RULES FOR CLASSIFICATION OF

Ships / High Speed, Light Craft and

Naval Surface Craft
PART 4 CHAPTER 7

NEWBUILDINGS
MACHINERY AND SYSTEMS MAIN CLASS

Pressure Vessels
JANUARY 2012
This chapter has been amended since the main revision (January 2012), most recently in July 2013.
See Changes on page 3.

The electronic pdf version of this document found through http://www.dnv.com is the officially binding version
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accepts that it is prohibited by anyone else but DNV and/or its licensees to offer and/or perform classification, certification and/or
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consequences arising from any use of this document by others.

DET NORSKE VERITAS AS

FOREWORD
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to operate and a competitive advantage. Our core competence is to identify, assess, and advise on risk management. From
our leading position in certification, classification, verification, and training, we develop and apply standards and best
practices. This helps our customers safely and responsibly improve their business performance. DNV is an independent
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and the environment.
The Rules lay down technical and procedural requirements related to obtaining and retaining a Class Certificate. It is used
as a contractual document and includes both requirements and acceptance criteria.

Det Norske Veritas AS January 2012

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Changes Page 3

CHANGES CURRENT
The present edition of the rules includes amendments and additions approved by the Executive Committee as
of November 2011 and supersedes the January 2011 edition of the same chapter.
The rule changes come into force as described below.
Text affected by the main rule changes in this edition is highlighted in red colour. However, where the changes
involve a whole chapter, section or sub-section, only the title may be in red colour.
This chapter is valid until superseded by a revised chapter.
Amendments July 2013
Sec.8 Manufacture, Workmanship and Testing
In item D414 a reference to Pt.2 Ch.3 has been corrected.
Main changes coming into force 1 July 2012:
Sec.1 General Requirements
Table B1 Increase of acceptable minimum specified tensile strength for class II pressure vessels
New table C1 Documentation requirements and text correction in C 100.

Sec.4 General Design Requirements

D The term cylinders is replaced with accumulators for hydraulic systems
D101 Reference to reinforcement for flat plates have been added
D501 Reference to acceptable flange welding details changed
Fig.(e2): A note regarding thickness of more than 16 mm have been added.

Sec.8 Manufacture, Workmanship and Testing

B200 Opening up for more extensive use of permanent backing strip for pressure vessels in refrigerating
plants
C Clarification of heat treatment requirements.
Editorial Corrections
In addition to the above stated main changes, editorial corrections may have been made.

DET NORSKE VERITAS AS

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Contents Page 4

CONTENTS
Sec. 1

General Requirements ....................................................................................................................... 7

A. Classification.................................................................................................................................................................. 7
A 100 Application............................................................................................................................................................ 7
A 200 Cross-references.................................................................................................................................................... 7
B.
B
B
B
B

Definitions ...................................................................................................................................................................... 7
100 Terms .................................................................................................................................................................... 7
200 Symbols ................................................................................................................................................................ 7
300 Units...................................................................................................................................................................... 8
400 Grading ................................................................................................................................................................. 8

C. Documentation .............................................................................................................................................................. 9
C 100 Documentation requirements ................................................................................................................................ 9
D.
D
D
D

Accumulators for Hydraulic Systems ....................................................................................................................... 10

100 Design ................................................................................................................................................................. 10
200 Fabrication .......................................................................................................................................................... 10
300 Certification ........................................................................................................................................................ 10

E.
E
E
E
E

Cylinders for Fire Extinguishing System.................................................................................................................. 10

100 General................................................................................................................................................................ 10
200 Design ................................................................................................................................................................. 10
300 Fabrication .......................................................................................................................................................... 10
400 Certification ........................................................................................................................................................ 10

F. Signboards ................................................................................................................................................................... 10
F 100 General................................................................................................................................................................ 10

Sec. 2
A.
A
A
A

Materials ........................................................................................................................................... 11

Material Requirements............................................................................................................................................... 11
100 General................................................................................................................................................................ 11
200 Boilers and pressure vessels................................................................................................................................ 11
300 Thermal-oil installations ..................................................................................................................................... 12

Sec. 3

Arrangement..................................................................................................................................... 13

A.
A
A
A
A
A
A

Boilers and Pressure Vessels ..................................................................................................................................... 13

100 Instruments.......................................................................................................................................................... 13
200 Inspection openings ............................................................................................................................................ 13
300 Drains.................................................................................................................................................................. 13
400 Fuel oil supply .................................................................................................................................................... 13
500 Combustion air supply ........................................................................................................................................ 13
600 Positioning .......................................................................................................................................................... 13

B.
B
B
B
B
B
B
B

Thermal-oil Installations ............................................................................................................................................ 14

100 Installation .......................................................................................................................................................... 14
200 Circulation system .............................................................................................................................................. 14
300 Control and monitoring system........................................................................................................................... 14
400 Safety arrangements............................................................................................................................................ 14
500 Insulation and shielding ...................................................................................................................................... 15
600 Exhaust-fired thermal-oil heaters........................................................................................................................ 15
700 Test equipment and signboards........................................................................................................................... 15

C. Exhaust Gas Boiler or Economisers .......................................................................................................................... 16

C 100 Circulation systems............................................................................................................................................. 16
C 200 Soot-cleaning arrangement ................................................................................................................................. 16

Sec. 4

General Design Requirements......................................................................................................... 17

A. General ......................................................................................................................................................................... 17
A 100 Application.......................................................................................................................................................... 17
B.
B
B
B
B
B
B
B
B

Design Criteria ............................................................................................................................................................ 17

100 Design pressure................................................................................................................................................... 17
200 Calculating pressure............................................................................................................................................ 17
300 Other loadings..................................................................................................................................................... 18
400 Design material temperature ............................................................................................................................... 18
500 Nominal design stress ......................................................................................................................................... 18
600 Shell thickness .................................................................................................................................................... 19
700 Corrosion allowance ........................................................................................................................................... 20
800 Tolerance and fabrication allowance .................................................................................................................. 20

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Pt.4 Ch.7 Contents Page 5

C.
C
C
C
C
C
C

Scantlings of Shells and Flat and Dished Ends......................................................................................................... 20

100 Conditions ........................................................................................................................................................... 20
200 Cylindrical shells ................................................................................................................................................ 20
300 Spherical shells ................................................................................................................................................... 20
400 Conical shells of circular sections....................................................................................................................... 21
500 Dished ends......................................................................................................................................................... 24
600 Un-stayed flat end plates..................................................................................................................................... 28

D.
D
D
D
D
D

Openings and Compensations.................................................................................................................................... 29

100 General................................................................................................................................................................ 29
200 Openings not requiring reinforcement ................................................................................................................ 30
300 Openings requiring reinforcement ...................................................................................................................... 30
400 Minimum thickness of standpipes and branches ................................................................................................ 32
500 Welded branch connections ................................................................................................................................ 32

E. Covers for Inspection Openings and Manholes ....................................................................................................... 37

E 100 General................................................................................................................................................................ 37
F. Heat Exchanger Tubes................................................................................................................................................ 38
F 100 General................................................................................................................................................................ 38

Sec. 5
A.
A
A
A

Particular Design Requirements for Boilers.................................................................................. 39

Shells and Headers of Cylindrical Sections .............................................................................................................. 39

100 Scantlings............................................................................................................................................................ 39
200 Efficiency of ligaments between tube holes ....................................................................................................... 39
300 Compensating effect of tube stubs...................................................................................................................... 41

B. Headers of Rectangular or Irregular Sections ......................................................................................................... 44

B 100 Headers of rectangular section............................................................................................................................ 44
B 200 Headers of irregular form.................................................................................................................................... 46
C. Dished Ends ................................................................................................................................................................. 46
C 100 Dished ends subject to pressure on the concave side.......................................................................................... 46
C 200 Dished ends subject to pressure on the convex side ........................................................................................... 46
D.
D
D
D
D
D
D

Flat Plates Supported by Stays .................................................................................................................................. 46

100 General................................................................................................................................................................ 46
200 Scantlings............................................................................................................................................................ 48
300 Stay tubes and tube plates within tube nests ...................................................................................................... 49
400 Vertical tube plates in vertical boilers ................................................................................................................ 51
500 Firebox plates under compression ...................................................................................................................... 54
600 Openings in flat plates ........................................................................................................................................ 54

E.
E
E
E
E
E
E
E
E
E

Furnaces and Fireboxes of Cylindrical Form, Uptakes, Cross-tubes and Ogee Rings ........................................ 57
100 Plain furnaces ..................................................................................................................................................... 57
200 Corrugated furnaces ............................................................................................................................................ 58
300 Stiffeners ............................................................................................................................................................. 58
400 Fireboxes for vertical boilers .............................................................................................................................. 59
500 Openings in furnaces........................................................................................................................................... 59
600 Dished ends for vertical boiler fireboxes ............................................................................................................ 60
700 Internal uptakes in vertical boilers...................................................................................................................... 60
800 Cross-tubes in vertical boilers............................................................................................................................. 61
900 Connection of firebox to shell in vertical boilers................................................................................................ 61

F. Stays.............................................................................................................................................................................. 61
F 100 Stay tubes and bar stays ..................................................................................................................................... 61
F 200 Girders for flat firebox and reversal chambers' top plates .................................................................................. 62
G. Tubes ............................................................................................................................................................................ 62
G 100 Boiler tubes subjected to internal pressure ......................................................................................................... 62
G 200 Boiler tubes subjected to external pressure......................................................................................................... 63
H. Access and Inspection Openings ............................................................................................................................... 63
H 100 General................................................................................................................................................................ 63

Sec. 6

Mountings and Fittings ................................................................................................................... 65

A. General ......................................................................................................................................................................... 65
A 100 Construction........................................................................................................................................................ 65
B.
B
B
B

Safety Valves................................................................................................................................................................ 65
100 Valves on boilers and steam-heated steam generators........................................................................................ 65
200 Valves on pressure vessels other than boilers and steam-heated steam generators............................................ 66
300 Protection of condensers against overpressure ................................................................................................... 67

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Contents Page 6

C. Stop Valves and Check Valves .................................................................................................................................. 67

C 100 Valves on boilers and steam-heated steam generators........................................................................................ 67
C 200 Valves on pressure vessels other than boilers and steam-heated steam generators............................................ 67
D. Blow-down Valves and Test Valves for Boiler Water ............................................................................................. 68
D 100 Blow-down valves .............................................................................................................................................. 68
D 200 Test valves .......................................................................................................................................................... 68
E. Gauges .......................................................................................................................................................................... 68
E 100 Water gauges....................................................................................................................................................... 68
E 200 Pressure gauges................................................................................................................................................... 68

Sec. 7

Instrumentation and Automation .................................................................................................. 69

A. General ......................................................................................................................................................................... 69
A 100 Cross reference.................................................................................................................................................... 69
A 200 Oil burner control system ................................................................................................................................... 69
B. Boilers........................................................................................................................................................................... 69
B 100 Automatic control ............................................................................................................................................... 69
B 200 Monitoring .......................................................................................................................................................... 70
C. Exhaust Gas Boilers or Economisers ........................................................................................................................ 70
C 100 Instruments and Monitoring................................................................................................................................ 70
D. Water Heaters ............................................................................................................................................................. 71
D 100 Monitoring .......................................................................................................................................................... 71
E.
E
E
E

Thermal-oil Heaters .................................................................................................................................................... 71

100 Automatic control ............................................................................................................................................... 71
200 Monitoring .......................................................................................................................................................... 71
300 Indication ............................................................................................................................................................ 71

Sec. 8

Manufacture, Workmanship and Testing...................................................................................... 72

A. Manufacture ................................................................................................................................................................ 72
A 100 General................................................................................................................................................................ 72
B.
B
B
B
B
B

Workmanship .............................................................................................................................................................. 72
100 Cutting of plates.................................................................................................................................................. 72
200 Welded joints ...................................................................................................................................................... 72
300 Tolerances for shells ........................................................................................................................................... 73
400 Fitting of tubes .................................................................................................................................................... 73
500 Doors and plugs .................................................................................................................................................. 74

C.
C
C
C

Heat Treatment ........................................................................................................................................................... 74

100 Post-weld heat treatment..................................................................................................................................... 74
200 Heat treatment of plates after hot or cold forming.............................................................................................. 74
300 Heat treatment of tubes after bending................................................................................................................. 75

D.
D
D
D
D
D
D

Testing .......................................................................................................................................................................... 75
100 Extent of non-destructive testing (NDT) ............................................................................................................ 75
200 Performance of non-destructive testing (NDT) .................................................................................................. 76
300 Acceptance criteria for non-destructive testing and repair of defects................................................................. 77
400 Welding production test (WPT).......................................................................................................................... 78
500 Hydraulic test ...................................................................................................................................................... 80
600 Performance test.................................................................................................................................................. 80

E. Marking........................................................................................................................................................................ 80
E 100 General................................................................................................................................................................ 80

App. A Types and Minimum Dimensions of the Inspection Openings in Boilers and Pressure Vessels....
81
A. Definitions and Dimensions........................................................................................................................................ 81
A 100 Examination holes............................................................................................................................................... 81
A 200 Man-holes ........................................................................................................................................................... 81

DET NORSKE VERITAS AS

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Sec.1 Page 7

SECTION 1 GENERAL REQUIREMENTS

A. Classification
A 100 Application
101

The rules in this chapter apply to:

boilers, including mountings

pressure vessels, including mountings, necessary for performing the main functions listed in Pt.1 Ch.1
Sec.1 A200 of the Rules for Classification of Ships
other pressure vessels containing:

toxic fluids
fluids with flash point below 100C
fluids with temperature above 220C
fluids with pressure above 40 bar
compressed gases where pV 1.5

p = design pressure in bar

V= volume in m3
thermal-oil installations.
102

Boilers and pressure vessels according to 101 are subject to certification by the Society.

103

The control and monitoring systems shall be certified according to Ch.9 for the following:

boilers
thermal-oil installations
oil fired water heaters.
A 200 Cross-references
201 Pressure vessels for liquefied gases shall meet the requirements in the Rules for Classification of Ships
Pt.5 Ch.5 Sec.5.
Cargo process pressure vessels, as defined in the Rules for Classification of Ships Pt.5 Ch.5 Sec.1, shall be
graded as class I pressure vessels. However, the selections of materials, qualification of welding procedures
and production weld tests shall be according to the Rules for Classification of Ships Pt.5 Ch.5 Sec.2 and Sec.5.
Non-cargo process pressure vessels, as defined in the Rules for Classification of Ships Pt.5 Ch.5 Sec.1, shall
meet the requirements of Ch.7.
Boiler installations on liquefied gas carriers with gas operated machinery shall meet the requirements in the
Rules for Classification of Ships Pt.5 Ch.5 Sec.16.
202 Pressure vessels for refrigerating plants are, in addition to the requirements in this chapter, to meet the
requirements of the Rules for Classification of Ships Pt.5 Ch.10.

B. Definitions
B 100 Terms
101 A boiler is defined as a welded container or a pipe arrangement in which steam or hot water with a
temperature exceeding 120C is generated by the application of heat.
Superheaters, economisers, reheaters and other pressure parts including valves and fittings, connected directly
to the boiler without intervening valves, shall be considered as parts of the boiler.
102 A thermal-oil installation is defined as an arrangement in which thermal-oil is heated and circulated for
the purpose of heating cargo- or fuel oil or for production of steam and hot water for auxiliary purposes.
B 200 Symbols
201
p
D
T
c

The symbols used are as given below in addition to those specifically stated in the relevant sections.
=
=
=
=

calculating pressure, in bar

nominal diameter, in mm
design temperature, in C
corrosion margin, see Sec.4 B700

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Sec.1 Page 8

nominal design stress at design metal temperature, in N/mm2

specified minimum tensile strength at room temperature, in N/mm2
specified minimum tensile strength at design material temperature in N/mm2
specified minimum upper yield stress at room temperature, in N/mm2. If the stress-strain curve
does not show a defined yield stress, the 0.2% proof stress shall be applied
= specified minimum lower yield stress at design material temperature in N/mm2. If the stressstrain curve does not show a defined yield stress, the 0.2% proof stress shall be applied
= average stress to produce rupture in 100 000 hours at design material temperature in N/mm2
= 1.0% proof stress in N/mm2.

=
=
=
=

Rm
R mt
R eH
R et
Rm/100000
Rp1.0

B 300 Units
301

Unless otherwise specified the following units are used in this chapter:
dimensions (lengths, diameters, thicknesses etc.): mm
areas: mm2
pressures: bar
mechanical properties of materials (ultimate tensile strength, yield strength etc.): N/mm2.

B 400 Grading
401 For rule purposes, boilers and pressure vessels are graded in classes as shown in Table B1.
It may be required that a pressure vessel is manufactured in accordance with the requirements of a superior
class when considering material, temperature, type of fluid, etc.
Pressure vessels containing toxic fluids shall be graded as class I pressure vessels.
402 Requirements for manufacturers, material certificates, testing and heat treatment for the different classes
are indicated in Table B2.
Table B1 Grading of pressure vessels
Steam
Other pressure vessels
Class Boilers generators
15000 1)
I
p > 3.5 p > ----------------------D i + 1000 p > 50 or t > 38

II 2)

III 2)

p 3.5

15000
p -----------------------D i + 1000

20000 ----------------------< p 50
D i + 1000

Material limitations
All grades permitted
Carbon and carbon-manganese steels 3)
shall have a specified minimum tensile
strength 550 N/mm2

or 16 < t 38
or material design temperature >
150C
Pressure vessels not included in class I Carbon and carbon-manganese steels 3)
shall have a specified minimum tensile
and II
condensers, vacuum and atmospheric strength < 460 N/mm2
and plate heat exchangers

p = design pressure in bar, Di = internal diameter in mm, t = shell thickness in mm.

