:

(a) Forgo Lap Welded.

(b) Fusion Butt Welded,

(o) Riveted.

Longitudinal seams of furnaces exoeeding 3/8* thickness shall uot be riveted.

125. Fusion Welded Longitudinal Seams.—Where the longihidinal Keam is fusion welded tho following precautions shall be observed :—

(a) Plates over 5/8 in. in tliicknosH shall be bevolled from both sides of oaoh abutting edgo, but the bevel need not necessarily be the same on each side (HPO Figs.

1 and 2). Plates less than 5/8 in. in Lhicknesa may be bevelled from ono aide only of eaoh abutting edge (soe Figs. 3 and 4).

The included angle of the bevel shall be not less than 60° ,nnd the bevelling may be any one of tho forms shown in Figs. 1—4.

Fig. 6. Fusion Welding oJ Gross Tubes ol Vertical Cross Tube Boilers.

(b) In ordor to obtain full penetration of the weld metal a gap shall be maintalned between the plates when they are being welded. Joints shall be welded from both aides, and the dag shall be removed after making eaoh run. Before 044 THE GAZETTE OF INDIA EXTRAORDINARY [PART U the socond side of the joint is welded tuiy slag 01 defect at the bottom of the first) run shall be remoxed by grinding, chipping or machining. There shall be no appreciable undercutting of the plate.

(c) Por the purpose of relieving internal stresses the plates adjacent to a fusion, •weld shall be efficiently annealed after welding, and when the firebox i« forge-welded!

it should be allowed to cool gradually.

126. Furnace Crown.—(a) Tho furnace crown f.eum shall not fa 11 in line with any circumferential scam of the boiler shell.

(b) the furau.ee crown nmy be riveted to tho vertical portion of tlic fijphox, or alternatively, the ioint nitty bo fusion hu1t welded by the electric are process, provided the conditions, as to fusion welding in Regulation 125 are observed. Where the joint is to be welded the edges of tho furnace crown and the firebox body shall be bevelled in accordance with Tig. 3 or Fig. 4. The depth of tho flange of the furnace crown •plate from the commencement of tho curvature of the flanging radius shall be not lesi« than four times the plate thickness with a minimum of 1̂ inches.

On completion of voiding the fiiebox nh&ll be effectively stress relieved by heat treatment (net JHO Ke^. 128.)

127. Cross Tubes.—(a) Cross tubes shall b< made from wckllesB .stoel tube or from plate or strip rolled and forgo water gas welded. Where welded tubes are used the longitudinal welds shall be so situated that they are not exposed to the direct impact of the flame.

(b) The minimum thioknees shall be 5/16 in,

(c) Where cross tubes are flanged and riveted to the furnaoe, the flanges shall bo set to the ourvature and taper of the furnace, and shall be a good fit before rivettog-

(d) Where welded construction is employed the tubes shall be of sufficient length to enter the furnace plate and be flush with the water side all round or project not more than 6/8 in. into the water space at any part of the circumference. Where the tubes are fusion welded in position, the firebox plates shall be suitably ohamfored and the joints shall be welded externally and internally (see Fig. 5).

128. Uptakes.—(a) Tho uptakes shall be foimed from woldless., forge water gas welded or fusion butt welded steel tube and shall be securely riveted to the fur« nace crown plate and riveted to the shell crown plate.

(b) As an alternative to riveting, the uptake may be fusion butt welded by the electric arc process to the upward flange of the opening in the fire box crown plate provided the conditions ajs to fusion welding in Regulation 125 are observed. The edges of the upward flange and the adjacent end of the uptake shall be bevelled in accordance with Fig. 3 or Fig. 4. The depth of the crown plate opening from the commencement of the ourvature of tho flanging radius shall be not less than twice the plate thickness with a minimum of 1 inch. On completion of welding the uptake and crown plate shall be effectively stress relieved by heat treatment.

Where the firebox crown plate Is also fusion welded to the body of the firebox, the firebox complete with uptake shall be effectively stress relieved by heat treatment on completion of the welding.

129. Loco Type Fireloxcs.—(n) The foundation M>sm whall be of rivetul conatruction but all other seams may be welded subject to the depth of the flange being such that the welded seams fall between the 1st and 2nd rows of screwed «taye or between the flange and the adjacent row of sorewed stays.

Sue. 8] THE GAZETTE OF INDIA EXTEAOBDINAEY 645

(b) The firohole mouthpiece may be similarly welded when the firebox and shell are flanged for the purpose.

(o) The welding shall oomply with Regulation 125.

STAYS

130. Bai Stays.—JSar staya shall not b<i w^Mod at any part. They Hhall pre.

ferably have plus threads, the ends of the stays being upset or the middle portion being reduced for this purpose. Stay bars -which have been worked in the tire shall be subsequently annealed.

131. Longitudinal Stays.—(a) Longitudinal and nmnlai solid SUIVMI hta\s shall be efficiently secured with nuts at euch end and not merely riveted over.

Where they are over 12 feet in length, they shall be supported at intervals of fl ft.

along its length,

(b) Where the stay is screwed through both platos, the stay and h

Indian Boiler Regulations, 1950

The enactment

Full text

Find the provision, not just read it