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Gopal Rai
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Annexure - VIII

Form VI
Counterfoil D.B.No……………...
No. DBL  
Registry Number of Boiler Type of Boiler
Boiler Rating Place and year of manufacture
Name of Owner  
Situation of Boiler  
Repairs  
Remarks  
Hydraulically Tested on……………. to ……………………… kgs/lbs. per sq. cms/inch
Maximum pressure permitted………….kgs/lbs. lo the square cms/inch for the period from ………… to ……………………. The loading of the ……………………….. safety valve not to exceed ……………………………………………. The main steam pipe tested hydraulically to a pressure of ……………….. kgs/lbs. per square cms/inch ast on …………. Fee Rs …………………. Paid on ……………………… Dated at ………… DELHI …………………………. This …………………………. Day of ……………. 19
   
  Countersigned
Inspector Chief Inspector


No. DBL                                                               D.B. No …………….

Registry Number of Boiler Type of Boiler
Boiler Rating Place and year of manufacture
Name of Owner  
Situation of Boiler  
Repairs............................................................................................................................................................... ......................................................................................................................................................
Remarks ............................................................................................................................................................ .......................................................................................................................................................
Hydraulically Tested on........................ to.................. Kgs/lbs. sq. cms/inch. I hereby certify that the above described boiler is permitted by (me) ................(the chief Inspector) under the provisions of Section 7/8 of Indian Boilers Act. No V of 1923, to be worked at a maximum pressure of .................. Kgs/lbs. to the square cms./ inch for the period from ................ to .................... The loading of the ............................safety valve is not to exceed................................................................................................
I further certify that the main steam pipe was tested hydraulically to a pressure of ………………….. kgs/lbs per square cms/inch last on ………………………….. Fee Rs …………………………. Paid on ………………………….. Dated at Delhi ……………. This ………………………… day of …………………………….. 19 .
   
  Countersigned
Inspector Chief Inspector

No structural alteration, addition or renewal shall be made to the boiler other-wise 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 :
(a) On the expiry of the period for which it was granted; or
(b) When any accident occurs to the boiler; or
(c) 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
(d) When any structural alteration, addition or renewal is made in or to the boiler; or
(e) 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
(f) 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 the he 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 reffered to in clauses (a), (b), (c), (d), (e) & (f) of Sub-section (1) of section 8 occuring after the expiry of the period of the certificate.
The boiler shall not be used at a pressure greater than the pressure entered in the certificate as a maximum pressure nor with the safety valve set to a pressure exceeding such maximum pressure.
The boiler shall not be used otherwise than in a condition which the owner reasonably belives to be compatible with safe working.
N.B.- 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.
Annxeure IX

INSPECTION OF STEAM PIPES
(a)

Steam pipes shall be inspected and hydraulically tested before erection in place, in test pressure to be that prescribed in the standard conditions for steam pipes. A certificate from the Inspecting Authority in Form III A, stating that this has been done by him may be accepted. If the Inspector is satisfied with the test, the pipes may be erected in position. The Chief Inspector shall intimate his approval to the owner regarding the suitability of the pipe line for use at the pressure and temperature to be specified.

*(b)

At subsequent inspections of the boiler or at any other time, the Inspector may make an external inspection of the steam-pipes and for this purpose may require a part of the lagging at the flanges to be removed, and the pipe made bare. If as a result of this inspection the inspector is of opinion that the pipes or any positions of then are in an unsatisfactory condition he shall report the matter to the Chief Inspector, who may require the whole of the lagging to be removed and may require any pipe or pipes to be hydraulically tested. The test pressure at such hydraulic test shall be not less than one and half times, the working pressure of the boiler of the intended working pressure of pipe as the case may be.

*(c)

A memorandum of Inspection Book shall be prepared in respect. of steam-pipe and fittings in Form No. XIV. In this book, the Inspector shall enter in ink all particulars and dimensions of the steam pipe and fitting with calculations for the various parts in detail, particulars of hydraulic test and his inspection notes.