Cargo process vessels for liquefied gas carriers are graded as class I pressure vessels.
1)
2)

3)

Pressure vessels not containing compressible fluids, fluids with flashpoint below 100C or fluids with temperature above 220C
may be graded as class II pressure vessels even if p > 50 bar.
Pressure vessels of class II and III which are calculated with higher joint efficiency factor for welds than the values listed for the
class of vessels, and have scantlings appropriate to a superior class, may be approved for the superior class if the manufacturing
and testing are carried out according to the requirements of that class.
For materials other than carbon and carbon-manganese steels, the limitations for use in class II and III pressure vessels will be
specially considered, taking into account the weldability of the materials.

Table B2 Requirements to different classes of pressure vessels.

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Amended July 2013, see page 3

Approved
Clas manufacturer
s
Sec.8 A101

Material
certificates

Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Sec.1 Page 9

Visual and
Welding
dimensional procedure
inspection qualification
Sec.8 A102

Required

See
Sec.2 A103

Required

Required

II

Required

See
Sec.2 A103

Required

Required

See
Sec.2 A103

Required

III

Nondestructive
testing
Sec.8 D100

Heat
Welding
Hydraulic
treatment production
test
tests
Sec.8 D500
Sec.8 D400
See
Required
Required
Required
Sec.8 C
Required
See
Spot required
for
Required
Sec.8 C
t 16 mm
Required

C. Documentation
C 100 Documentation requirements
101

Documentation shall be submitted as required by Table C1.

Table C1 Documentation requirements

Object
Documentation type

C010-Design criteria

Boilers and
pressure vessels

C020 - Assembly or
arrangement drawing
C030 - Detailed drawing
C040-Design analysis
C050 Non-destructive
testing (NDT) plan
I200 Control and monitoring
system documentation
C010 - Design criteria
C020 - Assembly or
arrangement drawing
C020 - Assembly or
arrangement drawing
C030 - Detailed drawing

Thermal oil heaters

C040 - Design analysis

Additional description
Info
heating surface of boiler and superheater
pressure drop through superheater
estimated evaporation
proposed setting pressure of safety valves on steam FI
drum superheater and economizer
pressure vessel class.
Including valves and fittings.
FI
Including attachments and supports.

FI
AP
Data for the applicable thermal-oils.
Including valves and fittings.

FI
FI

Fire protection and fire extinguishing in the heater

AP
furnace and in the heater vicinity.
Cross sectional and plan views. Including details of
flange connections with gaskets and packing
AP
arrangements for valve spindles and pump shaft seals.
Calculations of maximum temperature of oil film in the
furnace tubes, in accordance with a recognized
FI, R
standard, e.g. DIN 4754.

C050 Non-destructive
testing (NDT) plan
I200 Control and monitoring
system documentation
Z130 Report from test at
manufacturer
Z160 Operation manual

AP
FI

FI
AP
FI, R
Including detailed instructions for starting up,
emptying, dehumidifying and recharging.

FI

102

For general requirements to documentation, including definition of the Info codes, see Pt.0 Ch.3 Sec.1.

103

For a full definition of the documentation types, see Pt.0 Ch.3 Sec.2.

104 For class III pressure vessels intended for water and lubricating oil, documentation needs not be
submitted if the temperature of the fluid is less than 95 C. In such cases, certification shall be based on visual
inspection, review of materials certificates and pressure testing.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Sec.1 Page 10

D. Accumulators for Hydraulic Systems

D 100 Design
101 The accumulators shall be designed according to a recognised international standard: EN-14359, ISO
11120 or ISO 9809, where applicable.
The information or documentation, as required by the standard, shall be submitted for approval.
Corrosion allowance shall be specified in the terms of delivery reflecting the intended use of the gas cylinder,
but shall not be less than 1 mm.
D 200 Fabrication
201 The accumulators shall be manufactured by a DNV Approved Manufacturer for class I and II.
The accumulators shall be manufactured to the same standard which form basis of the design.
All materials, forming, heat treatment, prototype testing and product testing shall meet with the requirements
of the standard.
D 300 Certification
301 The accumulators shall be certified by the Society. DNV product certificate shall be issued based on
successfully testing as specified in the standard.

E. Cylinders for Fire Extinguishing System

E 100 General
101 Cylinders under this chapter are defined to be mass produced seamless or welded transportable refillable
pressure vessels used in fixed extinguishing systems.
E 200 Design
201 Mass produced cylinders certified as part of a batch which are , UN, DOT marked will be accepted for
fixed fire fighting systems considered the applicable manufacturing and approval procedure is fully complied
with.
202 Under these certification regimes the following standards are acceptable:
EN14208, EN13322, ISO 9809 or CFR 49, as applicable.
E 300 Fabrication
301 The cylinders shall be manufactured to the same standard which form basis of the design.
All materials, forming, heat treatment, prototype testing and product testing shall meet with the requirements
of the standard.
E 400 Certification
401 The cylinders shall be certified by DNV, or by a recognized certification authority according to national
regulations and marked accordingly: , UN, DOT.
402 When certified by a recognized authority other than DNV, the cylinders shall be documented by means
of certificates identifying the serial No. of each cylinder. The certificates shall be made available to the
attending surveyor.
403 When certified by DNV, the design must be approved in each case, or by an obtained type approval. The
type approval will be issued on the basis of the design requirements and prototype testing as specified in the
standard. The product certification shall be according to the requirements of the standard.

F. Signboards
F 100 General
101

Signboards are required by the rules in:

Sec.3 A500 Purging of boilers before firing.

Sec.3 B700 Thermal-oil installations.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012
Pt.4 Ch.7 Sec.2 Page 11

SECTION 2 MATERIALS
A. Material Requirements
A 100 General
101 Materials for boilers and pressure vessels and thermal-oil heaters together with their valves, fittings, etc.
shall meet the requirements given in the relevant chapters and sections for pressure vessels in Pt.2 Ch.2.
102 Materials used in cargo process pressure vessels on liquefied gas carriers are in addition to meet the
requirements in the Rules for Classification of Ships Pt.5 Ch.5 Sec.2.
103 The materials used shall have certificates according to Table A1. For definition of the different types of
certificates, see Pt.1 Ch.1 Sec.4 of the Rules for Classification of Ships.
Table A1 Certificates for materials
Pressure vessel class
I and II
III
Plates
NV
W
Pipes, tubes and flanges
W
W
Bolts
TR
TR
Forgings and castings
W
TR

104 For valves and fittings, requirements for certificates and certification are specified in Ch.6 Sec.6 C300
of the Rules for Classification of Ships.
A 200 Boilers and pressure vessels
201 Rolled steels for boilers and pressure vessels designed for material temperatures not lower than 0C shall
comply with the specifications given in Pt.2 Ch.2 Sec.2 B.
Semi-killed, fully killed and fine grain, normal strength structural steels complying with the specifications
given in Pt.2 Ch.2 Sec.1 will, however, be accepted for end plates for plate heat exchangers and the following
class III pressure vessels:
pressure vessels intended for water or lubricating oil if the fluid temperature is less than 95C
other pressure vessels where
15000
p < -----------------------D i + 2000

202 The steel grades NV 360-0A, 410-0A and 460-0A will be accepted only for class II and III pressure
vessels with material thickness maximum 25 mm.
203 Steel grades complying with recognised national or proprietary standards with chemical composition and
mechanical properties differing from the specifications referred to above, and with minimum specified tensile
strength not exceeding 550 N/mm2, may be accepted subject to approval in each case. In such cases the values
of the mechanical properties used for deriving the allowable stress shall be subject to agreement by the Society.
204 Materials for pressure vessels designed for material temperatures below 0C are subject to approval in
each case.
205

Grey cast iron is in general not to be used for the following:

class I and II pressure vessels

class III pressure vessels where:
15000
p > -----------------------D i + 2000

pressure vessels containing toxic fluids and fluids with a flash point below 100C.
However, for bolted heads, covers or closures not forming a major part of the pressure vessel, grey cast iron
may be used for p 10 bar.
The use of grey cast iron in economisers will be subject to special consideration.
206 Nodular cast iron of the ferritic/pearlitic and pearlitic type is in general subject to the limitation of use as
grey cast iron as specified in 205.
207

Nodular cast iron of the ferritic type with specified minimum elongation of 12%, shall not be used for
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Pt.4 Ch.7 Sec.2 Page 12

temperatures exceeding 350C.

A 300 Thermal-oil installations
301 Tubes and pipes for thermal-oil shall be seamless steel tubes and pipes or welded steel tubes and pipes
which are approved as equivalent to seamless types.
302

Pump housings, valves and fittings shall be of steel or nodular cast iron, grade 1 or 2.

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SECTION 3 ARRANGEMENT
A. Boilers and Pressure Vessels
A 100 Instruments
101

All oil-fired boilers shall be provided with instrumentation permitting local surveillance.

A 200 Inspection openings

201 Pressure vessels shall have openings sufficient in number and size for internal examination, cleaning and
maintenance operations such as fitting and expanding of tubes.
Guidance note:
See Appendix A regarding number, type and locations of openings.
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202 Manholes shall not be less than 300 x 400 mm or 400 mm in inside diameter. Where the neck height of
a manhole is excessive, the size of the manhole shall be suitably increased.
203

Detachable ends or covers and suitably located, removable pipe connections may be used as inspection openings.

204

For boilers see also Sec.5 H.

A 300 Drains
301

All pressure vessels shall be provided with drainage positioned at the lowest part.

A 400 Fuel oil supply

401 Manual rapid shut-off of fuel oil supply shall be possible locally at the boiler. This quick closing device
shall be so arranged that reopening is possible only locally at the boiler.
402 For steam-atomising burners, and when steam blowing is used for cleaning of the burners, effective
precautions shall be taken in order to prevent fuel oil from penetrating into the steam system.
403 If electric preheaters are applied, precautions shall be taken in order to prevent the temperature at the
heating element from rising too high, if the flow stops.
A 500 Combustion air supply
501 The boiler shall be ensured a sufficient air supply during all working conditions. When the boiler is
installed in the same room as other large air consumers, ventilation shall be arranged so that no disturbance in
the air supply to the boiler occurs.
502 At the operating stations for the boilers there shall be placed a readily visible signboard with the
following instructions:
CAUTION!
NO BURNER TO BE FIRED BEFORE
THE FURNACE HAS BEEN PROPERLY PURGED
503 Oil-fired boilers are in general not to have flaps or other arrangements which may interfere with the
draught in funnels or uptakes.
A 600 Positioning
601 Boilers and pressure vessels shall be installed on foundations of substantial strength and in such a
position that there is sufficient access for cleaning, examination and repair anywhere on the outside.
602 The clearance between boiler with uptake and tanks for fuel oil, lubricating oil and cargo oil and cargo
hold bulkheads shall be adequate for free circulation of air to keep the temperature of the oil well below the
flashpoint and to avoid unacceptable heating of the cargo.
Alternatively the tank surfaces and bulkheads shall be insulated.
Guidance note:
The following clearances are considered to be sufficient:
- Distance between fuel oil tanks or hold bulkheads to:
- flat surfaces of boilers and uptakes: 500 mm
- cylindrical surfaces of boilers and uptakes: 300 mm.
- Vertical distance from top of boiler to nearest deck: 1300 mm.
- For watertube boilers, distance between the tank top and the underside of the bottom of the combustion chamber

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space: 750 mm.

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603 If oil-fired boilers are placed in the engine casing or in the funnel, the arrangements shall be such that oil
spray, in the case of leakage, will be intercepted and will not reach heated surfaces beneath. Coamings for
stairs, pipe openings, etc. shall be of ample height.
The platforms shall be fitted with sufficient drains to a waste-oil tank in the double bottom. These drains shall
be fitted in addition to those specified for drip trays of oil tanks and fuel-oil pump units.

B. Thermal-oil Installations
B 100 Installation
101 Oil fired thermal-oil heaters are normally to be located in separate rooms. The arrangement shall provide
easy access to all parts of the plant for operation, inspection, maintenance and cleaning.
102 If oil fired thermal-oil heaters are not located in separate rooms they shall be surrounded by coamings of
height not less than 150 mm and with drainage to a closed tank.
103 If oil fired thermal oil heaters are installed in separate room, the room shall have mechanical ventilation,
automatic fire detecting and an approved fixed fire-extinguishing system, operated from an easily accessible
place outside the room. Stop of ventilation, oil-burner and oil-booster pumps is also to be arranged outside the
room. Ventilating ducts shall be possible to close by means of flaps.
104 Oil piping in the exhaust fired thermal-oil heater area shall be so arranged that spray or drip from
detachable pipe and valve connections can neither reach the heater and exhaust ducts nor flow to the engine
room below.
105 Thermal-oil piping shall be installed so as to provide sufficient flexibility to accommodate thermal
expansion. The use of bellows or similar expansion elements in thermal-oil piping is not permitted within
machinery spaces.
106 Thermal-oil pipes shall have welded connections, with the exception of flange connections required for
the servicing of system components. The requirements for NDT of welded joints for thermal oil piping can be
found in the Rules for Classification of Ships Pt.4 Ch.6 Sec.7 A500.
B 200 Circulation system
201 Arrangements shall be made to ensure a minimum circulation through the heater in case consumers are
shut-off. Such arrangements shall be automatically operated.
202 Each circulation system shall have a minimum of two circulation pumps. One pump shall be in
continuous operation, the other in auto stand-by. Starting of the stand-by pump shall be initiated by the
dropping out of the contactor for the pump in operation.
203 For heating of liquid cargoes with flashpoint below 60C, see the Rules for Classification of Ships Pt.5
Ch.3 Sec.4 D.
204 The oil fired heater main inlet and main outlet pipes for thermal-oil shall have stop-valves, arranged for
local and remote manual operation from an easily accessible location outside the heater room.
B 300 Control and monitoring system
301 Circulation pumps and heater burners shall be arranged for local start and stop and remote stop from an
easily accessible location outside the thermal-oil heater room.
302 The heater regulation and the burner management shall be capable of ensuring that, under all operating
conditions, the thermal-oil temperature at no place in the heater will exceed a temperature which would cause
an unacceptable rate of deterioration of the thermal-oil.
303

For extent of monitoring see Sec.7 E.

304

For requirements for oil burner control system see Sec.7 A200.

B 400 Safety arrangements

401 The thermal-oil heater and heat exchangers in the system shall have liquid relief valves.
The relief set-point shall not be higher than 10% above maximum operating pressure. The relief pipes shall lead
to a sludge tank.
402 The heater shall be so designed that release of internally stored heat in case of unintended stop of
thermal-oil circulation pumps (e.g. black-out) will not cause the thermal-oil temperature to exceed the
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permissible level.
403 The plant arrangement shall ensure that the temperature of thermal-oil coming into direct contact with
air will be below 50C in order to prevent excessive oxidation.
404

Fast gravity discharge of the oil into a separate collecting tank shall be possible.

405 The expansion tanks shall have overflow pipes leading to the collecting tank. The discharge valve shall
be arranged for remote operation from the machinery central control position.
406

System tanks and vessels where water may accumulate, shall be arranged with drain cocks.

407

All vent pipes shall be led to open deck and shall be arranged with drainable water traps at the lowest points.

408 Drip trays with drains to a waste oil tank shall be arranged under all plant components where leakage
may occur.
409 The boiler furnace shall be fitted with a fixed fire-extinguishing system, subject to approval. Manual
release shall be arranged locally and remote.
B 500 Insulation and shielding
501 All insulation shall be covered with an outer barrier, which shall be impervious to liquid. In areas and
locations where pipes may be exposed to mechanical impact, the outer barrier shall be made of galvanised steel
plates or aluminium plates of sufficient impact strength to resist deformations from normal wear and strain.
502 The arrangement of pipes and components shall provide sufficient space for satisfactory insulation
installations. Flanged pipe connections shall have installed effective detachable shielding, which will prevent
oil leakage from reaching potential danger areas.
B 600 Exhaust-fired thermal-oil heaters
601 The heater shall be so designed and installed that all tubes may be easily and readily inspected for signs
of corrosion and leakage.
602

The heater shall be fitted with temperature sensor(s) (exhaust gas side) with an alarm for fire detection.

603 The thermal-oil heater shall be arranged with the possibility for bypassing the exhaust by means of
damper(s).
The dampers will not be accepted as a means for controlling the temperature of the thermal-oil heaters.
The bypass may be internal or external to the heater. In either case, the arrangements shall be such that fire
extinguishing in the heater is possible without stopping the propulsion of the vessel.
Guidance note:
For heaters with smooth surface heater tubes. Temperature control by means of exhaust gas dampers may be accepted
on the condition that it can be shown that a minimum gas velocity of 12 m/s through the heater is maintained,
throughout the control range.
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604 A fixed fire extinguishing and cooling system shall be fitted. A drenching system providing copious
amounts of water may be accepted. The exhaust ducting below the heater shall be arranged for adequate
collection and drainage, to prevent water flowing into the diesel engine. The drain shall be led to a suitable
location.
605

High temperature alarm(s) in the thermal oil outlet, from the heater, shall be fitted.

606

Soot cleaning arrangements shall be fitted in accordance with D200.

B 700 Test equipment and signboards

701

Cocks or valves for taking thermal-oil samples in a safe manner shall be arranged.

702 Notices shall be posted at the control stations of the circulating pumps stating that the pumps shall be in
operation at least for 10 minutes after stop of burners.
703

Further notices shall state:

plant manufacturer
year installed
maximum operating pressure
maximum operating temperature
maximum thermal output.

