Department of Labour  |      Employees State Insurance Scheme     |       Employment & Training                                                
INDIAN BOILER ACT , 1923

INDIAN BOILER ACT, 1923
PROCEDURE FOR REGISTRATION
PROCEDURE FOR INSPECTION
PROCEDURE FOR REPAIRS
PROCEDURE FOR CONDUCTING BOILER ATTENDANTS & OPERATION ENGINEERS EXAM
FEE CHART UNDER BOILER ACT
SUMMARY OF BOILER ACCIDENTS

INDIAN BOILER ACT, 1923
(RULES MADE
THERE UNDER)
   
Objective of the Act:
 

An act to consolidate and amend the law relating to steam boilers to ensure the safety 
           in its manufacture and use.

The connected regulations and rules enforced: 

i.                    The Indian Boiler regulation 1950 

ii.                  The Karnataka  Boiler Rules 1982 

iii.                The Karnataka Economisers Rules 1959 

iv.                The Karnataka Boiler operation Rules  1959 

v.                  The Karnataka Boiler Attendants Rules 1962   

“Boiler” means any closed vessel exceeding (22.75 litres) in capacity which is used expressly for generating steam under pressure and includes any mountings or other fitting attached to such vessel, which is wholly or partly under pressure when steam is  shut off.

“Economiser” means any part of a feed-pipe that is wholly or partly expressed to the action of flue gases for the purpose of recovery of waste heat.

“Steam –pipe” means any pipe through which steam passes from a boiler to a prime mover or other user or both,  If

i.                    The pressure at which steam passes through such pipe exceeds 3.5 kilograms  per sq. cm  above atmospheric pressure or

ii.                  Such pipe exceeds 254 mm in internal diameter  and includes in either case any connected  fitting of a steam pipe

PROCEDURES FOR REGISTRATIONS OF BOILERS AND ECONOMISERS. 

a.     Package Boiler 

Submit following Original documents pertaining to the Boiler intended for registration to the concerned Divisional Inspector. 

i.                    Form-II, Form-III and Form-IVA 

ii.                  Form-IIIC of all mountings and fittings 

iii.                Boiler drawings   in original 

iv.                Form-IIIA  of  feed pipe 

v.                  Registration fee paid in challan 

The registration of the Boiler will be done within 30 days or shorter period as may be prescribed from the date of the receipt for examination of the boiler giving not less than 10 days notice of the date fixed. 

      After satisfactory completion of open inspection and hydraulic test provisional order will be issued pending steam test. 

b.     Water tube  Boiler 

  • Obtain permission to erect the Boiler through an authorised Boiler repairer from the Chief Inspector of Boilers.

 

  • Submit following Original documents pertaining to the Boiler  intended for 

 

  • Registration to the concerned divisional Inspector.  

i.                   Form-II, Form-III, and Form-IVA  

ii.                 Form-IIIC of all mounting s and fittings 

iii.               Form-IIIC of all mountings and fittings 

iv.               Boiler Drawings in original  

v.                 Form-IIIA of feed pipe  

vi.               Registration fee paid in challan  

  • Offer the Boiler for carrying out  stage inspection  to the concerned divisional inspector and obtain his clearance at every stage

PROCEDURES FOR REGISTRATIONS OF STEAM LINE 

a.      Obtain approval of the proposed steam line drawing from the Chief Inspector of Boilers by submitting following documents. 

i.                    Steam line drawing in triplicate showing clearly welding details, materials specifications, working pressure of boilers and feed pipeline and registration Number of Boilers 

ii.                  Steam line drawing   scrutiny fee paid in challan
( Fee is Rupees 50/- for every 30 meters or part thereof)

iii.                Mention the authorised boiler repairer through whom you are getting the same erected

b.     After obtaining approval of proposed steam line drawing from the Chief Inspector of Boilers  make application for registration  of proposed steam line with the divisional inspector by submitting the following original documents

i.                    steam line certificates in Form-IIIA   

ii.                  Mounting And fittings certificates in Form-IIIC  

iii.                Welders certificate    

iv.                Registration fee paid in challan. 

 c.   Offer steam pipe and fittings for material inspection and obtain clearance for erection from the inspector of boilers. 

         d.  Offer the weld set up and weld edge preparation for inspection and obtain clearance for erection from the inspector of boilers.  

       e.    Subject  the weld joint joints for radiographic examination  if needed   

       f.      Subject the erected steam line  for hydraulic  test to the inspector of boiler

      g.     Submit revised steam line drawing incorporating any deviations caused during the erection due site 
           condition for approval to the Chief Inspector of boiler through inspector of Boiler drawing scrutiny fee.

