MINISTRY OF COMMERCE AND INDUSTRY
(Department for Promotion of Industry and Internal Trade)
(CENTRAL BOILERS BOARD)
NOTIFICATION
New Delhi, the 21st May, 2020
G.S.R. 343(E).The following draft regulations to amend the Indian Boiler Regulations, 1950, which the Central Boilers Board proposes to make in exercise of the powers conferred by section 28 of the Boilers Act, 1923 (5 of 1923), is hereby published as required by sub-section (1) of section 31 of the said Act for the information of all persons likely to be affected thereby and notice is hereby given that the said draft regulations will be taken into consideration after expiry of a period of forty-five days from the date the Gazette containing the publication of this notification is made available to the public;
Any objections or suggestions which may be received from any person with respect to the said draft regulations within the period so specified will be considered by the Central Boilers Board;
Objections or suggestions, if any, may be addressed to the Secretary, Central Boilers Board, Ministry of Commerce and Industry (Department for Promotion of Industry and Internal Trade), Room No. 358, Udyog Bhawan, New Delhi- 110 011 or sent by email (tsg.narayannen@nic.in) within the period specified above.
DRAFT REGULATIONS
1. Short title and commencement.-
(1) These regulations may be called the Indian Boiler (Second amendment) Regulations, 2020.
(2) They shall come into force on the date of their final publication in the Official Gazette.
2. In the Indian Boiler Regulations, 1950 (hereinafter referred to as the principal regulations), in regulation 4, in clause (c), in sub- clause (vi), for the “Note”, the following “Note” shall be substituted, namely:-
“Note: Until 33,000 hours tests are carried out by the National Metallurgical Laboratory or Corporate Research and Development Laboratory of Bharat Heavy Electricals Limited, Hyderabad or any other well-known material testing laboratory recognized by the Central Boilers Board for creep testing for collecting elevated temperature data of alloy steel produced indigenously or from a Nationally recognized/accredited testing laboratory for creep testing in the country of manufacture for alloy steel produced outside India, against American Society of Mechanical Engineers (ASME) or British Standards (BS) or European Standards (EN) Code, these grades of steel may be accepted and long time elevated temperature properties/maximum allowable stress values given in American Society of Mechanical Engineers (ASME) or British Standards (BS) or European Standards (EN) Code, as the case may be, used for the purpose of design:
Provided that:
(I) a certificate is furnished by the producer of the steel to the effect that the steel has been manufactured strictly in accordance with the technical requirements of the American Society of Mechanical Engineers (ASME) or British Standards (BS) or European Standards (EN) Code to assure that the creep rupture requirements are complied with;
(II) the steel maker furnishes the necessary certificate that the steel conforms to the chemical analysis, room and elevated temperature mechanical properties given in American Society of Mechanical Engineers (ASME) or British Standards (BS) or European Standards (EN) Code as the case may be;
(III) the short-term stress-rupture tests for 1000 hours as described below are carried out by National Metallurgical Laboratory/well known steel makers or any other material testing laboratory recognized by the Central Boilers Board for creep testing for collecting elevated temperature data of alloy steel produced indigenously or from a Nationally recognized /accredited testing laboratory for creep testing in the country of manufacture for alloy steel produced out side India, for the purpose of checking whether the steel is up to the specification and also to ensure that the steel is capable of meeting the long-term rupture stress values/maximum allowable stress values given in American Society of Mechanical Engineers (ASME) or British Standards (BS) or European Standards (EN) Code, as the case may be, and a certificate is given by National Metallurgical Laboratory or steel plant to this effect;
(IV) two numbers of 1000 hour creep rupture tests shall be carried out at a temperature 50°C above the service temperature for each grade of steel for tubing or piping or castings or plates grades; when in furnace or in superheater zone:
Provided further that:
(A) the forging to be used in valves should be tested at 550°C for 1000 hours and the stress to cause rupture in 1000 hours at above temperatures may be taken from the master curve corresponding to – 20 percent line;
(B) at this stress, a minimum rupture life of 1000 hours is expected and both the samples should pass 1000 hour tests at the above stress and temperature;
(C) in India, these samples may be selected at random by the Chief Inspector of Boilers of the respective State and outside India by an Inspecting Authority, and the samples could be in the form of semi-finished products, say, forged bars of about 25 mm2 which will undergo heat treatment as prescribed by the relevant specifications .”