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C. Exhaust Gas Boiler or Economisers

C 100 Circulation systems
101 One stand-by pump is required when forced circulation is necessary for operation of the boiler or
economiser.
C 200 Soot-cleaning arrangement
201 Water tube exhaust gas boilers or economisers of a design where soot deposit may create a problem
regarding fire hazard, e.g. exhaust gas boilers with extended surface tubes shall have a soot-cleaning
arrangement for use in the operation mode. In such cases, the soot cleaners shall be equipped with automatic
start and arranged for sequential operation and possibility for manual over-ride.
Guidance note:
For extended surface tubes, soot deposits may create a problem when exhaust gas velocity is less than 12 m/s at normal
operating condition.
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202 Exhaust gas collecting pipes shall be provided with drain. The drainage system shall be capable of
draining all water when the water washing or water fire extinguishing system in the exhaust gas boiler or
economizers are in operation.
Necessary protection shall be made, so that water can not enter into any of the engines.
The drainage shall be led to a tank of suitable size.

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SECTION 4 GENERAL DESIGN REQUIREMENTS

A. General
A 100 Application
101 The requirements in this section apply to pressure vessels under internal pressure and subjected mainly
to static loadings.
102 Where fatigue is considered to be a possible mode of failure, fatigue calculations may be required. The
calculations may be carried out according to a recognised pressure vessel code.
103 Pressure vessels subjected to external pressure, except furnaces, fireboxes and uptakes (see Sec.5), shall
be calculated according to the Rules for Classification of Ships Pt.5 Ch.5 Sec.5, items I700 and I800.
104 Parts of pressure vessels not covered by these rules, e.g. flanges, bolts and tube plates in heat exchangers,
end plates in plate heat exchangers or parts having geometrical properties outside the limits of application of
the calculating formulae, shall be designed and calculated according to a recognised code.
In general the nominal design stress shall not exceed that given in B500.
The allowable stresses for the bolts shall be as specified in the recognised code.
105 The rules do not take into account thermal stresses. It is a condition for approval that the thermal stresses
are accounted for by a sufficiently flexible construction and a sufficiently slow heating up and cooling down
period.
In special cases an analysis of thermal stresses may be required.
106 For terms used in stress analysis, equivalent stress and stress limits, see the Rules for Classification of
Ships Pt.5 Ch.5 Sec.5 G.
107 Where parts of pressure vessels cannot be calculated with satisfactory accuracy and if empirical data are
insufficient, strain gauge measurements and/or hydraulic proof test may be required.
Information on test pressure, testing method and results obtained shall be submitted for approval.

B. Design Criteria
B 100 Design pressure
101 The design pressure, pd, is defined as the pressure at the top of the pressure vessel and shall not be less
than the highest nominal set pressure of the safety valve(s).
The design pressure shall not be less than the maximum allowable working pressure.
Guidance note:
It is advised that a suitable margin should be provided above the pressure at which the pressure vessel will normally
be operated to avoid unnecessary lifting of the safety valve(s).
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B 200 Calculating pressure

201 The calculating pressure, p, is the pressure used for the purpose of determining the thickness of the vessel
section or component under consideration.
202 The calculating pressure is normally to be taken as the design pressure with additional pressure due to
static head of the fluid exceeding 3% of the design pressure.
The calculating pressure, p, is the greater of:
g0 h
p d and p d + ----------- 0.03p d
100

g0
h

= density of fluid in t/m3

= standard acceleration of gravity = 9.81 m/s2
= vertical distance from load point to top of pressure vessel in m.

203 In special cases, see note, the calculations are also to be carried out with a calculating pressure taking
dynamic loads due to the ship's motions from wave actions into account.
The calculating pressure shall be:
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g0 h
a
p = p d + ------------ 1 + ----v- 0.03p d
100
g 0

av = the most probable largest combined vertical acceleration in 108 wave encounters (probability level
Q = 10-8).
Values for av may be as given in the Rules for Classification of Ships Pt.3 Ch.1 Sec.4 B600 or Pt.3 Ch.2 Sec.5
and Sec.7.
When this calculating pressure is used a 15% increase in the nominal design stress as given in 500 will be
permitted.
Guidance note:
The above calculating pressure may be determining for the scantlings of large vertical low pressure storage tanks, e.g.
bulk mud and cement tanks.
Tanks for liquefied gases shall meet the requirements in the Rules for Classification of Ships Pt.5 Ch.5.
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B 300 Other loadings

301 In the design of a pressure vessel it may be necessary to take into account the effect of the following
loadings in addition to the calculating pressure:

additional loads due to pressure testing

loadings from supports and connected piping
loadings from different thermal expansion
fluctuating pressure and temperatures
shock loads due to water hammer or surging of vessel's content.
Guidance note:
The effect of loadings from supports and connected piping on the shell may be calculated according to PD 5500,
Appendix A and G.
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B 400 Design material temperature

401 The design material temperature is defined as the temperature in the middle of the shell thickness.
Generally the design material temperature shall not be taken less than the maximum temperature of the internal
fluid.
402 For boilers the design material temperature is made up of a reference temperature and a temperature
allowance in accordance with the Table B1 unless a lower temperature is justified by detailed calculations. The
design material temperature is, however, not to be taken less than 250C.
For furnaces, fireboxes and other pressure parts subjected to similar rates of heat transfer, the reference
temperature shall be the saturation temperature at design pressure of the internal fluid and the temperature
allowance shall not be less than 4 times the material thickness plus 15C.
For economiser tubes the reference temperature shall be the maximum temperature of the internal fluid and the
temperature allowance shall not be less than 35C for finned tubes and 25C for plain tubes.
403 By unheated parts for superheated steam the temperature allowance of 15C may be reduced to 7C
provided that special measures are taken to ensure that the design material temperature is not exceeded.
404 Drums and headers of thickness exceeding 30 mm shall not be exposed to combustion gases having an
anticipated temperature exceeding 650C, unless they are efficiently cooled by closely arranged tubes
accommodated therein.
B 500 Nominal design stress
501 For carbon, carbon-manganese and low-alloy steels the nominal design stress, t, is defined as the lowest
of the following values:
For pressure vessels operating at a temperature up to and including 50C:
R eH
Rm
---------- and ------1.8
2.7

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For pressure vessels operating at a temperature higher than 50C:

R eH R et R m
R m 100000
---------- , -------- , -------- and -----------------------1.8 1.6 2.7
1.6

502

For austenitic stainless steel the nominal design stress is defined as the lowest of
R p1, 0
Rm
-------------- and ------1.5
2.7

503 For steel castings the nominal design stress is limited to 80% of the value determined according to 501
or 502.
Where steel castings are subjected to non-destructive tests, consideration will be given to increase the nominal
design stress up to 90% of the value determined according to 501 or 502.
504 For ferritic nodular cast iron with special requirements, Pt.2 Ch.2 Sec.8, Table B1, the nominal design
stress shall not exceed 60% of the value determined according to 501.
505

For grey cast iron the nominal design stress shall not exceed Rm/10.

506

For copper alloys the nominal design stress shall not exceed R mt / 4.

507

For aluminium alloys the nominal design stress shall not exceed the lowest value of:
R mt
R et
--------- and ------4
1.5

508 Values for Rm, ReH, Ret, Rp1.0 and Rm/100000 are given for different grades of rolled steel in Pt.2 Ch.2
Sec.2 and for steel tubes in Pt.2 Ch.2 Sec.4.
For steel tubes the design stresses at elevated temperatures are given in Ch.6 Sec.6 of the Rules for
Classification of Ships.
Where other materials are proposed, the values of mechanical properties to be used for deriving the nominal
design stresses are subject to consideration by the Society.
If higher values for Ret than given in Pt.2 Ch.2 Sec.2 are used for deriving the nominal design stress, the
requirements given in Pt.2 Ch.2 Sec.2 B302 shall be complied with.
509

For boilers the nominal design stress shall not exceed 170 N/mm2.
Guidance note:
The mechanical properties used for deriving the nominal design stress are specified minimum values according to the
material specification. If higher values are measured in material tests, these may therefore not be used to determine
the design stress.
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Table B1 Temperature allowances

Reference temperature
Saturation temperature at design pressure
Superheated steam temperature

Minimum temperature allowance

Heated parts subjected mainly to:
Unheated parts
convection heat
radiant heat
0C
25C
50C
15C
35C
50C
See also 403

B 600 Shell thickness

601 The nominal thickness after forming of any shell or head shall not be less than:
For carbon and low-alloy steel:
Di
3 + ------------ (mm)
1500

with a minimum of 7 mm for boilers.

For stainless steel and non-ferrous materials: 3 mm.
Di = inside diameter of shell or inside diameter of cylindrical shirt for dished ends.
602 For pressure vessels where the cylindrical part is made of a pipe, a smaller minimum thickness may be
approved.
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B 700 Corrosion allowance

701 For carbon and low-alloy steels, the corrosion allowance, c, is in general 1.0 mm.
For austenitic steels, no corrosion allowance will in general be required.
Where adverse corrosion or erosion conditions exist a greater allowance may be required.
B 800 Tolerance and fabrication allowance
801 The calculated thicknesses according to the formulae are the minimum required.
Minus tolerance on wall thickness and a possible reduction in wall thickness due to fabrication, e.g. flanging
or bending, shall be added to the calculated thicknesses.
For assessment of a design, e.g. reinforced openings or dished ends, the minus tolerance and fabrication
allowance shall be deducted from the design wall thickness.

C. Scantlings of Shells and Flat and Dished Ends

C 100 Conditions
101

The formulae given in 200, 300 and 400 are based on the following conditions:

The ratio of the outside radius to the inside radius does not exceed 1.5.
In the case of shells consisting of sections of different thicknesses, the median lines of the sections shall be
in line with each other at each longitudinal joint within the limits of tolerances specified in Sec.8 B300 (see
Fig.1).

Fig. 1
Shell section

102

Joint efficiencies for lw1welded joints, e, used in the formulae in 200, 300 and 400 shall be taken equal to:

1.00 for class I pressure vessels

0.80 for class II pressure vessels
0.60 for class III pressure vessels.
C 200 Cylindrical shells
201

The thickness of a cylindrical shell shall not be less than:

pR
t = -------------------------------- + c (mm)
10 t e 0.5p

R
e

= inside radius of shell or shell section

= joint efficiency as given in 102.

C 300 Spherical shells

301

The thickness of a spherical shell shall not be less than:

pR
t = ------------------------------- + c (mm)
20 t e 0.5p

R
e

= inside radius of shell or shell section

= joint efficiency as given in 102.
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C 400 Conical shells of circular sections

401

The thickness of a conical shell shall not be less than:

pD C
1
t = -------------------------------- ------------ + c (mm)
20 t e 0.5p cos

DC = internal diameter at the large end of the cone

= the half apex angle of the section
e = joint efficiency as given in 102.
402 The formula in 401 applies only if the half apex angle does not exceed 75 and the thickness t obtained
is less than one sixth of the external diameter at the large end of the cone.
403 Conical shells may be constructed of several ring sections of decreasing thickness and the formula in 401
shall be applied to each section.
404 The thickness of the large end of a cone/cylinder or cone/cone junction and adjoining parts of the shells
within a distance L from the junction shall be determined by the following formula:
pD 0 k
- + c + c 1 (mm)
t = ------------20 t e

Do = outside diameter of the conical section, see Fig.2

e = joint efficiency (as given in 102) of junction or of circumferential welds located within a distance L from
the knuckle, see Fig.2
L = length equal to:
D0 ( t c )
0, 5 --------------------- (mm)
cos

c1 = 0 for t c/Do 0.005

= 1 mm for t c/Do < 0.005
K = a factor taking into account the stress in the junction.
Values of K are given in Table C1 as a function of and ri/Do, where:

ri

= difference between angle of slope of the adjoining parts

= inside radius of transition knuckle in mm, which shall be taken as 0.01 DC in the case of butt welded
junctions.

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Fig. 2
Junction arrangements

The thickness of the junction or knuckle and the adjacent parts shall not be less than that for the cone
determined by the formula in 401.
If the difference in angle of slope exceeds 30, welded junctions are not permitted. In these cases, knuckle
connections with a minimum inside radius ri of 0.06 Do shall be applied.
Table C1 Values of K as a function of and ri/Do
Values of K for ri / Do for ratios of

0.01
0.06
0.08
0.10
0.15
0.20
10
0.70
0.55
0.55
0.55
0.55
0.55
20
1.00
0.70
0.65
0.60
0.55
0.55
30
1.35
0.90
0.85
0.80
0.70
0.65
45
2.05
1.30
1.20
1.10
0.95
0.90
60
3.20
2.00
1.75
1.60
1.40
1.25
75
6.80
3.85
3.50
3.15
2.70
2.40

0.30
0.55
0.55
0.55
0.70
1.00
1.55

0.40
0.55
0.55
0.55
0.55
0.70
1.00

0.50
0.55
0.55
0.55
0.55
0.55
0.55

405 The thickness of conical sections having a half apex angle of more than 75 shall be determined as for a
flat plate.
406 Cone and cylinder forming a junction at the small end of a cone shall have the thickness of the adjoining
parts determined by
tr = M t (mm)
M = a factor given in Fig.3 as a function of the ratio p/t e
t
= the thickness of the cylinder determined by the formula in 201.

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Fig. 3
Values of M for small end cone-cylinder junction

The above formula applies only for junctions with half apex angles of the cone less than 30.
In no case is tr to be less than the thickness for the cone determined by the formula in 401. The increased
cylinder thickness tr shall extend a minimum distance D 0 ( t r c ) from the junction and the increased cone
thickness tr shall extend a minimum distance:
D0 ( tr c )
------------------------ (mm)
cos

from the junction.

407 Cone or cylinder connections at the small end of cones with half apex angles exceeding 30 shall be
manufactured by means of knuckle transitions. The thickness of the knuckle will be considered in each case.

Fig. 4
Elliptical end

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Fig. 5
Torispherical end

Fig. 6
End with opening

C 500 Dished ends

The thickness of dished ends without stays, concave to the pressure side, shall not be less than:

501

pD 0
t = -------------- K + c (mm)
20 t e

t
Do
e
K

=
=
=
=

required end plate thickness after dishing

outside diameter of end plate, in mm
joint efficiency for welded joints, see 505
shape factor defined in 503.

The thickness t shall not be less than the thickness required for a seamless, un-pierced, cylindrical shell of the
same diameter and material, except where the end plate is a complete hemisphere.
The required thickness shall be obtained through an iteration process.
502

The formula in 501 applies to:

hemispherical ends
elliptical ends with H 0.2 Do
tori-spherical ends satisfying the following conditions:
H 0.18 Do; R Do; r 0.1 Do; r 3 t; L 2 t
H = outside height of the end, in mm, measured from the junction of the dished part with the cylindrical
shell
r = inside knuckle radius of tori-spherical ends, in mm
R = inside radius of spherical part of tori-spherical ends, in mm
L = length of the cylindrical part of the end, in mm.
See also Fig.4 and 5.
The formula in 501 is not valid for ends with openings exceeding d/Do = 0.5 where:
d

= diameter of opening, in mm.

See also Fig.6.

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Guidance note:
The outside height of tori-spherical ends may be determined from the following formula:
2

H = R + t ( R r ) ( D0 2 t r )

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503 The shape factor K to be used in the formula in 501 shall be determined from the curves in Fig.7
depending on the ratio H/Do as follows:
Plain ends without openings or with openings reinforced in accordance with D300 or with small openings
not requiring reinforcement according to D200, the shape factor K depends on the ratio (t c)/Do as well
as on the H/Do ratio. The unbroken line curves shall be used and trial calculations may be necessary.
For ends with un-reinforced openings and for flanged openings, the shape factor shall be as given in Fig.7,
depending on the ratio H/Do and with:
d
-------------------------D0 ( t c )

as a parameter, where d is the diameter of the largest opening in the end plate (in the case of an elliptical
opening, the larger axis of the ellipse).
In addition, the following conditions shall be satisfied:
tc
---------- 0.1
D0

K shall not be less than given for a plain end with the same
t c/Do-ratio.
The radius r1 of the flanging shall not be less than 25 mm. The thickness of the flanged portion may be less
than the calculated thickness t. See Fig.6.
Guidance note 1:
In the case of ends containing only compensated openings, read K from full curves of (t c)/D = 0.002 to (t c)/D =
0.04 interpolating as necessary.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Guidance note 2:
In the case of ends containing uncompensated openings, read K from the broken line curves d ( Dt c ) = 5.0 to
d ( Dt c ) = 0.5 interpolating as necessary. In no case, K shall be taken as smaller than the value for a similar unpierced end.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

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Fig. 7
Graph of shape factor K for dished ends

504

The thickness of dished ends without stays, convex to the pressure side shall not be less than:
p D0
t = --------------- K + c
16 t e

t, Do, e and K is defined in 501.

In addition the spherical section of the end shall be checked against elastic instability. The pressure, pc,
corresponding to elastic instability shall be determined from the following formula:
tc 2
p c = 2.4 E ----------
R

= modulus of elasticity in N/mm2 at design material temperature, see table in Sec.5 E107.

The design pressure shall not exceed:

p
p = -----cSF
tc
SF = 3.7 for ---------- 0.001
r

tc

SF = 3 for ---------- 0.003

r
Intermediate values may be interpolated.

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Fig. 8
Dished ends cylindrical shell connections

505 For tori-spherical and elliptical ends dished from one plate, e = 1.
For hemispherical ends, e shall be taken as given in 102.
For tori-spherical and elliptical ends made of welded plates, e shall be taken as given in 102, except that e = 1
may be used also for class II and III pressure vessels for welded seams situated within the area 0.6 Do of the
spherical part.
506 Examples of connections between dished ends and cylindrical shells are shown in Fig.8.
Alternative methods of attachment may be accepted provided details are submitted for consideration.

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C 600 Un-stayed flat end plates

601

The thickness of an un-stayed flat end plate shall be determined by the following formula:
14 t
k ----------p

k is a calculation factor depending upon t1 c/t c and

100 (t1 c)/Di where:
t
= thickness of end plate, in mm
t1 = thickness of cylindrical shell, in mm
Di = inside diameter of cylindrical shell, in mm.
For determining k, see Fig.9.

