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. W.P =

2fe(t-c) D-t+c

.Eqqn. (91)

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

Where, t = Minimum thickness, W.P. = Minimum working pressure, f = Allowable stress determined on the following basis:

(i) For temperatures at or below 454C, the lower of the following two values:

(ii) for temperatures above 454C, the least of the following three values:

= working metal temperature, = minimum tensile strength of the steel at room temperature, = Yield point (0.2% proof stress at the temperature), = 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 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 comply with the requirements of Chapter II in which the weld is fully radio graphed 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 22 mm, = 0.85 for welded steel pipes for values of t over 22 mm and up to and including = 0.80 for welded steel pipes for values of over 29 mm, 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

Where, t R Et Sc

351.

Cast Steel Pipes- (a) The material shall comply with Regulations 73 to 80. [Regulation73. Scope- (a) This regulation shall cover carbon steel castings used

in the construction of boilers and steam pipes including their fittings. (b) For all types of steel castings conforming to these regulations only the minimum values for tensile strength are fixed. The maximum values shall be between 40 and 50 Kgf / mm2.] (b)The maximum working pressure allowed on cast steel pipes shall be determined by the following formula:-

where, t = minimum thickness, W.P. = Working Pressure, D = External diameter of pipe, *S= Allowable working stress as specified in table 4 or Regulatzion 343, C = 0.64 cm (0.25 in.) TABLE 4 * ** Maximum Permissible Working Stress for Carbon and Alloy Cast Steel Pipes (See Regulation 351) Lower value obtained in each case at the specified temperature calculated on the following basis For service temperature at or below 454C (850F)

For service temperature above 454C (850F)

T.S. = Minimum Tensile strength of the material at room temperature , Et = Warm yield point (0.2% proof stress) at temperature t, Sc = The average stress at service temperature to produce an elongation of 1% (creep) in 100,000 hours , SR = The average stress at the service temperature to produce rupture in 100,000 hours at the temperature and in no case more than 1.33 times the lowest stress to produce rupture at service temperature . 352. Copper Pipes- (a) The material shall comply with Regulation 35. (b) Copper pipes may be used for maximum design pressures and temperature as given in the Table.

(c)Copper pipes shall not be used for superheated steam. (d) The maximum working pressure on such pipes shall be determined by the following formula

where, W.P. = Working pressure is kg/mm2 t = minimum thickness of tubes, that is nominal thickness less the permissible negative tolerance in mm., D = Outside diameter of pipe in mm., S= maximum permissible design stress at the appropriate maximum design temperature in kg/mm2

SEAMLESS CARBON STEEL PIPES FOR HIGH TEMPERATURE SERVICE FOR DESIGN METAL TEMPERATURE NOT EXCEEDING 454 DEGREE C( 850 DEGREE F)

43.(a) General: (i) These regulations cover both hot finished and cold drawn seamless carbon steel pipes for high temperature service. The pipes shall conform in all respects with the requirements herein specified. (ii) The seamless pipes conforming to other national/international standards which are known to be commonly used as being suitable for high temperature service can also be used with the designations of the national/international standards, provided such material are not specifically prohibited by the regulations. (iii) While making pipes to other national/internationals standards the allowable stresses of the respective nation/international standards shall be strictly followed while designing the tubes. (b) Material:- (i) The pipes shall be seamless and manufactured from steel produced by an Open hearth or electric process or any of the oxygen processes. The steel shall be fully killed. (ii) The steel shall conform to the following limits of chemical composition.

(b) Heat Treatment:- Hot finished pipes need not be heat treated. Cold drawn pipes shall be given a sub-critical anneal, a full anneal, or a normalizing heat treatment after the final cold finishing process (c) Workmanship and tolerance: The pipes shall be well finished, cleaned free from harmful defects. They shall be reasonably straight, smooth, cylindrical and subject to the following tolerance. Pipes manufacturer shall explore a sufficient number of visual inspections to provide reasonable assurance that they have been properly evaluated. (i) Permissible variations in outside diameter: Hot finished and cold finished seamless pipes

