THE INDIAN BOILERS ACT, 1923

and
THE INDIAN BOILER REGULATIONS, 1950
The Indian Boilers Act was promulgated in 1923 to
consolidate and amend the then laws relating to
Steam Boilers. It was made effective from 1st January
1924 and has been amended several times since
then.
The Act extends to the whole of India except
the State of J & K.
The Act does not apply in case of any boiler or steam
pipe
(1) In any steam-ship as defined in
The Indian Steam-Ships Act, 1884
(2) In any steam-vessel as defined in
The Indian Steam-Vessels Act, 1917
(3))Belonging to or under the control of the
Army, Navy or Air Force
(4)Appertaining to a sterilizer of disinfector of a type
as is commonly used in hospitals, if
the boiler does not exceed 91 litres in capacity.
The Act stipulates that no Owner of a boiler shall use or permit use
of boiler
(1) unless it has been registered in accordance with the
provisions of the Act.
(2) In the case of any boiler which has been transferred from
one State to another, until the transfer has been reported
in the prescribed manner.
(3) unless a certificate or provisional order authorising the
use of the boiler is for the time being in force under the
Act.
(4) at a pressure higher than the maximum pressure recorded
in such certificate or provisional order.
(5) where the State Government has made rules requiring
that boilers shall be in charge of persons holding
certificates of proficiency or competency, unless the boiler
is in charge of a person holding the certificate required by
such rules.
For a boiler to be registered, the material, design and
construction of the boiler (including economiser) as
well as its steam and feed pipes shall have to comply
with the requirements laid down in The Indian Boiler
Regulations, 1950 (IBR) considered together with the
amendments.
As defined in The Indian Boilers Act, 1923 as well
as in the Indian Boiler Regulations, 1950,
Boiler means any closed vessel exceeding 22.75
litres 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.
As defined in The Indian Boilers Act, 1923 as well as in
the Indian Boiler Regulations, 1950,

Boiler means any closed vessel exceeding 22.75

litres 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.
Economiser means any part of a feed pipe that is
wholly or partly exposed to the action of flue gases
for the purpose of recovery of waste heat.
Steam-pipe means any pipe through which steam
passes from a boiler to a prime mover or other user or
both if-
(1) the pressure at which steam passes through such
pipe exceeds 3.5 kg/sq.cm (g) or
(2)such pipe exceeds 254 mm in internal diameter and
includes in either case any connected fitting of a
steam pipe.
Feed-pipe means any pipe or
connected fitting wholly or partly
under pressure through which feed
water passes directly to a boiler and
which does not form an integral part
thereof.
SCOPE OF IBR:

Boilers other than those excluded as above are under the

purview of the IBR irrespective of its steam generation
pressure provided capacity of the closed vessel is more
than 22.75 litres.

Even if the generation of steam is at a pressure < 3.5

kg/cm2(g) and the boiler is under the purview of the IBR
because of its capacity (> 22.75 litres), the connected
pipeline shall be considered as under the purview of the
IBR in spite of its pressure being not more than 3.5
kg/cm2(g) since a boiler cannot be registered without a
pipeline connected to it for transporting the generated
steam to some user.
Users of steam are not under the IBR. Examples:
Steam Turbine, Steam Engines, Steam Heating
Coils, Steam Tracers, Process Equipment using
steam such as Steam Jet Air Ejector, Deaerator,
Gland Steam Condenser etc.
Feed Water Heaters on the discharge side of boiler
feed pump are under the purview of the IBR since they
are considered as connected fitting through which feed
water passes directly to a boiler.