Fig. 9
Calculation factor K

The formula in 601 is based on the following conditions:

p 30 bar
t1 t 5 t1
Cases where p, t and t1 are outside these limits, will be specially considered.
602

603 If t1 is locally increased to obtain a reduction of t, the increased shell thickness shall extend at least a
length D 0 ( t 1 c ) from the end plate, where Do = outside diameter of cylindrical shell, in mm.
604 Examples of acceptable connections between flat end plates and cylindrical shells are shown in Fig.10.
Alternative methods of attachment may be accepted provided details are submitted for consideration.

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Fig. 10
Acceptable methods of attaching flat end plates to cylindrical shells

D. Openings and Compensations

D 100 General
101

The rules apply only when the following conditions are simultaneously satisfied:

Openings are circular, elliptical or around with a ratio of major to minor inside diameters not exceeding 2.
The axis of the branch is not having an angle with the normal to the shell greater than 15.
For cylindrical, conical and spherical shells:
the major inside diameter of the opening is not exceeding one third of the shell inner diameter.
For dished ends:
the major inner diameter of the opening is not exceeding one half of the outside diameter of the end
the opening is so situated that in projection its outer extremity or that of its reinforcement is at least one
tenth of the end external diameter from the outer surface of the cylindrical shell, see Fig.11
in case of multiple openings, the distance between the openings shall comply with the requirement in
Fig.11.
For opening in flat plates. See Sec.5 D600 for requirements of reinforcement.
102 The rules do not apply to multiple openings in cylindrical shells where the distance between the axes is
less than 1.5 times the average diameter of the openings.
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103 Openings not complying with the requirements in 101 and 102 will be subjected to special consideration.
Calculations according to a recognised code may be approved.

Fig. 11
Opening arrangement

D 200 Openings not requiring reinforcement

Reinforcements are not required for isolated openings provided:

201

d i 0.3 ( D i + t a )t a

with a maximum of 150 mm.

An opening is considered isolated if its centre is at a distance greater than:
d a + 3 ( D i + t a )t a

from the centre of another opening.

Di =
=
=
=
di

da =
t
=
ta =

the inner diameter of a cylindrical or spherical shell

twice the inner radius of the spherical part of a tori-spherical end
for semi-ellipsoidal ends, twice the inner radius of curvature at centre of head
for a conical shell, twice the distance along the shell normal, from the point where the axis of the
opening intersects the inner surface, to the shell axis
the inner diameter of the opening or branch for a circular opening and the chord length in the plane being
considered for elliptical and ob-round openings
mean inner diameter of the two openings
thickness as calculated from the formula in C200, C300 or C400 using e = 1 and c = 0
actual thickness of the shell before corrosion allowance is added.

D 300 Openings requiring reinforcement

301

Openings not conforming to 200 shall be reinforced in accordance with 302 and 303.

302

On each side of the centre line of the opening the required area of reinforcement is:
d
K ----i + t b t
2

tb

(mm )

= thickness in mm of the branch calculated from the formula in Sec.5 G101 with c = 0. For elliptical or
around reinforcement rings the chord length in the plane being considered shall be used in determining
tb.

For di and t, see 201.

For openings fitted with an internal cover such that the bore is not subjected to pressure, the required area of
reinforcement on each side of the opening is:
K di t
------------2

(mm )

= 1 for spherical shells and for planes passing through the generatrix for cylindrical and conical shells
= 0.7 for planes normal to the generatrix for cylindrical and conical shells.

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Guidance note:
Generatrix is a line parallel to the centre line of the cylindrical or conical shells.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

For oval openings in cylindrical and conical shells the reinforcement shall be determined in a plane passing
through the generatrix (Fig.12 a, K = 1) and in a plane normal to the generatrix (Fig.12 b, K = 0.7). For spherical
shells the reinforcement shall be determined in a plane passing through the major diameter of the opening. All
planes shall pass through the centre of the opening and shall be normal to the wall.
303

Only material located within the following limits will be accepted as reinforcement:

For the shell, measured from the outer surface of the branch along the outer surface of the shell:
Ls =

( D i + t a )t a (mm)

For the branch, and internal protrusion, if fitted, measured from the relevant surface of the shell:
L = 0.8 ( d i + t ba )t ba (mm)

The area A, available as reinforcement on each side of the centre line of the opening, is shown shaded in Fig.12.
When ta/Di 0.02, two-thirds of the area of compensation required shall be at a distance less than:
d i 2 + 0.35 ( D i + t a )t a

measured from the axis of the opening on the external surface of the shell.
The reinforcement is adequate if:
d
A K ----i + t b t
2

( mm )

t ba = actual thickness in mm of the branch before corrosion allowance is added.

For Di, di, t, ta and tb, see 201 and 302.
304 Where two openings or branches are sufficiently closed spaced for the limits of compensation in the shell
to overlap, the limits of compensation shall be reduced so that no overlap is present.
305 Material in the reinforcement, or in a branch, is normally to have the same mechanical properties as that
in the shell. In no case is the reinforcement, or the branch, to be made from a material having a nominal design
stress less than 0.6 times the nominal design stress for the shell. Where material with a lower nominal design
stress than that of the shell is used for reinforcement, its effective area shall be assumed reduced in the ratio of
the nominal design stresses at design temperature.
No reduction will be accepted for material with a nominal design stress greater than that of the shell.
306 Reinforcements, not in compliance with the requirements above may be approved if justified by a
detailed calculation.
Additional reinforcement may be required where closing appliances can cause deformation of the shell.

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Fig. 12
Reinforcement area

D 400 Minimum thickness of standpipes and branches

401 The wall thickness of standpipes and branches shall not be less than determined by Sec.5 G. Additional
thickness may be necessary on account of loads from connected piping and vibrations.
For class I and II pressure vessels the nominal wall thickness of standpipes and branches is, however, not to be
less than:
t = 0.04 do + 2.5 (mm)
but need not be greater than the shell thickness.
do = outer diameter of the branch.
D 500 Welded branch connections
501 Acceptable welded branch connections are shown in Fig.13.
Alternative methods of attachment may be accepted provided details are submitted for consideration.
For acceptable flange welding details, see Rules for Classification of Ships Pt.4 Ch.6 Sec.6 E.

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Notes to Fig.(e2):
1) Fillet welds are not suitable in cases where there are fluctuating loads.
2) Weld detail (e2) shall not be used for openings that require reinforcement i.e. the required reinforcement
for the openings shall be integrated in the shell plate.
3) Thickness of more than 16 mm will be evaluated in each different case when welding procedure is
submitted.

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Fig. 13
Details of branch connections

Studded connections, weld details k, l, m and n are acceptable for use only on class II and III vessel with
limitations as listed below.
1) Weld details k and l are only accepted for shell thickness up to 16 mm in carbon manganese steels with
specified minimum tensile strength not exceeding 430 N/mm2 and when design temperature of the vessel
is maximum 120C. Weld detail m is accepted on the same conditions, but only for shell thickness up to 10
mm.
2) Weld details k, l, and m shall not be used for openings which require reinforcement, i.e. the required
reinforcement for the openings shall be integrated in the shell plate.
3) The size of fillet welds L as indicated, shall be equal to the smaller of t or td but not be less than 6 mm.
4) The threaded depth a shall not be less than diameter of screw or stud.

E. Covers for Inspection Openings and Manholes

E 100 General
101 The rules apply to flat circular and oval covers formed from steel plate and of the internal type, as shown
in Fig.14.
102

The thickness shall not be less than:

Cp- + c
t = b ---------10 t

(mm)

minimum 15 mm for manhole covers

e = breadth of jointing surface, see Fig.14

a, b = longer and shorter half-axes in mm, as indicated in Fig.14
C = a coefficient given in Table E1.

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Fig. 14
Covers

Table E1 Coefficient C
a
--1
1.1
1.2
b
C
1.24 1.41 1.57

1.3

1.4

1.5

1.69

1.82

1.93

2.27

2.60

2.79

F. Heat Exchanger Tubes

F 100 General
101

The wall thickness of straight tubes shall not be less than:

pd
t = -------------------- + c
20 t + p

or according to Table F1 whichever is greatest

d = outside diameter
c = corrosion allowance.
102 The corrosion allowance shall be as follows, unless the conditions of service make a different allowance
more suitable:
- Carbon and low-alloy steels: c = 1 mm
- Copper and copper alloys:
c = 0.3 mm
- Stainless austenitic steels:
c = 0 mm

103 If the tubes are ordered with a minus tolerance, the minimum thickness according to the formula shall be
increased by the necessary amount.
Where tubes are bent, the thickness of the thinnest part of the tubes shall not be less than the calculated thickness,
unless it can be demonstrated that the method of bending results in no decrease in strength at the bend as
compared with the straight tube.
In connection with any new method of bending, the manufacturer shall prove that this condition is satisfied.
Table F1 Nominal wall thickness
Outside
diameter mm
10
12
16
19
25
32
38
51

Minimum nominal wall thickness, mm

Copper and copper
Austenitic
Carbon steel
alloys
steel
0.7
0.7
0.9
0.9
0.9
1.2
0.9
1.2
1.5
0.9
1.5
2.0
1.2
1.5
2.0
1.5
2.0
2.0
1.5
2.0
2.0
2.0

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SECTION 5 PARTICULAR DESIGN REQUIREMENTS FOR BOILERS

A. Shells and Headers of Cylindrical Sections
A 100 Scantlings
101 The thickness of cylindrical shells shall be determined in accordance with the requirements in Sec.4.
For drums and headers in watertube boilers, the joint efficiency factor e shall be taken as the efficiency of the
ligaments between tube holes, in accordance with 200.
For shell boilers where set-in end plates are used, see Fig.8, the thickness of the shell plates within a distance
250 mm from the end plate is, however, not to be less than determined from the following formula:
pR
t 1 = --------------------------------- + c
10 t X 0.5p

R
X
t2

=
=
=
=

inside radius of shell or shell section

0.8 for t2/(t1 c) 1.4
1.0 for t2/(t1 c) 1.0
calculated thickness of end plate at the junction with the shell without corrosion allowance.

For intermediate values of t2/(t1 c) the values of X shall be found by linear interpolation.
The required shell thickness shall be obtained through an iteration process.
102

The nominal thickness of a boiler shell shall not be less than 7 mm.

Fig. 1
Parallel drilling

A 200 Efficiency of ligaments between tube holes

201

When drilling holes parallel to the axis, the efficiency e of ligament is given by:
sd
e = ----------- for eqal spacing for holes, and
s
s 1 + s 2 2d
e = ---------------------------- for irregular spacing of holes
s1 + s2

d
s
s1
s2

= mean effective diameter of the tube holes, after allowing for any counter boring or recessing, in mm.
For compensating effect of tube stubs, see 301
= pitch of tube holes in mm
= the shorter of any two adjacent pitches, in mm
= the longer of any two adjacent pitches, in mm.

For irregular spacing, the value of the double pitch (s1 + s2), giving the lowest efficiency, shall be applied. The
value of one pitch is in no case to be taken as being greater than twice the other pitch.

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Fig. 2
Diagonal drilling

202 Provided that the spacing between holes, in the case of a circumferential drilling, gives an efficiency of
ligaments, calculated according to the formulae in 201, less than one half of the efficiency of longitudinal
ligaments, twice the efficiency of circumferential ligaments shall be used. The pitch of tubes for circumferential
drilling shall be measured along the median line.

Fig. 3
Ligament Efficiencies diagonal drilling

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Fig. 4
Regularly staggered spacing

203 When drilling holes along a diagonal line, the efficiency of corresponding ligaments is given in Fig.3
with the ratio
b
2a d
--- as abcissa and --------------- as parameter
a
2a

The figure applies to regular spacing of tube holes arranged along a straight line or in a saw-tooth pattern as
shown in
Fig.2.
The data given in Fig.3 are based on the following formula:
2
e = -------------------------------------------------------------2
2
A + B + ( A B ) + 4C
2

cos + 1
= ---------------------------------d cos
2 1 ----------------

2
1
cos
= --- 1 d--------------- ( sin + 1 )
2
a

sin cos
= ---------------------------------cos -

2 1d
--------------

a
b

= diagonal pitch of holes projected on longitudinal axis, in mm

= diagonal pitch of holes projected circumferentially, in mm
= angle of centre line of cylinder to centre line of diagonal holes.

For d, see 201.

In case of a regularly staggered spacing of tube holes, i.e. the centres are arranged on diagonal and
circumferential lines as well as on lines parallel to the longitudinal axis, as shown in Fig.4, the smallest value
e of all ligament efficiencies (longitudinally, circumferentially and diagonally) is given in Fig.5 by the ratio:
b--on the abcissa, and the ratio
a
2a d
--------------- or d/a used as a parameter
2a

A 300 Compensating effect of tube stubs

301 Where a drum or header is drilled for tube stubs fitted by strength welding, the effective diameter d of
holes shall be taken as:
A
d a ---t

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The compensating area A shall be measured in a plane through the axis of the tube stub parallel to the
longitudinal axis of the drum or header (see Fig.6), and shall be calculated as follows:
For a set-through stub:
A = 2 (ta tm) (t + h) + A1 + A2 (mm2)
For a set-on stub:
A = 2 (ta tm) h + A2 (mm2)
A1 = sectional area of the stub projecting inside the shell within the distance h from the inner surface of the
shell (maximum 2 ta h), in mm2
A2 = sectional area of fillet welds attaching the stub to inside and outside of shell, in mm2
t
= plate thickness, in mm
ta = actual wall thickness of tube stub minus corrosion allowance, in mm
tm = calculated minimum wall thickness of tube stub according to G, with c = 0, in mm
h = 0.8 ( d i + t a )t a
di = inner diameter of tube stub, in mm.
Where the material of the tube stub has a nominal design stress lower than that of the shell, the compensating
sectional area of the stub shall be multiplied by the ratio:
t of stub
------------------------ t of shell
No credit will be given for the additional strength of a material having a nominal design stress greater than that
of the shell.
302 The minimum pitch for roller-expanded boiler tubes, measured along the median line, shall not be less
than
1.25 d + 10 (mm)
d is as given in 201.
303 If more than three stay bolts pierce a cylindrical shell in the same horizontal line, the efficiency in this
line shall not be lower than that of the longitudinal weld, otherwise the stays shall be arranged in zigzag.

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Fig. 5
Ligament efficiencies staggered drilling

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Fig. 6
Stub connections

B. Headers of Rectangular or Irregular Sections

B 100 Headers of rectangular section
101 To determine the thickness, it is necessary to consider the thickness required in the centre line of the
sides, at all lines of holes and at the corners. The required thickness is the greater of these values.
102

The thickness t of the header shall not be less than:

pn
0.45pY
t = -------------- + ------------------- + c (mm)
20 t e
t e1

e = efficiency of ligaments referring to the membrane stresses as given in 103

e1 = efficiency of ligaments referring to the bending stresses as given in 103.
Y is a coefficient used in determining the required wall thickness of the side with internal width 2 m and is (the
numerical value shall be used):
at the centre line:
3

1 m +n m
Y = --- ------------------- ------3 m+n
2

at a line of holes parallel to the longitudinal axis of the header:

3

1 m +n m b
Y = --- ------------------- -----------------2
3 m+n

for checking the section A-A, where holes are arranged diagonally and situated equidistantly from the
centre line of the wall, as indicated in Fig.7d:
3

1 m +n m
Y = --- ------------------- ------- cos
3 m + n
2

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at the corners:
3

1 m +n
Y = --- ------------------3 m+n

2m = internal width in mm of header parallel with the side under consideration. See Fig.7
2n = internal width in mm of header measured at right angles to the side under consideration. See Fig.7
= angle as indicated in Fig.7.
103 When drilling holes parallel to the longitudinal axis the efficiency of ligaments is given by:
when considering membrane stresses:
de = s---------s

for d < 0.6 m when considering bending stresses:

s de 1 = ---------s

for d 0.6 m when considering bending stresses:

0.6me 1 = s-------------------s

In the case of considering the section A-A, where the holes are arranged diagonally, as indicated in Fig.7d, s1
to be used instead of s.
In Fig.7 the symbols used are as follows:
b
s
s1

d
r

=
=
=
=
=
=

distance from the row of holes under consideration to the centre line of the side, in mm
pitch of holes, in mm
diagonal pitch of holes, in mm
angle as indicated in the figure
diameter of holes, in mm
radius of curvature at corners, in mm.

Fig. 7
Hole arrangement in header

104 In the case of oval holes, the value of d used in the formulae for e and e1 shall be the inside dimension
of the hole, measured parallel to the longitudinal axis of the header. For evaluation of the limiting value of d in

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103 the inside dimension of the hole measured perpendicularly to the longitudinal axis of the header shall be
used (d1 in Fig.7b).
105

For corners and inspection openings the following shall be satisfied:

1
r --- t
3

t is the mean of the nominal thicknesses of the two sides.

r is in no case to be less than 8 mm.
106 At locally machined openings, the thickness may be 2 mm less than given by the above rules, but is
generally not to be less than 8 mm.
B 200 Headers of irregular form
201 Where the thickness of headers of irregular form, for instance corrugated headers, has not been calculated
with sufficient accuracy, and the empirical data available are insufficient, hydraulic deformation tests shall be
carried out.
Information on testing method and results obtained shall be submitted for approval.

C. Dished Ends
C 100 Dished ends subject to pressure on the concave side
101 The thickness of dished ends without stays concave to the pressure side shall be determined in
accordance with the requirements in Sec.4 C500.
102 The minimum thickness of dished ends forming the upper part of vertical boilers, subject to pressure on
the concave side and supported by a central uptake, shall be determined from the following formula:
pR
t = ----------i- + c
13 t

Ri = inside radius of curvature.

