Approval granted under the pregoing rules, shall be withdrawn if-
(i) the approval was obtained on furnishing incorrect or false information;
or
(ii) no manufacturing activities or fabrication work or repair work was carried out for a continuous period of six months.
Provided that before any such order for withdrawal of approval is passed, the owner or person incharge of the organisation shall be given due notice in writing calling upon the person concerned to show cause why an order for withdrawal of approval should not be made, the objections, if any, shall be considered and reasonable opportunity of being heard shall be given to such person by the Director.
G.C.P.H.4176-5 (2034-1093) The Maharashtra Boiler Rules, 1962 27 APPENDIX FORM A BOILER INSPECTION DEPARTMENT Register of Boilers (Rules 9, 18 and 22) Regist ry No.
Type of Boiler Boiler rating Name of Manufa cture Year and Place of Construction Date of Registr ation Name of Owner Place wher e in use Remarks (Transfe rs, etc.)
(1) (2) (3) (4) (5) (6) (7) (8) (9) Part II of the Register Column (I) should contain registry numbers and letters.
The Maharashtra Boiler Rules, 1962 28 Form B THE BOILERS ACT, 1923 (ACT V OF 1923) Notice for Examination of Boiler under sections 7 and 8 (Rule 34) No. of 20 STEAM BOILER INSPECTION OFFICE Dated the 2010 To Gentlemen/Sir, In reply to your application, dated you are hereby informed that Boiler Registry No. at the above named premises will be thoroughly examined/hydraulically tested by the Deputy Director on the To enable the examination to be made, you are bound—
(a) to afford to the Deputy Director all reasonable facilities for the examination and all such information as may reasonably be required of you;
(b) to have the boiler properly prepared and ready for examination in the prescribed manner; and
(c) in the case of an application for the registration of a boiler, to provide such drawings, specifications, certificates and other particulars as may be prescribed.
Voucher No. in acknowledgement of Bank/Treasury Receipt No.
For Rs. Accompanies.
Director of Steam Boilers, Maharashtra State (See reverse for preparation required) The Maharashtra Boiler Rules, 1962 29 REVERSE OF FORM B PREPARATION FOR EXAMINATION See Chapter IX of the Regulations (Regulation 376) (A) Preparation for inspection At every examination of a boiler for the grant of renewal of a certificate, the boiler shall be empty and thoroughly clean in all its parts. All doors of manholes, handholes and sightholes and cleaning plugs and all caps in the headers and mud drums of water tube boilers, all firebars, bearers, front plates, bridge plates fire bridges brick arches, oil fuel burners and mechanical stoker fittings shall be removed. All valves and cocks comprising the boiler mounting shall be opened up and taken a part and the valves or cocks ground, when necessary, before the Deputy Director’s visit.
Provision shall, if required by the Deputy Director, be made for the removal of lagging or brickwork or other concealing part and for the drilling of plates and for verifying the pressure gauge and safety valve dimensions and weights. All smoke tubes, exterior of water tubes, smoke boxes and external flues shall be swept clean.
Provisions shall be made for the effective disconnection of all steam and hot water communication with any other boiler under steam, as prescribed in Chapter X of the Regulations. This shall be effected either by the removal of a length of pipe from the steam and feed piping or by the insertion or substantial blank flanges. Where blank flanges are employed, they shall be inserted between the flange of the chest and the pipe attached to it. No blank flange shall be inserted between a safety valve chest and the boiler.
In the case of forced flow and forced circulation types of boilers, provision shall be made for checking that proper circulation is maintained through all sections of the circuit by the flow of water.
___________________________________________________ Note – These provisions to effective disconnection shall extend to every case wherein a person is sent or with the absent of the owner or person-in – charge goes into boiler for any purpose (See Part III of the Regulation) (Regulation 378) (B) Preparation for hydraulic test The chest of all mountings subject to steam pressure shall be in place an shut tight or black-flaged. The safety valves shall either be jammed down or removed and the chest opening blank-flaged. The attachment * for the The Maharashtra Boiler Rules, 1962 30 Deputy Directors pressure gauge and nipple + for connecting the Deputy Directors test pump house shall be in order. All doors shall be properly jointed and tightened up. The boiler shall be completely filled with water, care being taken to allow all air to escape and, if possible, a preliminary test not exceeding the working pressure of the boiler be taken before the Inspector’s visit to test the rightness of the joints. When a boiler is hydraulically tested for the first time, it shall be entirely cleared of lagging or brickworks; at subsequent tests the lagging or brickwork or portions thereof, shall be removed if required by the Dy. Director.
________________________________________________________________________________________ *Tapped 19 mm Whiteworth bolt and nut thread.
*Tapped 22 mm Whiteworth bolt and nut thread.
Preparation now required (A), (B) ________________________________________________________________________________________ Note:- The last certificate for the boiler should be shown to the Dy.
Director ________________________________________________________________________________________ The Maharashtra Boiler Rules, 1962 31 FORM C GENERAL WORKING OF BOILERS (See Rule 8) Instruction to Boiler Attendants These instructions should be frequently and carefully studied with a view to keeping in mind the precautions to be observed and ordinary procedure to be followed in the safe working of boilers.
