INDIAN BOILERS ACT, 1923
BOILER INSPECTION DEPARTMENT
BOILER
REGISTRY NUMBER
INDEX for FORMS
under Indian Boiler Regulations, 1950
| Form No | Description | Page |
| Form I | Memorandum of Inspection or Registration Book | 1 - 28 |
| Form II | Inspecting Authority's Certificate of Inspection during Construction (Reg. 4-C)…… | 29 |
| Form II-A | Inspecting Authority Certificate of Inspection during Construction in respect of the boiler made to foreign code | 30 |
| Form II-B | Inspecting Authority Certificate of Inspection during the Inspection of boilers for which variation from standard Have been permitted | 31 |
| Form III | Constructor's Certificate of Manufacture and Test (Reg.4-d) | 32-41 |
| Form III-A | Certificate of Manufacture and Test for Steam Pipes | 42-43 |
| Form III-A(I) | Certificate of manufacture and test of steam pipes for Which variations have been permitted | 44-45 |
| Form III-B | Certificate of Manufacture and Test for tubes | 46-47 |
| Form III-B(I) | Certificate of manufacture and test | 48-49 |
| Form III-C | Certificate of Manufacture and Test of Boiler mounting And Fittings. | 50-51 |
| Form III-D | Certificate of Manufacture and Test | 52 |
| Form III-E | Certificate of Manufacture and Test | 53 |
| Form IV | Steel Marker's Certificate of Manufacture and results of Test | 54 |
| Form IV-A | Certificate of Manufacture and Results of Tests in lieu of Form IV. | 55 |
| Form V | Provisional Order under section 9 of the Indian Boilers Act, 1923 | 56 |
| Form VI | Certificate for use of a Boiler | 58-59 |
| Form VII | Inspecting Authority's Certificate of Inspection under Construction | 60 |
| Form VIII | Constructor's Certificate of Manufacture and Test | 61-62 |
| Form IX | Memorandum of Inspections of Registration Book | 63-72 |
| Form X | Provisional Order under the Indian Boilers Act | 73 |
| Form XI | Certificate for the use of an Economiser | 74-76 |
| Form XII | Record of Welder's Qualification/Requalification Tests | 77-79 |
| Form XIII | Qualified Boiler Welder's Certificate | 80-82 |
| Form XIV | Steam Pipes and Connecting Fittings | 83-96 |
| Form XV-A | Questionnaire Inspecting Authority | 97 |
| Form XB-B | Questionnaire Competent Authority | 98 |
| Form XV-C | Questionnaire Well Known Steel Maker | 99 |
| Form XV-D | Questionnaire Well Known Foundry/Forge | 100 |
| Form XV-E | Questionnaire Well Known Tube/Pipe Maker | 101 |
| Form XV-F | Questionnaire Well Known Material Testing Laboratory | 102 |
| Form XV-G | Questionnaire for Well known Remnant Assessmant Organisation | 103 |
| Form XVI-A | Certificate of Approval for Inspection Authority | 104 |
| Form XVI-B | Certificate of Approval for Competent Authority | 105 |
| Form XVI-C | Certificate of Approval for Well Known Steel Maker | 106 |
| Form XVI-D | Certificate of Approval for Well Known Forge | 107 |
| Form XVI-E | Certificate of Approval for Well Known Forge | 108 |
| Form XVI-F | Certificate of Approval for a Well Known Tube Maker | 109 |
| Form XVI-F | Certificate of Approval for Well Known Tube Maker | 109 |
| Form XVI-G | Certificate of Approval for Well Known Pipe Maker | 110 |
| Form XVI-H | Certificate of Approval as Well Known Material Testing Laboratory | 111 |
| Form XVI-I | Certificate of approval as Well known Remnant Life Assessment Organisation | 112 |
| Form XVII | Certificate of Manufacture and Test for Small Industrial Boilers | 113-115 |
FORM I
(Regulation 386 and 487)
INDIAN BOILERS ACT, 1923
BOILER INSPECTION DEPARTMENT
BOILER
REGISTRY NUMBER
___________________________________________________________
Memorandum of Inspection
OR
Registration Book
MISCELLANEOUS
District: ……………………………………………………………………………………………………………………………………………….
Owner: ………………………………………………………………………………………………………………………………………………..
Address of Factory: …………………………………………………………………………………………………………………………………..
____________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________
Nearest Railway Station …………………………………………………………………………………………………
Factory is …………………………………… miles by ……………………………………………………. from station
Work or Factory………………………………………………………………………………………………………..
Working season…………………………………………………………………………………………………………..
____________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________
BOILER registered at : ………………………………………………… on………………………………………………
REGISTER BOOK No………………………………………………… PAGE……………………………………….
REGISTRY NUMBER ………………………………………………. verified on:…………………………………….
APPROVED WORKING PRESSURE:………………………………………………………………………………...
BOILER RATING: ………………………………………………….. INSPECTION FEE:……………………………
REGISTRATION BOOK filed at ……………………………………. on………………………………………………
____________________________________________________________________________________________________________________
Remarks on transfers, etc.: ______________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
PROVISIONAL ORDER AND CERTIFICATE RECORD
Fee |
Date of payment |
Date of Inspection |
Certificate No. and date |
Period of Certificate |
Working pressure |
Boiler Rating |
Evaporation |
Initials of Inspector |
|
PARTICULARS AND DIMENSIONS
Type of boiler: ……………………………………………………………...Leading dimensions …………………………………………………
Maker ………………………………………………………………………Intended working pressure………………..
Place and year of make: ………………………………………………….. Maker’s number:………………………….
Description of boiler:……………………………………………………………………………………………………
____________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Facsimile of }
Makers’ stamp }
Position of stamp:…………………………………………………………………………………………………….
MAKER’S CERTIFICATES
{Name:……………………………………………………………………………………………………………………….
Boiler Maker {
{Manufacture, hydraulic test to …………………………. lbs. Drawing No…………………………………received
Inspecting {Name:……………………………………………………………………………………………………….
Authority {
{Tests of material, construction, supervision, hydraulic test …………………received....................
{ {Name:………………………………………………………………………………………………………………
{Plates{
{ {Process: …………………………………………………………………………………. received…………………
Steel { {Name:…………………………………………………………………………………………………………
Makers {Bars {
{ {Process …………………………………………………………………………………. received…………………
{ {Name: ………………………………………………………………………………………………………………
{Rivets{
{ {Process …………………………………………………………………………………. received …………………
PARTICULARS AND DIMENSIONS – contd.
MAKER’S CERTIFICATE – contd.
Rolling {Plates …………………………………………………………………………………. received………………
Mill {Bars: …………………………………………………………………………………. received………………
{Rivets: …………………………………………………………………………………received …………………….
TEST RESULTS
{Shell ………………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
{Gusset Stays ………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
Plates {Girders ……………….T ………… to …………... tons E ………… to ……………% in ………………...in ……………
{End and side ………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
{Fire & Flanged ……….T ………… to …………... tons E ………… to ……………% in ………………...in.………
{…………..…………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
{………..……………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
{Bars ..………………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
{
{Screw ………………….T ………… to …………... tons E ………… to ……………% in ………………...in.……
{Bars …..……………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
Rivet {
{Manufactured ...……….T ………… to …………... tons E ………… to ……………% in ………………...in.………
{Plates ………………….T ………… to …………... tons E ………… to ……………% in ………………...in.……
Bends {
{Bars ..………………….T ………… to …………... tons E ………… to ……………% in ………………...in.………
Branding {Plates ………………….T ………… to …………... tons E ………… to ……………% in …….in………
Analysis
| Phosphorus | Sulphur |
| % | % |
PARTICULARS AND DIMENSIONS – contd.
CYLINDRICAL SHELL
(a)
Shell or Fire-box
Casing Crown(b)
Barrel or Mud Drum
(c)
Steam & Water Drum or Dome
Names of parts…………………… ________________________________ ______________________________ _______________________________ Number and material of each........................ ________________________________ ______________________________ _______________________________ Length between end plates………………. ________________________________ ______________________________ _______________________________ Length between end plates seam…………… ________________________________ ______________________________ _______________________________ Diameter inside largest belt…………………… ________________________________ ______________________________ _______________________________ Thickness of Plates……………………… ________________________________ ______________________________ _______________________________ Number of belts of plating……………… ________________________________ ______________________________ _______________________________ First or top belt, inside or outside………… ________________________________ ______________________________ _______________________________ Longitudinal seams Position (o’clock)……………………………...
______________________________
_____________________________
__________________________
Kind. L.,S.B., D.B., W………………………... ________________________________ ______________________________ _______________________________ Riveting, S., D., T., C., Z., H., M……………… ________________________________ ______________________________ _______________________________ No. of rivets per pitch…………………… ________________________________ ______________________________ _______________________________ Pitch of rivets……………………………… ________________________________ ______________________________ _______________________________ Diar. of holes, outer rows…………………… ________________________________ ______________________________ _______________________________ Diar. of holes, inner rows……………….............. ________________________________ ______________________________ _______________________________ Distance between rows, outer………………… ________________________________ ______________________________ _______________________________ Distance between rows, inner………………. ________________________________ ______________________________ _______________________________ Distance rivet centre to edge………………… ________________________________ ______________________________ _______________________________ Outer butt strap, width x thickness………… ________________________________ ______________________________ _______________________________ Inner butt strap, width x thickness……....... ________________________________ ______________________________ _______________________________ Circumferential seams No. of seams (end and inner)…………………
________________________________ ______________________________ _______________________________ Kind L., S.B., D.B., W.F. & B……………….... ________________________________ ______________________________ _______________________________ Riveting S., D.T., C.Z., H., M…………………… ________________________________ ______________________________ _______________________________ No. of rivets per pitch…………………… ________________________________ ______________________________ _______________________________ Pitch of rivets……………………………… ________________________________ ______________________________ _______________________________ Diar. of holes…………………………… Distance between rows…………………… ________________________________ ______________________________ _______________________________ Distance between rivet centre to edge………………………… ________________________________ ______________________________ _______________________________
PARTICULARS AND DIMENSIONS – contd.
SHELL END PLATES AND LONGITUDINAL STAYS
Parts and materials hereunder…………………………………………………………………………………………
{Flat, dished, hemispherical (in …………………………………………… pieces), not stayed, not flanged
{Diameter (outside), front ……………………… back, ………………….. crown ………………….. Largest circle ……………………...
{Radius of curvature front ……………………… back, ………………….. crown ……………… ……………………..
{Radius of curvature, corner of flange, shell, ……………..……….furnace,………… uptake,……………………………..
{Plate, thickness, front ………………………. back, ………………….crown ………………tubeplate F.,… B., ……………..
{Attacht. to shell, crown, or front,………………………………………………………………………………………
{Attacht. to shell, back end, ……………………………………………………………………………………………..
{Attacht. to uptake or furnace crown or front,………………………………………………………………….
{Attacht. to furnace flue, back end……………………………………………………………………………………..
Plates {Shell angle …………………………………………. riveting, S., d., pitch …………………….. holes,………….
{furnace or uptake riveting, pitch circle, ……………………………. pitch, ……………………. holes,……………….
{Heml. End sectors, No. ……………………………. riveting S., D., pitch, …………………… holes,………………..
{Steam space doubling plate, front, …………………………………………….. back…………………………………..
{Steam space stiffener or bulb, front, …………………………………………… back …………………………………………………….
{ ____________________________________________________________________________________________________________
{ ____________________________________________________________________________________________________________
{ ____________________________________________________________________________________________________________
{Gusset stay, No.F.E., top, ……………………bottom, …………………… B.E.,…….bottom, …………………..
{Longtl. stays No …………………………….. dia.,………………..threads, …………………………nutted, …………………...
Stays {Longtl. stays pitch, V, ………………………. H …………………………. circle, ………………………….. washers, ………………….
{ ____________________________________________________________________________________________________________
{Diagl. do., ……………………………………………………………………………………………………………………………………
PARTICULARS AND DIMENSIONS – contd.
MANHOLES, HAND AND SIGHT HOLES, DOORS AND STAND
Parts and materials hereunder…………………………………………………………………………………………………………………………
| {No. and position …………………… | ________________________ | _______________________ | _______________________ |
| {Framed or plate flanged………… | ________________________ | _______________________ | _______________________ |
| {Boiler opening, length x width …………… | ________________________ | _______________________ | _______________________ |
| {Frame opening, length x width ………………… | ________________________ | _______________________ | _______________________ |
| {Frame inside, outside, raised, pressed …………. | ________________________ | _______________________ | _______________________ |
| Manholes {Frame solid, welded, cast …………… | ________________________ | _______________________ | _______________________ |
| {Frame section on longtl. axis ………………….. | ________________________ | _______________________ | _______________________ |
| {Door, type and thickness …………………… | ________________________ | _______________________ | _______________________ |
| {Door, if inside, spigot clearance………… | ________________________ | _______________________ | _______________________ |
| {Bolts, No. dia, threads Nut………… | ________________________ | _______________________ | _______________________ |
| {Bolts, pitch circle………………………………. | ________________________ | _______________________ | _______________________ |
| {Compensation ring, width x thickness………… | ________________________ | _______________________ | _______________________ |
| {Riveting, S., D., T., No., rivets dia holes………. | ________________________ | _______________________ | _______________________ |
{No. …………………………… dimensions ………………………………….positions…………………………….
Sight {Compensation rings fitted …………………………………… section…………………………………………….
Holes {Doors, type ……………………... bolts dia., ………………... threads ………………………spigot clearance ……………………….
{Cleaning plugs, No. ……………… dia……………………….position……………………………………………...
