GUIDE TO

PRESSURE VESSEL CODES

BHARAT HEAVY ELECTRICALS LIMITED

CORPORATE QIALITY ASSURANCE

1
 BHARAT HEAVY ELECTRICALS LIMITED
CORPORATE QIALITY ASSURANCE

INTRODUCTION

There is an increasing use of national and international codes on unfired

pressure vessels in BHEL‟s Plants as well as in the works of BHEL‟s Vendors.
While interpretation of the Codes is possible by going through the actual
codes, it is felt necessary that salient features of some of the regularly used
national and international codes will be useful in concise form and in the form
of a comparative statement.

Some work in this regard was already done by Bhopal and Hyderabad Plants.
This Publication is an attempt to assist the Specialists, Executives and
Supervisors at Shop Floor level as a reference document. The efforts put in
by the Quality Services Group of Bhopal and Ramachandrapuram in
compiling this useful booklet is acknowledged.

Secunderabad (P.S.THILAK)
May 5, 1984. Dy. General Manger
Corporate Quality Assurance

2
 B.S.5500 : 1976 ASME SEC VIII : 1980 (Div .1)
A. SCOPE OF THE COSES
Covers design, constructions, Covers minimum construction
inspection, testing and requirements for design, fabrication
certification of unfired fusion inspection and certification of unfired
welded pressure vessels. pressure vessels.
Sections include: Sections Included:
1. General (Definitions and Subsection A (Covering general
responsibility of purchaser, requirements applicable to all types of
manufacturer, inspectors vessels)
etc.)
2. DESIGN SUB-SECTION B (Covering
requirements separately for welded
riveted forged or brazed methods)
3. MANUFACTURE & SUB-SECTION C (Covering
WORKMANSHIP requirements applicable to different
classes or materials i.e., cast iron, clad
and lined material and nodular iron etc.,)
4. INSPECTION & TESTING MANDATORY APPENDICES (including
design formulas, porosity charts,
methods, for Magnetic particle
inspection, Q.C. systems etc.,)
5. APPENDICES (all non- NON-MANDATORY APPENDICES
mandatory) (Some suggested good practices e.g. in
ultrasonic examinations for bolted flange
connection).
This standard does not cover This standard does not cover the
the following: following:
1. Storage tanks designed i) Vessels with design pressures
for the storage of liquids exceeding 3000 Psi (20, 670K Pa).
near atmospheric ii) Vessels with I. Dia width, height or
pressure (i.e. 140m-bar cross section diagonal less than 152
above and 6m-bar mm.
below atmospheric iii) Vessels for internal/external pressure
pressure). Low pressure operation not exceeding 15 Psi (103
storage tanks with one K Pa)
vertical axis of
revolution with pressure
less than I bar.
2. Vessels where stresses iv) Vessels subjected to federal control
calculated are 10% of
the design stress
permitted by section 3.
3. Scrip wound compound
or other special designs
of vessels for very high
pressures.

3
 B.S. 5500 : 1976 ASME SEC VIII : 1980 (Div.1)
4. Transportable vessels 5. Unfired steam boilers excluding
5. Vessels for specific evaporators heat exchangers and
applications which are covered vessels in chemical. Petroleum industries
by BSI year book where steam is generated incidental to
operation of a processing system
containing a number of pressure vessels.
. 6. Vessels used for hot water supply
storage tank heated by steam within the
following limitations:
a. Heat input of 20,000 Bt.U/hr. (58.6
Kw).
b. Water temp. of 210 o F (99o C).
c. Nominal Water capacity of 120
gallons (454 liters)
7. Pressure containers which are integral
parts of rotating or reciprocating
mechanical devices e.g. pumps, turbine
generators, hydraulic or pneumatic
cylinders where primary design
consideration and / or stresses are
derived from functional requirements of
the device.
8. Vessels with a nominal water
containing capacity of 120 gal (454 liters)
or less containing water under pressure
including those containing air the
compression of which service only as a
cushion.
9.Piping components such as pipes &
valves,

4
 IS 2525 : 1969 I.B.R
Covers minimum construction
Covers design, construction, testing and
requirements for design, fabrication,
certification of boilers mainly. However
inspector, testing, and certification of
chapter XV Heat exchangers etc., and
fusion welded unfired pressure similar vessels recommended that heat
vessels, in ferrous and non-ferrous exchangers and similar vessels be
materials. constructed following the applicable
regulations, covered under different
1) General, material & design. chapters.
2) Fabrication and welding Usually Chapter XII shell type boilers of
3) Inspection test, marking and welded construction is being followed.
records. Also regulation – 523A stipulates that
4) Appendices (both mandatory and feed water heaters may be constructed
non-mandatory) as per chapter XII.
Hence reference is mostly made to
chapter XII shell type boilers of welded
constructions is being followed.
Also regulation- 523 A stipulates that
feed water heaters may be constructed
as per chapter XII.
Hence reference as per chapter XII
ONLY. For workmanship various
chapters covered are:

Chapter I General requirement

II Material for construction
XII Shell type boilers of
welded construction.
Equipments governed by I.B.R. are as
noted below:
1) All boilers.
2) Steam pipes with pressure 3.5
Kg/ SQ. Cm. Or with dia
exceeding 254 mm in I.D and
with out limitations of pressure.
3) Equipments like feed water
heaters etc connected after
boilers etc connected after boiler
feed pump in which steam is the
medium.
This standard does not included the
following:
1.Vessels which design pressure
exceeding 210 KG/Cm2
2.Vessels with O.D/I.D > 1.5
3.Vessels operating under internal
pressure below 1 Kg/Cm2
4.Vessels with I.D. > 150 mm

5
 IS 2525: 1969 I.B.R
5. Equipments under I.B.R. per view
6. Vessels where internal pressure is
only due to static head of liquid
7. Vessels with a nominal capacity of
500 liters or less for containing water
under pressure including those
containing air, the compression of
which services only as a cusion.

6
 ASME SEC VIII: 1980
B.S. 5500: 1976
(Div.1)
Welded joints are
B. CLASSIFICATION OF VESSELS categorized into A, B, C, D
according to their location
Vessels are classified into three construction and special requirements
categories, on the bases of material, NDT are specified at different
temperatures etc., These are as follows: places in the code. No
classification of vessels in
line with the other codes.
It may be recalled that the
entire code has been
Construction classified as per the
1 2 3
category. materials, methods of
manufacture of the vessels,
quality control etc.,
NDT 100% Spot Visual A. Category A Long welded
permitted all M0 & M1,M2 only M0, joints in main shell, nozzles
material M 3, M4 Austenitic et. Any welded joint within a
Austenitic steels sphere, with in a formed or
steels. flat head, side plates of flat
sided vessel, circumferential
welded joints connecting
hemispherical heads to main
sheets, to transition in
diameters, to nozzles etc.
Max, None M0, M1-40 M0-25 Category B Circumferential
thickness except M2-30 Austenitic welded joints within the main
(mm) M3-20 steels shell, nozzles or transitions
M4-15 none. in diameter, circumferential
Austenitic joints in connecting formed
none heads other than
hemispherical to main
shells, nozzles etc.
Upper Values Same as 350o C Category C Joints
Temperature to be category connecting flanges, tube
limits based sheets or flat heads to main
on shell, to formed heads, to
design transitions in diameter, to
life nozzle etc., to transition in
time diameter, to nozzle etc.
etc., as
per
table
2.3
Lower Note For M0 For M0 Category D joints
temperature Note M1, M2, M1, M2, connecting communicating
limit M3, M4 M3, M4 chambers of nozzles to main
sheels, to heads, to
Less than Less
transitions in diameters
10oC above than
20oC
above

7
 IS 28 25 : 1969 I.B.R
B. CLASSIFICATION OF Classification: Class I limits of
VESSELS Application: No limits Minimum
thickness: ¼ inch
Classification: Class II
Limits of Application: When the
following limits are not exceeded:
a. Working pressure – 105 psi
b. Working pressure in psi
multiplied by ID in inches - 5250
Minimum thickness: Boilers upto 36
inches I D – 5/16 inch.
Classification: Class III
Limits of Application: when the
following limits are not exceeded:
Vessels are classified in three a. Working pressure – 30 psi
groups on the bases of use, b. Working pressure multiplied by I
thickness. Joint design and D in inches – 3000.
efficiency materials of construction
and Quality Control requirements.
Joints have been categorized as Minimum thickness: Boiler 36 inches
in ASME Sec. VIII in to A, B, C, D. I d – 3/8 inch
Class 1 vessels are those
intended for lethal substances or
for operation below 20o C or when
mutually agreed upon by
purchaser & manufacturer.
Category A & B joints in such
vessels to meet requirements of
Table 1.1, class 2.
Class 2 Vessels are medium, =
duty vessels and shall meet the
requirements of table 1.1, class2.
Class 3 Vessels are light duty
vessels here plates are less than
16 mm thick & working pressure
less than 3.5 Kgf/Cm2 hydrostatic
design pressure at temperature
less than 250o C and unfired.
Class 3 Vessels: are not
recommended below 0oC.