Ri shall not be greater than the external diameter of the cylinder to which it is attached.
The inside knuckle radius of the arc joining the cylindrical flange to the spherical surface of the end shall not
be less than four times the thickness of the end plate, and in no case less than 65 mm.
The inside radius of curvature of flange to uptake shall not be less than twice the thickness of the end plate, and
in no case less than 25 mm.
C 200 Dished ends subject to pressure on the convex side
201 The thickness of dished ends subject to pressure on the convex side shall be determined in accordance
with the requirements in Sec.4 C504, except for dished ends for vertical boiler fireboxes.
The thickness of dished ends for vertical boiler fireboxes shall be determined in accordance with the
requirements in E600.

D. Flat Plates Supported by Stays

D 100 General
101 Where a flat plate is flanged for connection to other parts, the inside radius of flanging shall not be less
than:
for connection with the boiler shell: twice the thickness of the plate with a minimum of 38 mm
for connection with a furnace or with the shell of fireboxes: the thickness of the plate with a minimum of
25 mm.
102 Where the flange curvature is a point of support, this shall be taken at the commencement of curvature,
or at a line 3.5 times the thickness of the plate measured from outside of the plate, whichever is nearer to the
flange.
Where a flat plate is welded directly to a shell, the point of support shall be taken at the inside of the shell.
103 The length of the cylindrical part of the flanged end plate shall not be less than 2.5 times the thickness
of the end plate.
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104 Where un-flanged flat plates are connected to a cylindrical shell by welding, the weld shall be a full
penetration weld, normally welded from both sides. The inside fillet weld shall have concave profile and shall
merge into the plate without undercutting or abrupt irregularity. The minimum throat thickness shall be as given
in Fig.8.
The inside fillet weld may only be omitted for small boilers not accessible for welding from the inside.
105 For un-flanged flat end plates the ratio of end plate thickness to shell thickness shall not exceed 2.0.
Where inside fillet weld is omitted the ratio shall not exceed 1.4.

Fig. 8
Attachment of un-flanged flat end plates or tube plates to shell

106 The spacing of tube holes shall be such that the minimum width of any ligament between tube holes is
not less than:
for expanded tubes:
0.125 d + 12.5
for welded tubes:
0.125 d + 9 for gas entry temperatures > 800C
0.125 d + 7 for gas entry temperatures 800C
d = diameter of tube hole.
Guidance note 1:
The shape of internal fillet weld shall be concave. The ratio of leg lengths l 1 / l 2 should be approximately 4 : 3. The
minimum throat thickness, a, shall be related to the shell thickness as follows:
Shell thickness (mm)
t < 12
12 t 16
16 < t

Minimum throat thickness

(mm)
4.5
5
6
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

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Guidance note 2:
For non-destructive testing, see Sec.8 D101
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Guidance note 3:
The use of minimum angle should be associated with a maximum radius r of 10 mm. Conversely, the maximum angle
should be associated with minimum radius r of 5 mm.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

D 200 Scantlings
201 The thickness of stayed flat plates shall not be less than the greater of the values determined by the
following formulae:
p
t = K C d e ----------- + c
10 t

(1)

p
t = y C b ----------- + c
10 t

(2)

or

K
C
de
a
b
y
202

=
=
=
=
=
=

a factor depending on number of supports, see 202

a factor depending on the method of support, see 203
the diameter of the largest circle passing through points of support, see 205
the major dimension of elliptical or rectangular unsupported areas
the minor dimension of elliptical or rectangular unsupported areas
a factor depending on the ratio b/a, see 206.
The value of the factor K is:

for four or more evenly distributed points of support: 1.0

for three points of support: 1.1
for annular areas, i.e. areas supported only by cylindrical shell and uptake, or cylindrical shell and lower
part of fire boxes (2 points of support): 1.56
203 The value of the factor C shall be as given in Table D1.
Where different methods of support are used, the factor C shall be taken as the mean of the values for the
respective methods adopted.
204 For parts supported by bar stays or stay tubes, de is the diameter of the largest circle passing through not
less than three points of support. The three points of support considered shall not be situated on the same side
of any diameter of this circle.
205 For parts situated near the edge of the plate or around a furnace, de is the diameter of the circle tangent
to the support at the cylindrical shell or furnace (see 102) and passing through the centres of at least two other
supports.
The three points of support considered shall not be situated on the same side of any diameter of this circle.
When, in addition to the above main circle, a sub-circle of diameter equal to 0.6 times that of the main circle
can be drawn passing through two points of support and such that its centre lies outside the main circle, the
thickness shall be determined from formula (2) using b as indicated in Fig.9 and y determined from the table
in 206.

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Fig. 9
Use of sub-circles and rectangular areas

206 The ratio y takes into account the increase in stress for rectangular or elliptical areas, compared with
circular areas as a function of the ratio b/a according to Table D2 or Fig.10.
D 300 Stay tubes and tube plates within tube nests
301 Stay tubes are tubes welded into the tube plates in accordance with Fig.12, having a weld depth equal to
the tube thickness + 3 mm.
These stay tubes are not required within tube nests except when the tube nests comprise tubes which are
expanded only. Stay tubes are however to be used in the boundary rows in sufficient numbers to carry the flat
plate loadings outside the tube area.
For loadings on stay tubes and required area, see F.

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Pt.4 Ch.7 Sec.5 Page 50

Table D1 Value of factor C

Type of support
Isolated plain bar stays or stay tubes, Fig.11 (a) and Fig.12
Note: An example of an isolated plain bar stay is given in Fig.9 b

C
0.45

Non-isolated plain bar stays or stay tubes

0.39

Bar stays welded to reinforced plate or plate fitted with washer, Fig.11 (b) and (c)

0.35

Un-stayed tube bank with plain tubes welded at both ends, Fig.13
Flat end plate or tube plate attachment to cylindrical shell

0.30

Flanged end plate

0.32

Set-in end plate with internal fillet weld. End plate thickness divided by shell plate thickness (Fig.8):
1.4
> 1.4 1.6
> 1.6 1.8
> 1.8

0.33
0.36
0.39
0.42

Set in end plate with no internal fillet weld

Flat end plate attachment to furnace and uptake

0.45

With internal fillet weld:

Plain furnace
Corrugated furnace with corrugations less than 50 mm deep
Corrugated furnace with corrugations 50 mm deep or greater:
length > 4 m
length 4 m
Bowling hoop furnace

0.30
0.32
0.37
0.34
0.32

With no internal fillet weld

0.45

Top plates of fireboxes supported by continuous welded girders

0.51

Table D2 Value of factor y

Ratio b/a
1.0
0.75
0.5
0.25
0.1

y
Rectangular plates
1.10
1.26
1.40
1.52
1.56

Elliptical plates
1.0
1.15
1.30
1.43

Intermediate values shall be interpolated.

Fig. 10
Determination of factor y

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Pt.4 Ch.7 Sec.5 Page 51

302 The thickness of tube plates within tube nests with welded plain tubes, Fig.13, shall not be less than
calculated according to formula (2) in 201 using b as the pitch of the plain tubes and y = 1.56. The thickness
shall not be less than 10 mm.
303 For tube plates with expanded tubes and stay tubes the thickness shall be calculated according to 201 and
shall not be less than:
12.5 mm when d 50 mm
14.0 mm when d > 50 mm
d = diameter of tube hole.
D 400 Vertical tube plates in vertical boilers
401 Where vertical boilers have a nest or nests of horizontal tubes, so that the tube plates are in direct tension,
due to the vertical load on the boiler ends or to their acting as horizontal ties across the shell, the thickness of
tube plates and the spacing of the tubes shall be such that the section of metal, taking the load, is sufficient to
keep the stress within that allowed for shell plates. The thickness shall not be less than:
4pRg
t = ------------------------------- + c
10 ( g d )R m

R
g
d

= radial distance, from centre of the outer row of tube holes to axis of the shell, in mm
= vertical pitch, of tubes in outer rows, in mm
= diameter of tube holes, in mm.

Every second tube in the outer vertical rows of tubes shall be a stay tube.
402 The arrangement of stay tubes in the nests shall be such that the thickness of the tube plates meets the
requirements in 200.

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Fig. 11
Stay connections
Guidance note 1:
The ends of the tube shall be dressed flush with the welds when exposed to flame or temperature exceeding 600C.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Guidance note 2:
Tubes should be lightly expanded before and after welding.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

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Fig. 12
Typical attachment of stay tubes
Guidance note 3:
Tubes should be lightly expanded before and after welding.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Guidance note 4:
For tubes exposed to flame or gas temperatures exceeding 600C the ends should be dressed flush with the welds.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

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Fig. 13
Typical attachment of welded plain tubes

D 500 Firebox plates under compression

501 The thickness of firebox tube plates under compression due to pressure on the crown plate shall not be
less than:
pls t = --------------------------1950 ( s d )

l
s
d

= length of firebox measured on the inside between tube plate and back plate
= distance between centres of tube holes
= internal diameter of plain tubes.

The thickness is, however, not to be less than determined by the formulae in 200.
D 600 Openings in flat plates
601 The maximum diameter of an un-reinforced opening in a flat plate shall be determined from the
following formula:
2

ta

d = 8 t a 1.5 ------ 1.0

2

ta
t

= actual thickness of flat plate minus corrosion allowance

= thickness of flat plate calculated from the formula in 201 for the part of the plate under consideration with
c = 0.

602 Openings larger than those permitted according to 601 shall be reinforced.
Compensation is adequate when the area y is equal to or greater than the area x requiring compensation. See
Fig.14.
603 The material in the branch, or in the pad reinforcement, is normally to have the same mechanical
properties as that in the flat plate. In no case is the material to have a nominal design stress less than 0.6 times
the nominal design stress of the flat plate.
Where material with a lower nominal design stress than that of the flat plate is used for reinforcement, its
effective area shall be reduced in the ratio of the nominal design stresses at design temperature.
No reduction will be accepted for material with a nominal design stress greater than that of the shell.

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Fig. 14
Compensation of openings in flat plates

x
y
ta , t
t ba
tb
D
C

=
=
=
=
=
=
=

the area requiring compensation, marked by xxxxx

the compensating area, marked by ///////
as defined in 600
the actual thickness of the branch minus corrosion allowance
the thickness of the branch calculated from the formula, in G101
the greater of the two values d/2 or (ta + 75) mm
the smaller of the two values 2.5 ta or (2.5 tba + tr).

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Fig. 15
Required thickness by calculation against elastic instability

Amended July 2013, see page 3

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E. Furnaces and Fireboxes of Cylindrical Form, Uptakes, Cross-tubes and Ogee Rings
E 100 Plain furnaces
101 The design of a plain furnace shall be checked to ensure that neither membrane yield nor elastic
instability occur.
102 For calculation against membrane yield, the design pressure shall not exceed that determined by the
following formula:
R et 2 ( t c )
1 + 0.1 D L
p = 10 -------- ------------------ ----------------------------------------------------------------S1
D
D
u
1 + 0.03 ---------- --------------------------tc 1+5 DL

L
D
u
S1

= the length of the furnace or distance between two effective points of support, see 301 and 401
= mean diameter of furnace
= percentage of out-of-roundness of the furnace. The value of u to be used in the formula shall be taken
as 1.5
= factor of safety.

103 For calculation against elastic instability, the design pressure shall not exceed that determined by the
following formula:
c 3
tc
t-----------------
Do
Do
E
p = 20 ------- ----------------------------------------------------- + ---------------------SK
2
2 2 3 ( 1 2 )
(n 1)[1 + (n z) ]
2
2
2n 1
-
n 1 + -------------------------2

( n z ) + 1

E
n

= modulus of elasticity in N/mm2 at design material temperatures, see table in 107

= integral number of waves. n 2 and n > z

0.5 D
= coefficient = --------------------oL

= Poisson's ratio
SK = safety factor
Do = outside diameter.
L is defined in 102.
n shall be chosen to minimise p.
n may be estimated by the following formula:
1
---

Do 2 Do 4
n = 1.63 ------ --------- L tc

For usual dimension of furnaces, p or t c may be determined from Fig.15.

104 The nominal thickness of plain furnaces shall not be less than 10 mm for horizontal furnaces and 8 mm
for vertical furnaces.
The nominal thickness shall not exceed 22 mm.
105

For ovality the percentage of out-of-roundness is:

200 ( D max D min )
u = --------------------------------------------D max + D min

Dmax =the maximum mean diameter of the furnace

Dmin =the minimum mean diameter of the furnace.
For local flat parts the percentage of out-of-roundness is:

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4a
u = ------ 100
Do

See Fig.16

Fig. 16
Local flat parts

106

The following values shall be used for the factor of safety:

against membrane yield:

horizontal furnaces: S1 = 2.75
vertical furnaces: S1 = 2.5
against elastic instability: SK = 4.5.
107

Values of E for carbon and carbon-manganese steels may be obtained from the following table:

Design material temperature (C)

E N/mm2 105

250
1.95

300
1.91

350
1.86

400
1.81

For intermediate temperatures linear interpolation shall be used.

108 Plain furnaces shall not exceed 3 m in length. If corrugations are used to provide flexibility, at least onethird of the furnace length shall be corrugated.
E 200 Corrugated furnaces
201 The design of corrugated furnaces shall be checked to ensure that membrane yield do not occur.
Check against elastic instability is in general not required for usual form of corrugations.
202 The minimum thickness of corrugated furnaces after corrugation may be determined from the following
formula:
p Do
t = ------------+c
K

Do = outside diameter at bottom of corrugations

K = 1060 for Fox, Morrison and Deighton corrugations.
203 Consideration will be given to a more accurate calculation taking depth, pitch, cross sectional area and
second moment of area of the corrugations into account.
The calculation may be carried out according to a recognised code. The factors of safety are in general not to
be less than that given in 106.
204

The nominal thickness shall not exceed 22 mm and shall not be less than 8 mm.

E 300 Stiffeners
301 Stiffening rings considered to give effective points of support, shall have a second moment of area not
less than given by the following formula:

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pD L
I x = -----------------------7
1.33 10

L and D are defined in 102.

302 The thickness of stiffening rings shall be kept to the minimum required. For limiting dimensions see
Fig.17. Stiffening rings shall extend completely around the circumference of the furnace, and shall be welded
to the furnace with full penetration weld.

Fig. 17
Furnace stiffeners

E 400 Fireboxes for vertical boilers

401 The required thickness of plain fireboxes in vertical boilers is given in 100.
Where the firebox is tapered, the outside diameter to be used in the calculation is mean of that at the top and
that at the bottom where it is substantially supported from flange, ring or row of stays.
The length of the firebox shall be taken as the length between points of substantial support, as indicated in
Fig.18.
A circumferential row of stays connecting the firebox to the shell is considered as a substantial support, if the
diameter of the stays is not less than 22 mm or twice the thickness of the firebox, whichever is the greater, and
the pitch of the stays at the firebox does not exceed 14 times the wall thickness of the firebox.
E 500 Openings in furnaces
501

Reinforcement of openings in cylindrical furnaces shall satisfy the requirements in Sec.4 D except that:

pad type reinforcement is not permitted

the required reinforcement may be based on the calculated thickness of the furnace assuming an internal
pressure equal to the design pressure of the boiler.

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Fig. 18
Support details

E 600 Dished ends for vertical boiler fireboxes

601 The internal radius, Ri, of the spherical part of the dished end shall not be greater than the external
diameter of the cylindrical firebox.
The inside radius of the flange to the cylindrical firebox shall not be less than four times the thickness of the
dished end with a minimum of 65 mm.
602 The minimum thickness of dished ends for vertical boiler fireboxes subjected to pressure on the convex
side and without support from stays of any kind, shall be determined from the following formula:
pR
t = ----------i + c
6 t

Ri is defined in 601.
The thickness shall not be less than the thickness of the firebox.
603 The minimum thickness of dished ends for vertical boiler fireboxes subjected to pressure on the convex
side and supported by a central uptake shall be determined from the following formula:
pR
t = ----------i- + c
10 t

Ri is defined in 601.
E 700 Internal uptakes in vertical boilers
701 The thickness of internal uptakes in vertical boilers shall not be less than determined by the formulae in
100.
The corrosion allowance, c, shall be 4 mm.
The safety factors may be taken as follows:
against membrane yield: S = 2.0
against elastic instability: SK = 3.5.

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E 800 Cross-tubes in vertical boilers

801 For vertical boilers with cross-tubes passing through the firebox shell, the minimum thickness of these
tubes shall not be less than:
pd
t = --------- + 6.5
450

= internal diameter of cross-tube.

The thickness is, however, not to be less than 9.5 mm.

802

The internal diameter of cross-tubes shall not exceed 300 mm.

E 900 Connection of firebox to shell in vertical boilers

901 Where the bottom of the firebox is connected to the shell by means of an ogee ring, and the ring sustains
the whole vertical load on the firebox, the thickness of the ring shall not be less than:
t =

p Di ( Di F )
------------------------------- + c
10000

Di = internal diameter of boiler shell

F = outside diameter of the firebox where it joins the ogee ring.
Where the bottom of the furnace is connected to the shell by an U-shaped ring, see Fig.19, the thickness shall
be at least 20% greater than determined by the above formula.

Fig. 19
Attachment of furnaces to shells for vertical boilers

F. Stays
F 100 Stay tubes and bar stays
101

The minimum required sectional area shall be determined from the following formula:
Fp
f = ----------10 t

t = 70 N/mm2 for stay tubes

R

m
= -------

5.9
Rm
= ------5.7

N/mm for stay bolts

N/mm for longitudinal stays

= area supported by the stay with reduction of area of holes embraced.

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For a stay tube or bar stay, the area to be supported shall be the area enclosed by the lines bisecting at right
angles the lines joining the stay and the adjacent points of support, less the area of any tubes or stays embraced,
see Fig.20.
The calculation may be carried out in the un-corroded condition and not taking minus tolerances into account.

Fig. 20
Loaded area on stays

102 For top and sides of combustion chambers, the distance between stays and the commencement of
curvature of tube plates and back plates at their flanges shall not be less than the distance between rows of stays.
103

For stays on furnaces for vertical boilers, see E400.