Blocks {Height …………………………… dia (outside), top, …………… bottom ……………………. thickness, …………………………
etc. {Standpipe below stop valve, ……………………height, ………….. dia., (outside) …………….. thickness, …………………………
{Flanges……………………………………………………………………………………………………………………………...
____________________________________________________________________________________________________________________
PARTICULARS AND DIMENSIONS – contd.
FIREBOX CASING
Parts and material hereunder…………………………………………………………………………………………
{Length over all, bottom, ………………………………………………………. width over all, bottom……………
{Height foundation seam to inside of crown plate…………………………………………………………………..
{Crown, arched or flat, riveted to or one piece with sides, dia.,………………………………………………………..
Plates {Plate thickness, front, ………………………….sides, …………………………. saddle, ……………….. crown, ……………….
{Radius of corner of flanges, front ………………………………………………. saddle, ………………..crown, ………………..
{Riveting, front to sides, S., D., pitch …………………………………………… holes, ……………….. spacing, ………………
{Riveting, saddle to sides, S., D., pitch …………………………………………… holes, …………………spacing, ……………...
{Crossstays No. …………………..Dia.,……………………threads, ………………………… nutted, riveted, pitch ……………..
RECTANGULAR FIREBOX, COMBUSTION CHAMBER, GIRDERS SMOKE OR WATER TUBES AND SCREW STAYS
Parts and material hereunder, ____________________________________________________________________________________________
{Length inside, bottom ……………………….. top ……………….Width inside, bottom, ……………….. top …………………
{Height, foundation., seam or chamber Bottom to roof ……….. Radius of curve, chamber bottom, …………roof side, ………….
{Roof, flat, curved, cambered, corrugated, stayed to shell or girders, type, ………………………………………………………….
Firebox {Plate thickness, firehole or chamber back, ………………………… sides, ………………….. roof, ……………………………..
of {Plate thickness, bottom ……………….. tube plate, F …………….. B., ……………………. roof and sides in one, …………….
Combustion {Attachment to firebox casing at bottom,……………………………………………………………………
Chamber {Attachment to firebox casing at firehole,………………………………………………………………………
{Foundation Ring section, …………………. riveting, pitch …………………………… holes,……………………….
{Firehole, ring, section, ……………………. riveting, pitch …………………………… holes,………………………
{Firehole, opening …………………………. distance of centre above found. seam,…………………………………..
{Side seams, distance between ……………… riveting, pitch …………………………… holes,……………………..
____________________________________________________________________________________________________________________
PARTICULARS AND DIMENSIONS – contd.
RECTANGULAR FIREBOX, COMBUSTION CHAMBER, GIRDERS SMOKE OR WATER TUBES AND SCREW STAYS – contd.
Firegrate dimensions, ……………………………………………………………….. type …………………………………………………………
{Type ……………………….. Section …………………No. ……………….. lengthwise, crosswise, rest on…………………….
{Distance apart …………….. Bolts, No. .. ……………. pitch, …………….. dia, …………………..threads, …………………..
Girders { nutted, screwed into girder.
{Slings No., ………………… distance apart …………… x ………………… Section ……….x ……… pins dia. ………………
{Slings, attacht. to Shell ………………………………………………………………………………………………………………
{No. plain, ……………………. Stay ………………….. length between tube plates …………………….. make …………………
{Plain, dia. (out) ……………… thickness, ……………. F.E., expd., bead, frld. S.E., Expnd., bead, or …………………………...
{Stay dia. (out) ……………….. thickness, ……………. F.E., expd., bead, nutted, S.E., Expnd., nutted, …………………………
Tubes {Stay dia. (out), over threads, F.E., ……………………. S.E., ………………. Threads ……………… nuts …………………..
{Pitch of plain tubes, V…………….. H …………………… D …………………… C.Z. straight curved. Lie, ……………………
{Pitch of stay tubes, V., ………….× ………………×………………×…………… Marginal pitch, ……………………………….
{Tube, plate No. of rows, V …………………H.,……………… Pitch, V., …………………….H., ………………………………
{F. hole or back do., V ……………………… H., …………….. Pitch, V., …………………….. H., ……………………………...
Screw {Sides, do., V ………………………H., ……………... Pitch, V., ……………………..H., ………………………………
Stays {Roof, do., L., wise ……………… C. wise………….Pitch, L., ……………………. C., ……………………………..
{Bottom, do., L., wise ………………. C. wise ………... Pitch, L., ……………………..C., ………………………………
{Ordinary stays, dia., ……………………….. threads, …………nuts ………………………. riveted, bodies turned to ………. in.
{Marginal, do., ……………………… threads, ……….. nuts ………………………. riveted, bodies turned to ……… in.
{Roof. do., ……………………….threads, … …….. nuts ………………………. riveted, bodies turned to ……… in.
PARTICULARS AND DIMENSIONS – contd.
CIRCULAR FURNACE, CROWN AND UPTAKE
Parts and material hereunder ………………………………………………………………………………………………………………………….
{No. of furnaces, ……………………………………………..….. Type …………………………………………………………
{No. of rings in each ………………………………………Longitudinal. Seams ……………………………………………….
{
{
| { | 1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
12 |
13 |
14 |
15 |
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R |
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L |
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R |
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L |
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R |
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L |
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R |
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L |
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PARTICULARS AND DIMENSIONS – contd.
CIRCULAR FURNACE, CROWN AND UPTAKE – contd.
{Flanges, type, ………………………….. riveting, pitch, …………………….. holes,………………………………
{Caulking ring, …………………………. Radius of corner …………………….Flange, width………………………..
Horizontal {Crosstubes, No. each furnace, ……………………… longitudinal seam, …………………………….. riveted, welded to Flu.and Vertical { Do. dia (outside), top ……………………….. bottom ……………………… Thickness ……………………..
Furnaces {Attacht. to shell at bottom………………………………………………………………………………….
{ Do. do. do. firehole, ………………………………………………………………………………………………….
{Foundn. ring section …………………………………………. riveting pitch, ………………………. holes…………..
{Firehole ring section …………………………………………. riveting pitch, ……………………… holes…………..
{Firehole opening …………………….. x …………………………… distance of centre above foundn. seam…………
{Screw Stays, No. of rows …………… Pitch V., …………….. H ……………………… nearest row to foundn. seam ………….
{Screw Stays, No. of dia. …………….. threads ……………… nuts, ………………….. riveted bodies turned to ……….……in.
____________________________________________________________________________________________________________________
Firegrate dimensions …………………………………………… type………………………………………………
{Flat, dished hemispherical, not stayed, not flanged, Dia. (outside)…………………………………………………
{Radius of curvature ……………………….. corner of flange, furnace ………………. uptake………… largest circle …………...
Crown {Plate thickness, crown …………………….. ogee ring ……………………… Boltstay pitch circle……………
{Attachment. to furnace or ……………………………………………….. to uptake………………………………
{Uptake riveting, pitch circle ……………………….. pitch ……………………………… holes………………….
{Cylindrical, tapered, flanged ………………… Longitudinal seam …………………. Length between seams……………
Uptake {Thickness …………………... Dia. (outside), top …………………… bottom ………………Liner not fitted ……………………
____________________________________________________________________________________________________________________
PARTICULARS AND DIMENSIONS – contd.
WATER TUBES, HEADERS, BOXES AND SUPERHEATER
Parts and material hereunder …………………………………………………………………………………………………………………………
{Main tubes, No. ………………………………………………………………… make ……………………………………….….. {Dia. (outside) …………………………. thickness ………………………… Length between headers or plates ………………….
Tube {Pitch V ……………………………. H …………………… D ………………… C. Z. Straight, curved, Lie, …………………….
{Ends expanded, beaded, belled to ……………………… in. in……………………………………………………….
{Downtake tubes, No. …………………. dia. (outside) ……………….. thickness ……………… Length (exposed) ……………..
{Headers, No. …………………… section (outside) …………………×………………… thickness …………… solid, welded.
Headers {Staggered or straight, Lie ……………………………….. No. tubes in each …………………………..
{Caps round, oval, square, inside, outside, Bolts, Dia. ………………………. threads …………………… nuts ………………...
Mud- {Mudbox, length, …………………….. section (outside) ………..…× …………. thickness ……………………... solid welded.
boxes {Cross boxes No. ……………………... section (outside) ….……… × ….……… thickness ……………………… solid welded.
{Tubes, No. …………………………. dia. (outside) ……………… thickness …………………. make ………………………….
{Straight, curved, Lie ……………………………………………………………………………… Position……………………….
{Ends expanded, beaded, belled to …………………………………………………………… in. in ……………………………....
Superheater {Description of superheating system …………………………………………………………………………………………………
{_______________________________________________________________________________________________________
{_______________________________________________________________________________________________________
{_______________________________________________________________________________________________________
{Firegrate dimension ………………………………………………………Type …………………………………………………...
____________________________________________________________________________________________________________________
DESCRIPTION OF INTEGRAL ECONOMISERS
PARTICULARS AND DIMENSIONS – contd.
MOUNTINGS AND FITTINGS
_________________________________________________
Number Diameter Type Material Bolted to
_________________________________________________
{Safety . . . . _________________________________________________
{Do . . . . _________________________________________________
{M. Stop . . . . _________________________________________________
Valves {A. Do . . . . _________________________________________________
etc. {Feed . . . . _________________________________________________
Chests {Blow down . . . . _________________________________________________
{Scum . . . . _________________________________________________
{Injector . . . . _________________________________________________
_________________________________________________
{Water gauges, No……………………… type ……………………. Test cocks No. ………………………………………………
{Water gauges, top of lower nut is ………………………………… inches above …………………………………………………
{Test cocks, bottom cock is ………………………………………… inches above …………………………………………………
{Pressure gauge, Type ………………………….. dia. …………….. in range ………………………………………………… lbs.
{Pressure gauge, Maker …………………………. No. …………….. red line at ………………………………………………. lbs.
Miscellaneous {Tester attachment type …………………………. screw ………………………. position ………………………………………...
Fittings {Hose attachment type ……………………………screw .………………………. position ………………………………………...
{Fusible plug, type ………………………………………………………………. position ………………………………………..
{Blow down elbow, material ………………………………………… waste pipe, separate, connected to …………………………
{Centre of feed inlet is ………………………….. inches above ……………….. on right, left, side ……………………………...
{Feed apparatus ……………………………………………………………………………………………………………………….
Additional fittings…………………………………………………………………………………………………………….……………….
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
CALCULATIONS
SHELL, BARREL, S. & W. DRUM, F.C. CROWN, DOME, M. DRUM RIVETED JOINTS
Parts |
Joint Fig. No. |
Longitudinal |
Joint Fig. No. |
Circumferential |
(A) ……………………………………. |
P…….D .…...T.… N C S1 |
P……. D……...T N. C. S1 |
||
(B) ……………………………………. |
||||
(C) ……………………………………. |
||||
Actual |
Rule |
Actual |
Rule |
|
Max. Pitch ……………………………. |
||||
Outer Rows …………………………... |
||||
Inner Rows …………………………… |
||||
Edges …………………………………. |
||||
Wide Strap ……………………………. |
||||
Narrow Strap …………………………. |
100 (P – D) 100 (P – D)
Plate %………………………………… -------------- = % -------------- = %
P P
100 x A x N x C x S1 100 x A x N x C x S1
Rivet %………………………………… ------------------------- = % ------------------------- = %
P x T x S P x T x S
100 (P – 2D) 100 x A x C x S
Combined %…………………………… --------------- + ------------------- %
P P x T x S
(t – 2) x S x J
Working Pressure ……………………… t……..S…....J…....C…....D…...W.P. = ---------------- = lbs. Least Pressure
C x D ………… lbs.
CALCULATIONS –contd.
FLAT END PLATES AND GUSSET STAYS
Plate stiffness
| Dimensions | Front | Back | FRONT END |
| {
t…………………………… Thickness { {t1………………………………… {I ……………………… { {I – II…………………….. { {II – III…………………… { {III…………………….. {IV………………………… {IV – V …………………………… { {Over Furnaces………... {Below Do …………….. {Manhole ………………
|
______________________
_____________________ _____________________ _____________________ ____________________ _____________________ ___________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ _____________________ |
____________________
_____________________ ______________________ _____________________ ______________________ _____________________ ______________________ _____________________ ______________________ _____________________ _____________________ _____________________ _____________________ _____________________ ____________________ |
(t – 1)2 W.P. = -------- = lbs. D2 Around Manhole [(t – 1)2 + (t1– 1)2] W.P.= ---------------------- = lbs. D2 BACK END (T – 1)2 W.P. = ----------------- = lbs. D2 |
CALCULATIONS – contd.
FLAT END PLATES AND GUSSET STAYS – contd.
AREAS (A) SUPPORTED BY GUSSET STAYS
| Dimensions {Mid.………………………… {I ……………………………. Length of Lines II……… {III………….. {IV.......…….. {V or Mid.{I – I……………… Distance {I – II …………….. between {II – III ………… Lines {III – Apex. ………… {IV – Apex. …………………. {IV – V or Mid. …………
|
Front ______________________ _______________________ ______________________ _______________________ _______________________ _______________________ _______________________ _______________________ |
Back ______________________ ______________________ _______________________ ______________________ _______________________ _______________________ _______________________ _______________________ |
FRONT END Gussets Areas I. = Sq. in. II. = " III. = " IV = " V = " BACK END I = " II = " III = " IV = " V = " |
PLATE MARGINS
W. P……………
3.7(t – 1) 3.47 (t – 1)
-------------------------- = ins. -------------------------- = ins.