8
 B.S. 5500: 1976 ASME SEC VIII: 1980 (Div. 1)
1 2 3
Minimum Minimum Other classifications are made on the
specified specified, bass of joints efficiency & extent of
in a None radiography. A short summary of the
Appendix austenitic classification is as follows:
D None steels. A. Efficiencies: Double welded butt joints
austenitic 0.7, 0.85, 1.00 (depending) on no
steels radiography, spot or full joint with back
strip (0.65, 0.8, 0.9) and without back
strip 0.6 double full fillet lap joint 0.55.
B. Radiography: A list of joints where full
radiography (e.g. all butt welds in
vessels containing lethal substances),
spot radiography (e.g. double welded
butt joints not required to be fully radio
graphed) and no radiography is required
is given.

9
I.S. 2825 : 1969 I.B.R.

10
 B.S. 5500: 1926
C. MATERIAL REQUIREMENTS
Materials should take into account the
fabrication and operating conditions.
Special consideration should be given
for use below 0o C. Any special limits
e.g. w.r.t. Composition, heat treatment
should be agreed upon at the time of
enquiry or order.
All material normally to conform to BS
unless otherwise mentioned Welding
material shall conform to the
requirements of section 4 & 5.
For casting, a quality specification is to
be draw for acceptance standards
between manufacturer and material
supplier. As a minimum, fillets and
changes of section to be Dye
penetration or magnetic crack detection
tested.
Bolts and nuts to conform to BS 4882.
Lugs, baffles and non-pressure parts to
be of established.
Materials used should be covered
under Table 2.3 (specs for C, c. – Mn
Low alloy, high alloys steels. In case
some other material is used it should
comply with the general requirements
mentioned and should be covered by a
written specification, at least as
comprehensive as the nearest
equivalent materials).
Nominal design strengths and methods
of calculations are given in Table 2.3 &
Appendix K. Details to be agreed upon
by manufacturer and purchaser and
recorded. Non-destructive testing
requirements for plates, forgings, pipes
and castings are given in Art 5.6.2.
General requirements for materials not
covered under Table 2.3.
ASME SEC. VIII DIV. 1: 1980
Materials subjected to stress due to
pressure shall conform to one of the
specifications given in ASME Sec. II and
shall be limited to those that are permitted
in the applicable part of subsection c-
expect as permitted UG-10 (procedure for
material not fully identified) and UG-II (misc
preformed or prefabricated pressure parts
like pipe fittings, valve flanges etc.,)
Material not conforming to the above will
require special approval of boiler and
pressure vessel committee.
Carbon or low alloy steels having a carbon
content or more than 0.35% by ladle
analysis shall not be used in welded
construction or oxygen cut List of approval
specs, given in UGS-23 along with stress
values at various temperatures. For service
temperatures above 850o F (454 o C) it is
recommended that killed residual silicon be
used. The stress values in table are to be
multiplied by a “ casting quality factors”
given in UG-24.
High alloy steels are listed in Table UHA-
23 and appendix HA given suggestions on
the selection and treatment of austenitic
chromium Nickel steels. High alloys steel
casting are mentioned in Table –23. The
stress values are to be multiplied by
casting quality factor of UG-24.
In recognition of controversial opinion
relative to the effects of post-weld heat
treatment on austenitic stainless steels,
mandatory requirement have been omitted.
However, for maximum corrosion
resistance, a suggested heat treatment
1850-20 50 o F (1010-1121o C) and
11
 IS 2525 : 1969 I.B.R
For class 1 & 2 vessels this standard R-537- Platters elt used in the
prohibits for pressure parts the use of construction of these Boilers shall
structural steels standard, high comply in all respects with the
tensile, fusion welding or ship requirements of chapter II and V, where,
building verity (IS 226, 961, 2062 & however, the tensile strength exceeds 32
339). The materials used for the Tons per SQ. in, the full details of
above classes should conform to welding and post heading, and the plate
table given in Appendix A. preparing to be used, shall be submitted
to the inspecting Authority for approval
before manufacture commences.
Class 3 vessels may use the above Electrodes (R: 538) – They shall comply
mentioned “ prohibited” materials and with the regulations of 94 to 98.
also IS 2041 (steel plates for
pressure vessels), IS 1570 (wrought
steels general engineering purposes),
IS 2002 (Steel plates for boilers).
Nothing in the foregoing precluded Tubes: They shall comply with the
the use of otherwise suitable material regulations of 36 to 63. The tubes shall
agreed upon. Special care to be be seamless and made by an open
taken for weld ability and ductility. No hearth or Electric Process, acid or basis,
such material shall have an and shall be certified as such by the
elongating (on 5.65 50) of less than makers of the steel by the tubes. The
100-Rm where Rm is the tensile material of the tubes shall shoe on
2.2 analysis not more than 0.05 percent of
strength in kgf/mm2 subjected to a sulphur and 0.05 percent phosphorus
minimum of 16% fore carbon and the manufacturer shall supply a
manganese steels. 14 % for alloy certificate of the analysis when required
steels other than austenitic and 25% to do so.
for austenitic steels. Material for lugs,
baffles, etc. to be weldable quality All
materials shall be supplied in
accordance with IS 1387 –1967, and
threaded fasteners in accordance
with IS 1369-1967.
Stress safety factors to calculate Note: Where the materials used for
allowable values are given in Table designed temperature for design
2.1 (varying from 1 to 3) and values temperature above 750o F (399 O C) the
calculated on these criteria given in steel shall be of non-segregated or fully
Appendix A. Shear and bearing killed type.
stress to be 50% of Appendix A
values. Compressive stresses to be
calculated as per appendix C, . For
castings, the factor of Table 2.1 shall
be divided by 0.75, except when the
casting has been radio graphed, dye
or magnaflux tested.

12
 B.S. 5500: 1976 ASME SEC VIII DIV. 1: 1980
Material spec. Should at least “ One hour per inch” of soaking time
specify making process. and rapid cooling from 700 o F to
Compositional limits deoxidation 1000 o F (371 – 538 o C ) has been
practice. Heat treatment and given.
appropriate mechanical
properties.
For forritic steels for welding C >
0.25%. For C> 0.25 % special
agreement between manufacturer
and purchaser. Phosphorus &
sulphur < 0.05%.
Deoxidation practice should be
appropriated to the type of steel
ordered, particularly when high or
low temp. Properties are affected.
Following are permissible.
Semiskilled steel-plates, seamless
& welded tubes in C.C. Mn steels
for U.T.S. < 640 N/mm2 and
thickness < 100 mm
Rimming steel- only for welded
tubes in C, C-Mn, steels with
U.T.S. < 490 N/mm2 temperature
0-1380 o C. 2
Mechanical properties (BS 18)
UTS, Lower stress or 0.2 % proof
stress (1% for austenitic),
minimum elongation at fracture
(L= 5.65 so, Charpy V-Notch (B.S.
131 Pt.2).
Permitted % elongation is 16% for
plates, > 15% for casting > 14%
for tubes and forgings.
For materials used over 20o C , a
certifiable lower Y.P. or proof,
stress (ref. BS 3688) to be
specified.
Stress reputed properties for
materials in creep range.
Plates fro hot forming to be
supplied condition as agreed
between suppliers & manufacturer

13
I.S. 2525 : 1969 I.B.R

14
 B.S. 550 : 1976 ASME SEC VIII DIV .1 : 1980
B. C, C-Mn plates for cold forming
to be normalized for thickness >
25 mm unless post weld heat
treatment is sufficient

15
I.S. 2525 : 1969 I.B.R

16
 B.S 5500: 1976 ASME SEC VIII (DIV.1) 1980
D. MANUFACTURE AND
WORKMANSHIP
GENERAL GENERAL
1. Fully dimensional drawings 1. Manufacturer must have ASME
giving material specn, Certificate of Authorization and
welding procedures, NDT must have in force a valid
and test plate requirements, inspection contracts. Inspector
pressures corrosion must be qualified by state.
allowance etc., to be Manufacturer must supply
submitted by the drawings and a host of other
manufacturer. documents listed in UG 90 (e.g.
design calculations written QC
System etc). to the inspector.
2. A position identification 2. Material must in general conform
system for pressure parts is to action II of ASME Boiler and
necessary so that they can pressure vessel code
be traced back to their origin. unidentified material may be
used for non-pressure parts e.g.
skirts, baffles, and lugs. For all
such parts 3/8” thick double-
welded butt joint shall be made
from each lot and guide bend
tested.
3. For vessels made in two or Partially identified, material may
more courses longitudinal be used as per a procedure
seams to be completed given. A table or sketch showing
before starting adjoining location on vessel of items and
circumferential seams and their identifications. Marking to
longitudinal seams to be be steel die stamped as specified
staggered wherever possible. in ASME sec. II.
Where more than two seams 3. Except when radio graphed 4”
meet at a point, intermediate (120 mm) on each welded
stress relief is desirable. intersection, vessels made up of
two or more courses, shall have
centers of longitudinal joints
staggered on separated by a
distance of five (5) times the
thickers plate.