3. In the principal regulations, in regulation 4A, for sub-regulation (1), the following sub-regulation shall be substituted, namely:-
“(1) An application for recognition as Competent Authority, Inspecting Authority, Well-known Material Testing Laboratory, Well-known Steel Maker, Well-known Foundry/Forge, Well-known Tube/Pipe Maker and Well-known Remnant Life Assessment Organisation shall be made by a firm to the Secretary, Central Boilers Board, Department for Promotion of Industry and Internal Trade, Ministry of Commerce and Industry, for recognition in one of the aforementioned areas of activity in which that firm is engaged .”
4. In the principal regulations, in regulation 4B, for sub-regulation (4), the following sub-regulation shall be substituted, namely:-
“(4) The Evaluation Committee or the Appraisal Committee, as the case may be, after satisfying itself that the requirements specified in sub-regulations (1) and (2) are fulfilled, shall submit a report to Secretary, Central Boiler Board to either grant or refuse recognition to such firm.”
5. In the principal regulations, for regulation 4C, the following regulation shall be substituted, namely:-
“4C. Recognition of a Firm as Competent Authority, Inspecting Authorities etc.
In case the Evaluation Committee or the Appraisal Committee decides to accord recognition to a firm, a certificate of recognition in one of the Forms (Forms XVI-A to XVI-I) applicable to the area of activity shall be issued by the Secretary, Central Boilers Board and in case the Evaluation Committee or the Appraisal Committee decides to refuse recognition, it shall inform the applicant in writing giving reasons there for.”
6. In the principal regulations, the regulation 4F shall be omitted.
7. In the principal regulations, in regulation 4G, for sub-regulation (1), the following sub-regulation shall be substituted, namely:-
“(1) Any firm not satisfied with the reasons given by the Evaluation Committee or the Appraisal Committee for refusing to accord recognition may file an appeal in writing to the Chairman, Central Boilers Board, for reconsidering its application.”
8. In the principal regulations, in regulation 4J, in sub-regulation (7)A, for clause (ii), the following clause shall be substituted, namely:-
“(ii) A copy of Memorandum of Inspection Book shall be obtained from the concerned boiler inspectorate though the inspecting Authority or directly if working independently, for in-service boilers which shall be returned within a period of one week from the date of completion of final inspection for making necessary entries in the Memorandum of Inspection Book.”
9. In the principal regulations, in regulation 5, in sub-regulation (ii), for the words “Chief Inspector” wherever they occur, the words “Inspecting Authority ” shall be substituted.”.
10. In the principal regulations, in regulation 290, in clause (a), for the first paragraph, the following paragraph shall be substituted, namely:-
“All chests and fittings shall be smooth, sound and free from flaws, cracks or other injurious defects and after completion, the chests shall be hydraulically tested at minimum one and half times the maximum allowable working pressure of the valve for which they are intended.”.
11. In the principal regulations for regulation 361, the following regulation shall be substituted, namely:-
“361. Wrought Bends
The minimum wall thickness at any point on the pipe bend shall be determined according to either of the following methods , namely, (A) or (B):
A) The minimum wall thickness at any point in the finished bend shall not be less than required by equation 91 or 91A given in regulation 350.
The bend thinning allowance shall be selected based on the manufacturing process to ensure the minimum thickness requirements after bending.
The bend thinning allowance thus selected is to be provided on all parts of the cross section of the pipe circumference without any detrimental effects on the final product.
B) The minimum required thickness tm of a bend, after bending, in its finished form, shall be determined in accordance with equation (i) or (ii)
where, tm =minimum wall thickness of a bend in mm,
P = maximum working pressure in Kgs./cm²,
D = outside diameter of pipe in mm,
d = inside diameter of pipe in mm,
f = allowable stress as provided under Regulation 271 in kg/cm²,
e = efficiency factor,
= 1.0 for seamless and for electric resistance welded steel pipes and for electric fusion welded steel pipes complying with the requirements of Chapter II in which the weld is fully radiographed or ultrasonically tested,
= 0.95 for electric fusion welded steel pipes complying with the requirements of Chapter II,
= 0.90 for welded steel pipes for values of t ( minimum thickness of pipe) upto and including 22 mm,
= 0.85 for welded steel pipes for values of t ( minimum thickness of pipe) over 22 mm and upto and including 29 mm,
= 0.80 for welded steel pipes for values of t( minimum thickness of pipe) over 29 mm,
C = 0.75 mm.
I = [4x (R/D)-1] { at the intrados (inside of bend)},
[4x (R/D)-2]
= [4x (R/D)+1] { at the extrados (outside of bend)},
[4x (R/D)+2]
= 1.0 { at the side wall of the bend centre line},
Where, R = Bend radius of pipe bend in mm (see figure below),
D = outside diameter of pipe
Thickness variations from the intrados to the extrados and at the ends of the bend shall be gradual.