At subsequent inspection, the Inspector shall enter the date of the inspection and hydraulic test together with notes thereon.

The Inspector shall also enter in the Memorandum of Inspection Book remarks regarding the general condition of the steam-pipes and fittings, and repairs, replacements of alterations, if any, and the extent to which the steam pipes have been cleaned of lagging and covering so that the book provides a useful record of the steam-pipes and fittings for the information and guidance of Inspectors at subsequent inspection.

In the event of an accident to a pipe line or its fittings, necessary remarks shall also be entered in the book.

The Memorandum Book shall be submitted to the Chief Inspector, who will check all particulars and calculations and approve the working pressure and temperatures that are to be permitted for the various parts of the pipe line and fittings. The pressure and temperature once approved for the particular steam pipe line shall not be altered except on a written authority from the Chief Inspector.

 
SUBMISSION OF PLANS OF STEAM-PIPES
(a)

Plans of steam pipes shall be submitted with the prescribed fee to the Chief Inspector before construction or at the time of the boiler for his decision whether the pipes and their arrangement comply with the Regulations.

** (b)

(i)

The fees for examination of plans and the particulars of materials, design and construction of steam pipes before the commencement of manufacture of the steam pipes shall be at the rate of Rs. 30/- for 30 meters of piping or part thereof, subject to a minimum of Rs. 50, inclusive of all fittings excepting the fittings like de-superheaters, steam receivers, feed heaters and separately fired superheaters. For any fittings like de-superheaters, steam receivers, separators and flanges, the fees shall be Rs. 150.00 for each category of such identical fittings.

(ii)

The fees for examination of layout plans of steam pipes shall be Rs. 20/- per 30 meters of piping or part thereof, subject to a minimum of Rs. 50/- inclusive of all fittings, except fittings like de-superheaters, steam receivers, feed heaters and separately fired superheaters. For any fittings like de-superheaters, steam receivers and separators, the fee shall be Rs. 150.00 for each such fittings.

EXAMINATION FEES
(1)

Candidate for examination for certificate of competency shall pay the following fees which shall not except as otherwise provided in these rules, be returnable:-

Examination for Ist class certificate.
Rs. 100/-
Examination for IInd class certificate. Rs. 75-
Duplicate certificate. Rs. 50/-
Endorsement of certificate. Rs. 25/-
(2) All fees for examination for certificate of competency as boiler attendant leviable under these rules shall be deposited in the Government Treasury, National Capital Territory of Delhi under the head-

"P. & AO. -XI Old Sectt.
0230 -Labour & employment
103 -Fees for Boiler Attendant Examination."
   
   AGE & TRAINING OF FIRST CLASS BOILER ATTENDANT
   
 

A candidate for a certificate of competency as a boiler attendant of first class shall not be less than twenty one years of age and shall not be admitted to the examination unless he has passed the High School Certificate Examination from the recognized board and possess a certificate of the Second Class Boiler Attendant Competency examination and in addition thereof-

(a) has served for not less than two years as a boiler attendant with a second class certificate of competency in sole working charge of a boiler whose rated heating surface is not less than 46.47M square (500 square feet):
OR
(b)

produce from the head of an industrial or technical institution a certificate stating that he has completed three years' course of training, one year of which must have been as an apprentice in a steam power plant of a mill or factory or an engineering workshop where engines and boilers are repaired or made and in addition has served for not less than two years in sole working charge of a boiler not less than 46.47M square (500 square feet) of heating surface with a second class Boiler Attendant Certificate."

   
   AGE & TRAINING OF SECOND CLASS BOILER ATTENDANT
   
 

A candidate for the certificate of competency as a Boiler Attendant of the second class shall not be less than twenty years of age and shall not be admitted to the examination unless he knows to read and write and proves to the satisfaction of the Chairman, Board of Examiners that he.