17
 I S 2525 : 1969
GENERAL
1. Manufacturer shall normally 1.
submit drawings material
specn. Welding processes
weld designs design
parameters, amount and
location of allowances etc., to
purchaser
2. Procedure for identification 2.
and its transfer on cut items
for pressure parts is given.
3. Concentration of joints 3.
should be avoided such that
no two main seams come
together under an acre angle
or cross each other. Where
unavoidable, the
intersections should be radio
graphed 100 mm on each
side of inter section be
staggered by five (5) times
the thickness of thicker plate.
Welding of attachments near
main seams to be avoided. If
unavoidable welds should
cross rather than stop
abruptly near seams.
18
I.B.R
GENERAL
Manufacturer shall be submit the
detailed drawings including weld
details, calculations and
materials to the inspecting
Authority for approval prior to the
construction.
MATERIALS (Procedure for
identification):
All plates, rivets and bars used in
the construction of boilers shall
be tested and found to conform
with the regulations to conform
with the regulations. A certificate
in form II, III, III-A and IV.
Shall Courses assly etc (R 543)
The longitudinal seam or seams
may be placed in any suitable
position but the seams in
successive rings shall not fall in
line.
 B S 5500: 1976 ASME SECI VIII: 1980 (Div.1)
CUTTING FORMING &
TOLERANCE
1. Cold shearing may be used for 1. All cutting methods may be used in
plates < 25 mm but edges to be general Exposed inside edges to be
ground at least 1.5 mm. Grinding not rounded off to a radius at least 1/8
required for sheared plates < 10mm. “(4mm) flat.
Thermal cutting on machining are For plates over ½ “ (12.5 mm) thick
preferable. For materials requiring used for corner joints (joints at
preheat during welding, thermal approx, 90o), edges to be tested by
cutting should be done with preheat. D.P. or M.C.D
Thermal cut ferritic alloy steel shall be All materials to be impact tested shall
dresses by grinding or machining. be inspected for surface cracks.
Visual examination for laminations, Adjoining edges of longitudinal joints
crackers, slag inclusions may be to be preliminary formed to avoid flat
supplemented by N.D.T. spots after rolling.
2. Prior to forming, visual examination
of plates, followed by thickness
measurement, to be done.
3. Austenitic steels for hot working 3. For P.W.H.T (post weld heat
shall be heated uniformly in neutral or treatment) of austenitic stainless
oxidizing temp. Deformation below steels mandatory requirements have
900o C and local heating is been omitted. However for maximum
prohibited. After hot working, corrosion resistances, a suggested
softening to be carried out by heating, heat treatment (1850o – 2000o F)
at a recommended temp, hot less tan (1010O-1104o C) and one hour per
30 minutes. Descalling to done. inch of thickness as soaking time with
rapid cooling from time (1000o F) has
been given.
Austenitic steels after cold working
shall be subsequently softened &
descabed unless thickness is less
than 10 mm or the purchaser waives
this requirements.
4. All plates after being formed shall
be check visually and checked for
thickness. Places where attachments
are to come may be non-destructive
tested if specially called for in design.

19
 IS 2825: 1969
1. Where thickness < 25 mm, cold
shearing may be used provided
edges are chipped or machined
one quarter of plate thickness or
minimum. 3 mm.
Caron steels may be mained,
chipped ground or flame cut but
alloy steels and non-ferrous
materials shall not be flame cut
unless agreed upon.
Preheating may be required and
visual examination for flaws
laminations, inclusions shall be
made special inspection may be
required for cracks on cut surfaces
and HAZ in high carbon and alloy
steels
Hand flame cut edges shall be
chipped or machined 3 mm
minimum or one quarter plate
thickness
2. Seams may be welded prior to
forming but must be radio graphed
fully after wards. In carbon steels
< 25 mm and alloy steels DP or
MCD to be done.
20
I.B.R
1. Chapter XII. Regulation 541
plates which are to flame- cut by
machine without subsequent heat-
treatment, grinding or machining,
shall not have or machining, shall
not have a carbon content higher
than 0.26 percent. Where the
carbon content exceeds 0.26
percent. Heart-treatment grinding
or machining shall be carried out.
2. Examination of Tubes before
forming: (R 338):
a. Where tubes are bent, the
deviation from circularity at any
cross section shall not exceed
20D/R.
where,
D nominal out side diameter and
R: radius of bend on the center
line of the bend.
b. Where the tubes are bent
resulting thickness of the tubes at
the thinnest part shall not be less
than that required for plain tubes.
Tolerance on thickness shall be –
5, + 10% of the specified
thickness.
c. All pipes shall be commercially
straight, free from longitudinal
seaming, grooving blistering or
other injurious surface marks – (R
35).
3. Ref I S D – R-831
4. Ref I S D – R-831
 BS 5500: 1976 ASME SEC VIII: 1980 (Div.1)
5. TOLERANCES
I) Assembly Tolerance: I) Alignment tolerance
a. Longitudinal joints and spherical joints Thickness Longitu- Circumfe-
for plate thickness “e”.
dinal rential
e Middle line Upto ½ in ¼ t ¼t
alignment (12.5 mm)
<10 mm 1 mm Over ½ 1/8 in (3 ¼ t
>10 and  50 mm 10% of “e” or 3 mm into ¾ mm mm)
(whichever smaller) (125-19
mm)
>50 and  220 mm e/16 or 10 mm Over ¾ to 1/8 in (3 3/16 in (5
(whichever smaller 1 ½ in (19- mm) mm)
) 38 mm)

> 200 mm As agreed upon Over 1 ½ 1/8 in (3 1/8 t

to 2 in (38- mm)
50 mm)
Over 2 in Lesser of Lesser of
(50 mm) 1/16 t or 1/8 t or ¾
3/8 in (9.5 in (19
mm) mm)
b) Circumferential joints:
e Middle line The above are the alignment at the
alignment edges to be but welded. Surface
alignments are not given
 10 mm 1 mm Any off set within the allowable
> 10 and 10% of „e‟ of the range shall be faired at a 3.1 taper
 60 mm thinner plate + over the width of the finished weld.
1mm or 6 mm Build up may be done.
(whichever
smaller).
>60 and  200 mm 10% of „e‟ or the
thinner part.
> 200 mm As agree upon.
Permissible surface alignments are as
shown below: If these are exceeded a taper
of 1:4 to be given which should include the
weld. The lower surface may be build up to
given the 1:4 taper.
a. Longitudinal joints
e  12 mm E/4 mm
13 < 0  50 mm 3mm
e> 50 mm Lesser of e/16 or
10mm.