The minimum thickness requirements calculated above should be met at the extrados, intrados and bend centre line of the finished bend (see figure below).
The minimum thickness at the ends of the bends shall not be less than the requirements of equation 91 or 91A given in regulation 350.
The bend thinning allowance shall be selected based on the manufacturing process to ensure the minimum thickness requirements after bending.
12. In the principal regulations, in regulation 381, in sub-regulation (1), for clause (b), the following clause shall be substituted, namely:-
“(b) Subject to any discretionary power exercised by the Chief Inspector, he/she shall accept the permissible working pressure of the boiler as certified by the Inspecting Authority in Form-II and Form-III and after inspecting the boiler, the Inspector shall hydraulically test it in accordance with requirements of regulations 379 and a provisional order under section 9 in Form V shall be issued after the hydraulic test. In case the requirements of provisional order are not fulfilled, fresh provisional order shall be issued for a maximum of another six months subject to maximum period of twelve months from the date of issue of first provisional order, without any subsequent inspection and payment of fee.”
13. In the principal regulations, in regulation 382, in clause (a), in the list of States and Union territories, with their distinguishing letters,
(1) after the entry “Himachal Pradesh HP”, the following entry shall be inserted, namely:-
“Jammu and Kashmir JK ”;
(2) after the entry “Laccadive, Minicoy & Aminidivi Islands Li”, the following entry shall be inserted, namely:-
“Ladakh LA.”
14. In the principal regulations, in regulation 391A, in clause (a), after sub-clause (ii), the following sub-clause shall be inserted, namely:-
“(iii) Shell Type Waste Heat Boilers(un-fired) :-
Shell type waste heat boilers (unfired), on completion of a life of twenty-five years, shall be non destructively tested by a Remnant Life Assessment Organisation (RLAO) approved by a Central Boilers Board. Pressure parts, such as shell, endplates, stand pipes etc., of such boilers, shall be inspected by Ultrasonic testing, Magnetic Particle testing and Dye Penetrant testing.
If results are acceptable as per the standards laid down by the Central Boilers Board, a certificate shall be issued by the Chief Inspector! Director of Boilers as the case may be, for extending the life of the boiler for a further period of twelve years or such less period as recommended by the Remnant Life Assessment Organisation. The working pressure of such boilers may be reduced on the recommendation of the Remnant Life Assessment Organisation. This assessment or remnant life by non destructive testing shall be carried out thereafter every twelve years by a Remnant Life Assessment Organisation (RLAO) approved by the Central Boilers Board. Such agency shall work in close coordination with the office of the Chief inspector! Director of Boilers as the case may be.
Note: (1) It shall at the option of the owner to opt for the provisions of Para(i) or para (ii) above or opt for the Remnant Life Assessment of boiler as per para (iii).
(3) Wherever, it is not possible to carry out non destructively testing of boiler for Remnant Life Assessment, provisions of para(i) or para (ii) shall be applicable.”;
15. In the principal regulations, in regulation 393, in clause (d), after the words and figures “prescribed in regulation 385A”, the following shall be inserted, namely:-
“ subject to a maximum of Rs. 50,000.”
16. In the principal regulations, in regulation 395, in clause (b) ,─
(i) in sub-clause (i) for the words and figures “Rs 5000 ”, the following shall be sub st tuted , n mely:-
“Rs. 500” ;
(ii) in sub-clause (ii) for the words and figures “Rs 1,000 ” , the following shall be substituted, namely:-
“Rs. 500.”
17. In the principal regulations, for regulation 395C, the following regulation shall be substituted, namely:-
“395C. Inspection fee for Valves and Flanges.–
(1) Subject to a minimum inspection fee of Rs. 600 per inspection, the fees for inspection of valves shall be charged as under:
(a) Upto 25 mm :- Rs. 15 per piece.
(b) Above 25 mm and upto 100 mm :- Rs. 45 per piece.
(c) Above 100 mm and upto 250 mm :- Rs. 270 per piece.
(d) Above 250 mm :- Rs. 720 per piece.
(2) Fees for inspection of flanges shall be charged as under:
(i) For forged and cast flanges:
(a) upto and including 25 mm for a batch of 50 or part thereof :- Rs. 225
(b) upto and including 25 mm for a batch of 100 or part thereof :- Rs. 390
(c) over 25 mm upto and including 50 mm for a batch of 50 or part thereof :- Rs. 435
(d) over 50 mm upto and including 100 mm for a batch of 25 or part thereof :- Rs. 435
(e) over 100 mm upto and including 250 mm for a batch of 10 or part thereof :- Rs. 465
(f) over 250 mm for a batch of 5 or part thereof :- Rs. 540
(ii) For plate flanges: The fees shall be charged at half the rate as charged for forged and cast flanges .”