Ö W. P. Ö W. P.
_______________________________________________________________________________________________
LEAST PRESSURE lbs.
_____________________________________________________________________________________________________
CALCULATIONS – contd.
FLAT END PLATES AND GUSSET STAYS – contd.
GUSSET STAYS PARTICULARS
Gusset Plate, thickness ……………………….. tons ……………………………….. angles ………... x ……….. x ………….
{Gusset N1 N2 N3 N4 D1 D2 D3 D4 G G1 Toe Rivets
{ ___________________________________________________________________________________
{ F
{ I. _____________________________________________________________________________
{ B
{ ___________________________________________________________________________________
{ F
Number and { II. _____________________________________________________________________________
Diameter { B
of Rivets { ___________________________________________________________________________________
and Section { F
& of Stays { III. _____________________________________________________________________________
{ B
{ ___________________________________________________________________________________
{ F
{ IV. _____________________________________________________________________________
{ B
{ ___________________________________________________________________________________
{ F
{ V. _____________________________________________________________________________
{ B
{ ___________________________________________________________________________________
CALCULATIONS – contd.
GUSSET STAY CALCULATIONS
I II III IV V { F{N1 x A1…. _________________________________________________________________________________
{ B
{_______________________________________________________________________________________________
{ F
{N2 x A2 x 1.875 __________________________________________________________________________________
{ B
Coefficient {_______________________________________________________________________________________________
{ F
{N3 x A3 x 1.875 __________________________________________________________________________________
{ B
{_______________________________________________________________________________________________
{ F
{N4 x A4………___________________________________________________________________________________
{ B
{_______________________________________________________________________________________________
{ F
{(G-N2D2)(t-2) .037 ________________________________________________________________________________
{ B
{________________________________________________________________________________________________
{ F
{(G1-D2)(t-2) .037__________________________________________________________________________________
Working { B
Pressur {________________________________________________________________________________________________
{ F
{8500 x C ……____________________________________________________________________________________ Least Pressure
{ A B ……….…… lbs.
{_________________________________________________________________________________________________________
CALCULATIONS – contd.
Least Pressure
CALCULATIONS – contd.
| SAFETY VALVES (A) (B) (C) |
LEVER AND WEIGHT VALVES High Steam and Low Water Type ( ) ( ) |
||
| No. valves each chest……… | _______________________ | Weights {B………………… |
_____________________ |
| Type ……………………… | _______________________ | {L………………… | _____________________ |
| Diameter of valve………… | _______________________ | {V……………… | _____________________ |
| Diameter of neck…………. | _______________________ | Distances {B to F……………… |
_____________________ |
| Diameter of outlet………… | _______________________ | {G to F…………… | _____________________ |
| Distances {G to F……………… | _______________________ | {V to F…………… | _____________________ |
| {V to F……………… | _______________________ | ||
| Balanced Lever ( ) | Unbalanced Lever ( ) | ||
| [W.P. (A - a) – V] V
to F = ins --------------------------------- B Small Valve ( )
|
[W.P. (A - a) – V] V
to F – (G to F) L ------------------------------------ B Ordinary Type Unbalanced (Lever) ( ) W.P. (A – V)] V to F – (G to F) L -------------------------------------- B DEAD WEIGHT VALVE ( ) =W.P. x A lbs.
|
= ins
= ins |
|
| Weights { Plates_______________ {Casing_______________ {Valve _______________ |
|||
CALCULATIONS – contd.
SAFETY VALVES – contd.
SPRING LOADED VALVE
Range of compression ………………………………. inches. Load compression……………………… inches.
L = (A x W.P.) ; D = ; C ; K = ; d = "
B = ; H = ; W.P. ; A = ;
Round Section Square Section Rectangular Section
10000n x d2 33333 x d2 160000 B2 x H2
W.P. = -------------- W.P. = ------------- W.P. = -----------------------
DACK DACK DACK (3B + 1.8H)
REQUISITE AREA OF SAFETY VALVES
For Saturated steam For Superheaded steam
As = A Ö 1.5T
E 1 + -------
A = -------- 1000
C.P.
E = ; C = ; P = ; A =
AS = T = ; A =
NOTES ON WORKING OF BOILER
Boiler is used for……………………………………………………………………………………………………...
Constant, intermittent or seasonal work………………………………………………………………………………..
Is boiler relieved by square boiler? …………………………………………………………………………………..
How long worked between cleanings? ……………………………………………………………………………….
Most suitable time for inspection ………………………………………………………………………………………….
Pump available for hydraulically testing boiler? ……………………………………………………………………………
Feed water used, town well, surface or jet condenser……………………………………………………………………..
Nature of water ……………………………………………………………………………………………………….
Fuel used ……………………………………………….
Are printed instructions kept near boiler? ………………………………………………..
Period between cleanings approved by Inspector…………………………………………………………………….
CALCULATIONS – contd.
HEATING SURFACE
Total Heating Surface ……………………………………………………………………………………………… sq. ft.
Boiler Rating ……………………………………………………………………………………………………………
__________________________________________________________________________________________________________________
Calculations made by ……………………………. on ………………………… submitted on…………………………..
Calculations checked by …………………………. on…………………..………………………………………………
Least Pressure, that for …………………..…………………………………………………………………………..… lbs.
Approved working pressure………………..………………………………………………………………………… lbs.
Chief Inspector’s remarks and signature …………………..……………………….…………..…………………………
____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
HYDRAULIC TEST REGISTRATION
Inspector ………………………………….. Date of test ………………………… Test pressure …………………………………………… lbs.
Duration of test ……………………….. mins. Boiler pressure, gauge No. ………………………………..use at test …………………………….
Boiler pressure gauge compared with ………………………... on ……………………………………… found ………………………………….
Position of boiler at test ……………………………………………………………………………………………………………………………….
Brickwork ………………………………………………………………… Lagging ……………………………………………………………….
Condition of boiler under test …………………………………………………………………………………………………………………………
Condition of boiler mountings under test ……………………………………………………………………………………………………………
RIGHT HAND
Ring |
Nos |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
12 |
13 |
14 |
15 |
Before Test |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
During Test |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
After Test |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Bulging |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Permt. Set |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
16.10.2001
HYDRAULIC TEST (REGISTRATION) – contd.
LEFT HAND
Furnace Gaugings
Ring |
Nos. |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
12 |
13 |
14 |
15 |
Before Test… |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| FFDuring Furnace Gaugings During Test Test… |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
After Test…... |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Bulging……... |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Permt. Set…… |
V H |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
FRONT END BACK END Sketch position of gauge points
End Plate Gaugings
_____________________________________________
Gauge Points |
A |
B |
C |
D |
A |
B |
C |
D |
Before Test….. |
||||||||
During Test…. |
||||||||
After Test…… |
||||||||
Bulging……… |
||||||||
Permt. Set…… |
STEAM TEST (REGISTRATION)
Inspector _____________________________________ Date of test ______________________________________________
Approved working pressure ______________________ lbs.__________ Test pressure ______________________ lbs. ______
Inspector’s pressure gauge _______________________ Boiler pressure gauge No.___________________________________
Boiler connections _____________________________ Condition of fire __________________________________________
Fuel used _____________________________________ Draught _________________________________________________
Safety Valves lifted at (A) ________________________ lbs. (B) _________________ lbs. (C) _____________________ lbs.
Beginning |
5 mins. |
10 mins. |
14 mins. |
Difference |
|
Timing of test ….……………………………… |
|||||
Height of water in glass ………………………. |
|||||
Pressure by Inspector’s gauge ………………… |
|||||
Pressure by Boiler gauge ……………………… |
Accumulation of pressure, 100(-) = % ______________________________________________________________________
Do safety valves efficiently relieve boiler? ___________________________________________________________________
Condition of boiler under steam ___________________________________________________________________________
Condition of mountings under steam ________________________________________________________________________
Loading of valves at blowing pressure (A) ___________________________________________________________________
Loading of valves at blowing pressure (B) ___________________________________________________________________
Loading of valves at blowing pressure (C) ___________________________________________________________________
Thickness of washers or ferrules ___________________________________________________________________________
_____________________________________________________________________________________________________
Feed pump or injector worked _____________________________________________________________________________
Water gauges tested _____________________________________________________________________________________
Boiler Attendant _______________________________________________________________________________________
Limit of load on safety valves to be entered in Certificate _______________________________________________________
INSPECTOR’S NOTES
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PARTICULARS OF BOILER ATTENDANTS
Grade |
Name |
No. and year of Certificate |
Date of Employment |
FORM II
INSPECTING AUTHORITIES CERTIFICATE OF
INSPECTION DURING CONSTRUCTION
[REGULATION 4 (c)(1)]
DESIGNATION OF INSPECTING AUTHORITY
We hereby certify that the __________ type, boilers; length __________ feet ________ inches; diameter __________ feet ______________ inches; working pressure _____________ lbs. built by Messrs _________________________________________________________________________________________
at _______________________ under shop Number _______________ was constructed under our supervision and inspected at various stages of construction by the Inspecting Officer and that the construction and workmanship were satisfactory and in accordance with the Standard Conditions for the design and construction of land boilers under the Indian Boilers Act, 1923.
The boiler is stamped on the front end plate with our stamp as shown hereunder:-
_________________________________________________________________________________________
Maker’s Name _______________________ Year of Make _____________
Works number _______________________
Tested to _____________ lbs. ___________ on ___________
W. P.________________ lbs.
Inspecting Officer’s or Inspecting Authority’s Official Stamp.
*The boiler on completion was
------------------------------------ subjected to a water pressure test of ___ lbs.
The drum and headers were
per square inch in the presence of the Inspecting Officer on ________ 19 _______
and satisfactorily withstood the test.
*Samples of materials used in the constructions of the boiler were tested in the presence of the Inspecting Officer and found to comply with the requirements.
All welded seams were subjected to physical tests and radiographic examination wherever applicable and found satisfactory.
NOTE.- Strike off this paragraph where no such test has been carried out and the certificate in Form IV by a Well-known Maker is intended to be furnished.
We have satisfied ourselves that the construction and dimensions of the boiler are as shown in the Maker’s Drawing No.___________________ signed by us, and that the particulars entered in the Maker’s certificate of manufacture in Form III countersigned by us are correct to the best of our knowledge and belief.
Signature of Inspecting Authority
Dated at ____________ this ________________ day of _____________19 .
____________________________________________
*Strike out what is not applicable.
FORM II-A
INSPECTING AUTHROTIES CERTIFICATE OF INSPECTION
DURING CONSTRUCTION IN RESPECT OF A BOILER MADE
TO FOREIGN CODE FOR EXPORT.
(Regulation 3 A.)
Designation of Inspecting Authority
We hereby certify that the ___________________ type, boilers; length, _____________ diameter, _________ working pressure ___________ built by Messrs _________________________________________ at _________________
under shop Number ________________ was constructed under our supervision and inspected at various stages of construction by the Inspecting Officer and that the design, construction and workmanship were satisfactory and in every respect in accordance with _______________ Code/Specification.
The boiler is stamped as under:-
The boiler on completion was tested to ____________ in the presence of the Inspecting Officer on _________________ and it satisfactorily withstood the test. Details of tests and inspections are furnished with this certificate.
We have satisfied ourselves that the design, construction and dimensions of the boiler are as shown in the Maker’s Drawing No.________________ approved and signed by us, and that the particulars entered in the Maker’s certificate of manufacture are correct to the best of our knowledge and belief. Maker’s certificate signed by them and countersigned by us, as required by the _____________ Code/Specification, is enclosed.
Signature of Inspecting Authority
FORM II-B
INSPECTING AUTHORITIES CERTIFICATE OF INSPECTION DURING
CONSTRUCTION OF BOILERS FOR WHICH VARIATIONS FROM
STANDARD CONDITIONS HAVE BEEN PERMITTED.
(Regulation 4 (c) (i) Note)
DESIGNATION OF INSPECTING AUTHORITY
We hereby certify that the ________________ type boilers; length ___________ diameter _________ working pressure ____________ built by Messrs ________________________ at _______________ under Shop Number ______________ was constructed under our supervision and inspected at various stages of construction by the Inspecting Officer, and that the design, construction and workmanship were satisfactory and in accordance with the variations from the standard conditions laid down in the Indian Boiler Regulations, 1950, for material, design and construction features have been permitted by the Board or Inspecting Authority under the Indian Boilers Act, 1923.
The Boiler is stamped on the front end plate with our stamp as shown hereunder:-
Maker’s Name _______________________ Year of Make ___________________
Works Number ______________________________
Tested to _________________________ on ________________
W. P. _____________ Inspecting Officer’s or Inspecting Authority’s official stamp.
*The boiler on completion was
The drum and header were subjected to a water pressure test of __________________
in the presence of the Inspecting Officer on ___________ 19 _____ and satisfactorily withstood the test.
Samples of materials used in the construction of the boiler were tested in the presence of the Inspecting Officer and found to comply with requirements. All welded seams were subjected to physical tests and radiographic examination wherever applicable and found satisfactory.
Note:- Strike off this paragraph where no such tests have been carried out and the certificate in Form IV by a well-known maker is intended to be furnished.
We have satisfied ourselves that the constructions and dimensions of the boiler are as shown in the Maker’s Drawing No.______________________ signed by us and that the particulars entered in the Maker’s certificate of manufacture in Form III countersigned by us, are correct to the best of our knowledge and belief. Particulars of variations from the standard conditions laid down in the said regulations as permitted by the Board or Inspecting Authority are enclosed.