21
 I.S. 2525 : 1969
I) Alignment tolerance
Defects in alignment at surface (R-250) and (5-544)
shall be less than the followings:
For plated less than 5 mm thick t/6 5.1.a) Before welding of the joint
for long seams and t/4 for
circumferential seams, subject to
a maximum of 1 mm.
For plates more than 3 mm thick
10% of nominal thickness wit a
maximum of 3 mm for long. Joints.
But for plates upto 10 m / for
circumferential joints, the values
are 10% of max. nominal plate
thickness plus 1 mm subject to a
maximum of 4 mm.
(Welds with backing strip require
better alignment).
The increase or decrease in root
gap at any point in seam after
tacking shall not exceed 1 mm.
L a misalignment of 1 mm
permitted.
22
I.B.R.
5. TOLERANCES:
is commenced it shall be
ascertained that the edges
are in alignment and the
defects in alignment shall
not exceed the following
limits:
1. 10 % of the nominal plate
thickness with a maximum
of 3 mm for long seams.
2. 10% of nominal plate
thickness plus 1 mm with a
maximum of 4 mm for C/
seam joints.
b) If the edges of unequal
plate thickness are abutted
and the difference between
the two exceeds the above
limits 1 in 4 tapper shall be
provided on the thicker
plate.
 B.S. 5500: 1976 ASME SEC VIII: 1980 (Div. 1)
b) Circumferential joints
e  20 mm e/4 mm
20 < e  40 mm 5 mm
E > 40 mm Lesser of e/8
or 20 mm
ii) All pads, reinforcing plates man- ii) All lugs, brackets, saddle type
hole frames lugs, brackets, nozzle, manhole frames etc, shall
supports or other attachments. conform reasonably to surface to
Shall have a gap at exposed which they are attached.
edges to be welded < 2 mm or
1/20th of the thickness of
attachment, whichever is greater.
Except where shown otherwise on
drawing maximum gap between
outside of branch & in side of
edge of hole in shell, flange
reinforcing ring or backing ring
shall be < 1.5 mm for opening up
to 300mm and 3mm for openings
above 300mm. To achieve this the
branch may be machined, but the
machined surface should not
extend beyond the toe of weld and
shall not reduce the thickness of
branch below design thickness
plus corrosion allowance.
iii) Tolerance for ends
a) Circumference as calculated a) Circumference not mentioned
from Nominal I.D + Actual anywhere.
thickness and the actual
circumference should agree as
follows:
O.D. Circumference
(nominal Tolerance
Dia + actual
thickness)
 550 mm  5 mm
> 650 mm  0.25%
of circumference.

23
 I.S. 2525: 1969 I.B.R
ii) All lugs, brackets, saddle type 5.2 (R-544)
nozzles, manhole frames etc. shall a) The difference between the
conform reasonably to the internal diameter of the drum
curvature of the shell or surface to measured at any cross section
which they are attached. shall not exceed 1 % nominal I.D.
The departure shall not exceed:
i) Upto and including 36” I.D.
0.375%
ii) Over 36” upto and including 45”
I.D. – 0.35%
iii) Over 45” I.D.
a) Circumference same as for 5.3 there shall be no flats at the
shells. welded seams and any local
departure from circularity shall be
graded.

24
 B.S 5500: 1976 ASME SEC. VIII: 1980 (Div.1)
b) Circularity shall be same as that b) Circularity (out of roundness
for shall. shall be the same as that for shell
i.e. 1% of nominal I.D.)
c) Thickness is that after the c)
manufacture of and shall be
uniform over the whole area
knuckle. From this point, a gradual
thinning of upto 10% is
permissible.
*Nor inside of 5/8% of I.D.
d) Profile: the depth of dishing „d‟ d) The inner surface of head shall
should never be less than not deviate out side of – the
theoretical or more than that given specified shape by more than 1
below: ¼% of I.D. *charge shall be
Knuckle radius shall not be less gradual and decimations shall be
than theoretical and shall have measured perpendicular to the
common tangents with straight specified shape.
flange and dishes profile.
Dia of end permissible When the skirt of an un-stayed
increase in the head is machined to make a close
fit in to or over a shell, the
depth of dishing
thickness shall not be reduced to
< 3000 mm 1.25% of dia less than 90%. The transition shall
3000-7600mm 3.8 mm be tapered to at least 3 times the
< 7600 mm 0.5% of dia thickness difference.
iv) Tolerance for shells a) No mention of circumference.
a) Circumference: as for e
ends.

b) Straightness: Max deviation

from straight line 0.3%
either of total

25
 I.S 2525: 1969 I.B.R
b) Circularity same as that for
shall.
c)

d) The inner surface shall not

deviate from the specified shape
by more than 1.25% of the I.D. of
head skirt, such deviations shall
not be abrupt, shall be outside of
the theoretical shape and
measured perpendicular to the
specified shape.
When the skirt of an unstayed
head is machined to make a close
fir into or over shell the thickness
shall not be reduced to less than
90% of original. Transition shall be
trapped to at least 4 times
difference.
a) The external circumference
based on nominal I.D. and actual
thickness should be within the foll.
tolerances:
O.D. Tolerance
300-600 mm  5 mm
over 600 mm  0.25%
Notwithstanding these, the
governing factor shall be the
misalignment tolerances.
Max. deviation from straightness
is to be 0.3% of total length or 5
meters length, for shells over 2
meters long.

26
 B.S. 5500: 1976 ASME SEC. VIII. 1980 (Div. 1)
cylindrical length or any individual
5 meters.
c) Circularity - Max and Min. dia c) out or roundness (circularity) to
difference at any cross section be less than 1% of the nominal dia
shall be less than specified below. of cross sec
<1900mm 1% of I.D. When the cross section passes
through an opening, the
1900- 4750mm 19 mm
permissible difference in I.D. given
> 4750 mm 0.4% of I.D. above may be increased by 2% of
D=shell O.D.  < .05e + the opening.
.002 D For vessels under external
(Max.25mm) pressure out of roundness shall be
 = Irregulari- as above, but the plus or minus
ties in profile deviation from the true circular
checked with form measured radially inside or
20 o gauge. out side shall be within values of
e= thickness pf plate. „e‟ obtained from graph UG-80.1.
A segmental circular template with
This maximum value may be specified dimensions to be used.
increased by 25% if the length of Templates are to be made by
irregularities does not exceed ¼ of manufacturer.
length of shell between two
circumferential seams with a max.
of 1 meter.

At nozzle positions, greater ovality Sharp bends, flat spots etc, are
is permitted if justified by not permitted.
calculations.
Measurement must be made to
surface of parent plate and not to
a weld, fitting or raised part.
For vessels to be vertically
installed but checked horizontally
dia, should be measured twice 90o
a part after turning the shell
through 90o. The sets should be
averaged and ovality calculated.

27
 I.S. 2525: 1969 I.B.R.
b) Out of roundness is to be
less than 1% of I.D. on
D1 + 1250 ; (D1 = I.D.)
200

Whichever is smaller.
At nozzle positions greater values
may be permitted. Irregularities in
profile (checked by 20o gauge)
shall not exceed 3 mm + 5% of
min. plate thickness. The max.
value may be increased by 25% if
the length of irregularity is less
than ¼ of length of shell ring.

When out of roundness is

measured with shell lying on its
side, the measurement shall be
repeated after tuning 90 o.
No flats at welded seams are
permitted, and departures from
circularity must be gradual.

28
 B.S. 5500: 1976
Cold rolling after forming permitted For vessels made or pipes, pipe
(for small rectification) but N.D.T. standards are applicable.
must be done. For vessels made
of pipes, pipe standards are
applicable.
6. WELDED JOINTS
Welding procedures and welders
to be qualifies. Test plates to be
used only on purchaser‟s request.
Consumables used shall be those
used in qualification tests.
Tack welds if made to approved
procedured procedure may be
retained.
The areas of removal of
attachments may be made
through intermediate pieces.
Permanente backing strips not
permitted in longitudinal joints but
permitted in circumferential joints.
No less than two runs to be used
for attachments expect where a
agreed by purchaser.
29
ASME SEC. VIII: 1980 (Div.1)
Welders, welding operators and
procedures to be qualified to
ASME Sec. IX before any
commencement of production
welding.
Welding procedures restricted to
SMSSW, SAW, GMAW, Oxy-
hydrogen. No mechanical
pressure or below to be applied
except peening, pressure welding
pricesses are limited to flash,
introduction, resistance, pressure,
thermit & pressure gas.
Tack welds to be either removed
or their ends grounds. Whether
removed on retained they should
be made by a qualified welder and
procedure
 I,S, 2525: 1969 I.B.R
Cold rolling for small rectification is
permitted but then N.D.T. is
essential.
For vessels made from pipes, pipe
standards are applicable.

6. WELDED JOINTS (R 604 and R 607)

6.1 a) No welder shall be engaged on
welding of boilers or steam
pipes unless he is qualified and
possesses a certificate.
b) The certificate shall be valid for
2 years.
c) The test specimens shall be
examined under X-ray. One
tensile test, forward bend test,
one reverse bend test two
macro examinations shall be
conducted. For fillet welds one
root bend and one face bend
test shall have to be conducted.
d) Record of all welding personnel
engaged on welding of boiler or
steam pipes particulars of each
welder qualification shall be
maintained.
6.2 a) If the defects in the weld are
distributed over the whole
length of the seam the total
length of the portions which may
be cut out from any longitudinal
or circumferential seam, shall
not exceed 15% of the total
length of the seam.
b) If the defects in the weld are all
located in a single continuous
length which may be cut out,
shall not exceed 10% of the
total length of the seam.
c) (R-599) The longitudinal and
intermediate circumferential
seams shall be made with butt
joints of the single or double U
or V type or any other type
approved by the inspecting
Authority.

