JAI GANESH
IBR-DESIGN
Chapter-1
Reg. 2
c) “Boiler” means any closed vessel exceeding 22.75 litres (five
gallons) in capacity which is used expressly for generating steam
under pressure and includes any mounting or other fitting
attached to such vessel, which is wholly or partly under pressure
when steam is shut off:
cc) “Calculation Pressure”, in relation to a boiler, means the design
pressure of any part adjusted to take into account the pressure
drops corresponding to the most severe conditions of pressure
drop and hydraulic head;
ddd) "Design Pressure" means:-
(i) in relation to a natural or assisted circulation boiler, the
maximum allowable working pressure in the steam drum
of the boiler;
(ii) in relation to a once through forced-circulation boiler, the
maximum allowable working pressure at the final
superheater steam outlet;
k) ”Steam-pipe” means any pipe through which steam passes from
a boiler to a prime-mover or other user or both if :-
(i) the pressure at which steam passes through such
pipe exceeds 3.5 Kilograms per square centimetre
above atmospheric pressure; or
(ii) such pipe exceeds 254 millimetres in internal
diameter; and includes in either case any
connected fitting of a steam-pipe.
(3) No structural part of a boiler, which is subject to pressure, shall be made of Bessemer process
steel or of Cast or Malleable Cast Iron.
Reg:3
(3) No structural part of a boiler, which is subject to pressure, shall be made of Bessemer process
steel or of Cast or Malleable Cast Iron.
(4) Where no specific provision is made in these regulations for design or manufacture of any
pressure part, the Inspecting Authority may permit the design, manufacture, stage inspections
and certification of such pressure parts including the valves, mountings and fittings conforming
to the Codes or Standards like BS, ASME Boiler and pressure vessels code, TEMA, TRD, GOST
and JIS which are known to be commonly used in industrially advanced countries. The decision
of Inspecting Authorities shall be binding on all Registering authorities.
(4A) The tubes of boilers and heat exchangers made of Titanium and other exotic metals may
be approved as per international codes, including ASME, BS, DIN, TEMA with the minimum
thickness specified in those codes of manufacture.
Reg. 4
STANDARD REQUIREMENTS
(iii A drawing or print to a scale, in the case of large boilers of not less than ¾ inch to the
) foot and, in the case of small boilers of not less than 1 ½ inches to the foot, showing the
principal dimensions and a longitudinal section and end view of the boiler, and bearing
the works number of the boiler and Maker’s office stamp. The drawing shall show details
of riveting of longitudinal and circumferential seams with pitch of rivets, cross spacing of
dished end plates, fillets and flanges and corners of bent plates, and where gusset stays
are fitted the number and diameter of rivet holes in each gusset stay.
In the case of water tube boilers, the foregoing scales shall apply to the main boiler drums
only, but in addition a general arrangement drawing of the boiler to a scale of not less
than ¼ inch to the foot shall be provided.
(d) Maker’s Stamp.- The boiler shall have stamped upon its front plate in a conspicuous
position the following particulars:-
MAKER’S NAME
Works’ Number_____________________________________ Year of
make__________________ Tested to __________________________
Lbs.________________________ on _______________
W.P.________________________________________________ Lbs._____________
Inspecting Officer’s or
Inspecting Authority’s Official
Stamp
___________________________________
Reg. 5
Modification of Formulae
(i) Under the Regulations for determining the working pressure to be allowed on various
parts of boilers, the material to which the formulae apply shall in the absence of express
provision to the contrary be steel complying with the requirements of Chapter II.
JAI GANESH
CHAPTER-4
Reg. 175, Reg. 176
REGULATIONS FOR DETERMINING THE WORKING PRESSURE TO BE
ALLOWED ON VARIOUS PARTS OF BOILERS OTHER THAN FUSION WELDED
AND SEAMLESS FORGED DRUMS
Reg. 175
Maximum pressure
The maximum pressure at which a boiler may be used shall be determined in accordance with the
provisions of this Chapter. The regulations in this chapter refer to material subjected to steam
temperature not exceeding 500° F.
Reg. 176
SHELLS
Formula for Working Pressure of Shell
a) For cylindrical shells, barrels, steam and water drums, and domes of boilers for maximum
working pressure per square inch to be allowed shall be calculated from the following
formula :-
(Note - Where parts of drums of water tube boilers are perforated for tubes, the working
pressure shall be calculated by equation (53) under 'Tube Plates')
(t - 2) x S x J
W. P .= Eqn. (1)
CxD
Where
W. P. = the working pressure in lbs. per square inch;
t = the thickness of shell plates in 32nds of an inch;
S = the minimum tensile breaking strength of the shell plates in tons per square inch or
whatever strength is allowed under Regulation 5;
J = the percentage of strength of the longitudinal seams of shell or of a line of holes in the
shell for stays, or rivets, or of an opening in the shell not fully compensated, whichever is
least calculated by the methods hereafter described;
C is a co-efficient as follows :-
2.75 when the longitudinal seams are made with double butt straps and when small shells
are formed from solid rolled sections.