ANNUAL INSPECTION OF BOILERS ECONOMISERS AND STEAM LINES

   a.      Make application to the Divisional Inspector in Form-I and Inspection fee paid in challen. 

         The inspection of the Boiler, Economiser and steam line will be done within 30 days or shorter period as may be
         prescribed from the date of the receipt for examination of the Boiler giving not less than 10 days notice
         of the date fixed. 

        After satisfactory completion of open inspection and hydraulic test certificate for the use of Boiler, Economiser 
        will be issued within 48 hours of making such examination.
 

REPAIRS TO BOILER ECONOMISER AND STEAM LINE.  

a.      The Inspector of Boiler after making examination of the Boiler, Economiser and Steam line will suggest any structural alteration. Addition or renewal will intimate the owner 48 hours of making the examination.

b.      After receiving the suggestions from the Inspector of Boilers  for carrying out needful repairs, make the boilers, Economisers and steam line serviceable, the owner shall make application to the Chief Inspector of Boilers seeking permission to carryout the repairs mentioning the authorised Boiler repairer name through whom he is getting the same repaired.

c.      After obtaining approval from the Chief Inspector of Boilers the owner should offer the Boiler Economiser and steam line for which repairs are being carried out for inspection to the inspector of Boilers and obtain his clearance.

d.    After satisfactory completion of open inspection and hydraulic test, after repairs.  Certificates for the use of Boilers.  Economiser will be issued within  48 hours of making examination.

PERSONS TO BE INCHARGE OF BOILERS:  

A certificate of Second class shall qualify the boiler thereof to be incharge of a single boiler of any kind, the heating surface of which does not exceed 139.5 sq. Mt.  a second class boiler attendant may , however, attendant to a battery of boilers ( not consisting of more than connected boilers  and not exceeding  139.5 sq. Mt. in aggregate  of total heating  surface)   provided he is assisted by the number of  firemen considered necessary by the Chief Inspector of Boilers.

A certificate of first class shall qualify the older thereof to be  incharge  of a single boiler  of any kind or capacity or two  or more boilers  in a battery  or  of so many separate individual boilers ,  the total heating surface of which does not  exceed  697.6 sq. Mt. provided  that  such boilers shall  be  situated within a radius  23 Mts.   in the same premises  belong to  one owner. 

PROCEDURES FOR APPEARING FIRST CLASS AND SECOND CLASS BOILER ATTENDANT EXAMINATION;  

a.       Requirement to appear for Second class examination

1.     Age – shall not be less than 20 years

2.     Experience – Has served for not less than  3 years as an engine fitter where boiler and engines  are repaired or made and worked under steam.  I year at least  of which  he should have worked as an assistant firemen, or

3.     Has served for not less than  3 years in the capacity of a  fireman or  an assistant firemen  on a steam  boiler  or a combined steam engine and boiler  or

4.     Produces from the  head of an industrial or technical institution a certificate stating that   he has completed  a three  years course of training,  one year of which  must have been as an  apprentice  in a steam power plant  of a mill or factory or an engineering  workshop for the  maintenance of boilers. 

b.       Requirement to appear for first class examination: 

1.     Age – shall not be less than 21 years  

2.     Experience -  Has served for not less than two years as a boiler attendant  with second class certificate of competency  in sole of working  charge of boiler whose rated  heating surface  is not less than  46.51  sq. Mt. or

3.       Produces from the head of an industrial or technical institution a certificate stating that he has completed a three years course of training  one of which  must have been as on apprentice in a steam power plant  of a mill or factory or an engineering workshop where engines and boilers or repaired or made and in addition as served  for not less than one year in sole working charge of a boiler not less than 46.51  of heating surface with a second class boiler attendants certificate.

c.        Procedures for making application for first class and second class examination

  I.                  FIRST CLASS;  

1.    Application shall made in Form-A duly attested by the Gazetted officer  

2.    Service certificate in original with copy 

3.    Character certificate issued by employer in original with a copy. 

4.    Two copies of recent bust photographs 

5.    Fee of Rs.100/-  paid in challan   

II.               SECOND CLASS 

1.    Application shall be made in a Form –A duly attested by a Gazetted officer. 

2.    Service certificate in original  with a copy  

3.    Character certificate issued by  employer in original with copy 

4.    Two copies of recent bust photographs 

5.     Fee of Rs.100/- paid in challan.   

BOILER OPERATION ENGINEERS EXAMINATION:

The qualified Boiler Operation Engineers are required to maintain a boiler or battery of boilers having a total heating
surface area of 697.6m2 .  The requirements are:

      age                                -     not less than 23 years of age;

     educational qualification   -     should have completed  apprentice engineers

course in a recognised workshop engaged in making or repairing of Boilers and Accessories OR should possess a degree in mechanical or electrical engg., or possess a  diploma recognised by the Institute of Engineers.

