Reg.

343
STEAM-PIPES AND FITTINGS Pipes 1) Steam-pipes may be carbon steel, cast steel, alloy steel and in some cases of copper. Steel pipes may be solid drawn (cold or hot finished), butt welded or electric resistance welded. Copper pipes shall be solid drawn and no pipe made from electrodeposition of copper on a mandrill shall be used for steam delivery. 2) 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 temperatures may be accepted in lieu of figures computed from the data required to be furnished under Regulation 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 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. 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 in Table 2 under Regulation 349 shall not apply. The requirements other than those relating to the minimum thickness of shell for fusion butt welding prescribed in Chapter XII shall be applicable to such pipes.

3) Notwithstanding anything contained in Chapter VIII, the hydraulic test for pipes in makers premises may be dispensed with by the Inspecting Authority provided these pipes are fully tested by approved radiographic or ultrasonic techniques; but this dispensation shall not apply to pipes having an internal diameter greater than 600 mm. In the event of a detection of any defect after conducting hydraulic test of these pipes at site, it shall be the responsibility of the manufacturer to repair or replace the defective pipes, as may be deemed necessary by the Inspecting Authority. 4) Electric fusion welded pipes in which the butt welds are fully radiographed or ultrasonically tested need not be hydraulically tested in the shops provided the pipe system as a whole is hydraulically tested at site to the requisite test pressure in accordance with regulation 374. 5) In the case of fusion welded pipes test plates to represent all welded seams shall be attached at each end of longitudinal seam and tested in accordance with the requirements of Chapter XII except that one test plate may represent a lot of pipes up to 60 metres in length and of the same grade of material and same thickness of the pipe subject to the same heat treatment.

Reg. 344
MATERIAL Steel Pipes a) The pipes shall be made from steel made by an Open Hearth or Electric Process or by any of the Oxygen Processes. Hot finished seamless pipes may, however, be made of Bessemer Steel. Bessemer Steel shall not be used for pressures exceeding 21 kg/cm (300 lbs./in) or temperatures exceeding 260C (500F). If the Bessemer Process is used, the steel shall be made by a manufacturer approved by the Inspecting Authority. When used for temperatures exceeding 399C (750F) the steel shall be of non-segregated or fully skilled type. b) Carbon and alloy steel pipes shall not be used for design temperatures exceeding those given in Table2 of regulation 349. c) For design temperature over 427 C (800 F) special precaution shall be taken to ensure that the surface condition of the pipe is suitable for these requirements. d) The material from which seamless and electric resistance welded pipes are made shall conform to the appropriate specification of tubes in Chapter II. The materials from which butt welded pipes are to be made shall conform to the requirements of Table 1 under Regulation 347. e) Notwithstanding anything contained in sub-regulation (a), the material specifications given in this Chapter shall not apply to

steam-pipes and fittings used for conveying steam at a pressure not exceeding 1 kg/cm, the approval in regard to the quality of the material being left to the discretion of the Chief Inspector of Boilers.

Reg. 345
Condition of Pipes a) All pipes shall be commercially straight free from longitudinal seaming, grooving, blistering or other injuries surface marks. The ends of the pipes shall be cut square. b) The pipes shall be made within the limits of tolerances given below:Class Upto and including 51 mm. (2) Seamless E.R.W. Butt welded + 0.4 mm. (1/64) - 0.8 mm. (1/32) 1% Tolerance on Outside diameter Over 51 mm (2) 1% + no limitation - 12.5% 1% + no limitation - 12.5% Nominal thickness

Reg. 346
MECHANICAL TESTS Number of sets of tests The number of pipes on which mechanical tests shall be performed shall be as follows:Seamless pipes: Up to and including 114 mm. (4-1/2 in.) o. d. Over 114 mm. o. d. As per requirements of Chapter II. 5 per cent of the lengths of pipe as made, or 2 per cent of the pipes from each cast where the cast (i.e. melt) can be identified. 2 per cent of the lengths of pipes as made.

Welded pipes

In the case of pipes for designed temperatures over 454C (850F) every pipe over 114 mm. (4-1/2 in.) outside diameter shall be tested.

Reg. 347 A Reg. 347 B

Flattening test (for pipes up to and including 102 mm. (4 in.) Nominal bore) As per requirements of Chapter II. (i) For cold drawn seamless construction-Regulation 39. (ii) For hot finished seamless construction-Regulation 44(b). (iii) For molybdenum seamless construction-Regulation 49 (b).