The Heaters on the condensate line from the

condensate pump discharge to the deaerator are not
under the purview of the IBR since feed water as
defined in the IBR does not pass through them.
Flow nozzles, orifice flanges, thermowells installed in
steam or feed water line under the IBR require IBR
certification.
Flow nozzles, orifice flanges, thermowells installed in
steam or feed water line under the IBR require IBR
certification.
Safety valves on IBR steam and feed pipes are
under IBR but not the safety valve discharge
pipes to atmosphere.
Blowdown tank is not under the IBR even when steam
is recovered. By the same logic, other drain flash
steam tanks should also be treated as such.
Unfired boilers are also under the purview of the
IBR.
Separately fired superheaters (not integral with a
boiler) are also under the IBR.
A plant may have many fluids in service such as
steam, water, oil, gas etc, and their design pressures
and design temperatures may be anything but IBR is
concerned with only steam and feed water (not any
other water) pipes and connected fittings matching
their definitions provided in the IBR.
Only feed water pipes are under the IBR (irrespective
of design pressure or design temperature);
condensate or other water pipes are not.
Boiler feed water suction line (from deaerator to
boiler feed pump inlet) is not under the IBR
Branch lines from feed water piping (not drains
or vents) such as recirculation, warm up and
attemperation lines may be treated as non-IBR
beyond the first isolation valve(s) as feed water
does not pass directly into the boiler through
these lines.
Boiler blowdown lines beyond blowdown valve
to blowdown tank is not under the IBR.
Drain and vent piping originating from steam and
feed water piping under IBR are considered to be
under the purview of IBR. The portion beyond the
last isolation valve may be excluded.
For piping connections to instruments
mounted on steam and feed water piping
under IBR, the portion of piping up to and
including the first isolation valve(s) are
under IBR.
Steam pipes having design pressure exceeding 3.5
kg/cm2(g) are under the IBR.
Steam pipes having inside diameter exceeding
254 mm are under the IBR irrespective of design
pressure.

Any low pressure extraction steam line having

vacuum inside will therefore be under the IBR, if
its inside diameter is more than 254 mm.
There were several representations to the Central Boiler
Board (constituted in 1937 and empowered to make the
Regulations) opining that extraction lines from steam
turbines are not under the purview of the IBR, since
these lines are not from the boiler to a prime mover or
other user or both.

Central Boiler Board, it is understood, gave a ruling that

these lines are within the purview of the IBR (except
when inside diameter is not exceeding 254 mm and
design pressure is not exceeding 3.5 kg/cm2(g).
Steam piping beyond turbine side isolation
valve(s) up to turbine is not under the IBR unless
it is considered too long and the piping is not
included in the scope of the turbine supplier.
Cross-over pipes between turbine cylinders are
also not under the IBR.
Boiler Inspector or Inspectorate may be found to
have different views in some cases. Secretary
(Technical Adviser), Central Boiler Board has
the final say regarding any interpretation of the
requirements of the IBR. The process may,
however, take a very long time.
DESIGN PRESSURE, DESIGN TEMPERATURE

The IBR has no stipulation regarding design pressure or

design temperature for steam pipes unlike BS 806 or ASME
B31.1.

For feed pipe, however, Reg. 520 stipulates as follows:

The design pressure shall be the maximum pressure
generated in overcoming friction and other losses in the feed
piping under ordinary working conditions or the maximum
pressure which can be generated by the boiler feed pumps
unless special provision is made to prevent that pressure
from being communicated to the pipe line.
PRESSURE-TEMPERATURE LIMITS FOR MATERIALS
The pressure and temperature limits within which pipes,
tees, branches etc., shall be used shall be in accordance
with the following:
Butt-welded carbon steel: 21 kg/sq,cm 260 0C
(max nom bore allowable is 102 mm)
SMLS and ERW carbon steel:No restriction 454 0C
carbon-moly steel: Do 524 0C
chrome-moly steel Do 621 0C

Where pipes have to be fabricated by longitudinal fusion

butt electric arc welding of plates rolled to shape, the
limits prescribed for butt welded pipes shall not apply.
THICKNESS OF WROUGHT STEEL STRAIGHT PIPES