Signature of Inspecting Authority
Dated at ________________ this _____________ day of _______________19___.
*Strike out what is not applicable.
FORM III
WORK ADDRESS
Constructor’s Certificate of Manufacture and Test
[REGULATION 4 (c)(III)]
1. Description …………………….. Constructor’s Name and address ______________________
Manufactured for/Stock purposes _____________________
_______________ Contract No._______________________
Type of boiler ________________ Length overall ________
Diameter inside Largest belt _________________________
Design pressure ___________________________ lbs./sq. in.
Intended working pressure __________________ lbs./sq. in.
Shop Number of boiler ______________________________
Year of Manufacture _______________________________
Total heating surface __________________________ sq. ft.
Final Temperature of steam (Design) _________________of
Grate area ___________________________________ sq. ft.
Brief description of boiler ___________________________
_________________________________________________
2. Parts Manufactured at the contractor’s works Name of part(s) ___________________________________
Description _______________________________________
_________________________________________________
Leading dimensions ________________________________
Manufactured by __________________________________
Identification marks ________________________________
Part(s) manufactured inspected at all stages of construction
by ______________________________________________
______________________________ (Inspecting Authority).
Certificates furnished (Constructor’s, Steel Maker’s and Inspecting Authority’s etc.) __________________________
Part(s) hydraulically tested and internally Inspected after test by ______________________________________________.
3. Parts manufactured outside the
constructor’s works. Name of part(s) _______________________
Description ___________________________
Leading dimensions ____________________
Manufactured by ______________________
Identification marks ____________________
Part(s) manufactured, inspected at all stages of construction by _____________________
_________________ (Inspecting Authority).
Certificates furnished (Constructor’s Steel Maker’s and Inspecting Authority’s etc.) ________________ Part(s) hydraulically tested and internally Inspected after test by ________________________________________________.
NOTE.- Similar information is to be furnished for each part manufactured outside the Constructor’s Works.
4. Construction:
Riveted/composite construction shells/drums/Miniature Boilers: The construction is in accordance with Chapter III/XIV of the Indian Boiler Regulations.
Number of longitudinal seams in shell/drum in each belt________________________________________
Number of longitudinal seams in furnace in each ring _________________________________________
Number of circumferential seams in shell/drum ______________________________________________
(including end seams) __________________________________________________________________
Number of circumferential seams in the furnace ______________________________________________
Details of repairs, if any, carried out in welded seams during construction _________________________
Details of heat treatment ________________________________________________________________
The longitudinal seams are welded/riveted and have ______________________________________
rows of rivets in inside strap and ___________________________________ rows of rivets in outside strap.
Rivet holes are ________________________ diameter and number ________________ per pitch of ______________________________.
Butt straps cut from plates and bent to required curvature in ____________________. The circumferential seams joining rings of shell are ________________________ Jointed and single/double riveted/welded.
Rivet holes are ____________________ diameter and number _______________ per pitch of ____________________________.
The shell end seams are _____________________________ Jointed and single/double riveted/welded.
Rivet holes are __________________________ diameter and number ____________________ per pitch of _____________________________.
Details of seams as in drawing No.___________________________.
All welded seams are subjected to Radiographic examination to the satisfaction of the Inspecting Authority, where required.
Shell type boilers of welded construction – The construction is in accordance with Chapter XII of the Indian Boiler Regulations.
Number of longitudinal seams in shell in each belt _______________________________.
Number of longitudinal seams in furnace _______________________________________.
Number of circumferential seams in shell _______________________________________.
Number of circumferential seams in furnace _____________________________________.
Details of repairs, if any, carried out to welded seams during construction _________________________.
Details of heat treatment __________________________________.
All welded seams were subjected to radiographic examination to the satisfaction of the Inspecting Authority, where required.
Fusion welded Electrode Boilers – The construction is in accordance with Chapter X of the Indian Boiler Regulations, 1950.
Number of longitudinal seams in shell _________________________________________________.
Number of circumferential seams (including end seams) ___________________________________.
Details of repairs, if any carried out to welded seams during construction _________________________.
Details of heat treatment _____________________________________.
All welded seams were subjected to radiographic examination to the satisfaction of the Inspecting Authority, where required.
(d) Fusion welded and seamless forged drums of water tube boilers - The construction is in accordance with Chapter V of the Indian Boiler Regulations, 1950.
Number of longitudinal seams in each ring _________________________________________________.
Number of circumferential seams _________________________________________________________.
Details of repairs, if any, carried out to seams during construction _______________________________.
All welded seams were subjected to radiographic examination to the satisfaction of the Inspecting Authority.
Furnace seams – The longitudinal seams are welded/riveted. The cross seams joining rings are of __________________________________ type ________________ riveted/welded".
Boiler parts and fittings |
Material |
Smelter |
Make |
Inspecting Officer |
Remarks |
5. Material Plates…………………… Manufacturer Plates…………………… Rivet bars………………. Stay bars………….……. Angles………………….. Bolts……………………. Tubes…………………… Tubes…………………… Tubes…………………… Girders…………………. Boxes…………………… Headers…………………. Headers…………………. Manhole frames………… Manhole doors…………. Manhole………………… Sighthole doors………….. Stand blocks……………… Stand pipes………………. Stop valve chests………… Safety valve chests………. Feed valve chests………… Blow down valve………… Blow down elbow pipe….. Water gauge mountings….. |
NOTE.- Under "material" enter against appropriate items: "Steel Simens Martin Open Hearth acid (or basic) process", "Wrought Iron, Brand………………………….", "Cast Steel Process" ….. etc. etc. and under "Remarks" a brief explanation of process of manufacture where necessary e.g., "Solid drawn Lap welded", "Solid Pressed", tested by Makers…………… lbs. per sq. inch etc.
Part of Boiler |
Thickness of plates in 32nd or diameter in inches |
Tensile strength limits to tons |
Elongation limits to % |
Gauge length inches |
Brand & No. of plate |
1 2 |
3 |
4 |
5 |
6 |
7 |
6. Thickness of Plates etc., and tensile test, Limit Cylindrical Shell plates Shell………….…………. Buttstraps………………... Steam & Water drums…… Wrapper plate (1)………... Tube plate (1)……………. Wrapper plate (2)……….. Tube plate (2)……………. Wrapper plate (3)………... Tube plate (3)……………. |
|||||
Cylindrical shell Plates Barrel…….………………. Fire Box casing crown…... Dome…………………….. Mud or bottom drum (1).... Mud or bottom drum (2)… Mud or bottom drum (3)… |
|||||
Shell end plate and drum Heads Front end shell……………….. Front end shell steam and water drum (1)…………...…... Front end shell steam and water drum (2)……………….. Front end shell steam and water drum (3)……………….. Front end shell Mud Drum (1)……………………… Front end shell Mud Drum (2)……………………… Front end shell Mud Drum (3)…………………….. Back end shell………………. Back end shell steam and water drum (1)………………. Back end shell steam and water drum (2)………………. Back end shell steam and water drum (3)……………… Back end shell Mud drum (1)…………………….. Back end shell Mud drum (2)……………………... Back end shell Mud drum (3)……………………... Shell crown………………….. Dome end……………………. Saddle……………………….. Fire box casing sides………... Doubling plate Front……….. Doubling plate back………… |
1 2 |
3 |
4 |
5 |
6 |
7 |
Flanged and fire exposed Plates Furnace circular (Plain)…... Furnace circular………….. Firnace circular (Corrugated)……………… Fire box crown…………... Fire box side……………... Fire box front…………….. Fire box tube……………... Uptake……………………. Smoke box tube………….. Com. Chbr. wrapper……... Com. Chbr. back…………. |
THICKNESS OF PLATES ETC. AND TENSILE TEST LIMITS
1 2 |
3 |
4 |
5 |
6 |
7 |
Tubes Cross tubes……………… Smoke tubes (Plain)……. Smoke tubes (Stay)…….. Water tubes (Bottom or Front bank)……………… Water tubes (top or rear Bank)…………………… Balance tubes (Steam)…. Balance tubes (Water)…. Superheater tubes………. Superheater tubes………. Superheater tubes………. Water wall tubes………... Water wall tubes………… Integral Economiser tubes. |
|||||
Headers and cross Boxes. Sectional headers………... Water wall headers (1)….. Water wall headers (2)….. Water wall headers (3)….. Water wall headers (4)….. Water wall headers (5)….. Water wall headers (6)….. Integral Economiser headers (1)……………… Integral Economiser headers (2) Superheater headers (1)…. Superheater headers (2)…. Superheater headers (3)…. Superheater headers (4)…. Superheater headers (5)…. Superheater headers (6)… Mud boxes (1)……….. Mud boxes (2)……….. Mud boxes (3)……….. Mud boxes (4)……….. |
|||||
Stays and Bolts Gusset stay plates……. Longitudinal…………. Cross…………………. Screw………………… Roof………………….. Firebox roof slings…… Firebox roof pins…….. Girder bolts…………... Shell angle bolts…….... Uptake angle bolts…… Manhole bolts………... Sighthole bolts……….. |
|||||
Miscellaneous Firebox girders……….. End plate stiffeners…... Shell angle…………… Furnace angle………… Uptake angle…………. Gusset angle………….. Manhole Compensation ring…………………... Manhole frame……….. Manhole cover……….. Sighthole compensation ring…………………... Sighthole doors………. Stand blocks………….. Stand pipes…………… |
7. Details of Drums
No. |
Nomen-clature |
Nominal dia. |
Length |
Shell Plate Thick- Inside ness radius in 32nds in. in. |
Tube Plate Thick- Inside ness radius in 22nds in. in. |
Head Thick- ** Radius Ness Type of dish in 32nds in. in. |
Manhole No. and size |
Hydro-static test lbs.sq. in. |
1 |
2 |
3 |
4 |
5 6 |
7 8 |
9 10 11 |
12 |
13 |
|
|
**Indicate (1) Flat (2) Dished (3) Ellipsoidal (4) Hemispherical.
8. Headers and Boxes
No. |
Size and shape |
Thick-ness in 32nds in. |
Head or end Shape Thickness in 32nds in. |
Hydrostatic test lbs./sq. in. |
Water Wall Headers 1 2 3 4 5 6 |
||||
Integral Economiser headers 1 2 |
||||
Superheaters Headers 1 2 3 4 5 6 |
||||
Mud boxes 1 2 3 4 |
9. Tubes
Sl. No. |
Nomenclature |
Outside diameter in inches |
Thickness in 100ths in. |
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. |
Cross tubes…………………………………………. Smoke tubes (Plain)………………………………… Smoke tubes (Stay)…………………………………. Water tubes (bottom or front bank)………………… Water tubes (rear or top bank)……………………… Balancer tubes (Steam)……………………………... Balancer tubes (Water)……………………………... Superheater tubes…………………………………… Superheater tubes…………………………………… Water wall tubes……………………………………. Integral economiser tubes………………………….. |
10. Mountings
No. |
Nomenclature |
Material |
Type |
No. |
Size |
1. 2. 3.
4. 5. |
Main stop valve…………… Auxiliary stop valves……... Safety valves (a)………….. (b)………….. (c)………….. Blow down valve(s)……… Feed check valves………… |
11. Boilers:
Details of safety valves and test results:
Manufacturer…………………………………………
Identification marks of valves……………………….
Maker’s No…………………………………………..
Type………………………………………………….
Lift (mm)……………… Drawing Nos……………...
Valves details:-
Material………………………………………………
Valve Seat……………………………………………
Flat/Bevel…………………………………………….
Diameter of valve seating…………………………….
Valve Body:-
Material………………………………………………
Opening at neck……………………………………..
Opening at outlet…………………………………….
Springs:-
Material………………………………………………
Process of manufacture………………………………
Chemical composition……………………………….
Dimensions:
Outside diameter of coil……………………………..
Section of wire………………………………………
Number of coils……………………………………..
Free length of coils………………………………….
Test results:-
Place of test………………….. date…………………
Closing down pressure………………………………
Remarks:-
Does the valve chatter?………………………………
Does the valve seat leak?…………………………….
Blow off pressure…………………………………….
Type of valve and extract of test results……………..
Type of valve…………………………………………
Place of test………………….. date …………………
Constant ‘C’ by test results…………………………..
Capacity of the valve for the intended blow
off pressure…………………………………………..
Signature of Maker’s representative Inspecting Authority
witnessing tests.
12. Certified that the particulars entered herein in manuscript by us are correct and that parts and fittings in sections 2 to 11, against the names of which entries are made, have been used in the construction and fittings of the boiler.
The particulars shown against the various parts used are in accordance with the enclosed certificates from the respective Makers.
The design of the boiler is that as shown in Drawing Nos……………………..
The boiler has been designed and constructed to comply with the Regulations under the Indian Boilers Act, 1923, for a working pressure of ______________lbs.
per square inch at our Works above-named and satisfactorily withstood a water test of ____________________ lbs. per square inch on the __________ day of _______________, 19___ in the presence of our responsible representative whose signature is appended hereunder.
MAKER
(Signature of Maker)
or
Secretary of Firm.
Name and Signature of Engineer who witnessed test.
Designation
Dated at ______________ the _____________ day of ____________ 19___.
Official Seal
Name and Signature of
Inspecting Authorities.
FORM III-A
Certificate of Manufacture and test
[REGULATION 4(e)]
Name of part…………………………………………………………………………
Maker’s name and address…………………………………………………………..
Design pressure………………………………………………………………………
Design temperature…………………………………………………………………..
Material
Process of manufacture………………………………………………………………
Fully killed/rimmed………………………………………………………………….
Chemical composition……………………………………………………………….