(ii) Permissible variation in wall thickness: The minimum wall thickness at any point shall not be more than 12.5% under the nominal wall thickness specified. (iii) Permissible variation in exact length: Seamless Hot finished and cold finished pipes can be ordered in specified length or in random length. If ordered in specified length, the tolerances for all sizes shall be +6.0mm/-0.0mm. ** (d) Test specimens:- (i) Test specimen required for flattening and expanding/flaring test specified in regulations 44(a) , 44(b) and 44(c) shall be taken from ends of finished pipes prior to upsetting, expanding or any other forming operations or being cut to length. They shall be smooth on ends and free from burrs and flaws. (ii) If desirable and practicable, tensile test may be carried out on full section of the pipe up to the capacity of the testing machine. For large size pipes, the tensile test specimen shall consist of strip cut longitudinally from the pipe and which is not straightened within the gauge length and further heat treated. (iii) If any test specimen shows flaws or defective machining it may be discarded and another specimen substituted. (iv) All specimens shall be tested at room temperature. (e) Number of tests: The tests specified in regulations 44(a) , 44(b) and 44(c) shall be made on minimum 2 pipes for first 100 pipes and 1 per 100 or part thereof

for pipes over 100 numbers.

366. Determination of working Pressure- (a) Shells- The maximum working pressure of shells shall be determined by the following formula

where, T is thickness in inches, D is Maximum internal diameter in inches,. W.P. is Working pressure in lbs./sq. inch, *f is Maximum permissible working as prescribed in Regulation 271 or 350 stress in lbs./sq. inch at the working metal temperature, E is Efficiency of longitudinal riveted seams given in Regulation 117, is Efficiency factor for fusion welded shells as given in table below,

is 1.00 for seamless shells or shells made from seamless tubes, is Efficiency of ligaments between holes or openings in shell expressed as a fraction. Minimum thickness of shells shall be as given in table below:

The maximum permissible stresses for cylindrical parts of seamless fusion welded and riveted shells not exceed those given below:

The maximum permissible stress (f) for shells made from weld less pipes shall be those as given in table :

Inter mediate values may be obtained by linear interpolation. Where steels are intended for service at temperatures in excess of 700F this shall be so stated and silicon contents shall be not less than 0.10 per cent or alternatively, the material must pass the 'Proof test for creep quality of carbon steel plate of boiler quality' as in Appendix D. Compensation for Openings in Shells-Where the major axis of diameter of any hole cut in cylindrical part of the shell is greater than 2- times the thickness of the shell plate plus 2-3/4 inches, compensation shall be provided. The sectional area to be compensated measured in the plane parallel to the longitudinal axis of the shell, which makes this area a maximum, shall-be the product of the length of the opening (including any rivet holes in the plane) and the thickness of a seamless shell of similar material calculated in accordance with Equation 72 (Regulation 270) for the same conditions of

pressure and temperatures. Where frames, pads or branches are secured by rivets, the compensating area shall be calculated by the method given in Regulation 170. Where frames, pads or branches are secured by welding & the compensating area shall be calculated by the method given in Regulation 170. (b) End Plates- (1)Dished End Plates- The maximum working pressure or dished end plates with pressure on concave side' shall be determined by Regulations 276 to 278. For manholes formed by welding on pressed frames to dished end plates as in Fig. No.366/1. (Click here to view the Figure) The value of E may be taken as unity when the diameteral cross sectional area of the compensating frame and/or ring is equal to or greater than the diameteral cross sectional area of the opening in the end plate to be compensated. For ends which are butt welded to the cylindrical parts of the shell the thickness of the edge of the flange for connection to the cylindrical part of the shell shall be not less than that required for seamless unpierced shell as determined by Equation 72. (2) Flat End Plates- The maximum working pressure for welded in flat end plates as in Fig. Nos. 365/2, 365/3 and 365/4, shall be determined by the following formula

where,T = Minimum thickness of end plate in inches,

d = Internal diameter of shell in inches, W.P. = Working pressure in lbs. /sq. in., C = 0.28. f= Maximum permissible working stress in lbs./in. as in the table:

Inter mediate values may be obtained by linear interpolation.

Where steels are intended for service at temperatures in excess of 700F. This shall be so stated and silicon content shall not be less than 0.10 per cent or alternatively, the material shall pass the 'Proof test for creep quality of carbon steel plates of boiler plate quality' as in Appendix D. Where flat end plates are bolted to flanges as in Fig.365/5 the dimensions of the 'flanges shall be as given in Appendix E. The thickness of the end plates shall be not less than that of the corresponding flanges. Where the diameter of a hole in the flat end plate exceeds 2 T + 2-3/4 inches compensation shall be provided in accordance with Regulations 170 and 279.