     Experience                     -     should have served  not less than 2 years as

Engineer/Asst. Engineer in running  and maintenance of battery of boilers not less than two in number and each boiler not having less than 93.02 m2 heating surface.

     Method of examination      -     Written examination consists of one paper in

Mathematics, applied mechanics, heat engines in each subject and one paper of drawing followed by oral examination.

   Mode of application        -     Prescribed application duly filled in

(i)                Form A attested by gazetted officer;

(ii)              Service certificate in original  along with a copy;

(iii)            Character certificate from the employer;

(iv)            Two recent passport size photographs;

(v)              Rs.150/- paid in challan or DD 

Contact person for further details : The secretary /Senior Inspector of Boilers, Boiler Operation Engineers Board. 

REGISTERS TO BE MAINTAINED 

      Register of boilers and scantlings in Form no. B;

      Registration book and Memorandum of Inspection book of all Boilers in Form no.I;

    Register of appeals in Form C;

     Register of accidents in Form no.D;

    Register of registration and inspection fees in Form NO.E;

      Register in Form F – all registered boiler;

     Register of steam pipelines in Form G;

FEE CHARTS UNDER THE BOILER ACT 

The management shall deposit all fees payable under the Act:

(I)               In the Govt. Treasury or the Reserve Bank of India in the state of Karnataka under the following prescribed Head of account through challan. “ 0230 Labour and Employment 103 Fees for Inspection of steam Boilers” OR

(II)            by cheque or DD drawn in favour “Chief Inspector of Factories and Boilers in Karnataka, Bangalore” payable at Bangalore. 

1.               FEE FOR INSPECTION OF BOILERS             

                                                        n.e-not exceeding                             

Sl.No.

Particulars

Sq.Mts

Sq. Mts

Rupees

1

For Boiler rating not exceeding

 

10

500-00

2

For Boiler rating exceeding

10 n.e

25

600-00

3

For Boiler rating exceeding

25n.e

50

750-00

4

For Boiler rating exceeding

50n.e

75

850-00

5

For Boiler rating exceeding

75n.e

100

1000-00

6

For Boiler rating exceeding

100n.e

150

1150-00

7

For Boiler rating exceeding

150n.e

200

1300-00

8

For Boiler rating exceeding

200n.e

400

1600-00

9

For Boiler rating exceeding

400n.e

600

1800-00

10

For Boiler rating exceeding

600n.e

800

2000-00

11

For Boiler rating exceeding

800n.e

1000

2400-00

12

For Boiler rating exceeding

1000n.e

1200

2500-00

13

For Boiler rating exceeding

1200n.e

1400

2700-00

14

For Boiler rating exceeding

1400n.e

1600

3000-00

15

For Boiler rating exceeding

1600n.e

1800

3200-00

16

For Boiler rating exceeding

1800n.e

2000

3600-00

17

For Boiler rating exceeding

2000n.e

2200

4000-00

18

For Boiler rating exceeding

2200n.e

2400

4800-00

19

For Boiler rating exceeding

2400n.e

2600

5200-00

20

For Boiler rating exceeding

2600n.e

2800

5600-00

21

For Boiler rating exceeding

2800n.e

3000

6000-00

                       In respect of boilers exceeding 3000sq.mts rating an additional fee of Rs.200/- for every 200 sq.mts or part thereof shall be charged. Fee for ordinary inspected of miniature boiler shall be Rs.250/-. 

2. FEES FOR INSPECTION OF ECONOMISER                                                                                                                              n.e – not exceeding

Sl.No

Particulars

Sq.mts

Sq.mts

Rupees

1

For economiser rating not exceeding

 

50

400-00

2

For economiser rating exceeding

50 n.e

100

500-00

3

For economiser rating exceeding

100 n.e

150

600-00

4

For economiser rating exceeding

150 n.e

200

700-00

5

For economiser rating exceeding

200 n.e

250

800-00

6

For economiser rating exceeding

250 n.e

300

900-00

7

For economiser rating exceeding

300n.e

350

1000-00

8

For economiser rating exceeding

350 n.e

400

1100-00

9

For economiser rating exceeding

400n.e

450

1200-00

10

For economiser rating exceeding

450 n.e

500

1300-00

11

For economiser rating exceeding

500

 