Pipes
Main dimensions……………………………………………………………………..
Tolerances……………………………………………………………………………
Mode of manufacture………………………………………………………………..
Identification marks………………………………………………………………….
Drawing numbers……………………………………………………………………
Bend test on pipe…………………………………………………………………….
Bend test on weld……………………………………………………………………
Flattening test………………………………………………………………………..
Tensile strength………………………………………………………………………
Mode of attachment of flanges………………………………………………………
Flange particulars……………………………………………………………………
Size of branches……………………………………………………………………..
Mode of attachment of branches…………………………………………………….
Heat treatment………………………………………………………………………..
Final hydraulic test…………………………………………………………………..
NOTE.- In addition, the following information in respect of the material shall be furnished in a tabular form in conformity with the requirements of regulation 4(c)(vi) or the note thereto, as the case may be. The information may be given from the established test data or if the material is of standard quality an extract from the standard may be furnished instead.
Met-al tem-erat-ure upto ° C |
250 |
275 |
300 |
325 |
350 |
375 |
400 |
425 |
450 |
475 |
500 |
525 |
550 |
575 |
600 |
Et |
|||||||||||||||
Sc |
|||||||||||||||
Sr |
Tensile strength at 20° C.
Where
Et = Yield point at temperature t (0.2% proof stress)
**Sc = Average stress to produce an elongation of 1% (creep) in 100,000 hours at various working metal temperatures.
**Sr = Average and lowest stress to produce rupture in 100,000 hours at the various working metal temperatures.
Temperature range in the table may extend upto the limit of applicability of the material.
The value of Sc and Sr need be furnished only in respect of Pipes/Tubes intended to be used for working metal temperature above 454° C (850° F).
Certified that the particulars entered herein are correct.
The particulars of fabricated component are show in drawing No._____.
The part has been designed and constructed to comply with the Indian Boiler Regulations for a working pressure of _______________________ and temperature ____________ and satisfactorily withstood a water test of _________
on the ___________ day of ____________ 19___, in the presence of our responsible representative whose signature is appended hereunder.
Maker’s Representative Maker ___________________
(Name and signature)
We have satisfied ourselves that the pipes have been constructed in accordance with chapter VIII. The tests conducted on the samples taken from the finished pipes have been witnessed by us and the particulars entered herein are correct.
Place _______________
Date ________________
Name and signature of
Inspecting Authority.
NOTE (1).- This form is intended for the use of both pipe manufacturers and pipe fabricators. Only such of the columns or paragraphs that are applicable, or information that can be obtained and furnished from other certificates, need be filled or entered in this form.
NOTE (2).- In the case of fabrications made from steel pipes obtained from elsewhere, particulars in regard to the "material" and "pipes" shall be taken from similar forms of certificates obtained in respect of pipes and noted in the appropriate columns or paragraphs.
In the case of pipes made from steel, made and tested by well known Steel Makers in India or other countries, particulars regarding the ‘material’ as certified by them (in any form) shall be noted in the appropriate columns or paragraphs in this certificate.
FORM III-A(i)
(Certificate of manufacture and test of steampipes for which variation has been permitted).
Regulation 4 (h)
Name of part…………………………………………………………………………
Maker’s name and address…………………………………………………………..
……………………………………………………………………………………….
Intended working pressure…………………………………………………………...
Recommended maximum temperature………………………………………………
Material
Process of manufacture………………………………………………………………
Fully killed/rimmed………………………………………………………………….
Chemical composition……………………………………………………………….
Pipes
Main dimensions…………………………………………………………………….
Tolerances……………………………………………………………………………
Mode of manufacture………………………………………………………………..
Identification marks…………………………………………………………………
Drawings numbers…………………………………………………………………..
Bend test on pipe…………………………………………………………………….
Bend test on weld……………………………………………………………………
Flattening test………………………………………………………………………..
Tensile strength………………………………………………………………………
Mode of attachment of flanges………………………………………………………
Flange particulars……………………………………………………………………
Size of branches…………………………………………………………………….
Mode of attachment of branches……………………………………………………
Heat treatment………………………………………………………………………
Final hydraulic test…………………………………………………………………
Note.- In addition, the following information in respect of the materials shall be furnished in a tabular form as indicated. The information may be given from the establishment test data or if the material is of standard quality an extract from the standards may be furnished instead.
Metal temperature upto ° C
250 275 300 325 350 375 400 425 450 475 500 525 550 575 600____
Et_____________________________________________________________________________________________________
Sc_____________________________________________________________________________________________________
Sr
Tensile strength at 20° C.
Et = Yield point at temperature t (0.2% proof stress)
Sc = Average stress to produce an elongation of 1% (Creep) in 100,000 hours at the various working metal temperatures.
Sr = Average and lowest stress to produce rupture in 100,000 hours at various working metal temperatures.
Temperatures range in the table may extend upto the limit of applicability of the material.
The values of Sc and Sr need be furnished only in respect of pipes/tubes intended to be used for working metal temperature above 454° C.
Certified that the particulars entered herein are correct.
The particulars of fabricated components are shown in drawing No._______.
The part has been designed and constructed to comply with the variations from the standard conditions laid down in the Indian Boiler Regulations, 1950, for materials, design and construction features which have been permitted by the Board or the Inspecting Authority under the Indian Boilers Act, 1923 and satisfactorily withstood a water test of ________________________ on the _________ day of ______________, 19__ in the presence of our responsible representative whose signature is appended hereunder.
Maker’s Representative
(Name and signature) Maker ___________________
We have satisfied ourselves that the pipes have been constructed in accordance with the variations, from the standard conditions laid down in the Indian Boiler Regulations, 1950, for material, design and construction permitted by the Board. The tests conducted on the sample taken from the finished pipes have been witnessed by us and the particulars entered herein are correct.
Place____________ Name and Signature of
Date _____________ Inspecting Authority
Note (1) This form is intended for the use of both pipe manufacturers and pipe fabricators. Only such of the columns or paragraphs that are applicable, or information that can be obtained and furnished from other certificates, need be filled or entered in this form.
Note (2) In the case of fabrications made from steel pipes obtained from elsewhere, particulars in regard to the "material" and "pipe" shall be taken from similar forms of certificates obtained in respect of pipes and noted in the appropriate columns of paragraphs.
In the case of pipes made from steel, made and tested by Well known steel Makers in India or other countries particulars regarding the ‘material’ as certified by them (in any form) shall be noted in the appropriate columns or paragraphs in this certificate.
FORM III-B
(Certificate of Manufacture and Test)
[REGULATION 4(f)]
Maker’s name………………………………………………………………………..
Design pressure………………………………………………………………………
Design temperature…………………………………………………………………..
Material
Process of manufacture………………………………………………………………
Fully killed/rimmed………………………………………………………………….
Chemical composition……………………………………………………………….
Tubes
Process of manufacture………………………………………………………………
Main dimensions……………………………………………………………………..
Tolerances……………………………………………………………………………
Tensile strength………………………………………………………………………
Elongation percentage……………………………………………………………….
Bend test……………………………………………………………………………..
Flattening test………………………………………………………………………..
Crushing test…………………………………………………………………………
Flare test……………………………………………………………………………..
Flange test……………………………………………………………………………
Bend test on weld……………………………………………………………………
Bulging test and drifting test (for copper and brass)………………………………..
Heat treatment………………………………………………………………………
Hydraulic test……………………………………………………………………….
NOTE.- In addition, the following information in respect of the material shall be furnished in a tabular form in conformity with the requirements of Regulation 4(c)(vi) or the note thereto, as the case may be. This information may be given from the established test data or if the material is of standard quality, an extract from the standard may be furnished instead.
Metal temperature |
250 |
275 |
300 |
325 |
350 |
375 |
400 |
425 |
450 |
475 |
500 |
525 |
550 |
575 |
600 |
Et |
|||||||||||||||
Sc |
|||||||||||||||
Sr |
Tensile strength at 20° C……………………………………………………
Where
Et = Yield at temperature t (0.2% proof stress).
**Sc = Average stress to produce an elongation of 1%(creep) in 100,000 hours at the various working metal temperatures.
**Sr = Average and lowest stress to produce rupture in 100,000 hours at various working metal temperatures.
Temperature range in the table may extend upto the limit of applicability of the material.
The value of Sc and Sr need be furnished only in respect of pipes/tubes intended to be used for working metal temperature above 454° C (850° F).
Certified that the particulars entered herein are correct.
The tubes have been manufactured to comply with the Indian Boiler Regulations for a maximum working pressure of ____________ and a maximum temperature of ______________________ at our works above named and satisfactorily withstood a water test of ______________on the ______ day of __________________, 19___, in the presence of our responsible representative whose signature is appended hereunder.
Maker’s Representative Maker ___________________
(Name and signature)
We have satisfied ourselves that the tubes have been constructed in accordance with Chapter II. The tests conducted on the samples taken from the finished tubes, have been witnessed by us and the particulars entered herein are correct.
Place ______________ Name and signature of
Date _______________ Inspecting Authority.
NOTE (1).- This form is intended for the use of both tube manufacturers and tube fabricators. Only such of the columns or paragraphs that are applicable, or information that can be obtained and furnished from other certificates, need be filled or entered in this form.
NOTE (2).- In the case of fabrications made from steel tubes obtained from elsewhere, particulars in regard to the "material" and "Tubes" shall be taken from similar forms of certificates obtained in respect of pipes and noted in the appropriate columns or paragraphs.
In the case of tubes made from steel, made and tested by well-known Steel Makers in India or other countries particulars regarding the ‘material’ as certified by them (in any form) shall be noted in the appropriate columns or paragraphs in this ‘certificate’.
FORM III-B (i)
(Certificate of Manufacture and Test)
REGULATION 4 (i)
Maker’s name………………………………………………………………………
Intended working pressure………………………………………………………….
Maximum recommended metal temperature……………………………………….
Material……………………………………………………………………………..
Process of manufacture……………………………………………………………..
Fully killed/rimmed…………………………………………………………………
Chemical composition………………………………………………………………
Tubes………………………………………………………………………………
Process of manufacture………………………………………………………………
Main dimensions……………………………………………………………………..
Tolerances……………………………………………………………………………
Tensile strength………………………………………………………………………
Elongation percentage……………………………………………………………….
Bend test……………………………………………………………………………..
Flattening test………………………………………………………………………..
Crushing test…………………………………………………………………………
Flare test……………………………………………………………………………..
Flange test……………………………………………………………………………
Bend test on weld……………………………………………………………………
Bending test and drifting test (for copper and brass)………………………………...
Heat treatment………………………………………………………………………..
Hydraulic test………………………………………………………………………...
Note.- In addition, the following information in respect of the material shall be furnished in a tabular form as indicated. The information may be given from the established test data or if the material is of standard quality, an extract from the standard may be furnished instead.
Metal temperature |
250 |
275 |
300 |
325 |
350 |
375 |
400 |
425 |
450 |
475 |
500 |
525 |
550 |
575 |
600 |
Et |
|||||||||||||||
Sc |
|||||||||||||||
Sr |
Tensile strength at 20° C………..
Where
Et = Yield point at temperature t (0.2% proof stress).
Sc = Average stress to produce an elongation of 1% (creep) in 100,000 hours at the various working metal temperatures.
Sr = Average and lowest stress to produce rupture in 100,000 hours at various working metal temperatures.
Temperature range in the table may extend upto the limit of applicability of the material.
The value of Sc and Sr need to be furnished only in respect of pipes/tubes intended to be used for working metal temperature above 454° C.
Certified that the particulars entered herein are correct.
The part has been designed and constructed to comply with the variations from the standard conditions laid down in the Indian Boiler Regulations, 1950, for material, design and construction features which have been permitted by the Board or the Inspecting Authority under the Indian Boilers Act, 1923 and satisfactorily withstood a water test of ______________ on the _________ day of ____________, 19__, in the presence of our responsible representative whose signature is appended hereunder.
Maker’s Representative
(Name and Signature) Maker ___________________
We have satisfied ourselves that the tubes have been constructed in accordance with the variations from the standard conditions laid down in the Indian Boiler Regulations, 1950, for material, design and construction permitted by the Board. The tests conducted on the sample taken from the finished tubes have been witnessed by us and the particulars entered herein are correct.
Place___________ Name and Signature of
Date ___________ Inspecting Authority
Note (1) This form is intended for the use of the both tube manufacturers and tube fabricators. Only such of the columns or paragraphs that are applicable, or information that can be obtained and furnished from other certificates, need be filled or entered in this form.
Note (2) In the case of fabrications made from steel tubes obtained from elsewhere, particulars in regard to the "material" and "Tubes" shall be taken from similar forms of certificates obtained in respect of tubes and noted in the appropriate columns or paragraphs.
In the case of tubes made from steel, made and tested by Well Known steel makers in India or other countries particulars regarding the ‘material’ as certified by them (in any form) shall be noted in the appropriate columns or paragraphs in this "certificate".
FORM III-C
Certificate of Manufacture and test of Boiler Mountings and Fittings
(REGULATION 269)
Name of part………………………………………………………………………
Maker’s name and address………………………………………………………….
………………………………………………………………………………………
Intended working pressure………………………………………………….kg./cm2
…………………………………………………………………………(lb./sq. inch)
Hydraulic test pressure……………………………………………………..kg./cm2
…………………………………………………………………………(lb./sq. inch)
Main dimensions……………………………………………………………………
Drawing Nos………………………………………………………………………..
Identification Marks…………………………………………………………………
……………………………………………………………………………………….
Chemical composition……………………………………………………………….