2.83 when the longitudinal seams are made with lap joints and are treble riveted.
2.9 when the longitudinal seams are made with lap joints and are double riveted
3.0 when the longitudinal seams are welded and are fitted with a single butt strap.
3.3 when the longitudinal seams are made with lap joints and are single riveted.
D = the inside diameter of the outer strake of plating of the cylindrical shell measured in
inches.
b) The factor of Safety shall in no case be less than 4.
The actual factor of Safety in each case may be found from the equation ;
t
F = 1.4 x C x
t-2
With the best form of joint and least co-efficient (c) the Factor of Safety for shell plates,
1/4 inch to 1-3/4 inches in thickness varies from 5.13 to 3.99.
An addition of 10 per cent, shall be made to the appropriate co-efficient for shells of
c) boilers in which the longitudinal seams are lap jointed and are not accessible to close
visual inspection and for shell plates of externally fired boilers exposed to the direct
impact of furnace flame; provided that this addition shall not apply to the steam and water
drums of water tube boilers where the drums are not close to the fire-grate and there are
tubes between the fire-grate and the drum.
The above co-efficient are standards and shall be used only for boiler open to inspection
d)
by an inspecting officer during the whole period of construction and which are certified
by him as having constructed in accordance with the standard condition laid down in
these Regulations
Reg. 177
SHELLS
Methods of calculating the strength of riveted joints
a) The percentage of strength of a riveted joint (J) shall be found from the following
formulae (i), (ii), (iii); (i) and (ii) are applicable to any ordinary type of joint, (iii) is
applicable only to that type of joint in which the number of rivets in the inner rows is
double that of the outer row. The lowest value given by the application of these formulae
is to be taken as the percentage of strength of the joint compared with the solid plate.
(i) 100(P - D) = Plate percentage Eqn.(2).
P
100 x A x N x C x S1
(ii) = Rivet percentage Eqn.(3)
PxTxS
100(P - 100 x A x C x
(iii) 2D) + S1 = Combined plate and rivet percentage . Eqn.(4)
P PxTxS
Where
P is the pitch of rivets of outer row in inches.
D is the diameter of rivet holes in inches.
A is the sectional area of one rivet hole in square inches.
N is the number of rivets per pitch (P).
T is the thickness of plate in inches.
C = 1 for rivets in single shear as in lap joints, and 1.875 for rivets in double shear as in
double butt strapped joints.
S1 is the shearing strength of rivets which shall be taken to be 23 tons per square inch for
steel and 18 tons per square inch for iron.
S is the minimum tensile breaking strength of shell plates in tons per square inch, or
whatever strength is allowed under Regulation 5 of chapter I,
In the first formula (i) D is the diameter of the rivet holes in the outer rows and in the third
formula D is the diameter of the rivet holes in the next rows. In the last formula A is the
area of one rivet hole in the outer row
b) When the sectional area of the rivet holes is not the same in all rows, and when some of
the rivets are in double shear and others in single shear the rivet sections per pitch of each
size in shear shall be computed separately and added together to form the total rivet
section.
Reg. 178, Reg. 179, Reg. 180, Reg. 181
SHELLS
When Pitch exceeds maximum allowed
Should the pitch of the rivets exceed the maximum pitch allowed, the permissible pitch shall be used in
place of the actual pitch in determining the percentage of plate section. No greater percentage than 85
shall be allowed for any type of riveted joint.
Reg. 179
SHELLS
Butt Straps and spacing of rivets below requirements
Should the spacing of the rows of rivets or the distance between edge of plate and rivet hole or the
thickness of butt straps be less than that specified in Regulations 182 and 184 the percentage
representing the strength of joint shall be modified as prescribed in those regulations.
Reg. 180
SHELLS
Percentage of Welded and Strapped Seams
In determining the percentage of strength of a welded seam covered by a strap or straps the formulae
and allowances in Regulations 177, 178 and 179 shall be applied, but 50 per cent shall be added to the
rivet percentage for the weld.
Reg. 181
SHELLS
Percentage to be allowed for Solid Rolled Shells
When small shells are rolled from the solid, J, in equation (1) shall be taken as 100 per cent.
Reg. 182
SHELLS
Thickness of Butt Straps
The minimum thickness of butt straps for the longitudinal seams of cylindrical shells shall be
determined by the following formulae but all straps should be of sufficient thickness to permit of
efficient caulking and in any case shall not be less than 3/8 inch in thickness.
Single butt straps having ordinary riveting :-
1.125T = T1 Eqn.(5)
Single butt straps having every alternate rivet in the outer rows omitted:-
(P – D)
1.125T x = T1 Eqn.(6)
(P – 2D)
Double butt straps of equal width having ordinary riveting :-
0.625 T = T1 Eqn.(7)
Double butt straps of equal width having every alternate rivet in the outer row omitted :-
(P – D)
0.625T x = T1 Eqn.(8)
(P – 2D)
Double butt straps of unequal width either having ordinary riveting, or having every alternate
riveting the outer rows omitted :-
0.75T = T1 (Wide strap) Eqn.(9)
0.625T = T1 (narrow strap) Eqn.(10)
Where
T = the thickness of the butt straps in inches. The other symbols have the same significance as in
Regulations 177.