30
 B.S. 5500: 1976 ASME SEC VIII 1980 (Div.1)
E.1. PREHEAT AND OTHER
REQUIREMENTS
Ferritic steels may require preheat. Pre-heating requirements given non-
Table of temperatures 4.4.1.1 and mandatory appendix-R.
B.S. 5135 may be used to calculate
preheat temperatures. Even tacking
No welding below 0 O F (-18 O C)
to be done with preheat. No welding
Between 0OF and 32OF, preheat to
to be done at tem. < 5 o C. Austenitic
above 60O F required
steels require no preheat Pre-heat
temperatures to be previously
decided by manufacturer and Vessels shell sections and heads of P 1
purchaser. Gr.1 & 2 materials fabricated by cold
forming shall be heat treatment when
resulting max. Fibre elongation is:
Hot-formed parts, if not formed in a 1. More than 40% from as rolled
range and cooled in a manner to give condition.
grain refinement, shall be normalized. 2. More than 5% when vessel
contain lethal substance or
requires impact testing or the
quires impact testing or the
thickness of part before cold
forming exceeds 5/8” (16 mm) or
reduction in thickness is more
than 10%. Formula are given for
calculation of extreme fibre
elongation.
F.2. POST WELD HEAT
TREATMENT (PWHT)
Require for:
a) Ferritic steel vessels where For carbon steels, lower thickness limit
wall thickness exceeds that for P.W.H.T. given in notes to Table
specified in Table 4.4.3.1. or UCS-56, which also gives the
designed to operate below Oo temperatures.
C. For ferritic vessels enhanced by heat
b) In general for C and C-Mn treatment, PWHT requirement given in
steels PWHT is mandatory UHT –56.
only above 35 mm thickness. PWHT shall be done before hydrostatic
c) Special Purchaser‟s test and after any weld repair. A
requirement. preliminary hydrostatic test to reveal
Intermediate stress relief leaks before PWHT is allowed.
should be carried out at lower In general, for carbon and low alloy
temperatures. steels PWHT is mandatory only for
No weld repairs allowed after thickness greater than 1 ½”.
stress relief except on lightly
loaded or non-pressure parts.
Suitable tests and controls to
be instituted to

31
 I.S 2825: 1969
No welding below a base metal
temperature of 0o C preheating of
200 mm area to 15o C-20o C to
be done before welding in such
cases.
Cold forming over 5% deformation (R 251) where the plates are bent to
is prohibited unless heat treatment a diameter less than 40 times
is done. Deformation is calculated thickness, they shall be heat-treated.
as follows:
Deformation = t x 100
D
t= Plate thickness
D= I D bending or forming.
Hot forming out-side normalizing
range shall be followed by
normalizing.
PWHT- required for ferritic carbon
and low alloy steels
normalizing or stress relieving
when:
i) It is intended for toxic on
inflammable material.
ii) Operation prone to stress
corrosion cracking.
iii) There is excessive stress
concentration.
iv) There is excessive stress
concentration.
v) There is risk of brittle fracture.
vi) Dimensional accuracy
required.
vii) Plate thickness exceeds those
given in Table 6.3 (Carbon
manganese steels > 30 mm & C-
Mn-Cr-Mo on carbon percentage
upto 0,35& > 20 mm)
I.B.R
(R234 b) plates over 2” in thickness
before being fabricated shall be
uniformly heat treated to produce
gain refinement. Quenching in liquid
medium id prohibited.
(Regulation No: 562).
by All boilers shall be post weld heat
treated after completion of all welding
and before hydraulic test, when the
thickness of the part/welded recess
exceeds 50 mm and the carbon
content exceeds 0.25%.
Heat Treatment: All boilers shall be
stress-relieved by heat treatment
after complication of all welding and
before hydraulic test, when,
a) Constructed to class I & II
requirements
id b) The shell thickness exceeds
(D/112) + C where D=I.D. of the
shell and C=5.6 mm for carbon
steel. A stress-relieving heat
treatment shall be performed by
heating part to at least
600  20 C. When required by
o
the characteristics of the
material,
32
 B.S.5500: 1976 ASME SEC. VIII: 1980
establish that material is not
adversely affected.

33
34
I.S. 2525: 1969 I.B.R.
Different temperatures may be
necessary to obtain proper stress
relieving. The part to be stress
relieved shall be brought slowly upto
the specific temperature and held at
that temperature for a period
proportionate on the basis of at least
2 minutes per millimeter of the
maximum thickness of the part
(approximately one hour per 25 mm of
thickness) and shall be left to cool in
the furnace to a temperature to which
for the parts with a thickness greater
than 20 mm does not exceed 400o C.
After withdraw from the furnace the
part shall be allowed to cool in a still
atmosphere.
A temperature time diagram of the
stress relieving process shall be
provided for a welded shell or drum
and a similar diagram for other
pressure parts when the Inspection
Authority requires it.
During heat treatment official test
plates shall be inside the boiler.
Where the shell is subjected to a
primary stress relieving treatment
identical to the final heat treatment to
be given to the boiler, the test shell
during primary treatment and
hereafter cut up and tested without
waiting for the final treatment of the
boiler.
Where the shell is not subject to
primary stress relieving treatment or is
subjected to primary stress relieving
treatment, which is not identical with
the final heat treatment the test plates
may be placed inside any other boiler
of comparable dimensions, which is to
be heat treated in accordance with
this chapter.
Temperature charts shall be
submitted to indicate that the test
plates and the boiler they represent,
have been subjected to identical
heating, soaking and cooling
treatment.

35
 B.S: 5500: 1976
E.3. METHODS OF P.W.H.T
Normally full vessel to be stress
relieved but in special cases the
following method may be applied.
1. In sections, with minimum 1500
mm or 5 Re overlap, whichever
greater (R= internal radius,
e=thickness). The portion outside
shall be shielded so that
longitudinal temp. gradient is such
that the distance between peak
and half peak temperature is more
than 2.5 Re .
2) Circumferential seams may be
heat treated locally by heating a
shielded band round the entire
circumference. Width of heated
band should exceed 5 Re is
recommended.
3) Branches/attachment shall be
locally heat treated by heating a
shielded circumferential band
round the entire vessel. The
requirements in (ii) apply except
that width of circumferential band
(2.5 Re ) shall be measured from
edge of welding which connects
nozzle/attachment to the vessel.
iv) Vessel may be internally
heated fully encased with thermal
insulating material.
v) Vessels with thickness ration
not more than 2:1 may be heat
treated in the same furnace
according to the same furnace
according to the requirements of
the thickest vessels.
For MO or M1 type materials
(carbon and carbon manganese
36
ASME SEC. VIII 1980 (Div.1)
Whenever practicable, vessels
should be PWHT as a whole, if
not, they may be heated
inspections with 5 feet overlap and
adequate shielding of portions
outside furnace.
Circumferential seams may be
heated locally, but width of band
on each side of weld shall be
more than two times shell
thickness. Shielding to be
provided outside the heated bond.
Heating the inside with adequate
insulation on the outside and
recording and measuring of
temperature is allowed provided
the internal pressure never
exceeds 50% of working pressure.
Heating a circumferential band-
containing nozzle on other
attachment which should extent
round the entire vessel and at
least 6 times the plate thickness
beyond attachment welding.
Circumferential joints in a pipe
may be treated by heating a band
on each side of center line wider
than 3 times the width of weld.
Thermocouples to be attached to
top center and bottom of charge
and any other zone of possible
temp. variation. Gas temp.
measurement is not enough.
No limit specified on the ratio of
thickness of vessels that can be
heat-treated together but cycle
should conform to the thickest
vessel.
 I.S. 2825: 1969 I.B.R
More or less same as in BS 5500
except the followings:
i) PWHT mandatory for:
a. Low strength carbon and
carbon manganese steels (yield
strength 26-38 kgf/mm2) 30 mm
and above, high strength carbon
and carbon manganese steels (YS
44Kgf/mm2 and containing Cr.V,
Mo etc. )20 mm & above.
b. Toxic or inflammable material
carrying vessels.
c. Operation below 0o C.
D. Vessels subjected to severe
local stress concentration.
e. Dimensional accuracy required

37
 B.S. 5500: 1976 ASME SEC VIII 1980 (Div.1)
steels the temp. and time given in
4.4.3.1. to be followed. For other
grades, the ranges are advisory.
The temp, in general for MO & M1
are 5800 to 6200c.
Normally, the temp, of furnace For carbon and low alloy steels the
while charging shall be 4000 C. foll. Hold:
For complex cases, e.g. thickness Temp, or furnace while charging shall
> 60 mm temp. is 3000 C. be less than 8000 F (4270 C)
Heating rates 2200c/hr for
thickness upto 25mm.
5500/ e00 /hr on 550C /hr which
ever greater, for thickness greater
than 25 mm.
During heating, temp, variation to
be less than 1500 C with 4500 mm
length.
Cooling rates (Cooling TO 4000 C)
275
2750 C /hr for t < 25 mm.
5870 C /e0 C /hr which – ever
greater for t>25 mm.
Below 4000 C, cooling in still air.
Temperature re the actual ones
determined by thermo couples.
Holding times are given in Table
4.4.5.1. but in general are 2 ½ Heating rate- 2200 C/hr divided by the
minutes per mm thickness. max. Metal thickness in inches. (but
not more than 2220 C/hr).
Cooling rate- 2780 C/hr divided by the
max. metal thickness in inches.
The heading and cooling rates need
not be less than 560 C/hr.
Soaking time-1 hr per inch thickness
upto 2 inches.