Physical test results………………………………………………………………….
tensile strength………………………………………………………
transverse bend test………………………………………………….
Elongation……………………………………………………………
Certified that the particulars entered herein by us are correct.
The part has been designed and constructed to comply with the Indian Boiler Regulations for a working pressure of ____________ and satisfactorily withstood a hydraulic test using water or kerosene or any other suitable liquid to a pressure ____________ on the __________ day of ________________ 19___ in the presence of our responsible representative whose signature is appended hereunder:
Maker Representative MAKERS________________
(Name and signature)
We have satisfied ourselves and the valve/fitting has been constructed and tested in accordance with the requirements of the Indian Boiler Regulations, 1950. We further certify that the particulars entered herein are correct.
Place_________ Name and signature of the
Inspecting Officer who
witnessed the tests.
Date____________ 19___. Name and signature of the
Inspecting Authority
Strike out which is not applicable.
Note: In the case of valve chest made and tested by well known Foundries or Forges recognised by the Central Boilers Board in the manner as laid down in regulations 4A to 4H, particulars regarding the material as certified by them, in any form, shall be noted in the appropriate columns or paragraphs in the certificates and in case of certificates from Well Known Foundries or Forges is produced, such certificate may be accepted in lieu of the certificate from Inspecting Authority in so far as it relates to the testing of material specified in the Form.
FORM III-D
Certificate of manufacture and test
[Regulation 4(c)]
Certificate No………………………………………………………………………..
Date of Manufacture…………………………………………………………………
Name of Part…………………………………………………………………………
Maker’s Name and address…………………………………………………………..
Code of Manufacture/Specifications………………………………………………...
Material
Heat No………………………………………………………………………………
Process of manufacture………………………………………………………………
Fully killed/rimmed/semi killed……………………………………………………..
Chemical composition……………………………………………………………….
Pipes
Main dimensions……………………………………………………………………..
Tolerances……………………………………………………………………………
Mode of manufacture………………………………………………………………...
Identification marks………………………………………………………………….
Bend Test…………………………………………………………………………….
Bend test on weld……………………………………………………………………
Flare test……………………………………………………………………………..
Flattening test………………………………………………………………………..
Drift test……………………………………………………………………………..
Tensile strength………………………………………………………………………
Crushing test…………………………………………………………………………
Heat treatment………………………………………………………………………..
Flange test……………………………………………………………………………
Final hydraulic test…………………………………………………………………..
Non-destructive examination………………………………………………………...
Certified that the particulars entered herein are correct.
The part has been manufactured to comply with the Indian Boiler Regulations at our Works above named and satisfactorily withstood a water test of _____________________ on the __________ day of _________________19___ in the presence of our responsible representative whose signature is appended hereunder:
Maker’s Representative Maker………………...
(Name and signature)
Note: In the case of pipes made from steel, made and certified by well-known Steel Makers in India or other countries, particulars regarding the ‘material’ as certified by them (in any form) shall be noted in the appropriate columns or paragraphs in this certificate.
FORM III-E
(Certificate of manufacture and test)
[Regulation 4(f)]
Maker’s Name………………………………………………………………………
Code of Manufacture/specifications………………………………………………..
Material
Heat No………………………………………………………………………………
Process of Manufacture……………………………………………………………...
Fully killed/rimmed/semi killed……………………………………………………..
Chemical composition……………………………………………………………….
Tubes
Process of manufacture………………………………………………………………
Main dimensions……………………………………………………………………..
Tolerances……………………………………………………………………………
Tensile strength………………………………………………………………………
Elongation percentage……………………………………………………………….
Bend test……………………………………………………………………………..
Flattening test………………………………………………………………………..
Crushing test…………………………………………………………………………
Flare test……………………………………………………………………………..
Flange test……………………………………………………………………………
Bend test of weld…………………………………………………………………….
Bulging test and drifting test
(for copper and brass)……………………………………………………….………
Heat treatment……………………………………………………………………….
Hydraulic test………………………………………………………………………..
Non-destructive examination………………………………………………………..
Certified that the particulars entered herein are correct.
The Tubes have been manufactured to comply with the Indian Boiler Regulations at our works above named and satisfactorily withstood a water test of _________________on the _______day of _______________ 19___ in the presence of our responsible representative whose signature is appended hereunder:
Maker’s Representative Maker ___________________
(Name and signature)
Note:- In the case of tubes made from steel, made and certified by the Well-known Steel Makers in India or other countries, particulars regarding the ‘material’ a certified by them (in any form) shall be noted in the appropriate columns or paragraphs in this certificate.
FORM IV
STEEL MAKER’S CERTIFICATE OF MANUFACTURE
AND RESULTS OF TESTS
[REGULATION 4(c) (iv)]
We hereby certify that the material described below has been made by M/s. _________________ by the *__________________ process, as per specifications _____________ and rolled by ________________ and has been satisfactorily tested in the presence of our Test House Manager or his representative in accordance with the stipulated tests and tolerances.
For gothic bars/scelps, billets and hot rolled strips which are to be processed further by the same manufacturer for making tubes/pipes, the physical properties are not required to be mentioned by the steel manufacturer.
Test certificate No.________________ Signature or initials of
Test House Manager
Dated______________
Order Cast Specification/ Deoxidation Plate No. of
No. No. and grade practice No. pieces
Wt Size Heat Chemical Analysis
Tonnes (mm) Treatment (Ladles)
________________________
C Mn P S Si Other alloying
Elements
_____________________________________________________________________
Mechanical Properties
Y.S. U.T.S. Elongation Bend Temp. Homo- Remarks
Kg/mm2 kg/mm2 % Bend geniety
Despatch Advice No. Dated Wagon No.
Consignee _________ *Actual process used out of
__________________ the following:-
__________________ (i) Basic Open-Hearth
(ii) Acid Open-Hearth
Basic Oxygen
Electric Furnace.
FORM IV-A
CERTIFICATE OF MANUFACTURE AND RESULTS OF TESTS
IN LIEU OF FORM IV
[Regulation 4 (c) (iv)]
It is hereby certified that original steel Maker’s certificate in Form IV contain following information in respect of the material used in the manufacture of boiler or parts thereof bearing Makers Number: Sample and according to Drawing Number:
Part Quantity Cast/Heat No .Plate No. Steel making Specifi- Deoxidation
of Process cation
Boiler
Name of Test piece Certificate Length/Breadth/ Heat Treatment
Steel Maker/ No. No. & Date O. D. Thickness
Part Maker
% Chemical Analysis
Cr Mn P S Si Other alloying elements
Mechanical Properties
Y.S. kg/mm2 UTS (kg/mm2) Elongation Bend Remarks
% GL Test
Official Seal INSPECTING AUTHORITY
No.
FORM V
Counterfoil [REGULATION 381 (C)]
PROVISIONAL ORDER UNDER SECTION 9
No. OF THE INDIAN BOILERS ACT OF 1923.
-----------------------------------------------------------------
-----------------------------------------------------------------
__________________________________________________
are hereby permitted to use the Boiler (Registry _________________________________________________
No. ) Boiler Rating
made by are hereby permitted to use the Boiler
(Register No. ) Boiler Rating
and bearing Maker’s number at a maximum pressure
of lbs.
made by
per square inch pending the issue of or refusal of a and bearing Maker’s number at a
certificate within six months from the date thereof. maximum pressure of lbs.
per square inch pending the issue of refusals of a
certificate within six months from the date thereof.
after which period this order will become void.
after which period this order will become void.
Dated Inspector of Boilers. Dated Inspector of Boilers
N.B..- This order must be produced on demand by any authorised persons
and surrendered to Chief Inspector on receipt of orders.
FORM VI
___________ BOILER INSPECTION DEPARTMENT
CERTIFICATE FOR USE OF A BOILER
(Regulation 389)
Registry Number of Boiler Type of Boiler
Boiler Rating Place and year of manufacture
Maximum Continuous Evaporation
Name of Owner
Situation of Boiler
Repairs
Remarks
Hydraulically Tested on to lbs. per sq. inch
I hereby certify that the above described boiler is permitted by me/the Chief Inspector under the provisions of Section 7/8 of the Indian Boilers Act, No. V of 1923, to be worked at a maximum pressure of lbs. to the square inch for the period from to .
The loading of the safety valve is not to exceed .
Fee Rs. Paid on
Dated at this day of , 19___.
Inspector
Countersigned
Chief Inspector
See reverse for "Conditions".
CONDITIONS
(Reverse of Form VI)
No structural alteration, addition of renewal shall be made to the boiler otherwise than in accordance with section 12 of the Act.
Under the provisions of Section 8 of the Act this certificate shall cease to be in force:
on the expiry of the period for which it was granted; or
when any accident occurs to the boiler; or
when the boiler is moved the boiler not being vertical boiler the heating surface of which is less than two hundred square feet, or a portable or vehicular boiler; or
when any structural alteration, addition or renewal is made in or to the boiler; or
if the Chief Inspector in any particular case so directs when any structural alteration, addition or renewal is made in or to any steam-pipe attached to the boiler; or
on the communication to the owner of the boiler of an order of the Chief Inspector or Inspector prohibiting its use on the ground that it or any steam-pipe attached thereto is in a dangerous condition.
Under Section 10 of the Act, when the period of a certificate relating to a boiler has expired, the owner shall, provided that he has applied before the expiry of that period for a renewal of the Certificate, be entitled to use the boiler at the maximum pressure entered in the former certificate, pending the issue of orders on the application but this shall not be deemed to authorise the use of a boiler in any of the cases referred to in clause (b), (c), (d), (e) and (f) of sub-section (1) of section 8 occurring after the expiry of the period of the certificate.
3. The boiler shall not be used at a pressure greater than the pressure entered in the certificate as the maximum pressure nor with the safety valve set to a pressure exceeding such maximum pressure.
4. The boiler shall not be used otherwise than in a condition which the owner reasonably believes to be compatible with safe working.
NOTE.- The particulars and dimensions regarding this boiler may be obtained by the owner on payment in the prescribed manner on application to the Chief Inspector.
FORM VII
INSPECTING AUTHORITY’S CERTIFICATE OF INSPECTION UNDER
CONSTRUCTION DESIGNATION OF INSPECTION AUTHORITY
[Regulation 501 (e)]
We hereby certify that type, Economiser, consisting of sections and tubes to each section was constructed for a working pressure of lbs. Messrs
under our supervision and inspected at various stages of construction by the Inspecting Officer and that the construction and workmanship were satisfactory and in accordance with the standard conditions for the design and construction of Economiser laid down in Chapter XI of the Indian Boiler Regulations, 1950.
Identification mark on each section.
Branch Pipe on other pressure part.
Position of same
The sections on completion were subjected to a water pressure of lbs.
per sq. in. for ten minutes in the presence of the Inspecting Officer on and
satisfactorily withstood the test in accordance with Regulation 504.
Samples of the material used in the constructions of the Economiser, were tested in the presence of the Inspecting Officer and were found to comply with the tests prescribed in Chapter XI of the Indian Boiler Regulations, 1950.
We have satisfied ourselves that the construction and dimensions of the Economiser are as shown in the Maker’s Drawing No. signed by us and that the particulars entered in the Maker’s certificate of manufacture in Form VIII countersigned by us are correct to the best of our knowledge and belief.
Dated at this day of , 19___.
Signature of Inspecting Authority
FORM VIII
Works Address
CONSTRUCTOR’S CERTIFICATE OF MANUFACTURE AND TEST
[Regulation 501 (d)]
1. Description Type of Economizer No. of tubes
No. of Sections lbs.
Intended working pressure Total heating surface of tubes
Year of manufacture
Description
2. Inspecting Authority Economizer constructed under supervision of …………….
-----------------------------------------------------------------------
Sections hydraulically tested for …. Minutes and inspected after test by ………………………………………………...
3. Construction and Details are in Drawing No.__________________________
Workmanship All castings are well finished free from external defects, porous places and blow-holes and true to dimensions without warping.
Where chaplets are used, there is satisfactory fusion with the metal.
Chaplets are properly tinned with metal free from lead.
All screw threads are of Whitworth form.
All component parts are manufactured to limit gauges to secure interchangeability throughout.
4. Economisers and fitting Parts Material Maker Inspecting Officer Remarks
Particulars of material used Headers
Tubes and/or
Pipes
Valve chests
Bolt
THICKNESS OF PARTS AND TENSILE TEST-LIMIT
5. Part of Economiser |
Thickness in 32nds |
Tensile strength limits to tons |
Elongation limits to % |
Gauge length |
Brand and No. |
Headers……………….. Tubes…………………. Bolts…………………... |
Certified that the particulars entered herein are correct and that the parts and fittings mentioned above have been used in the construction and fittings of the Economiser.
The particulars shown against the various parts used are in accordance with the Maker’s certificates in our possession.
The design of the economiser in section and end view with principal parts fully dimensioned is that shown in Drawing No. . The Economiser has been designed and constructed to comply with the Indian Boiler Regulations for a working pressure of ________ lbs. per sq. in. at our Works abovementioned and the sections satisfactorily withstood a water test of ______ lbs. per sq. in. for ___________ minutes on _________ day of __________19___ in the presence of our ______________ responsible representative whose signature is appended hereunder.
Designation of Maker
Signature of the Engineer who witnessed the test.
Dated at _______________ this ____________ day of ______________19___.
Signature of Inspecting Authority
NOTE.- The drawing of the Economiser and Maker’s certificate of manufacture showing results of tests for tensile strength and elongation must accompany this certificate and if the economiser has been built under the supervision of an Inspecting Authority their certificate in Form VII must accompany.