F 200 Girders for flat firebox and reversal chambers' top plates
201 The thickness of girders of rectangular section supporting flat top plates of combustion chambers shall
not be less than:
2

p l bt = ---------------2
15 t h

l
b
h

= length of the girder between supports, i.e. measured on the inside between tube plate and back chamber
plate or between side plates, according to the method of support
= distance between girders measured from centre to centre
= depth of girder.

The above formula is applicable to girders welded continuously to the top plate by full penetration weld. For
the depth h, a value not exceeding 8 t shall be inserted in the formula.

G. Tubes
G 100 Boiler tubes subjected to internal pressure
101

The wall thickness of straight tubes shall not be less than:

p d + c (mm)
t = -------------------20 t + p

d
c

= outside diameter in mm
= corrosion allowance.

102 The corrosion allowance shall be 1 mm, except for tubes used in boilers with open feed water systems
where the corrosion allowance shall be 2.5 mm.

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103 The thickness for boiler, superheater, reheater and economiser tubes, however, is in no case to be less
than the values given in Table G1.
Table G1 Minimum thickness of tubes
Outside diameter of tube (mm)
d 38
38 < d 51
51 < d 70
70 < d 76
76 < d 95
95 < d 102
102 < d 127

Minimum thickness (mm)

1.75
2.16
2.40
2.60
3.05
3.28
3.50

104 If the tubes are ordered with a minus tolerance, the minimum thickness according to the formula and the
table in 103 shall be increased by the necessary amount.
Where tubes are bent, the thickness of the thinnest part of the tubes shall not be less than the calculated
thickness, unless it can be demonstrated that the method of bending results in no decrease in strength at the
bend as compared with the straight tube. In connection with any new method of bending, the manufacturer shall
prove that this condition is satisfied.
105 Tubes strength welded to tube plates will be specially considered with respect to sufficient thickness for
sound welding.
106 The minimum thickness of downcomer tubes and pipes, which form an integral part of the boiler and
which are not exposed to combustion gases, shall comply with Ch.6 Sec.6 of the Rules for Classification of
Ships.
G 200 Boiler tubes subjected to external pressure
201

The wall thickness of tubes with outside diameter 100 mm and less shall not be less than:
pd
t = ----------- + c (mm)
16 t

= outside diameter of tube in mm.

202 For corrosion allowance shall be as given in 102. For additional thickness due to minus tolerances and
bending, see 104.
203

The nominal thickness of the tubes is, however, in no case to be less than given in Table G2.

Table G2 Nominal thickness of tubes

Outside
diameter of tube
2.9
(mm)
51
57
63.5
70
76.1
82.5
88.9

11.0
10.0
9.0
8.0

Nominal thickness of tube (mm)

3.2
3.6
4.0
Design pressure (bar)
15.0
21.0
13.5
18.0
22.0
12.5
16.0
21.0
11.0
15.0
19.5
10.0
13.5
17.5
9.0
12.5
16.0
8.5
11.5
15.0

4.5

21.0
19.5
18.0

For stay tubes, see F.

H. Access and Inspection Openings

H 100 General
101 All drums, headers and other large components for boilers shall be provided with openings, adequate in
number and size, to allow access for fabrication, cleaning and internal inspection. See also Sec.3 A200.
102 Shell boilers with a shell diameter of 1400 mm or greater shall be designed to permit entry of a person
and shall be provided with a manhole for this purpose.
Also boilers with a shell diameter less than 1400 mm which are capable of being entered by a person shall be
provided with a manhole. Otherwise boilers with a shell diameter between 800 mm and 1400 mm shall be
provided with a headhole as a minimum requirement.
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103 Special consideration shall be taken to the accessibility for inspection of welded connections subjected
to high bending stresses, e.g. corner welds between flat plates and cylindrical shells or furnaces and attachment
welds of stays.
In case of circumferential corner welds not more than one single length equal to half the shell diameter or a
number of lengths totalling one shell diameter are, in general, to be hidden by tube nests.
104

In all cases it shall be possible to inspect the bottom of the shell and the longitudinal welds.

105 Vertical boilers with large cross tubes shall have a sight hole in the shell opposite to one end of each tube
to permit the tubes to be examined and cleaned.
106 Fired boilers including exhaust gas heated boilers/economisers shall be fitted with adequate number and
size of openings and facilitates for internal inspection and cleaning of the gas side.

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SECTION 6 MOUNTINGS AND FITTINGS

A. General
A 100 Construction
101 Construction and arrangement of valves and cocks shall be such that it can be seen without difficulty
whether they are open or shut.
All valves shall be closed with a right-hand motion (clockwise rotation).
102 Valves exceeding 50 mm in diameter shall be fitted with outside screws, and the covers shall be secured
by bolts or studs.
103 Where mountings are secured by studs, the studs shall have full thread holding in the plate for a length
of a least one diameter. Holes for studs shall not penetrate the whole thickness of the plate. For welded
standpipes, see Sec.4 D.

B. Safety Valves
B 100 Valves on boilers and steam-heated steam generators
101 Boilers and steam-heated steam generators shall have not less than two safety valves with a total
discharge capacity equal to or greater than the total design evaporation in normal and shut-off condition.
102 Superheaters shall have at least one safety valve on the outlet side. Where a boiler is fitted with an
integral superheater without an intervening stop valve, the safety valve(s) on the superheater may be considered
as boiler safety valve(s). The safety valves shall be so proportioned and positioned that when relieving,
sufficient steam is forced through the superheater to prevent damage to the heater. At least 75% of the required
safety-valve capacity shall be placed on the boiler. Where a superheater, reheater or economiser is fitted with
a valve between one of these and the boiler, the unit shall have appropriate safety valves. Such safety valves
shall not be regarded as safety valves for the boiler.
103 All the safety valves on each boiler or steam-heated steam generator may be fitted in one chest, which
shall be separate from any other valve chest. The chest shall be connected directly to the shell by a strong and
stiff neck. Safety valve chests shall have drain pipes leading the drain to the bilge or to a tank, clear of the boiler.
No valves or cocks shall be fitted in these drain pipes.
104 The design of the safety valves shall be such that they cannot unintentionally be loaded beyond the set
pressure, and in the event of fracture cannot lift out of their seats.
For safety valves operating at pressures below 17.5 bar, it should be possible for the valves to be turned round
on their seats.
105 Easing gear shall be provided for lifting the safety valves on a boiler or steam-heated steam generator at
the same time and shall be operable from the boiler or engine room platforms.
The superheater safety valve(s) are also to be provided with easing gear, but this may be operable only from an
accessible place in the boiler room, free from steam danger.
106 The aggregate area of the orifices through the seatings of the safety valves (for full lift valves, the net
area through seats after deducting the guides and other obstructions, when the valves are fully lifted) on each
boiler shall not be less than:
For saturated steam:
2
KE
A 1 = ------------ (mm )
p+1

For superheated steam:

A2 = A1 (1 + 0.0018 TD) (mm2)
p
E
TD
K

=
=
=
=
=
=

design pressure of the boiler, in bar

designed evaporation, in kg/hour
difference between the temperature of superheated and saturated steam, in degrees Centigrade
21 for valves of the ordinary type having a lift of at least 1/24 of the internal diameter of the seating
14 for valves of high-lift type having a lift of at least 1/16 of the internal diameter of the seating
10.5 for valves of improved high-lift type having a lift of at least 1/12 of the internal diameter of the
seating
= 5.25 after special approval for valves of full-lift type having a lift of at least 1/4 of the internal diameter
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of the seating.
If a discharge capacity test, carried out in presence of the surveyor, proves that the capacity exceeds that
indicated by the constant K, consideration will be given to the use of a lower value of K based on up to 90% of
the measured capacity.
107 Notwithstanding the requirements in 106, the safety valves fitted to any boiler (and integral superheater)
shall be capable of discharging all the steam which can be generated without causing a pressure rise of more
than 10% in excess of the design pressure.
108 Steam-heated steam generators shall be protected from excessive pressure resulting from failure of the
high-pressure heating tubes.
For this purpose, it may be required that the area of the safety valves be somewhat greater than that calculated
in the formula in 106, unless other protective devices are provided to control the supply of steam to the heating
tubes.
109 Safety-valves of ordinary type with seats of less than 38 mm inside diameter shall not be used. For full
lift safety valves the inside seat diameter shall not be less than 20 mm.
Where only one safety valve of ordinary type is fitted, the inside diameter of the valve seat shall not be less
than 50 mm.
110 For ordinary, high-lift and improved high-lift type safety valves, the waste-steam pipe and the passages
leading to it shall have a cross-sectional area at least 10% greater than the aggregate valve area calculated by
the formulae in 106.
The pipe design must take into consideration possible pressure build up in the line.
For full-lift safety valves, the cross-sectional area of the waste-steam pipe and passages shall not be less than
twice the aggregate-valve area where K = 5.25, and not less than three times the aggregate-valve area where K
has a lower value.
Two or more safety valves may have a common waste-steam pipe, the cross-sectional area of which shall not
be less than the total cross-sectional areas of the branch waste-steam tube. The valves shall be such that the
back pressure from one blowing valve will not influence the functioning of the other valve(s). Balanced valves
will satisfy this requirement.
111 Where boilers are not fitted with superheater, the safety valves shall be set to open at a pressure of not
more than 3% above the approved design pressure, and in no case at a pressure higher than:
the design pressure of the steam piping, or
the least sum of the design pressure of machinery connected to the boiler and the pressure drop in the piping
between this machinery and the boiler.
112 Where boilers are fitted with superheaters, the safety valves on the superheater shall be set to a pressure
not higher than:
the design pressure of the steam piping, or
the least sum of the design pressure of machinery connected to the boiler and the pressure drop in the piping
between this machinery and the boiler.
The safety valves on the boiler drum shall be set to a pressure not less than the superheater valve setting plus
0.35 bar plus the pressure drop through the superheater, when the boiler stop valves are closed and the
superheater safety valves are relieving at their rated capacity. In no case, however, are the safety valves to be
set to a pressure higher than 3% above the design pressure of the boiler.
113 Tests for accumulation of pressure shall be carried out. The boiler pressure shall not rise more than 10%
above the design pressure, when the boiler stop valve is closed under full firing conditions. The boiler shall be
fired to steady state, and then maintained for 5 minutes. This test is also applicable for exhaust heated smoke
tube boilers/economisers with steam space. During this test, no more feed water shall be supplied than is
necessary to maintain a safe working water level.
The accumulation tests may upon application, be omitted. Acceptance may be given when design calculations
of the discharge piping is found acceptable. If it is desired to omit the tests, this shall be stated on the boiler and
safety-valve plans when these are submitted for approval. Capacity tests of the safety valves will be required,
and the valve makers shall provide a certificate stating the rated capacity of the safety valves at the approved
pressure and temperature of the boilers. The boiler makers shall provide a certificate for each boiler stating its
maximum evaporation.
B 200 Valves on pressure vessels other than boilers and steam-heated steam generators
201 Pressure vessels or systems of pressure vessels (see 203) shall have safety valves, except as provided for
in 204.

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202 Pressure vessels intended to operate completely filled with liquid shall have a liquid relief valve unless
otherwise protected against overpressure.
203 Pressure vessels connected together in a system by piping of adequate capacity containing no valve that
can isolate any pressure vessel, may be considered as a system of pressure vessels for the application of safety
valves.
204 Where the compressor for air receivers is fitted with a safety valve, so arranged and adjusted that the
receivers cannot be subjected to pressures greater than the design pressure, such receivers need not be fitted
with safety valves if they are fitted with fusion plugs for quick release of pressure in case of fire. The melting
point of the fusion plug shall be approximately 100C.
The same regulation may apply to other pressure vessels, when the source of pressure is external to the pressure
vessel and is under such positive control that the pressure cannot exceed the design pressure at operating
temperature.
205 When a pressure vessel is fitted with heating coils, and fracture in the coils may increase the normal
pressure of the fluid in the pressure vessel, the relieving capacity of the safety valve shall be sufficient for the
case of fracture of one tube.
206 The total capacity of the safety valves, fitted to any pressure vessel or system of pressure vessels, shall
be sufficient to discharge the maximum quantity of fluid (liquid or gaseous) that can be generated or supplied
without occurrence of a rise in the pressure of more than 10% above the design pressure.
207

The safety valves shall be set to open at a pressure of not more than 3% above the design pressure.

208 The use of bursting discs or a combination of bursting discs and safety valves instead of safety valves is
subject to consideration in each separate case.
B 300 Protection of condensers against overpressure
301

Vacuum condensers shall be protected against overpressure by one or more of the following means:

safety valve(s) set to open at the design pressure

bursting disc(s) with bursting pressure equal to the design pressure
automatic shut-off of steam exhausting into the condenser (steam dump valve, exhaust steam from turbines)
if the pressure exceeds the design pressure. In addition, an independent high pressure alarm set to warn at
a pressure lower than the automatic shut-off pressure shall be fitted.
302 For atmospheric condensers, the air vent shall have a size that accommodates the maximum steam flow
assuming no cooling water supply to the condenser. Alternatively, one of the means given in 301 shall be
provided.

C. Stop Valves and Check Valves

C 100 Valves on boilers and steam-heated steam generators
101 Feed water intakes of main boilers or auxiliary boilers for essential services and each steam-heated steam
generator shall have a stop valve and a check valve.
102 The feed water stop valve shall be attached directly to the boiler or to the economiser, if this forms an
integral part of the boiler, and the valve neck shall be of sufficient length to clear valve of boiler lagging and
sheathing. Where the arrangements necessitate the use of standpipes between the boiler and the valve, these
pipes shall be as short as possible, and shall be of substantial thickness. The check valve shall be placed as near
the stop valve as practicable.
103 Feed water shall be discharged into the boiler in such a manner that it does not impinge directly on
surfaces exposed to hot gases.
104 Standpipes for feed inlets on water-tube boilers with design pressure exceeding 40 bar shall be provided with
a thermal sleeve to minimize thermal stresses. Similar arrangements shall be provided for desuperheater inlets and
outlets, if the desuperheated steam conditions results in a residual superheat of 60C or higher at any rating.
105 Each steam outlet, except for safety valves and superheater inlet and reheater inlet and outlet, shall be
fitted with a stop valve located as near to the boiler as practicable.
106 Where two or more boilers are connected to a common header or steam manifold, see Ch.6 Sec.5 G300
of the Rules for Classification of Ships.
C 200 Valves on pressure vessels other than boilers and steam-heated steam generators
201 Each pressure pipe shall be fitted with a stop valve located on the shell or as near to the pressure vessel
as practicable. In a system of pressure vessels (see B203), each system shall be fitted with stop valves.
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D. Blow-down Valves and Test Valves for Boiler Water

D 100 Blow-down valves
101 Each boiler shall be fitted with a blow-down valve secured directly to the shell.
Where this is not practicable for water-tube boilers, the valve may be placed immediately outside the boiler
casing with a heavy gauge steel pipe fitted between the boiler and the valve. The pipe and valve shall be
adequately supported, and the pipe, if exposed to furnace heat, shall be protected by brickwork or other heatresisting material, so arranged that the pipe may be inspected and shall not be constrained against expansion.
102 The internal diameter of the valve and its connections to the sea shall not be less than 25 mm and need
not exceed 38 mm.
103 Where blow-downs from two or more boilers are connected to a common discharge, see Ch.6 Sec.5 G300
of the Rules for Classification of Ships.
104 Blow-down cocks fitted with taper plugs shall be of the bolted cover type with separately packed glands,
and shall not be used with pressures over 13 bar.
D 200 Test valves
201 At least one valve for testing boiler water shall be fitted directly to each boiler in a convenient position.
It shall not be fitted on the water-gauge mountings or standpipes.

E. Gauges
E 100 Water gauges
101 Every boiler and steam heated steam generator designed to contain water at specified levels shall be fitted
with at least two independent means of indicating the water level, one of which shall be a glass gauge. The other
means shall be either an additional glass gauge or an approved equivalent device.
Water and steam drums exceeding 4 metres in length and placed athwartships shall have a glass water gauge
at or near each end of the drum.
102 The water level indicators shall be so located that the water level can be ascertained despite the
movement and inclination of the ship at sea.
103 The water gauges shall be readily accessible and positioned so that the water level is clearly visible.
Water gauges shall be so located that the lowest visible water level in the glass is at the lowest, safe-working
water level.
In the case of water-tube boilers, the glass water gauges shall be located so that water is just showing when the
water level in the steam drum is just above the top row of tubes when the boiler is cold (generally about 25 mm
above). The length of the glass water gauges shall be sufficient for verifying the water levels in case of alarm
and oil supply cut-off.
In boilers where all tubes are not entirely submerged in water when cold, the glass water gauges shall be placed
to the satisfaction of the surveyor, and in positions which have been found by experience to indicate
satisfactorily that the water content is sufficient for safe working.
The combustion chamber top of a cylindrical, horizontal boiler and the furnace crown of a vertical boiler shall
be clearly marked in a position adjacent to the glass water gauge. Water gauges shall be fitted with cocks or
valves at each end of the glass gauge. The cocks shall be accessible for closing from positions free from danger
in the event of the glass breaking.
104 Mountings for glass water gauges shall be fitted directly to the boiler plating or to stand pillars or
columns. Stand pillars and columns shall be bolted directly to the boiler shell, but they may also be connected
to the boiler by means of pipes. These pipes shall be fitted with terminal valves or cocks secured directly to the
boiler shell. Valves and cocks shall have fixed hand-wheels or handles, and shall be provided with means for
clearly indicating whether they are open or closed.
The upper ends of pipes, connecting the water gauge column to the boiler, shall be arranged such that there is
no pocket or bend where an accumulation of water can lodge. They shall not pass through the uptake if they
can be otherwise arranged. If, however, this condition cannot be complied with, they may pass through it by
means of a passage at least 50 mm clear of the pipe all round and open for ventilation at both ends.
E 200 Pressure gauges
201 Each boiler and superheater shall be provided with a separate steam-pressure gauge. The gauges shall be
placed where they can easily be seen. The highest permissible working pressure shall be marked off on the
pressure gauge in red.