(a) has served for not less than three years in the capacity of a fireman on pressure parts of a steam boiler or a combined steam engine and a boiler ,
OR
(b) has served for not less than three years as a boiler fitter where boilers are repaired or made and worked under the steam, one year at least of which he should have worked as a fireman;
OR
(c)

produces from the head of an industrial or technical institution a certificate stating that he has completed a three years course of training, one year of which must have been as an apprentice in a steam power plant of a mill or factory or an engineering workshop for the maintenance of boiler."

 

A candidate, in order to be qualified for a certificate of competency of the second class, shall inter alia satisfy the examiners that:-
(a) He clearly understands -
 
(1)

The working and management of a steam boilers and economizer.

(2)

The use and purpose of the various valves, cocks, mountings and fittings.

(3)

The preventions to be taken and procedure to be observed before starting fires and when raising steam.

(4)

The use of a feed pump and injector.

(5)

The reading of the pressure gauge.

(6)

The need for periodical cleaning and pure water supply and for prevention of scale or other deposits on heating surfaces.

(7)

The need for periodical inspection of boilers and the manner in which they should be prepared for thorough inspection, hydraulic test and steam test.

(8)

The precautions to be taken before entering or allowing any person to enter a boiler that is connected to another boiler under steam.

(9)

The use of the best means of firing for the prevention of smoke

(10)

The danger of water lodging in steam pipes and the precautions to be observed in draining.

(11)

The procedure to be followed in the event of shortage of water, bulging or fracture of furnace or flat plates or bursting of tubes or of any accident to a boiler or steam pipe.

(12)

Precautions to be taken when starting an economizer to work after a period of rest.

(13)

Procedure to be adopted in bringing an economizer into commission and also to putting it out of commission while the boiler is on steam; and that

(b) He is able, inter alia -
 
(1)

To stoke a boiler including cleaning and banking fires in a workman like manner;

(2)

To show how avoidable smoke may be prevented.

(3)

To blow through and test the correctness of water - gauge glasses and test cocks.

(4)

To replace a gauge glass and show how a false water level might be shown.

(5)

To ease a safety valve and use a blow down cock or valve.

(6)

To adjust a high steam and water safety valves and renew a fusible plugs.

(7)

To pack pump or valve chest glands.

(8)

To grind and adjust cocks and valves.

(9)

To take a feed pump or injector to pieces and replace in working order.

(10)

To handle the appliances provided for keeping the economizers clean.

 
FIRST CLASS BOILER ATTENDANT

 

A candidate in order to qualified for certification of competency of the Ist class, shall satisfy the examiners that in addition to the subjects specified for candidates for certificate of competency of the second class, he has at least a rudimentary knowledge of the principal elementary facts relating to combustion, seats and steam; and that he is able to explain; interalia.

 
(1)

The principal causes and effects of corrosion and incrustation and the usual remedies employed.

(2)

The object of the use of water softeners.

(3)

The principles on which feed pumps and injectors works.

(4)

The principles on which appliances for the prevention of smoke work.

(5)

The purpose of super-heaters, economizers, feed heaters, feed filters, forced and induced draft appliances and mechanical stockers.


EXAMINATION IN WRITING OPTIONAL
 

The examination shall be conducted orally, but any candidate may, if he desires, write his answers to such written questions as may be given to him by the examiners.


GRANT OF CERTIFICATE OF COMPETENCY AND PROFICIENCY
 

If an candidate possess the examination the result will be displayed on the notice Board and notified in the official gazette He shall be granted a certificate in accordance with the class in which he passed as soon as practicable after the close of the examination.

 
FORM OF CERTIFICATE
 

Certificate of competency in Class I and II as a Boiler Attendant under rule 21 shall be in Form B and C respectively appended to these rules.

SCOPE

 

These Regulations shall apply to testing of welders engaged in India in the manufacture and site  welding connected with the erection and fabrication of boilers and steam-pipes of ferrous material.