FORM IX
(Regulation 528)
(National Emblem)
INDIAN BOILERS ACT, 1923
BOILER INSPECTION DEPARTMENT
ECONOMISERS
REGISTRY NUMBER
_________________________
_________________________
Memorandum of Inspection
or
Registration Book
MISCELLANEOUS
District ……………………………………………………………………………………
Owners……………………………………………………………………………………..
Address of Factory…………………………………………………………………………
_______________________________________________________________________
Nearest Railway Station……………………………………………………………………
_______________________________________________________________________
Economiser Registered at…………………………. on …………………………………..
Register Book No…………………………………. page ………………………………...
Registry Number………………………………….Verified on……………………………
Approved Working Pressure……………………… lbs…………………………………...
Economiser Rating………………………………… Inspection fee………………………
Registration Book filled at…………………………. on ………………………………….
Remarks on transfer etc…………………………………………………………………….
PROVISIONAL ORDER AND CERTIFICATE RECORD
Fee |
Date of Payment |
Date of Inspection |
Certifi-cate No. and date |
Period of Certifi-cate |
Working pressure |
Econo-miser Rating |
Remarks and Inspector’s initial |
|
Type of Economiser………………………………………………………………………..
Maker………………………………………………………………………………………
Intended Working Pressure………………………………………………………………...
Place and year of make…………………………………………………………………….
Maker’s No…………………………………………………………………………………
Description of Economiser…………………………………………………………………
No. of tubes…………………………. length………………….Dia……………………...
Thickness…………………………………………………………………………………...
Internal dimensions………………………………………………………………………...
No. of Headers……………………………………………………………………………..
Thickness of Headers………………………………………………………………………
Length of top Branch pipe …………………………… Thickness ……………………….
Length of Bottom Branch Pipe……………………………….Thickness…………………
Dimensions of cap openings……………………………………………………………….
Diameter of cap bolts………………………………………………………………………
MOUNTINGS
No. |
Diameter |
Type |
Position |
Material |
Relief Valve……………………. Stop Valve……………………... Blow Down…………………….. Thermometers………………….. Pressure Gauge………………… |
Additional Fittings…………………………………………………………………………
MAKER’S CERTIFICATE
Name of Maker……………………………………………………………………………
Maker’s Hydraulic Test Pressure…………………………………………………………..
Maker’s Drawing No……………………………………………………………………….
Name of Inspecting Authority……………………………………………………………...
Name of Maker of Material………………………………………………………………..
[Tubes……………………………………..
Process………………………………………[Headers…………………………………..
[Bolts………………………………………
Test Results
Tubes……………………………………………..T E
Headers…………………………………………...T E
Pipes………………………………………………T E
Bolts………………………………………………T
% Sulphur
% Phosphorus
Maker’s Identification Marks
Position
CALCULATIONS
HEADERS
TUBES
BRANCH PIPES
BOLTS
HEATING SURFACE
Total Heating Surface……………………………………………………
Economiser Rating………………………………………………………
Calculations made by submitted on
Calculations checked by on
Least pressure, that for lbs.
Approved working pressure lbs.
Chief Inspector’s remarks and signature
INSPECTOR’S NOTES
FORM X
Regulation 525 (e)
Counterfoil No. No.
Name of the person or firm PROVISIONAL ORDER UNDER THE INDIAN
to which Provisional Order BOILERS ACT, 1923
is granted.
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Description of Economiser
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are hereby permitted to use the
Maker’s No. Economiser Ry. No. and
Economiser Rating made by
and bearing Maker’s No.
Rating at a maximum pressure of lbs. per sq. in./
Maximum temperature of ° F pending the
Pressure permitted issue or refusal of a certificate within six months from the
date hereof after which period this order will become void.
Period
Date Dated at __________ this _____ day of _________19___.
Inspector INSPECTOR
FORM XI
_______________________________________________ Boiler Inspection Department
CERTIFICATE FOR THE USE OF AN ECONOMISER
(Regulation 530)
Registry Number of Economiser Type
_______________________________________________________________________
No. of tubes
Number of Headers
_______________________________________________________________________
Economiser Rating Place and year of manufacture
_______________________________________________________________________
Name of owner
_______________________________________________________________________
Situation of Economiser
_______________________________________________________________________
Repairs
*Remarks
kg. per sq. cm.
Hydraulically tested on _______ to ______ _______________________
lbs. per sq. in.
I/We hereby certify that the above described Economiser is permitted by me/Chief Inspector under the provisions of Section ________ of the Indian Boilers Act, 1923 (V of 1923) to be worked at a maximum pressure of ___________ lbs. per sq. in./maximum temperature of ° F or the period from _________ to __________.
The loading of the safety valve is not exceed. lbs.
Fee Rs. paid on
Dated at
This day of 19___.
COUNTER SIGNED
INSPECTOR
CHIEF INSPECTOR
REVERSE OF FORM XI
CONDITIONS
No structural alteration, addition or renewal shall be made to the Economiser without a written permission from the Chief Inspector.
This certificate shall cease to be in force –
on the expiry of the period for which it was granted, or
when any accident occurs to the Economiser, or
when any structural alteration, addition or renewal is made in or to the Economiser, or
if the Chief Inspector in any particular case so directs when any structural alteration, addition or renewal is made in or to the Economiser, or
on the communication to the owner of the Economiser of an order of the Chief Inspector or Inspector prohibiting its use on the ground that it is in a dangerous condition.
The Economiser shall not be used at a pressure greater than the pressure/temperature entered in the certificate as maximum pressure/temperature not with the relief valve set to pressure/temperature exceeding such maximum pressure/temperature.
The Economiser shall not be used otherwise than in a condition which the owner reasonably believes to be compatible with safe working.
N.B.- Details regarding this Economiser are recorded in a Registration Book No.________________ of which a copy may be obtained on payment on application to the Chief Inspector.
FORM XII
(Regulation 613)
Record of Welder’s Qualifications/Requalifications Tests (Indian Boiler Regulations, 1950).
Place of test_________
Date___________
Name of Welder……………………………………………………………………………
Father’s name………………………………………………………………………………
Date of birth…………………………………… Address…………………………………
Service of experience on Gas/Electric Arc…………………………………………..years
Signature of Welder………………………………………………………………………..
Names and addresses of the firms where trained…………………………………………..
……………………………………………………………………………………………..
……………………………………………………………………………………………..
Tested on…………………………………………………………………………………...
(Plate, pipe, tube)
Gas of electric A.C./D.C…………………………………………………………………...
Kind of test…………………………………………. Position…………………………….
(Groove/Fillet/Branch)
Thickness of material used……………………………… Diameter and thickness of pipe,
branch or tubes used……………………………………………………………………….
Quality of base material and electrode or filler rod………………………………………..
……………………………………………………………………………………………..
Results of Observations
Marks Marks
__________________ __________________
Maximum Awarded Maximum Awarded
PROCEDURE
1. Preparation of specimen……………………………… 3
2. Size & grade of electrode or filler rod………………… 2
3. Number of runs and manipulation of control…………. 5
VISUAL INSPECTION
4. Root penetration………………………………………. 10
5. Freedom from undercut……………………………….. 5
6. Disposition of runs……………………………………. 2
7. Uniformity of surface…………………………………. 1
8. Shape of profile………………………………………… 1
9. Smoothness of joints…………………………………… 2
10. Freedom from cavities & slags……………………….. 5
11. Dimensions of weld deposit…………………………… 1
12. Quality of weld metal (Overheating, surface cracks,
spongy surface etc.)……………………………………. 3
PHYSICAL TEST
13. Face bend test………………………………………….. 10
14. Root bend test………………………………………….. 20
ETCH TEST
15. Disposition of runs…………………………………….. 2
16. Degree of fusion……………………………………….. 5
17. Root penetration……………………………………….. 11
18. Slags inclusions and porosity………………………….. 5
FRACTURED SURFACE
19. Quality of weld metal (Excessive oxidation, carburisation,
overheating, roughness, porosity, appearance)…………… 7
______
100
______
Signature of Competent Authority
OBSERVATION ON RADIOGRAPHIC EXAMINATION (If conducted)……………
……………………………………………………………………………………………
……………………………………………………………………………………………
Marks awarded………………………………….%………………………………………
Results of Oral or Written examination……………………………………………………
Marks awarded……………………………%……………………………………………...
GENERAL REMARKS OF COMPETENT AUTHORITY………………………………
……………………………………………………………………………………………..
……………………………………………………………………………………………..
……………………………………………………………………………………………...
……………………………………………………………………………………………...
……………………………………………………………………………………………...
……………………………………………………………………………………………...
……………………………………………………………………………………………...
TYPE AND CLASS OF WELDING QUALIFIED………………………………………..
………………………………………………………….in Gas or Electric Arc welding.
PERIOD OF VALIDITY OF CERTIFICATE
FROM…………………. TO ………………..
PLACE……………………….
DATE…………………………
COMPETENT AUTHORITY
FORM NO.XIII
Qualified Boiler Welder’s Certificate
ISSUED UNDER
THE INDIAN BOILER REGULATIONS, 1950
Photo Name of Welder……………………………
Passport Size Father’s name………………………………
Date of birth………………………………..
Seal and
Signature of
Competent
Authority Identification marks………………………..
Left hand thumb impression ……………….
Signature of Welder………………………………..
Address of Welder………………………………….
……………………………………...
Period of Validity
_______________________________________________________________________
From To
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This is to certify that Shri……………………………………………………son of
Shri …………………………………………………………… has been examined and tested in the prescribed manner in the presence of ………………………………………..
* (Representative of Competent Authority)
and is deemed to have satisfactorily proved his ability to make sound welds as per particulars given below and is hereby authorised to undertake such welds. He is authorised/not authorised to undertake welding where radiographic examination is necessary under the Regulations.
Granted this………… day of ………………………. 19___ under the seal and authority of ………………………………………………………………………………...
* Seal (Competent Authority)
Particulars:-
_______________________________________________________________________
*Particulars shall contain information on the following:-
Tested on Plate/Pipe/Tube with position
Date
Material Mild steel or alloy steel
Process
Class of welding
Backing strip
Electrode Class (Carbon or alloy steel)
Filter rod Type
Test piece X-rayed or not.
Period of validity
From To
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Employment particulars
From |
To |
Name of Employer |
Work on which engaged |
Signature of employer |
|
(COVER PAGE)
FORM XIV[Regulation 394 (c)]
National Emblem to be printed here
Indian Boilers Act, 1923
Boiler Inspection Department
Steam Pipes and Connected Fittings
Identification Number
_________________
_________________
Memorandum of Inspection Book
FORM XIV
[Regulation 394 (c)]
National Emblem
Indian Boiler Act, 1923
Boiler Inspection Department
Steam Pipes and Connected Fittings
Identification Number
__________________
__________________
_______________________________________________________________________
Memorandum of Inspection Book
MISCELLANEOUS
District………………………..
Owner…………………………
Address of Factory…………………………………………………………………………
Work of Factory:
_______________________________________________________________________
Registration Number of Boilers to which the pipes and fittings, particulars of which are given in this Memorandum are connected.
Remarks
DATE PARTICULARS OF ADDITIONS & ALTERATIONS
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
PLAN OF STEAM PIPES & THEIR CONNECTED FITTINGS
FEE AND APPROVAL TO PLAN RECORD
Drawing No. Total length of No. of connected Fee Date of No. & date of W.P. Temp. Remarks &
Steam Pipes vessels payment approval of Plan approved allowed initial of
& Layout kg./cm2 ° C Inspector
STEAM PIPES – PARTICULARS AND DIMENSIONS
Situation ……………………………………………………………………………………………………………………………
Ry. No. of connected Boilers……………………………………………………………………………………………………….
Steam piping System include………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
Pipes Material……………………………………….Diameter (outside)………………………………………………………….
Pipes Thickness……………………………………… Make……………………………………………………………………...
Attachment of Flanges……………………………………………………………………………………………………………..
Elbows, Tees etc……………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
Support…………………………………………………………………………………………………………………………….
Flexibility…………………………………………………………………………………………………………………………..
Drainage……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
Feed Pipes…………………………………………………………………………………………………………………………
Outside Dia…………………………………………. Thickness…………………………………………………………………
Make………………………………………………………………………………………………………………………………
Max. Pressure………………………………………. Max. Temp………………………………………………………………..
Connected Vessel…………………………………………………………………………………………………………………
No.
Type……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
Max. Design Press………………………………….. Max. Design Temp………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
Date of Installation…………………………………………………………………………………………………………………
First Inspection inside & outside…………………………………………………………………………………………………...
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
First Hydraulic Test to………………………….kg/cm2……………By……………………………… on……………………...
Remarks ……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
CALCULATIONS
Steam Pipes:………………………………………………………………………………
……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………..
CALCULATIONS
Feed Pipes………………………………………………………………………………….
……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………... ……………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………... ……………………………………………………………………………………………... ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
CALCULATIONS
Steam Pipe Fittings and Vessels:…………………………………………………………..
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………...
…………………………………………………………………………………………...
CALCULATIONS
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………………………………………………………………
CALCULATIONS
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
INSPECTOR’S NOTES – contd.
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………….
…………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
FORM XV-A
(Regulation 4A (2)
QUESTIONNAIRE TO BE ANSWERED BY FIRMS SEEKING RECOGNITION BY THE CENTRAL BOILERS BOARD TO BECOME AN INSPECTING AUTHORITY UNDER THE INDIAN BOILER REGULATIONS, 1950.
The registered name and address of the association.
Address for correspondence
The year in which the association was established.