Precautions before starting the Fires Before starting the fires in a boiler the attendants should—
(1) see that here is sufficient water in the boiler and that the gauge cocks are working freely;
(2) see safety valves, or open cock on top of boiler to allow air to escape ;
(3) see that the blow-off cock is fully closed and tight;
(4) see that safety valves and fee check valve are free and workable;
(5) note if the pressure gauge pointer is at zero;
(6) see that the feed pump is in working order’ He must not rely on the supposition that the water he has previously put in it still in the boiler, as it may have tun out without the knowledge through a leak or open cock, nor can he be sure that the gauge glass shows the true water level until he has tested it. This is done in the following manner; shut off the lower gauge cock and empty the glass by the drain cock; then shut the drain cock and open the gauge cock; if everything is in order, the water will then rise in the glass to the same height as before.
Raising steam :-In getting up steam in all types of boilers, the operation should be as gradual as circumstances will allow. Nothing turns a new boiler into an old one sooner than getting up steam too quickly. Forcing the fires when starting work is liable to cause straining of the steams and tubes of the boiler. In the case of large boilers generally steam should not be got up in less than six hours. Before getting up steam the water level should be observed, to ensure that water is at the proper heights, in the glass, the pressure gauge noted and the safety valves tried to see they are free. The blow-off cock should be examined to see that it is completely shut and tight.
Pressure gauge :- The pressure or steam gauge should be kept in order and be in such a position as to be easily seen by the boiler attendant. There should be a plain mark on it showing the highest pressure allowed for the boiler and the dial should be kept clean so that the figures may easily be read.
Steam pressure : Ordinarily, the safety valves will prevent the steam from rising much above the working pressure, but if the steam gauge shows is rapid an increase of pressure as to indicate danger of exceeding the highest limit, The Maharashtra Boiler Rules, 1962 32 water should be immediately fed into the boiler, and the dampers partially closed in order to diminish the effect of the fire. If however, the water has fallen so low that there is danger of an accident from this cause the fires should be withdrawn before feeding in water the safety valves eased and if the engine is at rest it should be started so as to reduce the pressure.
The safety valves are provided to guard against over-pressure. They should be moved by hand every day so as to prevent them from sticking. If moved only occasionally, they are liable to leak.
The valve can be tested by slowly raising it a little and when let down, it should closed perfectly tight. It should never be opened by a sudden knock or pull. If it does not closed tight turn it on its seat until it fit, or when its construction does not permit this, rise it slowly a few times and let it down again, but on no account must the valve be screwed down further or loaded more than what has been allowed by the Inspector.
Safety valves must never be over-loaded and spring valve should have ferrules or other provisions against the valves being screwed down too far. In case of an accident resulting from wilful overloading culprit might be held criminally responsible at the official inquiry or inquest.
Low water safety valves—If there is low water safety valves, test it occasionally by lowering the water level to see that valve begins to blow at the right point. It should give warning “before” the water level has sunk too low and before damage can be done when the boiler is open, examine the floats and lever and see that they are free and that they give the valve the fuel rise. With the ordinary type of high steam and low water safety valve the float should be down at its lowest position and the valve full open when the boiler is empty.
The water gauge :- These will be kept in best order by frequently blowing through. The cocks are thus kept in good working condition without Jeaking.
Blow through the drain cock at the bottom of the gauge and shut and open the steam and water cocks every few hours. These cocks should be blown through more frequently when the water is dirty. Should either of the passage become choked, or whenever the water in the gauge glass moves sluggishly the passage must be cleaned. This is best done with a wire. The gauge glass is so arranged that its top cock connects with the steam space and its bottom cock is below the water line. The water line will ordinarily be near the middle of the glass tube.
Always test the glass water gauges thoroughly the first thing in the morning and at the commencement of every shift. This is done by first opening rain cock and then shutting the upper cock which should give water; the upper cock should then be opened and the bottom cock closed which should give steam during this test the drain cock should be kept open.
If water and steam do not appear in proper order the cocks are choked and the passage should be cleaned. To lessen the risk of breaking the gauge glass the water cock should always be re-opened after the steam cock.
The Maharashtra Boiler Rules, 1962 33 Gauge glasses with a narrow white strip running the whole length of the glass on the side next the boiler are recommended as they show the water line more clearly specially when the water is dirty.
The boiler regulations framed by the Board require every water gauge glass to be fitted with, a guard to prevent injury to the attendants. See that it is always in place and clean when there is steam in the boiler.
Special Note :- It does not follow that there is plenty of water in the boiler because there in plenty of water in the gauge glass. The passages may be choked and empty gauge glasses are some times mistaken for full ones and explosions have resulted there form. Hence the importance of keeping the gauge, cocks perfectly tight and clean and of blowing through the test cocks frequently.
A large number of accidents have been due to inoperative water gauges and to negligence of the attendants in not carefully reading the water level.