   
  DEFINITION
 

“WELDER” means a person engaged in manual welding (gas or electric).

   
  ENGAGING OF CERTIFIED WELDERS
 

No welder shall be engaged on welding of boilers or steam pipes under construction, erection or fabrication at site or in the repair of boilers or steam pipes, unless he posses a certificate as required under the regulations herein after contained.

   
 

INITIAL QUALIFICATION TEST & ISSUE OF CERTIFICATE

 

Every welder shall be duly tested & qualified to the satisfaction of the competent authority who shall assess his  performance for qualifying for the certificate. The competent authority may, there after, issue a certificate in FORM XIII indicating the class and type of welding in which he has qualified.

   
  AGE AND EXPERIENCE
 

This regulation deals with age and experience of a candidate wishing to qualify for a certificate under these regulations to the satisfaction of the competent authority.

A candidate who wishes to qualify for a certificate under these regulations shall not be less than eighteen years of age and shall have undergone a regular apprenticeship of two years in Industrial Training Institutes or an industrial organization followed by at least one year regular on-job experience as a welder in a workshop or industry.

   
 

TEST FOR INITIAL QUALIFICATION OF A WELDER

 
(A) Theoretical Examination:- A welder shall be required to answer questions on the following subjects orally or otherwise :-
1. Electric Welder :-
 
(i) Weld preparation.
(ii) Elementary knowledge of the working of welding equipment.
(iii) Properties of material to be welded-cold and hot working, thermal conductivity, fusion point, oxidation (for welders engaged in alloy steel welding).
(iv) Elementary knowledge of electro-technical principles,- kinds of current striking are voltage, welding-are voltage.
(v) Welding defects and their prevention-influence of length of electric are effect of excessive or too low amperage, slag inclusion porosity finishing the surface of welding bead.
(vi) Electrodes for different types of welds and steels and joints in different positions.
2. Gas Welder :-
 
(i) Weld preparation.
(ii) Working of welding equipment.
(iii) Elementary knowledge of properties of materials to be welded-cold and hot working, thermal conductivity, fusion point, oxidation (for welders engaged in alloy steel welding).
(iv) Elementary knowledge of fuel gas and flame adjustments for favourable welding condition.
(v) Kinds of welds, welding defects and their prevention, welding technique (right-ward and left-ward), welding with two torches on vertical surface, excess of gas or oxidation, pre-heating of base material and subsequent heat treatment.
(vi) Filler metals.
   
(B) A welder shall be required to undergo and pass the following practical tests.
 
1. Material for tests :-

The material of Plates, tubes, pipes and electrodes used for these tests shall conform to the requirements of appropriate Regulations as may be applicable in each case.
2. Test welds for initial qualification (Electric or Gas). -
  (a) Plate welding -
    (i) One groove welded joint of two pieces of plates with double Vee or Double U grooves on boiler quality plates over a length of 381 mm (15 inches) in the following positions (size of plates to be welded being not less than 229 mm. X 381 mm X16 mm. (9” X 15” X 5/8” each):-
(1) Flat Position XIII/6 - Plate in a horizontal plane with the weld metal deposited from above.
(2) Horizontal Position XIII/7- Plate in a vertical plane with the axis of the weld horizontal.
(3) Vertical Position XIII/8 - Plate in a vertical plane with the axis of the weld vertical.
(4) Overhead Position XIII/9 - Plate in a horizontal plane with the weld metal deposited from underneath.
Qualification in position XIII/7 or XIII/8 shall qualify also for position XIII/6
Qualification in position XIII/9 shall qualify for positions XIII/6, XIII/7 and XIII/8 also.
     