18. In the principal regulations, for regulation 395G, the following regulation shall be substituted, namely:-
“395G. Inspection fee for Spares and boiler components.-The inspection fee for all types of coils, namely, economiser coils, superheater coils, reheater coils, the fee shall be charged on the basis of surface area as provided in regulation 385A. For inspection of tube and tube-bends, the fee shall be charged at the rate of Rs. 10 per meter subject to a minimum of Rs. 500.”.
19. In the principal regulations, in regulation 525, in clause (e) the following shall be inserted at the end, namely:-
“In case the requirements of provisional order are not fulfilled, fresh provisional order shall be issued subject to maximum period of twenty four months from the date of issue of first provisional order, without any subsequent inspection and payment of fee.”.
20. In the principal regulations, in Form I, the formula for “Requisite area of Safety Valves” for superheated steam shall be corrected as namely:-
- In the principal regulations, for APPENDIX JB, the following Appendix shall be substituted, namely:-
“APPENDIX JB
[See regulation 376(fff)]
A. Waste Heat Boilers (Fired) upto twenty years of age used exclusively in continuous process plant.
(1) For Waste Heat Boilers (Fired) up to twenty years of age used exclusively in continuous process plant, at the expiry of twelve months and at twenty four months from the date of inspection carried out in accordance with the procedure provided in regulation 390 and certification of fitness issued by the concerned Competent Person in the State, and having satisfied with the operation records as given below received alongwith application in Form XIX duly filled in shall be allowed for running for another period of twelve months:
(a) Operation data for superheater and reheater temperature excursions from the output of Data Acquisition System (DAS) or operation data for superheater temperature excursions maintained in the log sheet temperature record;
(b) History of shut downs during the previous year with their causes and actions taken;
(c) Records of any Non-Destructive test carried out on the boiler pressure parts during the year;
(d) Water quality to the boiler is maintained as per the requirement of such boilers and on line data of the quality be provided through Data Acquisition System (DAS) or through water quality record logbook maintained at plant or at source of water;
(e) Boiler tube failure record (location, number of tubes repaired/replaced).
(2) Inspection shall be carried out by the concerned Competent Person at the expiry of thirty six months as provided in regulation 390. However, in case of shutdown of fifteen days or more any time before expiry of the certification period and after six months of the certification, Competent Person shall be duly informed so that inspection can be scheduled during the said shutdown period.
B. Waste Heat Boilers (Unfired) up to twenty years of age used exclusively in continuous process plant.
(1) For Waste Heat Boilers (Unfired) up to twenty years of age used exclusively in continuous process plant, at the expiry of twenty four months from the date of inspection carried out in accordance with the procedure provided in regulation 390 and certification of fitness by the concerned Competent Person in the State, and having satisfied with the operation records at paragraph “A”, shall be allowed for running for another period of twenty-four months.
(2) Inspection shall be carried out by the concerned Competent Person at the expiry of forty-eight months as provided in regulation 390. However, in case of shutdown of fifteen days or more any time before expiry of the certification period and after six months of the certification, Competent Person shall be duly informed so that inspection can be scheduled during the said shutdown period.
C. Waste Heat Boilers (Fired) more than twenty years of age used exclusively in continuous process plant.
Boiler more than twenty years of age shall continue to be subjected to inspection as provided in regulation 390 every year to the satisfaction of concerned Competent Person in the State. However, if Remnant Life Assessment (RLA) as per the provisions of these regulations is carried out on the boiler and if found satisfactory, then procedure as given at paragraph ‘A’ above shall be followed.
D. Waste Heat Boilers (Unfired) more than twenty years of age used exclusively in continuous process plant.
Boiler more than twenty years of age shall continue to be subjected to inspection as provided in regulation 390 every year to the satisfaction of concerned Competent Person in State. However, if Remnant Life Assessment (RLA) as per the provisions of these regulations is carried out on the boiler and if found satisfactory, then procedure as given at paragraph ‘B’ above would be applicable.”.
[F. No. P- 30011/1/2020–Boilers]
T. S. G. NARAYANNEN, Secy.
Note : The principal regulations were published in the Gazette of India, vide, number S.O. 600, dated the 15th day of September, 1950 and last amended vide G.S.R. 123(E), dated the 17th February, 2020.