Is your association recognised by the Government?
Have you any Branch or Associate Office?If so, please give their names and addresses.
How long has your Association been functioning as an Inspecting Authority? If it is a registered Company, please give the date of registration.
Please give details of classes of machinery which you have so far been authorised to examine and code under which this is being done.
Please state the types, size and the range of working pressure of the boilers which you have so far inspected during construction as an Inspecting Authority, also state the classes of service you render, namely:-
(a). Please name the various stages of manufacture at which inspections are carried out.
(b).Excluding inspection at the steel Works.
(c).Only hydraulic test after the manufacture of the boiler has been completed.
How many Inspecting Officers have you in your employment? Please give details of the qualifications held by those Officers.
Have you any Testing Laboratory of your own to conduct all destructive and non-destructive tests required in connection with the manufacture of boilers?
Are you prepared to conduct the work of Inspection of boilers, economisers and their accessories strictly in conformity with the Indian Boiler Regulations, 1950?
Are you prepared to accept full responsibility for the certificate issued by you?
Has your request for recognition as an Inspecting Authority been rejected by any Authority? If so, please give details.
Are you prepared to issue certificates for the products, you inspect, in the formats of the Indian Boiler Regulations?
Are you aware that the recognition is for a period of 3 years only which is renewable after every 3 years on fresh assessment?
FORM XV-B
[Regulation 4 A (2)]
QUESTIONNAIRE FOR ELICITING INFORMATION REGARDING THE COMPETENCY OF A FIRM TO BE RECOGNISED AS "COMPETENT AUTHORITY" UNDER REGULATION 4a (2) OF THE INDIAN BOILER REGULATIONS.
Registered name and address of the firm.
Address for Correspondence
Year in which the Organisation was established.
Address of branch or associate office, if any.
Principal work of the organisation.
Does the organisation have any training section for the welders? If so, details of the scheme to be stated.
Does the organisation regularly conduct tests on welds done by its welders? If so, the code followed and the details of tests carried out may please be stated.
What are the facilities that can be provided or availed of by the organisation for conducting the tests?
Is the organisation prepared to undertake testing of welders employed by other organisation?
Whether the organisation is prepared to conduct tests as per requirements of the IBR?
The amount of fee which the organisation would charge a candidate for conducting a test for the issue of certificate. Estimates under the following heads may be given:
(a).For the supply of tests pieces, electrodes and/or filler rods.
(b).For the use of welding machine.
(c).For machining the test pieces and preparation of specimen.
(d).For conducting mechanical tests (including specimens preparation).
(e).For non-destructive testing.
Is the organisation prepared to examine and issue certificate to welders in accordance with the requirements of the IBR, 1950?
Is the organisation prepared to take full responsibility for certificates issued by it.
Are you aware that the recognition is for a period of 3 years only which is renewable after every 3 years on fresh assessment.
FORM XV-C
[Regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY STEEL MAKER SEEKING RECOGNITION BY CENTRAL BOILERS BOARD TO BE NOTIFIED AS ‘WELL KNOWN STEEL MAKERS’ UNDER REGULATION 4A (2) OF THE INDIAN BOILER REGULATIONS, 1950.
Registered Name and address of the firm.
Works address
The year in which the factory was established:
Capacity for production of steel:
Process of Manufacture of Steel:
Variety of Steel Products:
Range of Steel Produced in each variety:
Various National and International Standards to which the Steel Products are manufactured:
Testing facilities available within the Works:
Types of tests conducted:
If so, by whom conducted:
Are the tests conducted by the firm acceptable to the other organisations of the Country? If so, by whom?
Is the firm prepared to conduct tests in accordance with the IBR?
Have they been recognised as "Well Known Steel Maker" in any other country?
Whether they manufacture steel from the Ore itself or from ore and Scrap or Scrap only:
Whether the firm is prepared to furnish certificates under the provision of IBR.
Whether the firm is agreeable to show their manufacturing process and in-House testing facilities to a team consisting of three members appointed by the Board.
Are you aware that the recognition is for a period of 3 years only which is renewable after every 3 years on fresh assessment?
FORM XV-D
[Regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY FOUNDRY/FORGE SEEKING RECOGNITION BY CENTRAL BOILERS BOARD TO BE NOTIFIED AS "WELL KNOWN FOUNDRY/FORGE UNDER REGULATION 4A (2) OF THE INDIAN BOILER REGULATIONS, 1950.
The Registered name and address of the firm:
Works address
The year in which the factory was established.
Capacity of the Foundry/Forge:
(i) Capacity for production of Forgings/Castings: (ii) Maximum weight and size of Forgings/Castings.
Detailed description of the type of job done by them.
Materials of Castings/Forgings (ferrous-plain or alloy steel, non-ferrous alloys).
Range of forgings/casting produced in each variety.
Testing facilities available within the works.
Details of testing facility, namely chemical and physical tests etc.
Types of test conducted.
If so, by whom conducted?
Are the tests conducted by the firm itself acceptable to the other organisations of the country? If so by whom?
Is the firm prepared to conduct tests in accordance with the Indian Boiler
Regulations, 1950?Have they been recognised as "Well Known foundry/forge" in any other country?
Whether the firm is in a position to produce Forgings/Casting in accordance with any national/International specifications fulfilling the minimum requirements of IBR, 1950.
Whether the firm has any previous experience to produce Forgings/Castings in accordance with the provision of IBR under the inspection of any recognised Inspecting Authority.
Whether the firm is prepared to furnish Certificates under the provision of IBR, 1950.
Whether the firm is agreeable to show their process of manufacture, in House testing facilities to a team of members appointed by Central Boilers Board.
Are you aware that the recognition is for a period of 3 years only which is renewable after every 3 years on fresh assessment?
FORM XV-E
[Regulation 4A (2)]
QUESTIONNAIRE TO BE ANSWERED BY TUBE/PIPE MAKER SEEKING RECOGNITION BY CENTRAL BOILERS BOARD AS ‘WELL KNOWN TUBE/PIPE MAKER UNDER IBR, 1950.
Registered name and address of the firm.
Works address
Registration No. and year of registration:
Capacity of production of Tube/Pipe and the tonnage details per year from the beginning.
Reasons for seeking recognition under IBR.
Steel grades of Tube/Pipes under production:
Size range of Tubes/Pipes under production:
Process of manufacture of Tube/Pipes:
(a) Whether the firm is producing the raw material or purchasing the raw material.
(b) If the raw material is purchased, give the details of purchase so far.
(i) from well known steel maker under IBR.
(ii) from non-recognised firm.
10. If purchase is as per 9 (b) (ii) state whether the raw material is tested at Tube maker’s/Pipe maker’s premises under IBR.
11. If the firm is producing raw material, state whether the firm is recognised as Well Known steel maker under IBR.
12. Major manufacturing facilities available with the firm:
13. Testing facilities available with the works:
14. Types of tests conducted on Tubes/Pipes (enclose complete quality control plan from raw material stage to finished stage alongwith the quality control & inspection personnel of the firm).
15. The details of failures and rejection
(i)By NDT
(ii)By Destructive Testing.
16. Whether the firm is in a position to manufacture Tubes/Pipes and also provide for their necessary testing facilities in accordance with the provision in IBR, 1950.
17. The name of the firms to whom the firm has supplied Tubes/Pipes:
18. Whether the firm is agreeable to show their manufacturing process and in-house facilities to a team consisting of three members appointed by the Board.
19. Whether the firm is aware of the fact that the recognition is for a period of three years only which is renewable after every three years term on fresh assessment.
FORM XV-F
(See regulation 4A (2)
QUESTIONNAIRE TO BE ANSWERED BY A LABORATORY SEEKING RECOGNITION BY CENTRAL BOILERS BOARD AS A WELL-KNOWN MATERIAL TESTING LABORATORY UNDER SUB-REGULATION (2) OF REGULATION 4A OF THE INDIAN BOILER REGULATIONS, 1950.
The Registered name and Address of the Laboratory:
Address of the Laboratory:
The year in which the laboratory was established:
(a) Whether the Laboratory is recognised by the Central Government or by a State Government: (b) If so, please furnish particulars of recognition:
Name and address of branch or associate Laboratory, if any:
How long the Laboratory has been functioning for testing of the products?
Equipments or machines available in the laboratory for carrying out the non-destructive or destructive testing:
Type and range of tests carried out by the Laboratory:
Details of testing personnel and their qualifications or experience:
Are you prepared to conduct the testing of specimens strictly as per the requirements of the Indian Boiler Regulations, 1950?
Has your request for recognition as an approved Laboratory been rejected by any authority? If so, please give details.
Are you prepared to issue the certificates for the products you test in the formats of the Indian Boiler Regulations?
Note: The recognition is valid for a period of 3 years only, which is renewable for 3 years on fresh assessment."
"FORM XV-G
[See regulation 4A (2)]
Questionnaire to be answered by firm seeking recognition by Central Boilers Board as Remnant Life Assessment Organisation under regulation 391A of the Indian Boiler Regulations, 1950.
1. The Registered Name and Address of the firm :
2. Address of the firm :
3. The year in which the firm was established :
4. (a) Whether the firm is recognised by the Central
Government or by State Government :
(b) If so, furnish particulars of recognition :
5. Name and address of branch or associate firm, if any :
6. How long your firm has been functioning for
Remnant Life Assessment of boilers and Boiler
Parts :
7.Equipment or machines available in the
Laboratory for carrying out the non-destructive
or destructive testing :
8. Type and range of tests carried out by the firm :
9. Details of testing personnel and their qualifications
and experience :
10.Are you prepared to conduct the testing of
specimens strictly as per the requirements
of the Indian Boiler Regulations, 1950? :
11.Has your request for recognition as an approved
organisation been rejected by any authority? If
so, please give details:
12.Are you prepared to issue the certificates for
the tests recommended in the formats of the
Indian Boiler Regulations?
:
SIGNATURE & SEAL
Note:- The recognition is valid for a period of three years only which is renewable for three years on fresh assessment.".
FORM XVI-A
(Regulation 4C (2)
Serial No.
National Emblem to be printed here
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR INSPECTING AUTHORITY
This is to certify that the Inspection and Quality Management System of:
M/s. ________________________________
________________________________
________________________________
has been evaluated by the Central Boilers Board and has been granted recognition under regulation 4C (2) of the Indian Boiler Regulations, 1950, as an INSPECTING AUTHORITY.
_______________________________________________________________________
This Certificate is valid for three years, i.e. upto…………………………..
_______________________________________________________________________
Validity is subject to the adherence to the quality Control prescribed under the provisions of the Indian Boiler Regulations.
_________________
Date of Issue
Approval Certificate No.____________
Secretary
FORM XVI-B
(Regulation 4C (2)
Serial No.
National Emblem to be printed here
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR COMPETENT AUTHORITY
This is to certify that the Examination of Welder System of:
M/s. _______________________
_______________________
_______________________
has been evaluated by the Central Boilers Board and has been granted recognition under regulation 4C (2) of the Indian Boiler Regulations, 1950, as a COMPETENT AUTHORITY.
_______________________________________________________________________
This Certificate is valid for three years, i.e. upto………………………..
_______________________________________________________________________
Validity is subject to the adherence to the quality Control prescribed under the provisions of the Indian Boiler Regulations.
_________________
Date of Issue
Approval Certificate No.___________
Secretary
FORM XVI-C
(Regulation 4C (2)
Serial No.
National Emblem to be printed here
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL-KNOWN STEEL MAKER
This is to certify that the Inspection and Quality Management System of:
M/s. _________________________
_________________________
_________________________
has been evaluated by the Central Boilers Board and has been granted recognition under regulation 4C (2) of the Indian Boiler Regulations, 1950, as WELL KNOWN STEEL MAKER, for the manufacture of __________________________
_______________________________________________________________________
This Certificate is valid for three years, i.e. upto_______________________
_______________________________________________________________________
Validity is subject to the adherence to the quality Control prescribed under the provisions of the Indian Boiler Regulations.
_________________
Date of Issue
Approval Certificate No.____________
Secretary
FORM XVI-D
(Regulation 4C (2)
Serial No.
National Emblem to be printed here
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL-KNOWN FORGE
This is to certify that the Inspection and Quality Management System of:
M/s. _______________________
_______________________
_______________________
has been evaluated by the Central Boilers Board and has been granted recognition under regulation 4C (2) of the Indian Boiler Regulations, 1950 as a WELL KNOWN FORGE.
_______________________________________________________________________
This Certificate is valid for three years, i.e. upto _____________________
_______________________________________________________________________
Validity is subject to the adherence to the quality control prescribed under the provisions of the Indian Boiler Regulations.
______________
Date of Issue
Approval Certificate No.__________
Secretary
FORM XVI-E
(Regulation 4C (2)
Serial No.
National Emblem to be printed here
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL KNOWN FORGE
This is to certify that the Inspection and Quality Management System of:
M/s. __________________________
__________________________
__________________________
has been evaluated by the Central Boilers Board and has been granted recognition under regulation 4C (2) of the Indian Boiler Regulations, 1950 as a WELL KNOWN FORGE.
_______________________________________________________________________
This Certificate is valid for three years, i.e. upto__________________
_______________________________________________________________________
Validity is subject to the adherence to the quality control prescribed under the provisions of the Indian Boiler Regulations.
____________
Date of Issue
Approval Certificate No.___________
Secretary
FORM XVI-F
(Regulation 4C (2)
Serial No.
National Emblem to be printed here
CENTRAL BOILERS BOARD
CERTIFICATE OF APPROVAL FOR WELL KNOWN TUBE MAKER<