    (ii) One fillet welded joint over a length of 381 mm. (15 inches) using plate not less than 16mm. (5/8 inches) in the following positions :-
   
(1) Flat Position XIII/10 - Plates so placed that the weld is deposited with its axis horizontal and its throat vertical.
(2) Horizontal Position XIII/11 - Plates so placed that the weld is deposited with its axis horizontal on the upper side of the horizontal surface and against the vertical surface.
(3) Vertical Position XIII/12 - Plates so placed that the weld is deposited with its axis horizontal on the under side of the horizontal surface and against the vertical surface.
Qualification in position XIII/11, or XIII/12 shall qualify for position XIII/10
Qualification in position XIII/12 shall qualify for positions XIII/10, XIII/11 and XIII/12.
 
  b) For pipe Welding :-
    (1) One test on groove weld joint for each of the following welding positions:
   
(i) Horizontal Rolled -

Pipe with its axis horizontal and rolled during welding so that the weld metal is deposited from above with the axis of the weld horizontal
(ii) Horizontal Turned -

Pipe with its axis horizontal the upper half welded first, the pipe then being turned through 180 degree and the other half then welded.
(iii) Vertically fixed -

One test of groove welded joint with the axis of the pipe in a vertical position and the seam welded circumferentially in a horizontal position.
(iv) Horizontal fixed -

One test of groove welded joint with the axis of the pipe in a horizontal position and the seam welded without rotating the pipe.
Qualification in positions (ii) or (iii) shall qualify also for position (i) qualification in position (iv) shall qualify for position (i) or (ii).
   
 

 

(2) One weld of a branch to a pipe.

The size of pipe to be welded shall be not less than 127 mm. (5 inches) in external diameter and 10mm. (3/8 inch) thick, and a branch pipe shall not be less than 89mm. (3-1/2 inches) Outside diameter and 6mm. (1/4 inch) thick.
    *(c) For Tube Welding :-
 

 

A butt welded joint of two pieces of boiler tubes with the axis in a vertical position and tubes of same size fixed in adjoining positions. This test shall be in addition to the test for pipe welding under CI. (b).
 
TEST FOR REQUALIFICATION

At a requalification test a welder need not be examined in theoretical subjects, but he shall be required to qualify in the following practical tests :-

 
(a)

Plate Welding -

A grove - welded joint of two pieces of plates not less than 16mm (5/8 inch) thick over a length of 152mm. (6 inches) in a position 45 degree to vertical size of Plates to be welded being 229 mm. X 152 mm. (9 inches X 6  inches). The main welding is to be carried from the underside only.

(b)

Tube Welding -

(i)

A groove welded joint with the axis of the pipe in a horizontal position and without rotating the pipe.

(ii) One weld of a branch to a pipe, as prescribed in Regulation 609.
(c)

Tube Welding :-

A butt welded joint of two pieces of boiler tubes with the axis in a vertical position, and tubes of same size fixed in adjoining positions. This test shall be in addition to the test for pipe welding under CI. (b).

(d)

When a welder is continuously engaged on production weld, tests on the work in actual production to the satisfaction of the Competent Authority may be accepted as an alternative to the tests prescribed as above under Cls. (a), (b) and (c).

 
(a)

Groove-welded plate specimens.-

The groove-welded plate specimens after welding may be lightly pressed cold to remove any distortion due to welding. The test specimen shall be similarly treated as required for the actua1 production weld.

 

After visual examination, the welded specimen shall be subjected to X-ray examination in the manner as provided in Regulation 265 (b), provided that this requirement may be waived when the welder is to be engaged on production work where radiographic examination is not required under these Regulations.

 

Thereafter test pieces shall be marked and cut out in the order shown in Figure XIII/l.

 

*The bend test specimens (B1 and B2) shall be prepared and tested as per Regulations 261 and 262. In the case of alloy steel specimen, the angle of the bend is to be decided by the competent authority, provided that the angle shall, in no case, be less than 120°.

 

Two each specimens (EI and E2) shall be prepared, one for micro and the other for macro-examination as per Regulations 265(a).