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SECTION 7 INSTRUMENTATION AND AUTOMATION

A. General
A 100 Cross reference
101 General requirements for instrumentation and automation, see Ch.9. Additional requirements for gasfired boiler installations on liquefied gas carriers, see the Rules for Classification of Ships Pt.5 Ch.5 Sec.16
C100.
A 200 Oil burner control system
201 Before ignition of first burner, the boiler shall be purged to such an extent that air quantity through the
boiler is at least the greater of:
three times the volume of the flue gas (from the burner to the chimney), or
five times the furnace volume of the boiler.
This condition is considered as satisfied if the pre-purge is carried out for 15 s, the amount of air being equal
to the air flow corresponding to the nominal output of the burner.
Guidance note:
Post-purge after stopping the last burner is advised. This operation does not, however, replace the pre-purge.
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202 If air supply is continuous and above 20% of the air flow at full load, a new ignition after normal stop of
burner is acceptable, irrespective of the restrictions given in 201.
203 Ignition of burners is normally to take place at reduced fuel oil supply. Fuel oil shall not be supplied
before ignition device produces sufficient energy for safe ignition.
204 The safety device for flame monitoring shall ensure that the safety times given in Table A1, which
depend on the oil throughput of the oil burner, are complied with.
Table A1 Safety times
Oil throughput (kg/h)
up to 30
above 30
1)

Safety times (s) (maximum) 1)

At start-up
In operation
10
10
5
1

The safety time is the maximum permissible period of time during which the fuel oil may be
delivered into the combustion space without a flame burning.

205 Automatic restarting after an unsuccessful ignition shall not take place till after manual resetting. After
a flame failure during the operation, manual resetting locally on the control panel is required.
206 During stop of burners, including the pre-purge time before ignition, safe shut-off of fuel oil shall be
ensured. If the fuel oil will be under pressure during shut-off of burners, the shut-off device shall be duplicated.
A single shut-off device will be accepted if the burners are drained off.
207 The burner(s) shall be equipped with a safety device that shut off the fuel oil supply, when the burners
are retracted or swung out of position.

B. Boilers
B 100 Automatic control
101 When a combustion control system is fitted, the feed water control system shall have a control range at
least equal to that of the combustion control system.
During all normal load variations, the water level shall be kept within the dynamic and stationary limits for
reliable operation.
Guidance note:
On water tube boilers, the feed-water supply should preferably be continuous, because such boilers have a high rate
of evaporation in relation to their water content.
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102

When combustion control systems is fitted, the steam pressure shall be kept within limits appropriate to

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the steam consuming machinery over the entire control range.

During all normal operating conditions, the air/fuel ratio and the air distribution between burners shall be such
that a reliable and nearly complete combustion takes place.
Guidance note:
Routine work, such as cleaning of burners and filters, soot blowing, change over to stand-by pumps, etc. should
preferably be possible without switching off the automatic system.
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B 200 Monitoring
201

Monitoring shall be arranged according to Table B1.

202 Boilers which are operated under constant attending, are at least to have alarm and shut-down at low
water level and stop of circulation.
203 For main boilers, monitoring shall be according to the Rules for Classification of Ships Pt.6 Ch.3 Sec.3,
Table A3.
Table B1 Monitoring of oil fired auxiliary boilers
Alarm and safety action
(stated by an x)
Automatic
shutdown of
Alarm
boiler with
alarm
x
x
x
x
x
x
x
x

Item

Water level, not

double pressure
boiler
Water level double
pressure boilers
Circulation
Combustion air
supply
Heavy fuel oil

Steam

Flame

Level low
Level lower
Level high
Primary system low
Primary system lower
Secondary system low
Secondary system high
Stopped
Fan stopped

Comments

Independent of safety system

Independent of safety system

Forced circulation boilers

Temperature or viscosity
high
Temperature or viscosity low
Pressure high

x
x
x

Pressure higher

Temperature high

Failed ignition
and/or flame failure

When the automatic control

system does not cover the entire
load range from zero load.
For superheated steam >350C
Each burner to have separate
monitoring device and
individual shut-off

C. Exhaust Gas Boilers or Economisers

C 100 Instruments and Monitoring
101 Exhaust gas boilers or economisers with extended surface water tubes are, in addition to the monitoring
given in Table B1, to be monitored as listed below:
Stand-by circulating pump, when required according to Sec.3 D101, to be equipped with automatic start
activated by low flow in the circulating system. Alarm to be given when the pump is started.
Soot cleaners, when required in Sec.3 D201, shall be equipped with automatic start and arranged for
sequential operation.
Alarm for high gas temperature located after the exhaust gas boiler or economiser. The alarm to be given
in case of soot fire.

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D. Water Heaters
D 100 Monitoring
101

Monitoring shall be arranged according to Table D1.

Table D1 Monitoring of oil-fired water heaters

Item
Water level
Water temperature
Flame

Level low
Temperature high
Failed ignition
and/or flame failure

Alarm and safety action

(stated by an x)
Automatic shutdown of heater
with alarm
x
x
x

Comments

Each burner to have separate monitoring

device and individual shut-off

E. Thermal-oil Heaters
E 100 Automatic control
101 Automatic control of thermal-oil outlet temperature shall to be able to keep the oil temperature within
the limits for safe operation under all load conditions.
102 The temperature set point shall be at a sufficiently low level to keep all peak temperatures, dependent on
regulating system transients or on heat transfer functions, below the safe temperature limit of the thermal oil.
E 200 Monitoring
201

Monitoring shall be arranged according to Table E1.

E 300 Indication
301

Thermal-oil heaters shall be equipped with instruments for continuous indication of:
total thermal-oil flow at heater outlet
pressure drop in thermal-oil between heater inlet and outlet
thermal-oil temperature at heater outlet and inlet
flue gas temperature.

Table E1 Monitoring of oil-fired thermal-oil heaters

Alarm and safety action
(stated by an x)
Automatic
Item
Comments
shutdown of oil
Alarm
burner with
alarm
Temperature outlet
x
high
Thermal-oil
Flow low
x
Separate for each coil 1)
Pressure low
x
Flue gas
Temperature high
x
Level low
x
Expansion tank
Temperature high
x
Forced draught
Fan stopped
x
Temperature or
x
viscosity high
Heavy fuel oil
Temperature or
x
viscosity low
Each burner to be monitored, and be
Failed ignition
Flame
x
fitted with separate automatic shut-off
and/or flame failure
valves
1)

Alternatively, the temperature detection for each coil and common low flow detection, may be accepted.

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SECTION 8 MANUFACTURE, WORKMANSHIP AND TESTING

A. Manufacture
A 100 General
101

Class I and II pressure vessels shall be manufactured by works approved by the Society.

102 Welding shall be carried out by approved welders, see Pt.2 Ch.3 Sec.3, and in accordance with approved
drawings and specifications.
For class I and II pressure vessels, welding procedures shall be qualified as specified in Pt.2 Ch.3 or according
to a recognised code.

B. Workmanship
B 100 Cutting of plates
101 Flame-cutting of the plates is normally to be used. Shearing of plates shall not be used, unless the sheared
edge is removed by machining for a distance of one quarter of the plate thickness, minimum 3 mm.
B 200 Welded joints
201 Only full penetration butt welds are acceptable for longitudinal and circumferential main joints.
Circumferential main joints other than butt welds are acceptable for shell to flat end and to tube plate
connections, see Sec.5.
202 The joints shall be welded from both sides of the plates unless otherwise approved.
Circumferential joints in headers, pipes and tubes may be welded from one side only with or without backing strip.
The design of the joint and the method of welding shall provide full penetration, and it shall be demonstrated to the
satisfaction of the surveyor that the welding method gives a weld free from significant defects. If a backing strip is
used, it shall be removed after welding and prior to any required non-destructive tests.
However, permanent backing strips can be accepted for circumferential welds when the second side is
inaccessible for welding and the following conditions are satisfied:
class III pressure vessels, or class II when the cylindrical part is seamless
welding procedures are qualified with backing strip
non-corrosive media.
For pressure vessels in refrigerating plants, permanent backing strips will be accepted when the following
conditions are satisfied:

Seamless cylindrical part

Design with backing strip shall be verified by a recognized pressure vessel code
Fatigue assessment shall be carried out
Where ultrasonic testing is required by the rules, but can not be performed, another equivalent method of
NDT shall be applied

203 Wherever practicable, no attachment shall be welded on in the immediate vicinity of a welded joint. If
this cannot be avoided, the welds shall cross each other completely.
204 Where ends are made of welded plates, the welds shall be so arranged that they are exposed to the least
possible stress. Welded joints passing through flanged curvatures shall be at right angles to these.
205 Unless the pressure vessel is stress-relieved after welding (see C100), not more than two weld seams
shall meet at one point.
Guidance note:
Whenever possible, openings in or near welded joints should be avoided.
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206 Before welding is commenced, it shall be ascertained that the plate edges are in alignment within the
following limits:
10% of the plate thickness with a maximum of 3 mm for longitudinal joints
10% of the plate thickness plus 1 mm with a maximum of 4 mm for circumferential joints.

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Fig. 1
Welded joints

207 If the plates are of unequal thickness, and the difference between the surfaces exceeds that given in 206
for the thicker plate, the thicker plate shall have a smooth taper with a slope not exceeding 15, see Fig.1.
Guidance note:
In the case of pressure vessels for which full radiographic examination is required, it is advised that the thicker plate
be made with a parallel section of the same thickness as the thinner plate. The width L of this parallel section should
be at least 30 mm. E should not exceed 10% of B. The greatest acceptable value of E is 3 mm.
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208 Wherever practicable, the welding shall be carried out in the downhand position. In the case of
circumferential joints in cylindrical shells, means shall be adopted to ensure compliance with this requirement.
209 Welds shall have a smooth finish and shall merge into the plate without abrupt irregularity. The surface
of the weld metal is at no point to fall below the surface of adjoining plates. The reinforcements of the weld
shall not exceed 20% of the plate thickness, with a maximum of 4 mm on either side of the plate.
B 300 Tolerances for shells
301 Shells for class I and II welded pressure vessels shall be within the limits for out-of-roundness and local
departure from circularity after heat treatment has been carried out as given in 304 and 305 respectively.
302 The measurement of out-of-roundness may be carried out either when the shell is laid flat on its side or
when set up on end. When the shell is checked whilst lying on its side, each measurement for diameter shall be
repeated after turning the shell through 90 about its longitudinal axis. The two measurements for each
diameter shall be averaged, and the amount of out-of roundness calculated from the average values so
determined.
303 Measurements may be made on the inside or outside of the shell. If the shell is made of plates of unequal
thicknesses, the measurements shall be corrected for the plate thickness to determine the diameters at the
middle line of the plates.
304 The difference between the maximum and minimum diameter at any cross section of a shell welded
longitudinally, shall not exceed 1% of the nominal internal diameter, D, with a maximum of:
D
+ 1250--------------------200

(mm)

305 There shall be no flat or peak at joints, and any local departure from circularity shall be gradual.
Irregularities in profile, checked by a 20 degree gauge, shall not exceed 5% of the plate thickness plus 3 mm.
This maximum value may be increased by 25%, if the length of the irregularities does not exceed the lesser of
1 metre and one quarter of the length of the shell between two circumferential joints.
B 400 Fitting of tubes
401 The tube holes in water tube boilers shall be made in such a way that an effective tightening of the tubes
is attained. Where the tube ends are not normal to the tube plates, there is either to be a neck or the tube hole
ends shall be made parallel for a depth of at least 13 mm, measured in a plane through the axis of the tube at
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the hole. Where the tubes are practically normal to the tube plates, the depth of this parallel seating shall not be
less than 10 mm.
The tubes shall be carefully fitted in the holes by means of expanding and belling, expanding and welding,
strength welding or by other approved methods. The tubes belled end shall project through the neck or bearing
part of the holes by at least 6 mm. They shall be secured to prevent drawing out at each end, and if this is done
by bell-mounting only, the included angle of belling shall not be less than 30.
402 The tubes in smoke tube boilers shall have their ends firmly expanded and flared, expanded and beaded,
expanded and welded or strength-welded.
403 If tubes are welded to the tube plate in accordance with Fig.12 and 13 in Sec.5, the unwelded portion of
the tube within the tube hole shall be in full contact with the tube plate.
B 500 Doors and plugs
501 Doors and crossbars shall be of steel, and jointing surfaces shall be machined. Doors in boilers shall be
of the internal type. The clearance between the manhole frame and the spigot or recess shall not exceed 1.5 mm
all round.
502

For smaller circular openings in headers and similar fittings, a suitable type of plug may be used.

C. Heat Treatment
C 100 Post-weld heat treatment
101 Pressure vessels including boilers shall be thermally stress relieved after welding when the material
thicknesses at any welded connection exceed the limits given in Table C1 for the steel grade in question.
Vessels intended for service with fluids liable to cause stress corrosion cracking in service shall be stress
relieved independent of material thickness. For ammonia as operating media, see Rules for Classification of
Ships Pt.5 Ch.5 Sec.15 B400
102 When welded joints connect parts of different thickness, the thickness to be considered in applying the
limits given in Table C1 for heat treatment after welding shall be:
the thinner of two adjacent butt-welded plates including dished end and flanged plate to shell connections
where flat plates are inset into the shell: the greater of the thickness of the shell and 2/3 of the thickness of
the flat plate
the thickness of shell or flat plate, as appropriate, in nozzle or pad attachment welds
the thickness of nozzle neck at joint in nozzle neck to flange connections
the thickness of pressure part, at point of attachment where a non-pressure part is welded to a pressure part.
103 The heat treatment shall be carried out after welding of the seams and of all attachments to the shell and
ends prior to the hydraulic pressure test.
104 Wherever possible, pressure vessels shall be heat treated by heating as a whole in an enclosed furnace.
The furnace shall be fitted with instruments for measuring and recording the actual temperatures of the vessel
during the heat treatment process.
105 Where it is found necessary to adopt special methods of heat treatment, full particulars shall be submitted
for consideration.
106 Thermal stress relieving shall be carried out by heating the vessel uniformly and slowly to a suitable
temperature, followed by cooling slowly and uniformly in the furnace to a temperature not exceeding 400C.
Below this temperature the vessel may be cooled in still air. Suitable soaking temperatures and time at
temperature are stated in Table C2.
The heating and cooling processes and the soaking period shall be recorded in a temperature-time diagram.
C 200 Heat treatment of plates after hot or cold forming
201 For components which have been hot formed or locally heated for forming, the following requirements apply:
Components of carbon and carbon-manganese steels, NV 0.3 Mo, NV 1 Cr 0.5 Mo and NV 2.25 Cr 1 Mo shall
be normalised on the completion of the operation, except that the heat treatment may be omitted if the forming
operation has been carried out at a temperature within the normalising range.
The steel grades NV 1 Cr 0.5 Mo and NV 2.25 Cr 1 Mo are in addition to be tempered.
202 Components which have been cold formed shall be heat treated on the completion of the operation in the
following cases:
Components intended for low temperature service, if the cold forming introduces a plastic deformation
exceeding 3%.
Components for other applications if the cold forming introduces a plastic deformation exceeding 5%.

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Carbon and carbon-manganese steels shall be normalised. NV 1 Cr 0.5 Mo and NV 2.25 Cr 1 Mo shall be
normalised and tempered. In special cases a stress relieving heat treatment may be accepted in lieu of
normalising. In such cases testing of the material in cold formed and aged condition may be required.
The soaking temperature shall be at least 30C below the final tempering temperature of the base material.
Table C1 Post-weld heat treatment

Steel grade

NV 360-0A-0N
NV 410-0A-0N
NV 460-0A-0N
NV 490-0A-0N
NV 360-1 FN
NV 410-1 FN
NV 460-1 FN
NV 490-1 FN
NV 510-1 FN
NV 0.3 Mo
NV 1 Cr 0.5 Mo
NV 2.25 Cr 1 Mo

Plate thicknesses above which

post-weld heat treatment
is required
Unfired
Boilers
pressure vessels
20 mm
30 mm
20 mm
30 mm
20 mm
30 mm
20 mm
30 mm
20 mm
38 mm
20 mm
38 mm
20 mm
38 mm
20 mm
38 mm
20 mm
38 mm
20 mm
All thicknesses to be
heat treated

Table C2 Soaking temperatures and time at temperature

Steel grade
C and C-Mn
steel grades
NV 0.3 Mo
NV 1 Cr 0.5 Mo
NV 2.25 Cr 1 Mo

Soaking temperature C
520 - 580
530 - 580
600 - 650
650 - 700

Time at
soaking temperature
60 minutes per
25 mm thickness.
Minimum 30 minutes

C 300 Heat treatment of tubes after bending

301 Tubes shall be heat treated after bending when required in Ch.6 Sec.7 C of the Rules for Classification
of Ships.

D. Testing
D 100 Extent of non-destructive testing (NDT)
101

For class I pressure vessels, non-destructive testing shall be carried out as follows:

a) All longitudinal butt welded joints in drums, shells and headers shall be subjected to 100% radiographic
testing.
b) 25% of the length of circumferential butt welded joints in drums, shells and headers shall be subjected to
radiographic testing.
c) 10% of the total number of circumferential butt welded joints in pipes and tubes shall be subjected to
radiographic testing.
d) For set-in flat plates the cylindrical shell shall be ultrasonically tested for lamellar tearing in way of the
circumferential weld to the flat plate. For shell plate thickness 15 mm and less the extent of testing shall be
at least 10% and for greater thickness at least 20% of the total length of the weld. The internal fillet weld,
see Fig.8 in Sec.5, shall be 100% magnetic particle tested for surface flaws.
e) For standpipes and branches with outside diameter exceeding 100 mm, all weld connections to shell and
reinforcement rings shall be subjected to magnetic particle testing. For outside diameters 100 mm and less,
spot testing shall be carried out. The magnetic particle testing is also to cover weld joints between
reinforcement rings and shell.
f) All welded joints shall be subjected to visual inspection.
102

For class II pressure vessels, non-destructive testing shall be carried out as follows:

a) Longitudinal butt weld joints in drums, shells and headers shall be subjected to radiographic testing at the
rate of 20% of the length. All crossings between longitudinal and circumferential joints shall be included
in the testing.
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Pt.4 Ch.7 Sec.8 Page 76

b) All welded joints shall be subjected to visual inspection.