Single and wide butt straps shall, wherever practicable, be on the inside of the shell.
Should the thickness of butt straps be less than that above described, the least percentage of joint
as determined under Regulation 177 shall be reduced in the proportion of the actual thickness to
the prescribed thickness.
Reg. 183
SHELLS
Maximum Pitch of Rivets in longitudinal joints
The maximum pitch of the rivets in the longitudinal joints of boiler shells shall be :-
C x T + 1.625 = maximum pitch in inches Eqn. (11)
Where
T = the thickness of the shell plate in inches.
C is a co-efficient as given in the following table : -
Co-efficient for
Number of Rivets Per Co -efficient for Lap Co-efficient for single
double Butt-strapped
pitch joints Butt- strapped Joints
joints
1 1.31 1.53 1.75
2 2.62 3.06 3.50
3 3.47 4.05 4.63
4 4.14 - 5.52
5 - - 6.00
Reg. 184
SHELLS
Spacing of rows of rivets
a) In joints, whether lapped or fitted with butt straps, in which there are more than one row of
rivets and in which there is an equal number of rivets in each row, the distance between the
rows of rivets shall be not less than-
Zig-zag riveting :-
0.33P + 0.67D = distance between centre lines of rows (R) Eqn. (12)
Chain riveting :-
2D = distance between centre lines of rows (R) Eqn. (13)
b) In joints in which the number of rivets in the outer rows in one-half of the number in each of
the inner rows, and in which the inner rows are chain rivets the distance between the outer
rows and the next rows shall be not less than as required by equations (12) and (13)
whichever is the greater, and the distance between the rows in which there are the full
number of rivets shall be not less than 2D(R1).
c) In joints in which the number of rivets in the outer rows in one-half of the number in each of
the inner rows and in which the inner rows are zig-zag, the distance between the outer rows
and the next rows shall be not less than-
0.2P + 1.15D = distance between centre lines of outer and next rows (R) Eqn. (14)
The distance between the rows in which there are the full number of rivets shall be not less
than :-
0.165P + 0.67D = distance between centre lines of inner rows (R1 ) Eqn. (15)
Where
P is the pitch of the rivet in the outer rows.
D is the diameter of the rivet holes in inches or the mean of the diameter of rivet holes when
the distance to be determined is between two rows of the different diameters.
d) Should the distance between rows of rivets be less than as prescribed above the plate
percentage determined by equation (2) shall be modified thus –
100 [ P - ( 2 - actual distance ) D ]
prescribed distance
= modified plate percentage
P Eqn. (16)
e) In all cases the clear space between a rivet hole and the edge of a plate shall not be less than
the diameter of the rivet holes, i.e. the centre of the rivet hole shall be at least 1-1/2
diameters distant from the edge of the plate (E);
Provided that if this condition be not observed, the strength value of the rivet affected shall
be reduced in the proportion of the actual distance between the outer edge of the rivets and
the edge of the plate to the prescribed distance
Reg. 185
SHELLS
Circumferential and End Seams of Water Tube Boilers
The suitability of circumferential seams including the seams joining ends to shells shall be
verified by the following formula : -
K x J x (t-2)
is equal to or greater than W.P. Eqn. (17)
DxC
Where
K = 150 for 26/30 tons tensile plates.
K = 157 for 28/32 tons tensile plates.
Due to higher stresses, see regulations 271 and 340.
WP = The working pressure in lbs per sq. in.
D = The diameter of shell in inches, measured inside the outer ring of plates.
J = Circumferential Joint efficiency calculated by Eqn.2 or 3.
C = 8.24 where the seams are made with lap joints and are treble riveted.
= 8.44 where the seams are made with lap joints and are double riveted.
= 9.60 where the seams are made with lap joints and are single riveted.
t = thickness of plate in 32nd of an inch.
Reg. 186
SHELLS
Compensation for Manholes and other openings
The percentage of compensating section shall be determined by the following formulae:-
200(W - D) x Tr
= Percentage strength of compensating section Eqn. (18)
(L + 2D) x Ts
80 x A x N
= Percentage strength of rivet section Eqn. (19)
(L + 2D) x Ts
Where
W is the width of compensation ring in inches measured in the direction of the longitudinal axis
of the boiler,
L is the length of opening in shell in inches measured in the direction of the longitudinal axis of
the boiler,
D is the diameter of rivet holes in inches,
Tr is the thickness of compensation ring in inches,
Ts is the thickness of shell plate in inches.
A is the area of one rivet hole in inches,
N is the number of rivets on one side of the longitudinal line. When the rivets are in double shear
1.875 times the single rivet section shall be allowed.
Parts of raised manhole mouthpieces within four inches of the shell shall, in addition to the ring,
be included in the compensating section.