The blow-off cock :- The blow-off should be used daily if the water is at all dirty or sedimentary, especially with Locomotive type and Vertical Boilers as their narrow water spaces are liable to get choked with mud, which soon hardness into a solid mass. The amount of water to be blown out depends on the size of the boiler and can be determined only from experience. When blowing out the best result is obtained if the water has been at rest for some time ( say before the engine is stared) thus giving the sediment time to settle; if the feed waters cleaned merely turn the cock round.
The scum cock :- When scum cocks are fitted, if the feed water is dirty, a little should be blown off daily; if the water is clean, merely turn the cock round.
Before opening the scum cock, see that the water is at the height indicated by the water level pointer; otherwise the scumming will be ineffective. Water should be blown from the surface through the scum cock when steam is being drawn off, i.e. when the engine or other machinery is working.
Manhole and other door joints.- When making such joints the jointing materials should never be of round sectioned packing. Care must be taken that the spigot of the door is centrally placed in the hole, as many accidents have resulted from packing bring blown out between the spigot and side of hole, even when the clearance was only 3 mm. The nuts must be carefully and evenly tightened. Further tightening should be made during the process of heating up the boiler when raising steam.
Steam-pipes :- When properly arranged should give no trouble. Frequently however, they are so designed as to contain pickets, in which, while out of us, condensed steam accumulates. Such water is exceedingly, dangerous and great care should be taken to see that the pipes are properly drained before the stopvalve is opened otherwise “water hammer” will take place even with the best designed steam pipes, and disastrous explosions causing loss of life and property may occur.
The Maharashtra Boiler Rules, 1962 34 Scale and grease :- Roughly speaking, scale offers a hundred times as much resistance to the passage of beat as does a similar thickness of the steel or iron. A 12mm furnace plate covered with 2 mm. scale is as efficient a heat retarder as steel furnace 0.250 mm, thick. Grease is about ten times worse than scale. In a boiler at work the temperature of a clean furnace plate is only slightly in excess of that of the water in the boiler; but is scale or grease is interposed between the water and the plate, the latter acquires a temperature more nearly approximately that of the flame with which it is in contact. If the fire is fierce (artificial draught) the furnace tube may grow so hot that it elongates considerable. If in addition, cold air is admitted during each firing, a concerting action of the furnace takes place, which is one of the worst causes of boiler wear and tear.
Wear and Tear can be reduced and the life of a boiler prolonged if scale and grease are prevented from accumulating in a boiler. The combined effects of scale or grease and artificial draught are disastrous. Scale or grease also causes waste of fuel.
Grease :- A mixture of sedimentary water , soda and grease produces an adhesive scum, Where this is suspected, the water level should never be lowered below the furnace top unless the boiler is afterwards entered and this scum cleaned off the furnace plate before the firing again.
Scale removal :- The customary method is not a satisfactory one. The boiler is emptied and then cooled down by opening all the manholes, and the result is that the scale which would otherwise be soft, hardens through contact with the air and requires laborious chipping off.
A very effective, but slower method is to retain the water in the boiler until cool, and not to run it out until the men are ready to enter the boiler with water house brushers and scrapers, The scale will then be soft and easily removable.
If time is a consideration, the cooling can be accelerated by adding cold feed to the hot water in the boiler and slowly running off the cold water. Another method is to blow off the boiler with the lowest possible pressure (not more than 1 Kilogram per sq.cm) and to keep it closed until cold. The scale will then be easily removed.
Treatment of feed water :- Many feed waters require soda or other chemicals to arrest corrosion or to change the nature of the scale.
There is no harmless chemical which will remove scale or sediment when it has once got into the boiler and the only effective process is to purify the feed water before it enters the boiler. By this means, the sediment, and generally too, the added chemical, can be deposited in tanks or in filters, and therefore never goes into the boiler, excepting when the water obtainable is very good, waterpurifying apparatus ought to pay any boiler-owners, particularly at those works where three or more boilers are in constant work. Boiler Owners wishing to have definite advice as to the best treatment of their feed water should have it The Maharashtra Boiler Rules, 1962 35 analyzed at some chemical laboratory and ascertain the best treatment in the particular circumstances.
Special attention is drawn to the not in frequent but very bad practice of allowing the waste steam from the Engine Cylinders or Pumps to be drained into the Boiler Feed Water Tanks. The waste steam from cylinders is always mixed with a certain amount of oily matter which will be deposited in the feed water tanks and ultimately be pumped into the boiler, with possible disastrous results, as it will be obvious to every careful boiler attendant that should the oil be deposited on the furnace crowns, they may become overheated and collapse.
It should be the first care of the boiler-owner, and the Boiler Attendant to see that the feed water is kept as pure as possible. Impure feed water means additional expense on the upkeep of the boiler.
Preservation of boilers when not in use:- steam boilers, when not in use are liable to deterioration from corrosion and unless well cared for and made rustproof; they may depreciate more rapidly than when in use. They should be thoroughly drained and thoroughly dried and all valves, cocks and openings closed so as to exclude moisture. Another plan is to fill the boiler with water to which about 1/100 per cent caustic soda has been added.
Special instructions for Boiler No. :- this boiler should be opened up and thoroughly cleaned after a period of work which should not exceed (as indicated in certificate). A record of such cleanings should be maintained and produced, when required by the Deputy Director.