(iv) For Chrome molybdenum seamless construction-Regulation 54(b). (v) For electric resistance welded tubes-Regulation 59(a). (vi) For copper steam pipes-Regulation 35. For pipes where the ratio between the wall thickness and the diameter would not permit the maintenance of the distance between the flat surfaces specified in the above regulation, this shall be limited to 2/3rd the bore of the pipe.

Reg. 347 B
Cold bend test (for pipes over 102 mm. (4in.) Nominal bore) strip not less than 38 mm. (1-1/2 in.) wide cut circumferentially from one end of each selected pipe shall when cold withstand, without showing either crack or flaw being doubled over in the direction of original curvature round a bar, the diameter of the bar being:-

For pipes up to and including 10mm (3/8 in.) thick For pipes over 10mm. thick

3 times the

thickness

4 times the thickness

Reg. 347 C Reg. 347 D, Reg. 347 E

Bend test on the weld A strip not less than 38mm. (1-1/2 in.) Wide cut circumferentially from one end of each selected pipe with the weld near the middle of the strip, shall when cold withstand, without showing either crack or flaw, being doubled over in the direction of original curvature round a bar, the diameter of the bar being equal to eight times the thickness of the test piece, the weld being placed at the point of maximum bending. In cases where the outside diameter of the pipe is less than 8 times the wall thickness, the diameter of the former shall be equal to 4t or 2/3rd of the nominal bore of the pipe, whichever is less.

Reg. 347 D
Additional test Should a pipe selected for testing fail in any one or more of the tests specified above, two further tests of the same kind may be made from the same or another pipe from the same batch. Should either of these further tests fail, the pipes represented may be reheat treated and then re-tested. If the repeat tests are satisfactory, the pipes shall be accepted provided they comply with other requirements but if failure again occurs, the pipes which the test pieces represent shall be rejected.

Reg. 347 E
Tensile test As per requirements of Chapter II.

Reg. 347 F
STEAM-PIPES AND FITTINGS

Test for valves and fittings:- As per requirement of clause (e) of regulations 290. TABLE 1-CARBON STEELS Butt welded pipes Minimum elongation per cent Ultimate tensile strength in kg./sq. On 203 mm. (8 mm (tons per sq. in.) in.) Not Not more less than than Strips cut from the pipes clear of the welds and tested in their curved condition 6 mm. (1/4") thick and over less than 6 mm. (1/4") thick On 51 mm. (2 in.) Less 6mm. than 6 (1/4") mm. thick (1/4") and over thick Sulphur per cent. max. Phosphorous per cent max.

Kind of pipes

35 (22)

44 (28)

20

18

32

30 0.6 0.6

Test lengths taken from finished pipes 35 (ends of pipes to be (22) plugged for grips)

44 (28)

25

23

TABLE 1 - CARBON STEELS Ultimate tensile stress in kg./sq. mm.(tons/sq. in.) Selected Samples cut transversely Not Less Not Than More Than Min. Elongation per cent on 203 mm. Sulphur (8") maximum % 13 mm. 1/2" thick and over 23 Less than 13 Less than mm. thick and 6m. thick not less than 6mm. (1/4") thick 20 18 0.05 0.05 Phosphorus maximum %

36 (23)

44 (28)

Reg. 348
Method of manufacture, Heat treatment and Marking a) (i) The cold drawn seamless carbon steel pipes and welded carbon steel pipes shall be supplied in normalised condition (ii) Hot finished seamless carbon steel pipes shall be supplied in hot finished condition or in normalised condition at the option of the manufacturer. (iii) The seamless alloy steel pipe either cold finished or hot finished and welded pipes shall be supplied in normalised and tempered condition. (iv) By agreement between the users and the manufacturer, the pipes may be delivered in a condition other than normalised and tempered condition in which case they shall be suitable for subsequent manipulation and the user shall be informed of the heat-treatment necessary to give required properties. b) (i) Pipe bending and forming (viz. reducing/swaging) operation shall be done by any hot or cold method and to any radius which shall result in a surface free from cracks, buckles or other defects as determined by the method of inspection specified in the design. A post bending or post forming heat-treatment for carbon steel material is required with a nominal wall thickness in excess of 19.0 millimetres unless the bending or forming operation are performed and completed at

normalizing temperatures, where no further heat treatment is required. The heat treatment where required shall be normalized or stress-relieved, as the case may be. (ii) A post bending or post forming heat treatment shall be required for all ferritic alloy steel material with nominal pipe size 100.00 millimetres and larger or with a nominal thickness 13.0 millimetres or greater. (iii) If hot bending or forming is performed, the material shall receive normalize and temper or tempering heat-treatment as required by the design. For cold operation, tempering heat-treatment shall be applied. c) Marking:-Marking shall be carried out in accordance with regulation 395F.