38
 I.S. 2525: 1969 I.B.R.

Cooling rate upto 25mm metal

thickness 2750C/hr and over 25
mm, 7000/metal thickness 0C/hr or
550C/hr whichever greater

39
 B.S. 5500: 1976
F.1. PROCEDURE AND WELDER Below 4270C, cooling in still air.
QUALIFICATION:
A list of all welding procedure to be
supplied by manufacturer. Welding
of test plates and testing to be
witnessed by purchaser unless
previous qualification records are
produced.
For low temp, operation, impact
testing as per Appendix-D to be
done.
List of welders to be presented to
purchaser. Welder qualified by one
inspected authority may be
accepted by another. A welder who
qualifies a procedure is him-self
qualified. Qualification of welder is
valid for six months of inactivity.
Relevant specification are:
Procedure qualification BS 4870
Part I.
Welder qualification BS 4871 Part I.
F.2. PRODUCTION CONTROL
TEST PLATES
Not normally required unless
insisted by purchaser. The length of
plates to be at least 350 mm.
Number and size have to be agreed
upon. Circumferential joint test
plates to be welded separately.
At the option of the manufacturer
N.D.T. to be done on test plates like
on the production weld. If defects
found somewhere, test pieces may
be out from remaining portion.
ASME SEC VIII, 1980 (Div .1)
-2 hrs plus 15 min for every inch of
ma. Metal thickness above 2 inches
Qualification records to be supplied to
inspector before commencement of
work, Welds to be identified by
welder‟s number at every 3 feet.
Welder or operator qualified for one
manufacturer shall not be used for
another manufacturer. Qualification
as per ASME Sec. IX.
Impact test requirements given in
subsection C, (Requirements
pertaining to classes of materials)
UCS-65 for carbon & low alloy steels
UHA-51 for high alloy steels.
Test plates are not required for
production control, but for carbon and
low alloy steels, test piece to be made
for vessel material and subjected to
the same heat treatment as vessel
(with slight variation). P-1 Gr.1 & 2
and standard materials listed in UG-
11 (a) and excluded.
For vessels constructed of type 405
Material, which vessels constructed of
Type 405 material which are not
PWHT (post weld heat treated),
welding test plates for two face bend
specimens required.
40
 I.S 2825 : 1969
Records shall be made available to
inspector. Each welder shall stamp
his number.
A welder is qualified for 6 months of
in-activity. Re-qualification is not
necessary if the company proves
having made such jobs if (or better
jobs) for past 3 years.
Qualification requirements given in
art 7.1 of IS 5825 (including impact
test requirements).
a) Vessels subjected to serve duty
(efficiency factor 0.9-1.0 ) to be
provided with two test plates to
represent longitudinal seam of first
six shells of vessel. No test plate
normally required for circumferential
seam- unless welded by a different
process.
Test to be conducted are:
All weld metal tensile (1), Reduced
section tensile (1)
Bend (2), Notched bar impact (3)
Macro (1).
41
I.B.R.
(604)
a) No welder shall be engaged on
welding o boilers or steam pipes
unless he is qualified and
possesses a certificate.
(607)
b) The certificate shall be valid for 2
years.
c) The test specimens shall be
examined under x-ray. One tensile
test, forward bend test one reverse
bend test, two macro examinations
shall be conducted. For filler welds
one root bend and one face bend
test shall have to be conducted.
d) Record of all welding personnel
engaged on welding of Boiler or
steam pipes particulars of each
welder qualification shall be
maintained.
(561)
2.1 Class 1 Boilers: Test specimen
shall be attached to each L-seam.
a)One Tensile test specimen for the
weld seam.
b) One all weld metal tensile test.
c) Two bend test specimens.
d) Two impact specimens.
e) One specimen each for micro
and macro examinations.
 B.S. 5500: 1976 ASME SEC VIII: 1980 (Div .1)
Tests specified on production
control test plates are, macro
examination, hardness survey,
transverse tensile, all weld tensile,
face, side and root bend and fillet
weld fracture.

F.3.DETAILS OF DESTRUCTIVE
TESTS FOR ALL APPROVAL
TESTS:
a) All weld tensile strength and If tensile specimen breaks in base
parent metal strength metal outside the fusion line, then
difference to be agreed upon. specimen is acceptable provided
b) Reduction in area for weld the strength is not more than 5%
metal in Mo & M1 to be > below the specified minimum
35% and at least equal to tensile strength for base metal.
parents metal for alloy steels.
c) In transverse bend (t < 10
mm) cracks upto 1.5 mm
allowed.
d) In transverse bend (t> 10
mm) cracks upto 3 mm
allowed.
e) An excess of 50 HV over that
specified for weld metal (in
the procedure) is allowed.
f) For tensile bend tests, two
retests allowed.

42
 I.S. 2825: 1969
b) Vessels subjected to medium
duty (efficiency factor 0.8 – 0.85) shall be attached to each (561) L-
shall be provided with two plates
to represent all long seams. No
welds for circumferential seam
unless welded by a different
process.
Tests to be conducted are:
i) Reduced section tensile (1)
ii) Bend test (2)
iii) Nick break
Production test plates may be b) Flattening test Specimen
radiographed and defective c) Bend test specimen
portions discarded in cutting 3.1 Tensile tests:
specimen.
Macro examination of fillet weld
specimen should not reveal
cracks, incomplete root fusion,
inequality in leg length more than
1.5 mm.
I.B.R.
2.2 Class II Boilers: Test pieces
seam
a) One tensile test specimen for
weld seam.
b) One bend test specimen
c) One reverse bend test
specimen.
d) One nick break test specimen.
2.3 Pipes
a) Tensile test specimen
The ultimate tensile stress shall be
not less than the lower limits
specified for the plates.
3.2 All weld metal: (561)
(a) The UTS shall not be less than
the lower limits specified for the
plate.
(b) The elongation shall be not
less than 20% of the gauge length
or four times the square root of the
cross sectional area.
(c) Reduction in area shall nor be
less than 35%.
3.3 Bend Test: (561)
No cracks or defects on the outer
surface of the specimen shall be
greater than /16” (1.5 mm)
measured across the specimen or
1/8” (3 mm) measured along the
lengths of the specimen.
3.4 Izod Impact Test: (561):
Impact values shall not be less
than 20 FT. Ib.
3.5 Radiography (265)
a) Where defects occur in
distributed positions in a seam,
repairs to the extent of 15%
43
B.S. 5500: 1976 ASME SEC. VIII: 1980 (Div.1)

44
I.S. 2825: 1969 I.B.R.
of the total length of the seam
shall be permitted.
b) Where the defects are located
in a single continuous length the
permissible extent of repair shall
be decided by the Inspecting
Authority.
3.6 Additional Tests before
Rejection (561):
If the tests show a definite sign of
failure, two further tests of the
same king shall be conducted in
the same manner. The two tests
should satisfy the requirements of
the standards. If either of the two
tests fail the representative weld is
liable for rejection.
3.7 Macro and Micro:
A specimen of the full thickness of
the plate and not les tan half an
inch wised shall be provided from
each set be test plates for the
purposes of Macro examination.