Pipe size is usually designated by its outside diameter

and thickness.
Pipe sizes designated by inside diameter and
minimum thickness are also used, at times, for critical
applications.
Unlike ASME B31.1 and BS 806, the IBR does not
specify any formula for direct determination of pipe
thickness but instead specifies formula for direct
determination of maximum working pressure allowed
on steel pipe whose diameter (inside or outside) and
thickness have already been chosen.
IBR formulae are:
P= 2Se(t-c) / (D-t+c), for use where OD is known
P= 2Se(t-c) / (d+t-c), for use where ID is known
Where
P = maximum working pressure(design
pressure)
t = nominal pipe thickness minus the permissible
negative tolerance.
D = outside diameter of pipe
d = inside diameter of pipe
c = 0.75 mm
e = efficiency factor
e = efficiency factor
= 1.0 for seamless and for ERW steel pipes and
for EFW steel pipes complying with the
requirements of Chapter II (of the IBR) in which
the weld is fully radiographed or ultrasonically
tested
= 0.95 for EFW steel pipes complying with the
requirement of Chapter II
= 0.90 for welded steel pipes for values of t up
to and including 22 mm
= 0.85 for welded steel pipes for values of t
over 22 mm and up to and including 29 mm
= 0.80 for welded steel pipes for values of t
over 29 mm
S = allowable stress
= lower of the values obtained from R/2.7 and
Et/1.5 for temperatures at or below 454 0C
= lowest of the values obtained from Et/1.5, Sr/1.5
and Sc for temperatures above 454 0C
Where,
R = minimum T.S of the steel at room temp
Et = yield point (0.2% proof stress) at the working
metal temp. (design temp.)
Sr = the average stress to produce rupture in
100,000 hours at the (design) temp. and in no case
more than 1.33 times the lowest stress to produce
rupture at the (design) temp.
Sc = the average stress to produce an elongation
of 1% (creep) in 100,000 hours at the (design)
In case Sc values are not available in the
material standard and such material are
known to have been used in boilers in India
or abroad, then for such materials the
allowable stress may be taken as the lower of
the values obtained from Et/1.5 and Sr/1.5.
IBR also stipulates that:
Where however material used is in conformity
with the code of the country of manufacture and
it is covered by these Regulations, the
permissible stress figures specified in the code
at different temperature may be accepted in lieu
of figures computed from the data required to be
furnished under Reg.350 in any of the following
cases.
(i) Where a certificate is furnished from the Inspecting
Authority to the effect that the steel complies with the
requirements of the grade steel (to be specified) and that the
permissible stress for the working conditions as allowed for
in the code of the country of manufacture falls within the
limits permissible under the regulations.

(ii) Where the basis upon which these stresses have been
arrived at is made available and such basis is not found to be
such as to give rise to stresses higher than those permissible
under the regulations.
THICKNESS OF WROUGHT BEND