(b)

Fillet Welded plate specimens  :-

The dimensions and preparation of the fillet-weld test specimen shall conform to Figure XIII/2. The test specimen shall not contain any visible cracks. It shall be cut transversely to provide a center section. (254 mm.) (10 in.) long and two end sections each approximately (25 mm.) (1 in.) long.

 

The stem of the 254 mm. (10 in.) center section shall be loaded laterally in such a way that the root of the weld is in tension. The load shall be steadily increased until the specimen fractures or bends flat upon itself. In order to pass the test,-

(1) The specimen shall not fracture, or
(2) If it fractures; the fractured surface shall show no evidence of cracks or incomplete root penetration, and the sum of the lengths of inclusions and gas pockets visible on the fractured surface shall not exceed (51mm) (2in.).
 

The cut end of one of the end sections shall be polished and etched with a suitable reagent to give a clear definition of the structure of the weld.

 

In order to pass the test:-

 

(i)                Visual examination of the cross-section of the weld shall show complete fusion at the root and freedom from cracks.

(ii)             The weld shall not have a concavity or convexity greater than 1.6 mm (1/16 in.); and

(iii)           there shall be not more than 1.6 mm (1/16 in.) difference in the length of the legs of the fillet.

   

(c)

Groove-and-fillet-welded pipe and tube specimens :-
 

The groove-welded pipe and tube specimens shall be marked and test-pieces cut out as in figure XIII/3. The test pieces shall be prepared for face bend, root bend and tech test.

The pieces shall not be flattened, but tested in their current conditions. The penetration bead may be removed to 0.8 mm (1/32 in.) round of the surface of the material.

Fillet-welded branches shall be tested for:-

 
(i)

Visual examination- The test welds so obtained shall be visually examined for root penetration, freedom from undercut, deposition of runs, uniformity of surface, shape of profile, smoothness of joints, freedom from cavities and slag, dimensions of weld deposit, quality of weld metal (over-heating, surface cracks, spongy surface, etc.). Any piece showing serious defect shall be rejected.

(ii)

Macro examination- Each branch weld test piece shall be sawn as shown in the figure XIII/4 and each portion so produced shall be prepared and etched. The section shall then be examined for degree of fusion, degree of root penetration, absence of non-metallic (slag) inclusions and quality of weld metal. The joint should show good root fusion, complete freedom from basal cracking, and the absence of any, but very minor defects.

(d)

Welded Tube Joints :-
 

A test length approximately 203 mm long shall be cut from the tube with the welded joint disposed approximately at the centre. After visual examination, one test piece not exceeding 13 mm for tubes, 6mm in thickness and below and thrice the thickness of the tube for thickness of over 6mm shall be cut longitudinally.

The test piece shall not be less than 76 mm in length on either side of the weld. The slight excess of internal bead may be filled until it is not more than 0.8 mm round on the general surface. The test piece shall then be bent back with the root in tension through 90 degrees round a former of diameter equal to three times the thickness of the tubes. With regard to alloy steel pipes and tubes, the bend test specimen shall be bent without being straightened, but after removal of the weld reinforcement drawn to the level of but not below the surface round a former of diameter 4t and through an angle of 90 degrees. The bending may be carried out by blows or by pressure. Care shall be taken to ensure that the former is so positioned that the weld is maintained at the crown of the bend. The test specimen shall be capable of being bent through 90 degree without signs of failure, although slight premature failure at the edges of a specimen need not be considered a cause of rejection. The opening out of a slight defect due to incomplete root penetration or lack of root fusion need not be considered a cause of rejection, provided the defect has sound metal at the back and on either side of it.

(e)

Additional test before rejection :-
 

Should any of the test pieces tested in accordance with the above sub-regulations fail to meet the specified requirements, one further strip may be cut from the specimen and subjected to the same test.

If any test piece does not reach the required standard two further welds shall be made and the procedure in the above sub-regulation repeated. If any of these welds does not reach the required standards, the welder shall be deemed not to have qualified for a certificate.

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