45
 B.S. 5500: 1976
G.NON DISTRUCTIVE TESTING
This is required for final
acceptance but may be used
before also. The N.D.T. personnel
to be qualified (with certificates).
All N.D.T. stages, standards and
procedure to be written down an
agreed upon.
Before examining welds, plate
material adjacent to welds shall
be ultrasonically tested to
establish thickness and defect
flaws.
For category 1 vessels final N.D.T.
to be done after PWHT and before
any pressure test. 100% X-ray or
U.T. of pressure welds where
thickness part exceeds. Table
5.6.4.11. Welds other than full
penetration but shall be D.P/
M.C.D. tested.
For Category 2 vessels, 100% X-
ray/U.T. of full penetration butt
welds (which shall include each T-
joint). For each seam there shall
be one radiograph or U.T. for 200
mm.
At least 10% of all welds other
than main seams to be
D.P/M.C.D. tested. Also when
openings occur in or within 12 mm
of weld-welded seams, such seam
shall be additionally N.D.T. tested
on each side of opening for a
distance equal to the diameters of
opening.
When a particular representative
N.D.T. Is found unsatisfactory
(with reference to Art 5.7) the
whole seam represented by it
shall be scrapped.
For Category 3 vessels N.D.T. is
not required. However, in so far as
M.C.D and D.P. are
46
ASME SEC VIII: 1980 (Div.1)
The manufacturer shall certify the
competence of D.P/M.C.D. testers
including their eyesight. For U.T.
personnel and radiography
personnel qualification to be in
accordance with SNT-TC IA.
N.D.T. procedures to be outlined
in the written QC system ahs to be
submitted to inspector.
All material should be examined
before fabrication to defect as far
as possible defects that would
affect the safety of the vessel.
Particular attention should be
given to the edges and other parts
or rolled plates for serious
laminations, shearing cracks etc.
Foll. Joints are to be 100% radio
graphed
1) All but welds in vessels
containing lethal substances.
ii) All butt welds in plates or vessel
walls where thinner plate exceeds
1 ½ inches (38 mm) or exceed the
lesser thickness in UCS – 57.
III) All butt welds in unfired steam
boilers with pressures more than
50 psi (3.5 Kg/Cm2)
iv) All category A& D butt welds
with efficiency 1.00 for double
welds joints and 0.9 for single
welds joints (Ref. UM-11).
For foll joints spot radiography is
to be done
i) Double welded but joints with
efficiency 0.85 and single welded
joints with backing strip and
efficiency 0.8.
No radiography required for the
following.
1) Double welded butt joints with
efficiency 0.70.
 I.S. 2825: 1969
Stages of inspection are decided
by the class vessel. Records of
inspection and tests to be
maintained for the inspector.
All anstenitic chromium – Nickel
alloy steel welds in plates over 20
mm thick shall be examined by
dye penetration test.
Radiography
i) For circumferential butt
welds in extruded
connections, pipes, tubes,
hearers etc;
a) No radiography for t <
6mm
b) No radiography fort =
6~12mm and O.D. < 102
mm.
c) Where 12< t< 20mm and
102< random selected from
each welder‟s work a
maximum of 5% length shall
be examined.
d) For constructions
exceeding Limits of (c), all
welds to be examined.
ii) Butt welds in furnaces
combustion chambers and
other pressure parts
subjected to external
pressure to be spot radio
graphed. Butt weld in fully
supported end plated not to
be radio graphed.
iii) Spot radiography is to be
at lest 10% of the total
length. Each radiograph to
be at lest 25 Cm.
Other N.D.T. methods may
be agreed upon and used
where radiography is not
possible i.g. fillet welds or
braches etc. or where it is
expedient.
47
I.B.R
(561)
Every portion of the longitudinal
and circumferential butt-welded
seams or the shell of the boiler
shall be subjected to radiographic
examinations.
The methods employed in
obtaining the radiographs shall be
such as to show clearly difference
equal to 2% of the thickness at the
welded joints. To determine
whether this result is being
attained an indicator of approved
form which includes a portion,
equivalent to not more than 2% of
the joint thickness shall be placed
in the thickness shall be placed in
the vicinity of the weld so as to
make a record on each
radiograph.
Each section of every weld shall
be marked so that the radiographs
can be easily correlated to the
particular part of the seam
represented.
The examination shall be made
from the original films and the
acceptability of the welds shall be
decided by the inspecting
Authority. The welds deemed
unsatisfactory shall be rejected or
dealt with under the condition of %
R 560 and be radio graphed
again. The films shall be retained
by the manufacturer for a
reasonable period for reference
and be available to the Inspecting
Authority, if required.
 B.S. 5500: 1976
aids to visual examination, they
may be used
Choice of N.D.T. for Welds
There is a guidance for selection
between radiography and U.T. for
internal flaws (e.g. the two
methods being suitable the two
methods being suitable for
“Volume “ and Planner” defects
repressively and that sensitive
U.T. techniques may be given too
conservative results.
For surface flaws, difference
between M.C.D. and D.P. has
been given.
General guidance for N.D.T.
Radiography
1. For thickness upto 50 mm X-ray
to be normally used.
2. Marking on radiography to
indicate work piece reference
no.(ORDER NO., S.No. etc.,)
joints, selection of joints, arrows or
other symbol to identify its position
radiographs of repair welds shall
be marked R1, R2 (First repair,
second repair etc.,)
3. Radiographs should have
sufficient overlap.
Ultrasonic Testing
i) Before testing weld, the present
material shall be ultrasonically
tested to establish thickness and
any flaws, which might prevent
effective weld examinations.
MARKING
Permanent marking beside the
weld shall be made to correlate
with N.D.T. reports stamping shall
not be done vessels fro low
temperature service.
48
ASME SEC VIII: 1980 (Div .1)
ii) Single welds/ butt joints (with
backing strip) with efficiency 0.65.
iii) Single welded butt joints
without backing strip and
efficiency 0.6.
iv) Lap joints.
U.T. may be substituted for
radiography for the final closing
seam of a vessel if the
construction does not permit
interpretable radiographs.
In addition to radiography electron
bean welds should be 100%
ultrasonically tested.
Opening that do not meet
reinforcement requirements in
UG-37 may be located in
circumferential joints provided
radiographic requirements of UW-
51 for a length equal to 3 times
dis. Of hole are met.
When a pressure part i.e, head or
shall or is to be welded to a forged
or rolled plate thicker than ½” to
form a corner joint under the
provisions of UM-13 (e), all cut
edges including by M.C.D. or D.P.
Tests.
I.S. 2825: 1969 I.B.R

49
 B.S. 5500: 1976
ACCEPTANCE LEVERS FOR
N.D.T.
Notations
e - parent metal thickness
(thinner part for dissimilar
joints)
w - Width of defect
L - Length of defect
h - Height of defect
ASME SEC. VIII: 1980 (Div .1)
All material that are to be impact tested
shall be inspected for surf cracks.
Pressure vessels, which are to be
pneumatically tested, shall have full
length of the foll. Welds crack detected
by D.P. or M.C.D.
1. All welds round openings.
2. All attachment welds, including welds
attaching non-pressure ½ arts to
pressure parts having a throat than ¼
inch. (6.5 mm).
Heads attached with one plate off set
circumferential joints, which have a
longitudinal joint shall be M.C.D. or D.P.
tested from the edge of plate tested
from the edges of plate through the off
set as shown. (See sketch).
All austenitic Cr-Ni alloy steels in plates
our ¾” thick and all 36% nickel steel
welds shall be D.P. tested after heat
treatment (Ref. U.H.A.-34).
All electro slag welding in ferritic
materials shall be 100‟ ultrasonically
tested after gain refining (austenising)
heat treatment or P.W.H.T.
General Guidance for N.D.T
All radiography to be as per ASME Sec.
V article 2. A complete set or
radiographs and records (T 283(a) & (b)
Article 2 ASME SEC V) TO BE retained
by manufacturer for 5 years spot
radiographs may be discarded after the
acceptance of vessel by inspector.
FULL RADIOGRAPHY
For radiography and U.T. the foll. Are
unacceptable.
1. Any crack, zone of incomplete fusion
or penetration.
2. Any elongated slag inclusion which is
longer than:
50
51
 I.S. 2825: 1969 I.B.R

In butt welds concavity in root and

excessive penetration may be
permitted subject to approval of
inspector, but lack of root of side
fusion are not permitted.
Undercuts overlaps, abrupt rides
or valleys or irregular beads are
not permitted.