Pipes thickness determined in accordance with IBR

formula and with increase of 12.5% shall not be bent to
radii less than those given in the Table 1. Where
smaller radii are necessary, further allowance shall be
made for thinning at the back of the bend except where
it can be demonstrated to the satisfaction of the
Inspecting Authority that the use of tb will not reduce
the thickness below t at any point after bending.
Where
t = min. thickness as per IBR formula
tb = min. thickness before bending
Table-1 Minimum bending radii for pipes
Outside Diameter, mm Radii measured to centreline of pipe, mm
tb =1.125t (all thicknesses) tb= 1.1t (tb= 34.92 mm or above)
26.9 63.5
33.7 76.2
42.4 101.6
48.3 114.3
60.3 152.4
76.1 190.5
88.9 228.6
101.6 266.7
114.3 304.8
127.0 355.6
139.7 381.0
152.4 431.8
168.3 457.2
193.7 635.0
219.1 711.2
244.5 812.8 1143.0
273.0 1016.0 1270.0
298.5 1117.0 1397.0
323.9 1219.2 1524.0
355.6 1498.6 1778.0
406.4 1727.2 2032.0
457.0 2032.0 2086.0
The thickness of the pipes from which bends are
made shall be such that the minimum thickness
required by eq. (1) is maintained throughout after the
bending operation. The deviation from circularity in
percentage at any cross-section of a bend shall be
calculated any the following formula:
C = 100 (Dmax Dmin.) / D
This deviation shall not be exceed 20D / R.
Where
C = The percentage deviation in circularity
Dmax = maximum external diameter of the
pipe as gauged at the bend
Dmin = minimum external diameter of the
pipe as gauged at the bend.
D = nominal external diameter of the pipe
R= radius of the bend on its central line
Fabricated Bend:
Fabricated pipe bends may be made welding together
bevelled sections of straight pipes provided:
The angle between the axis of the adjoining sections does
not exceed 300 and
The thickness is at least (K-0.5) / (K-1) times the minimum
thickness required for the straight pipe to which the bend
is joined.
Where
K= ration of the radius of the bend (from centre of
curvature to centre of pipe) to the inside radius of
pipe.
Gusseted bends shall be used for pressure not exceeding
21 Kg/sq.cm and temp not exceeding 260 0C
FORGED BEND
For the forged bends the radii shall be not less
than those given below:
Long radii forged bends R =1.5d
Short radii forged bends R = 1.0d
The thickness at any point of the bend shall not
be less than 87.5% of the nominal thickness of
the bend. The thickness at any point of the bend
shall be such that the minimum thickness
required by IBR is maintained throughout after
finishing operation
DRAINAGE
In the case of steam mains, attention should be paid to
the adequate provision of drainage points in the form of
dram pockets. Drainage points connected to steam traps
shall be provided wherever water can collect under
working conditions.
Hand drains shall be provided at all points at which water
can collect in any portion of the steam main by valve
leakage or other means, when shut down or when
warming up prior to use.
Where practicable, a suitable gradient shall be provided
in the pipe work to ensure the passage of condensed
water in the direction of flow of steam towards the
drainage point.
It is recommended that a by-pass should be
provided at each steam trap.

Where the volume of water deposited is likely to

be of serious proportions, separators should be
installed. Each separator shall be furnished
with a steam trap which shall be connected to it
by means of a three-way cock one end of which
is connected to a manually operated drain.
ERECTION

Erector should obtain approval of concerned

Inspecting Authority, where required, to work as
erector for the boiler and its steam and feed water
pipes at the particular construction site.
Reg. 392 requires repairers of boilers, steam and
feed pipes to satisfy the Chief Inspector regarding
the quality of welding and other repairs done by his
organisation but this requirement is known to have
been applied in case of Erector also.
Erector should ensure that each welder engaged by
him has valid Qualified Boiler Welders Certificate in
Form XIII of the IBR issued by a Competent Authority, a
list of which is given in Appendix I of the IBR. The valid
certificate of a welder may need endorsement of CIB of
the State where boiler is to be erected authorising the
welder to work at that site. When validity has already
expired or IBR qualified welders are not available,
welders may be got certified by presenting them for
tests to a Competent Authority.
The details of welder qualification tests are given in
Chapter XIII of the IBR. Validity is for two years
maximum at a time for qualification as well as
requalification. Even when a valid Qualified Boiler
Welders Certificate is available, the welder is obliged
to pass a site simulation test before he is permitted to
do production welding at site.
Erector should have the following documents:
-Relevant plans for steam and feed water pipes approved
by CIB of the user State. Reg. 395
-Relevant manufacturing drawings and the
particulars of materials, design and construction of
boiler, steam and feed pipes approved by CIB of the
State where the principal parts of the boiler have
been manufactured.
-Relevant certificates of manufacture and test in
prescribed Forms of the IBR issued bv concerned
Inspecting Authorities. Erection of components
without such certificates may, however, be allowed
if Final Inspection Reports (FIR) issued by
Inspecting Officers are made available for scrutiny
to the Inspector visiting site before site hydrotest
after erection is completed, the certificates issued
by concerned Inspecting Authorities must be
submitted.
-Relevant erection welding schedules approved
by CIB of the user State. The schedules should
contain at least the following information for the
parts to be joined by welding:
material specification
dimensions (diameter, thickness)
joint type
filler wire/electrode specification
preheat temperature
postweld heat treatment temperature and
soaking time
extent of tests, NDE or otherwise
HEAT TREATMENT:

Boiler

Carbon steel butt-welded joints shall be

effectively stress relieved when
wall thickness exceeds 20 mm or
carbon content exceeds 0.30% and
thickness exceeds 9 mm
Alloy steel butt-welded joints shall be effectively stress
relieved except when
.In case of 0.5% molybdenum steel,
thickness does not exceed 13 mm and
O.D does not exceed 127 mm
.In case of 1% Cr and 0.5% Mo steel,
thickness does not exceed 13 mm
O.D does not exceed 127 mm and
Joint is preheated to 125 C
.In case of 2.25% Cr and 1% Mo steel,
maximum Cr content is limited to 3.0%
O.D does not exceed 102 mm
Thickness does not exceed 8 mm
Carbon content does not exceed 0.15% and
Joint is preheated to 150 C
Steam and Feed Piping

Carbon steel butt-welded joints shall be effectively

stress relieved when
wall thickness exceeds 20 mm or
carbon content exceeds 0.25%

Alloy steel butt-welded joints shall be effectively stress

relieved.

Heat treatment requirements for Boiler and Piping are

clearly seen to be different and should not be so.
Soaking temperatures and time recommended
in the IBR need not be followed since Reg,
3(2)(I) amended in March 1997, makes it
mandatory to conform to the heat treatment
requirements of the specified code or standard
for the materials involved.
HYDRAULIC TEST
Boiler
Boiler shall be hydrotested after erection at 1.25 times
the working pressure as certified by Inspecting Authority
in Form II of IBR. If components of boiler have not been
tested hydraulically after manufacture in the
manufacturers premises as stipulated in Reg. 268, the
test on erection completion shall be at 1.5 times instead.
The test pressure shall be maintained for 30 minutes and
then reduced to aforesaid working pressure and
maintained for sufficient time to permit close visual
inspection for leakage of pressure parts.

The temperature of water used shall not be less than 20

C or greater than 50 C.
Hydrotest for Reheater is not specifically
mentioned in the IBR but the same may be
done by blanking both ends from connecting
piping or along with the hot and cold reheat
piping in consultation with the Boiler
Inspector.
Steam and Feed Water Piping

Steam and Feed pipes shall be hydraulically tested at

site before erection unless certificates in Form IIIA of
IBR for the pipes issued by an Inspecting Authority
are produced.

Fabricated pipes having attachment of flanges,

fittings, butt-joints, branch joints and weldolets shall
be hydro-tested at manufacturers premises or
alternatively at site at 1.5 times the design pressure.
When hydro-test is not carried out as such, dye
penetrant test shall be carried out on the welded
joints along with 5% radiography for such joints.
Hydraulic test pressure after erection at any point in
the piping system shall not be less than 1.5 times the
design pressure but shall not exceed the maximum
allowable test pressure of any non-isolated
components such as valves, vessels or pumps. At no
time during hydraulic test shall any part of the piping
system be subjected to a stress greater than 90% of its
yield strength (0.2% offset) at test temperature.
FEES
Fees are to be paid into the Government Treasury
using appropriate Challan No. and Head of Accounts
for various services rendered by the concerned
Inspecting Authority such as:
scrutiny of Plan for Steam and Feed Pipes
{Reg. 395b(ii), 534-B}
scrutiny of manufacturing drawings (Reg. 393-
A, 395b(I), 534-B}
inspection of boiler and boiler parts at site
{Reg. 395-A(4)}
registration of boiler (Reg. 385)
welder qualification/requalification (Reg. 616)
Reg. No. indicated in the parenthesis may be referred for
the amount of fees to be paid. However, the concerned
Inspecting Authority should better be consulted on this
since the State Governments are empowered to make
rules for prescribing the fees payable for the inspection
and examination of boilers or parts thereof, or drawings
for steam pipes, for the testing of welders or for any
other matter which in the opinion of the State
Government would involve time and labour. e.g, in West
Bengal fees are also to be paid for verification of
flexibility of pipes.

Further, additional fees are payable for inspection on

Sundays and other public holidays under the Negotiable
Instruments Act, 1881.However, Owners request and
CIBs approval are both necessary for the same.