103

For class III pressure vessels, all welded joints shall be subjected to visual inspection.

104

For furnaces and fireboxes non-destructive testing shall be carried out as follows:

a) 10% of the length of longitudinal butt welded joints shall be subjected to radiographic examination.
b) 10% of the length of circumferential butt welded joints shall be subjected to radiographic examination.
c) 25% of the length of T-welds and corner welds shall be subjected to ultrasonic examination.
105 For non-ferromagnetic materials or materials with changes in magnetic permeability liquid penetrant
testing replaces magnetic particle testing in 101.
106 For carbon and carbon-manganese steels of grades given in Pt.2 Ch.2 Sec.2 Table B1 with thickness less
than 38 mm, the radiographic and ultrasonic testing may be carried out before post-weld heat treatment.
Magnetic particle or liquid penetrant testing shall be carried out when all heat treatment has been completed.
Ultrasonic testing may be used in lieu of radiographic testing for thicknesses equal to or above 10 mm, and
shall be carried out as specified in written procedures established in accordance with Classification Note No.
7 or recognised standards.
107 The requirements for NDT of welded joints for thermal oil piping can be found in Pt.4 Ch.6 Sec.7 A500
of the Rules for Classification of Ships.
D 200 Performance of non-destructive testing (NDT)
201 For carbon and carbon-manganese steel with thicknesses greater than 30 mm and for alloy steels the nondestructive testing is normally to be carried out not earlier than 48 hours after completion of the welds in
question. For carbon and carbon-manganese steels with thicknesses 30 mm and less the time limit may be
reduced to 24 hours.
202 NDT shall be performed by qualified operators. The qualification and certification of NDT-operator shall
be in accordance with a recognised certification scheme accepted by the Society.
203

Radiographic testing shall be carried out as specified in Table D1.

Table D1 Radiographic testing

Item
Requirement
Radiation source
For steel thickness t < 19 mm, x-rays are preferably to be used.
For t 19 mm, Ir 192 isotope may be used.
Film
Fine grained (BAM class G II, ASTM/ ASME class 2 or equivalent or better).
Screens
0.02 mm Pb or more if insufficient.
Geometric unsharpness
Maximum 0.3 mm.
Density
1.8 to 3.0 on weld.
Image quality indicator (IQI)
Wire type (see doc. IIW/IIS-62-60).
Other types of IQI's may be accepted, provided they comply with nationally accepted
standards.
Required IQI sensitivity
See Fig.2.

Fig. 2
Required IQI sensitivity. Source side parameter

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204 For ultrasonic testing the following apply:

The welded connections in question shall be tested for laminations, transverse and longitudinal defects in
accordance with the procedures and technique described in Classification Note No. 7.
205 For magnetic particle testing the following apply:
The object may be directly or indirectly magnetised.
AC yoke or prods shall be used. Care shall be taken to avoid local heating of the test surface. Prods shall be of
the type soft prods, lead tipped or aluminium alloy.
Use of permanent magnets is not permitted.
Required magnetic field strength:
2.4 4.0

kA
------m

The testing is on each area to be performed with the magnetic field shifted in at least two directions
approximately perpendicular to each other.
206 For liquid penetrant testing the following apply:
Coloured or fluorescent water washable penetrants shall be used.
For smooth (flush grinded welds) post emulsifying or solvent removable penetrants may preferably be used.
The surface temperature during testing shall be within the temperature range 15 to 35C, if not, a procedure
qualification test shall be carried out.
The penetration time shall be at least 15 min.
D 300 Acceptance criteria for non-destructive testing and repair of defects
301 Normally the welds are at least to meet the requirements stated in Tables D2, D3 and D4.
As the test methods differ in their limitations and/or possibilities of recording and documentation, special
acceptance criteria are given for each method where necessary.
Alternative evaluations ensuring an equivalent level of quality may in special cases be considered.
302 If indications of defects reach or pass the reference curve during ultrasonic test, the defects shall be
repaired, unless otherwise stated in the Tables D2, D3 or D4.
Table D2 Radiographic testing
Type of defects
Porosity 1) 2)
Isolated: Largest pore diameter in mm:
Cluster: Largest pore diameter in mm:
Maximum length along the weld of projected area in mm:
Slag inclusion 1) 3)
Maximum width in mm:
Maximum length in mm:
Incomplete penetration
Lack of fusion
Cracks

Acceptance criteria
t/4, maximum 4
3
25
t/4, maximum 3
t/2, maximum 25
Not accepted
Not accepted
Not accepted

t = the parent metal thickness. In case of dissimilar thicknesses, t applies to the thinner component.
1)

2)
3)

If the distance between the similar defects (pore or slag) is less than the largest extent of one or more of the defects, it is regarded
as one continuous defect.
If the amount of pores or slag may mask other defects, the examination shall be substituted by ultrasonic testing.
If the distance between pores is less than 3 times the diameter, the pores are said to form a line or cluster. Pores on a line must
not be located in the weld surface.
Defects of lengths in the direction of the weld exceeding 3 times their width form a line. If the distance between slag lines is less
than 3 times the largest extent of the cross section of the defect, the lines are considered as one defect, see Fig.3.

Table D3 Ultrasonic testing 1)

Indication
Echo height above:
Maximum length 1), mm:
1)

Acceptance criteria
100%
t/2, maximum 10

Length is defined as a distance where indication reach or pass the stated percentage of reference level.
Cracks in transverse weld direction is not acceptable regardless of echo height above 20% of reference level.

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Pt.4 Ch.7 Sec.8 Page 78

Table D4 Visual, magnetic particle and liquid penetrant testing

Type of defect
Acceptance criteria
Incomplete penetration
Not accepted
or lack of fusion
Cracks
Not accepted
Undercut, maximum depth, mm
0.3 1)
1)

Provided round shape and insignificant notch effect (regardless of length).

Indications reaching a level of between 50% and 100% of the reference curve shall be evaluated in relation to
the welding process, groove geometry etc. If such an evaluation indicates a possibility of two-dimensional
defects (crack, lack of fusion etc.) all defects without exact identification larger than 10 mm shall be repaired.
Indications exceeding 20% of the reference curve and having an extent larger than 10 mm shall be reported for
consideration if there is a possibility of two-dimensional defects.
303

NDT shall be reported, and all essential control parameters shall be given.

304 Defects which exceed the acceptance limits shall be completely removed and repaired according to an
approved repair procedure. Magnetic particle testing is normally to be used to ensure complete removal of
defects prior to repair welding.
305 When unaccepted defects are found in areas with less than 100% testing, the extent of testing is increased
with the double. If this increased testing reveal more defects, the entire length of the weld shall be tested.
SECTION NORMAL TO WELD LENGTH

Fig. 3
Slag line(s)

D 400 Welding production test (WPT)

401 For class I pressure vessels, welding production test (WPT) shall be performed for approximately each
50 m of longitudinal welded joint. For large units, having more than 50 m of longitudinal welded joint, the
number of tests may be reduced to one for each 100 m of production welded joint, provided the tests show
uniform and satisfactory results. In any case at least one WPT shall be carried out for each vessel.
402 For class II pressure vessels with shell thickness equal to or greater than 16 mm, one WPT representing
the longitudinal welded joints shall be performed for each vessel. Where similar vessels are produced in series,
one WPT may represent a test group of 5 vessels, but not more than 50 m of production weld joint. In such
cases, the plate thicknesses in the test group shall not differ by more than 5 mm and the thickest plate shall be
used for preparation of the test assembly.
403 WPT for circumferential seams is not required, except where a pressure vessel has circumferential joints
only or where the process for welding the circumferential joints is significantly different from that used for the
longitudinal joints. In such cases the number of tests shall be the same as specified for longitudinal weld joints
in 401 and 402.
404 The test assembly for WPT consists of two plates, and each plate shall have a width of minimum 150
mm. The length shall be sufficient for making all test specimens required according to 410 and for possible
retest purposes. Plates for the test assembly shall be cut from the plates forming the appropriate part of the
vessel, and shall be stamped by the surveyor before being detached. Alternatively the test plates may be cut
from another plate from the same cast, with the same thickness and in the same heat treatment condition as the
plate used for the vessel.
405 For longitudinal welded joints, the two plates forming the test assembly shall be tack welded to the vessel
and welded together so that the joint of the test plates forms a direct continuation of the production weld joint.
The orientation of the test plates shall be so that the rolling direction is parallel to the rolling direction of the
adjacent plates of the vessel.
406 For circumferential joints the joint of the test assembly is as far as possible to be a simulation of the
production weld.
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407 The welding of the test assembly shall be carried out at the same time as the production welding and by
the same welder, using the same welding parameters.
408

The test assembly shall be heat treated together with the vessel or one of the vessels which it represents.

409

The weld deposit shall be machined flush with the plate surface on both sides of the test assembly.

410

The following tests are required from each test assembly:

one root and one face bend test when plate 10 mm thick
two side bend tests when plate >10 mm thick
Charpy V-notch impact tests with the notch located in the centre of the weld and in the fusion line
macro section examination.

In addition one butt weld tensile test is required from one test assembly for each vessel. Where one test
assembly represents more vessels, only one tensile test is required. The necessary test specimens shall be cut
from the welded test assembly as shown in Fig.4.
411

Bend tests shall be performed as described in Pt.2 Ch.3 Sec.5 E201.

412 Six Charpy V-notch impact test specimens shall be cut transversely to the weld with the centre of the
specimen as near as practicable to a point midway between the surface and the centre of the thickness. Three
specimens shall be located with the notch in the centre of the weld and three specimens with the notch in the
fusion line. The average value and single specimen values for absorbed energy in fusion line are normally to
be in accordance with the transverse and longitudinal requirements of the base material, whichever is
applicable. The results of weld metal impact tests shall be in accordance with the transverse test requirements
given for the base material.

Fig. 4
Welding production tests (WPT)

Impact tests which do not meet the prescribed energy requirements in fusion line may still be accepted provided
drop-weight tests are carried out with satisfactory results. When drop-weight test is used, two test specimens
from the weld shall be tested and both specimens shall show no-break performance.
Additional testing according to Pt.2 Ch.3 will also be acceptable.
Where the thickness of the material does not permit standard Charpy V-notch test specimens with width 10
mm, the largest obtainable of sub size specimens with width 7.5 or 5 mm shall be used. In that case the
requirement on absorbed energy will be reduced to respectively 5/6 and 2/3 of the value specified for standard
test specimens.
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413 The complete cross section of the welded joint shall be etched for macro-examination. Cracks or lack of
fusion are not accepted.
414 The butt weld tensile test specimen shall be in compliance with Pt.2 Ch.3 Sec.5 L201, type B for testing
of the weld as a whole. Where the thickness of the plate exceeds 30 mm, the tensile test may be performed using
several test specimens, each with a thickness of at least 30 mm. The whole thickness of the joint shall be tested.
The tensile strength obtained shall be not less than the minimum tensile strength required for the plate material.
D 500 Hydraulic test
501

On completion, boilers shall be tested to a pressure of 1.5 times the calculating pressure.

502 As an alternative to the test prescribed in 501 the following pressure tests may be carried out for boilers
where feasible:
Each component of the boiler shall be tested on completion of the work, including heat treatment, to 1.5 times
the calculating pressure. In the case of drums and headers fitted with tubes, this test may be made before drilling
tube holes, but after the attachment of nozzles and similar fittings. When all components have been tested as
prescribed above, the completed boiler shall be tested to 1.25 times the calculating pressure.
503

Pressure vessels other than boilers shall be tested on completion to 1.3 times the calculating pressure.

504 The pressure test shall be such that it does not result in general membrane stress in any part of the vessel
during the test exceeding 90% of the lower yield stress at room temperature.
505 Hydraulic testing shall be performed in the presence of a surveyor, unless otherwise agreed. The test
pressure shall be applied and maintained for at least 30 minutes to permit visual examination of all surfaces and
joints. The vessel shall exhibit no sign of general plastic yielding or leakage.
506 Thermal-oil installations, with their system vessels, headers, heat exchangers etc. shall be pressure tested
to 1.5 times the calculating pressure, minimum 10 bar, the test being carried out at the manufacturers.
After assembly, but before insulation work on board commences, a pneumatic tightness test with a pressure of
1.5 to 2 bar shall be performed.
507 Mountings shall be tested by hydraulic pressure twice the approved calculating pressure, with the
exception of feed check and feed stop valves for boilers and steam-heated steam generators, which shall be
tested to 2.5 times the approved calculating pressure, or twice the maximum pressure which can be developed
in the feed line in normal service, whichever is the greater. The test pressure need not exceed the working
pressure by more than 70 bar.
D 600 Performance test
601 After installation on board, boilers and steam-heated steam generators shall be function tested. The test
shall include the instrumentation, automatic equipment and remote control systems. For boiler accumulation
test, see Sec.6 B113.
602 Thermal-oil heating installations shall be function and capacity tested according to an approved test
programme.
The test procedure shall include flow measurements for each coil, covering the whole range of heater loads.
The heater system charge shall be a thermal-oil which will allow maximum heater rating to be tested.

E. Marking
E 100 General
101 Each boiler and pressure vessel shall be permanently and legibly marked on the boiler or vessel or on a
nameplate permanently attached to a principal pressure part to show its identity and origin.
102
a)
b)
c)
d)
e)
f)
g)

The marking shall show the following particulars:

the name and domicile of the manufacturer
the manufacturer's type designation and serial number
the year of manufacture
the design pressure
the design temperature (s) in C
the hydraulic test pressure
DNV's identifying mark.

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Pt.4 Ch.7 App.A Page 81

APPENDIX A TYPES AND MINIMUM DIMENSIONS OF THE INSPECTION

OPENINGS IN BOILERS AND PRESSURE VESSELS
A. Definitions and Dimensions
A 100 Examination holes
101 Sight-holes are holes whose inside diameter is at least 50 mm (1.97 in) and whose neck height does not
exceed 50 mm (1.97 in).
102 Hand-holes are holes into which a lamp can be inserted. A hand-hole shall have a width of span of at
least 80 100 mm (3.15 3.94 in) or an inside diameter of 100 mm (3.94 in). The height of the neck or ring
shall not exceed 65 mm (2.45 in) and in the case of a conical shape 100 mm (3.94 in). If only one hand-hole is
provided, it shall not be less than 100 120 mm (3.94 4.02 in).
103 Head-holes are holes into which the head, an arm and a lamp can be introduced simultaneously. Their
dimensions shall be at least 220 320 mm (8.66 12.60 in) or 320 mm (12.60 in) in inside diameter. The height
of the neck or ring shall not exceed 100 mm (3.94 in).
104 Where neck heights exceed the limiting values given in 101 to 103, the size of hole shall be increased to
give an adequate inspection facility.
A 200 Man-holes
201 Man-holes are holes permitting entry and exit of a person not carrying any auxiliary equipment. They
shall not be less than 300 400 mm (11.81 15.75 in) or 400 mm (15.75 in) in inside diameter. Where the
neck height of a man-hole is excessive, the size of the man-hole shall be suitably increased.
Guidance note:
The number, type and locations of openings should be as given in Table A1.
---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

Table A1 Examination holes and man-holes for pressure vessels or boilers

No.
1

2 a)

2 b)

2 c)

3 a)
3 b)
4

Internal
diameter
450 mm (17.72
in) and less

Form of vessel

Types and number of holes

Length of cylindrical
body or diameter of
spherical shape up to
1500 mm (59.1 in)
inclusive
More than 450
Length of cylindrical
mm (17.72 in) up body or diameter of
to 800 mm
spherical shape up to
(31.50 in)
1500 mm (59.1 in)
inclusive
inclusive
Length of cylindrical
body greater than 1500
mm (59.1 in) up to 2000
mm (78.7 in) inclusive
Length of cylindrical
body greater than 2000
mm (78.7 in)

2 SIGHT-HOLES. Where the length is more than 1500 mm (59.1 in), additional
sight-holes shall be provided.

1 HAND-HOLE suitably placed or 2 SIGHT-HOLES, in the case of a

cylindrical
body the latter could each be sited either near the ends (within sight of the
longitudinal joint and of the base) or else at the centre of the ends.
1 HEAD-HOLE in the central third of the length of the cylindrical body or 2
HAND-HOLES each located either near or on the ends.

The number of inspection holes shall be increased accordingly. For a length of

less than 3000 mm (118 in) it is, however, sufficient to site a head-hole in the
centre of the cylindrical body. On the cylindrical body the greatest distance between the head-holes shall not exceed 3000 mm (118 in), those between handholes 2000 mm (78.7 in). The latter is each to be located either near or in the
ends.
More than 800
Length of cylindrical
1 HEAD-HOLE (in the case of a cylindrical body this is located in the central
mm (31.50 in) up body or spherical shape third of its length) or 2 HAND-HOLES near or in the ends.
to 1500 mm
up to 2000 mm (78.7 in)
(59.1 in)
Length of cylindrical
1 MAN-HOLE or siting of inspection holes as in the case of 2c) above.
inclusive
body more than 2000
mm (78.7 in)
More than 1500 Length of cylindrical
1 MAN-HOLE.
mm (59.1 in)
body unlimited

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