52
 B.S. 5500: 1976 ASME SEC. VIII. 1980 (Div.1)
ø = Diameter of defect. ¼ in (6.5 mm) for t upto ¾ in
(19mm).
C = Mean nozzle circumference. 1/3/ t for t ¾ in to 2 ¼ in (19-57
mm)
UNACCEPTABLE DEFECTS ¾ in (19 mm) for t over 2¼ in
(57mm)
Cracks or lamellar tears. Where it is the thickness of weld.
Planar Lack of root, Not For radiography, in addition to
defects side and permitted above, any group of slag
inter-run inclusions in line that have an
fusion aggregate length greater than “t”
in a length 12 t, except when the
Lack of root
distance between them exceed
penetration
6L where L is the longest
imperfection.
Porosity charts are given in
Appendix IV.
Isolated pores (for ø  e/4 and ø Spot Radiography
individual pores in 3.0 mm for e up One spot radiograph shall be
group) to 50 mm examined in each 50 ft. of welding
in each vessel. Minimum length of
spot radiograph is 6 inches. Foll.
Are the acceptance levels:
Uniformly distributed ø 4.5 mm for e 1. Any type of crack, zone of
localized porosity 50 to 75mm incomplete fusion on
penetration is unacceptable.
Linear Porosity ø 6.0 mm for e 2. Slag inclusion or cavities
> 75 mm graters than 2/3 T, where T
is the thinner or the two
plates welded.
Uniformly distributed 2% by area (on 3. The sum of the longest
localized porosity a radiography) dimensions of imperfections
for e > 50 mm should not be more than T in
and prorate for a length 6 T and the longest
higher imperfections considerate
thickness. are separated by at least 3I
where L is the length of
largest imperfection
Linear Porosity Linear porosity 4. Porosity is not a factor in
parallel to weld spot radiography.
axis may
indicated lack

53
 of fusion or
penetration and
thus not
permitted.
Worm holes 1 > 6 mm, W > LIQUID PENETRANT (D,P)
(isolated) 1.5 mm As EXAMINATION
linear porosity.
Worm holes (aligned) As worm holes 1. Linear indications, with length
crater pipes isolated more than 3 times the width will
be unacceptable if longer than
1/16 in (1.6 mm).
Surface cavities Not permitted 11. Four or more rounded defects
(I,e. those with length less than 3
times the width) in a

54
I.S 2825: 1969 I.B.R

55
 B.S. 5500: 1976 ASME SECI VIII 1980 (Div.1)
Line separated by 1/16 in
(1.6 mm) or less
Individual and Main L=e  100 mm Magnetic particle (M.C.D)
Parallel to butt worm e/10  4 Examination
major axis welds mm All linear discontinuities are
defects unless proved
Nozzle Inner Outer
otherwise by re-examination.
& half of quarter
branch cross of cross Some other criteria of
welds sec sec acceptance according to this
code are:
Worth Worth =
Butt joints shall have
= e/4 e/8 
complete joint penetration &
 4mm 4mm fusion shall be free from
I=c/4  I=c/8  undercuts, overlaps, abrupt
100mm 1000mm ridges or valleys.
Individual and Fillet welds shall have
randomly adequate penetration into the
oriented (not As isolated pores base metal.
parallel to axis Reinforcement not butt welds
of weld) not be exceed following:
Non linear Plate Reinforcement
As localized porosity
group thickness
Copper inclusions not permitted Up to 1/2 1/6 in (4 mm)
in (12
Under cut Slight intermitted permitted 12.5mm)
depth < 0.5 mm
Over ½”
Shrinkage Slight intermitted permitted (12.5 mm) 3/32 in (2.4 mm)
grooves & root depth < 1.5 mm Over 1”
concavity (25.4 mm) 1/8 in (3.2 mm)
Excess h  3mm to 2” (25.4
Penetration mm)
Reinforcement Smoot blending Over 2” 5/32 in (4 mm)
Overlap (50 mm)
Not permitted
In U.T defects with „h‟ 1.5 mm or less should
be ignored

56
 I.S. 2825: 1969 I.B.R

Reinforcement in severe and

medium duly vessels shall be:
Max,
Plate thickness
reinforcement
Up to 12 1.5
Over 12 up to 25 2.5
Over 25 up to 52 3.0
Over 4 52 4.0
For light duty vessels,
reinforcement shall be < 5 mm

57
 B.S 5500: 1976
H. PRESSURE TESTING
All completed vessel must pass either All complete vessels must pass the
of the following tests?
Standard hydraulic test: Where
required thickness of pressure parts
can be calculated.
Pneumatic test: Where thickness of
pressure parts can be calculated, but
liquid media are not practicable.
Proof hydraulic test: Where
thickness of pressure parts cannot be
calculated.
Combined: Hydraulic/pneumatic test.
Method of testing
Pressure to be increased to 50% of
test pressure gradually and then in
stage of 10% until test pressure is
reached before going close for
inspection, the pressure is to be
lowered below that previously
attained.
The pressure is to be maintained for
at least 30 minutes expect in case of
vessel less than 500 mm dia, and 10
mm thick when the period may be
agreed upon.
(No shock loading (hammer testing)
allowed.
Test Pressure
Pt= 1.25 (P fa/ft X t/t-c)
Where, P= design pressure
fa= Nominal design stress
at least temperature
ft= Nominal design stress
at design
ASE SEC VIII: 1980 (Div 1)
standard hydrostatic, pneumatic or
proof test.
Hydrostatic test: Except for enameled
ones vessels designed for internal
pressure, shall be subjected to a test
pressure at least 1 ½ time the max.
allowable working pressure (to be
marked on vessel multiplied by the
lowest ratio of stress value „S‟ for the
test temperature).
A calculated pressure may also be
used by mutual consist between user
and manufacturer which is 1 ½ times
the “ basis for calculated test
pressure” defined in U.S- 60 (e).
Any intermediate value between the
two given above may also be used.
There is no upper limit, but visible
permanent distortion may cause
rejection.
Following the application of test
pressure any inspection for leaks
shall be made at not less than to
thirds the test pressure unless
specially agreed upon (e.g. when gas
leak test is applied. Any non-
hazardous liquid at any temp. below
its boiling point may be used.)
Pneumatic test: except for
enameled vessels, for which the
pneumatic test pressure shall be at
least equal to the maximum allowable
test pressure, the pneumatic test
pressure shall be 1.25 times the
maximum allowable working pressure
multiplied by the lowest ratio of the
test value at test temperature to
stress value at design temp.
58
 I.S. 2825: 1969
The time of holding at the
calculated test pressure shall be a
minimum of 10 minutes.
Vessels shall be well hammered
on both sides of welds seam.
Materials deleteriously affected by
hammering and which have been
radio graphed on main seems
require no hammer test.
Test pressure:
Test Pressure
Pt= 1.3 x design pressure
x f1/f2
fi= allowed material stress at
test, temperature.
f2= Allowable material stress at
design temperature.
This test pressure includes
the amount of any static
head acting at a point
under consideration.
59
I.B.R.
(R 601 Hydraulic and Hammer
tests).
a. Class-I-Boilers: Each class
boiler shall on completion of all
welding and/or repair and after
heat treatment be subjected to a
hydraulic test of 1 ¼ times the
working pressure and while under
this pressure the welds shall be
given a through hammer test
throughout their length. The
pressure shall be released and
then raised to 1 ½ times the
working pressure + 50 psi and
steadily maintained for a length of
time sufficient to carryout
complete inspection but not less
than ½ hour.
b. Class ii-Boilers: Each class II
boiler shall aster heat treatment
be subjected to the same form of
test as for class-I boilers, except
that every Boiler shall be given a
hammer test and hydraulic
pressure to be applied for the test
shall be 1 ½ times the working
pressure. The pressure shall be
released and then raised to twice
the working pressure.
 B.S. 5500: 1976
temp. exceed the temp, for which
elevated temp, proof stress values
are available, then ft should be
derived from the proof stress at
the highest temp, for which values
are available.
t= Nominal thickness of
section under
consideration.
c= Corrosion allowance
For proof test, the brittle coating
test, displacement measuring test
or strain. I measuring test may be
used.
60
ASME SEC VIII 1980 (Div.1)
The pressure shall be increased to
half the test pressure and then in
steps of one teeth the test
pressure. Then the shall be
reduced to four fifths of the
pressure and held for a sufficient
time to permit the inspection of the
vessel unless waived by mutual
consent (e.g. when gas leak test
applied)
For proof test, the brittle coating
test displacement-measuring test
may be used.
 I.S. 2825: 1969 I.B.R
Vessels designed vacuum or
partial vacuum shall be subjected
to a pressure of 1.3 times the
difference between normal
atmospheric pressure and the
internal absolute pressure but no
in any case less than 1.5 Kg/Cm2
No procedure for proof test given.

61