Reg. 349
STEAM-PIPES AND FITTINGS The pressure and temperature limits within which pipes, tees, branches, etc., shall be used, shall be in accordance with Table 2. TABLE 2 Maximum permissible working pressure and temperature Maximum permissible temperature C 454 454 260 454 454 524 621 850 850 500 850 850 975 1150 F Straights, bends or fittings. Do Do Straights Straights, bends or fittings Do Do

Material

Maximum Method of manufacture permissible working pressure Cold drawn seamless Hot finished seamless No restriction Do

Form

Carbon steel

Butt welded [Max. 21 kg/cm nominal bore allowable (300 lb./sq. in.) 102 mm. (4 in)] Electric resistance welded No restriction No restriction No restriction No restriction 12.6 kg/cm (180 lbs./sq.in.)

Cast steel

Castings

Cold drawn seamless Molybdenum steel and castings. Cold drawn seamless Chromium and hot finished molybdenum Steel seamless Copper Solid drawn up to and including 127 mm.(5 in.) dia.

Not allowed for superheated steam

Straights and bends.

Reg. 350
Steel Pipes The maximum working pressure allowed on steel pipes shall be determined by the following formula: a) Where the outside diameter is the basis for calculation. 2 f e (t - c) D-t+c

W. P. =

Equation 91

b) Where the inside diameter is the basis for calculation.,

W. P. =

2 f e (t - c) d+t-c

Equation 91A

Where t = Minimum thickness W. P. = Maximum working pressure f = allowable stress determined on the following basis i) For temperature at or below 454 C, the lower of the following two values: Et 1.5 R 2.7

f=

or

(ii) for temperature above 454 C, the least of the following three values: Et 1.5 SR 1.5

(a) where

(b)

(c)

Sc

t = working metal temperature R = minimum tensile strength of the steel at room temperature Et = Yield point (0.2% proof stress at the temperature t) Sc =The average stress to produce an elongation of 1% (creep) in 100,000 hours at temperature t SR = The average stress to produce rupture in 100,000 hours at the temperature t and in no case more than 1.33 times the lowest stress to produce rupture at the temperature. D = Outside diameter of pipe d = Inside diameter of pipe e = Efficiency factor = 1.0 for seamless and for electric resistance welded steel pipes and for electric fusion welded steel pipes complying with the requirements of Chapter II in which the weld is fully radiographed or ultrasonically tested. = 0.95 for electric fusion welded steel pipes complying with the requirements of Chapter II, = 0.90 for welded steel pipes for values of t up to and including 22mm. = 0.85 for welded steel pipes for values of t over 22mm and up to and including 29mm. = 0.80 for welded steel pipes for values of t over 29 mm. C = 0.75mm. Note: In case Sc values are not available in Material Standard and such materials 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 Et 1.5 Sr 1.5

or

TABLE 3 Maximum permissible working stress for straights, bends or fittings Over 260C (500F) up to & including 288C (550F) Over 288C (550F) upto & including 316C (600F) Over 316C (600F) upto and including 343C (650F) Over 343C (650F) up to and including 371C (700F) Over 371C (700F) up to and including 399C (750F) Over 399C (750F) up to and including 427C

Material and method manufacture

Upto and including 260C (500F)

(800F) Carbon Steel A. Butt welded and Bessemer hot - Finished seamless. 865 kg./cm (12,300lb/ .sq. in.)

Not used for these temperatures

791 822 kg./cm kg./cm Castings. (11,300 (11,700 lbs sq. lb./sq. in.) in.)

703 745 kg.cm kg.cm (10,600 (10,000 lbs./sq.in.) lbs./sq.in.)

654 kg./cm (9,300 lbs./sq.in.)

605 kg./cm (8,600 lbs./sq.in.)

541 kg./cm (7,700 lbs./sq.in.)

Carbon Steel Seamless, hydraulic lap welded and The lower value obtained on the following basis from for temperatures up to and including Electric resistance welded 350C (662F) T.S 2.7 Et 1.5

or

For temperatures above 454(850F) Molybdenum steel seamless Chromium Molybdenum Steel seamless Et 1.5 or Sr 1.5 or Sc

where, T. S. = Minimum Tensile strength at 20C(68F) Et = Yield point (0.2% proff stress) at the temperature t. Sr = The average stress to produce rupture in 100,000 hours and in no case, times the lowest stress to produce rupture. Sc = The average stress to produce an elongation of 1% (creep) in 100,000 hours.

more than 1.33