1400-00

 3. FEES FOR REGISTRATION OF BOILER

Sl.No

Particulars

Rupees

1

For boiler rating not exceeding 10 sq.mts

600/-

2

For boiler rating exceeding 10 but not exceeding 30 sq.mts

800/-

3

For boiler rating exceeding 30 but not exceeding 50 sq.mts

900/-

4

For boiler rating exceeding 50 but not exceeding 70 sq.mts

1100/-

5

For boiler rating exceeding 70 but not exceeding 90 sq.mts

1300/-

6

For boiler rating exceeding 90 but not exceeding 110 sq.mts

1500/-

7

For boiler rating exceeding 110 but not exceeding 200 sq.mts

1700/-

8

For boiler rating exceeding 200 but not exceeding 400 sq.mts

1900/-

9

For boiler rating exceeding 400 but not exceeding 600 sq.mts

2200/-

10

For boiler rating exceeding 600 but not exceeding 800 sq.mts

2400/-

11

For boiler rating exceeding 800 but not exceeding 1000 sq.mts

2700/-

12

For boiler rating exceeding 1000 but not exceeding 1200 sq.mts

3200/-

13

For boiler rating exceeding 1200 but not exceeding 1400 sq.mts

3600/-

14

For boiler rating exceeding 1400 but not exceeding 1600 sq.mts

4200/-

15

For boiler rating exceeding 1600 but not exceeding 1800 sq.mts

4600/-

16

For boiler rating exceeding 1800 but not exceeding 2000 sq.mts

5000/-

17

For boiler rating exceeding 2000 but not exceeding 2200 sq.mts

5400/-

18

For boiler rating exceeding 2200 but not exceeding 2400 sq.mts

6000/-

19

For boiler rating exceeding 2400 but not exceeding 2600 sq.mts

6300/-

20

For boiler rating exceeding 2600 but not exceeding 2800 sq.mts

6800/-

21

For boiler rating exceeding 2800 but not exceeding 3000sq.mts

7200/-

       Above 3000 sq.mts for every 200 sq.mts or part thereof an additional fee of Rs.200/- shall be charged.

 4. FEES FOR REGISTRATION OF ECONOMISER

Sl.No

Particulars

Rupees

1

For  rating not exceeding 50 sq.mts

500/-

2

For  rating exceeding 50 but not exceeding 100 sq.mts

600/-

3

For  rating exceeding 100 but not exceeding 150 sq.mts

700/-

4

For  rating exceeding 150 but not exceeding 200 sq.mts

800/-

5

For  rating exceeding 200 but not exceeding 250 sq.mts

900/-

6

For  rating exceeding 250 but not exceeding 300 sq.mts

950/-

7

For  rating exceeding 300 but not exceeding 350 sq.mts

1000/-

8

For  rating exceeding 350 but not exceeding 400 sq.mts

1100/-

9

For  rating exceeding 400 but not exceeding 450 sq.mts

1200/-

10

For  rating exceeding 450 but not exceeding 500 sq.mts

1300/-

11

For  rating exceeding 500 but not exceeding 600 sq.mts

1400/-

12

For  rating exceeding 600 but not exceeding 700 sq.mts

1500/-

13

For  rating exceeding 700 but not exceeding 800 sq.mts

1600/-

14

For  rating exceeding 800 but not exceeding 900 sq.mts

1700/-

15

For  rating exceeding 900 but not exceeding 1000 sq.mts

1800/-

          Above 1000 sq.metrs for every 200 sq.mts or part thereof, an additional fee of Rs.100/- shall be charged.

TRANSFER OF BOILER:

Whenever a boiler is transferred from another state into the state of Karnataka, the owner shall make application for registration of the transfer. The boiler cannot be used until registration has been effected. 

The documents required to be submitted in respect of this to the Chief inspector of Boilers are:   
              1.Application along with no objection letter from the previous owner;
              2.A treasury receipted challan for Rs.2000/-
 

DETAILS OF BOILER ACCIDENTS OCCURRED IN THE STATE 

A.    Boiler Accident caused by starvation due to insufficient NPSH, 

Boilers installed at M/s The Mysore Sugar Company Ltd., Mandya were frequently failing due to starvation, thus resulting in tube damages and downtime of boiler causing production hamper. Upon thoroughly investigating the root cause, it was found that the starvation was due to insufficient NPSH provided. After providing required NPSH, no such failure of pressure parts have taken place and thus no downtime of boiler and also production hamper has not been caused. 

B.     Boiler accident caused by overheating due to accumulation of Sludge/Sediment/Scale. 

Fire Tube Boilers installed at M/s Wipro Ltd., Tumkur were frequently failing due to overheating caused by Scale accumulation, which is in turn was caused due to improper treatment of feed water. Feed water available in the factory site was contaminated by high percentage of Silica. The management was facing the problem of proper cleaning of adhered scale due to its inherent hardness and sticking property, thus resulted in tube replacement, 

       The management was advised to install Cation and Anion exchange bed to avoid slippage of Silica into the feed system. Accordingly after the installation of mixed bed, no need of replacement of the tube or any other pressure parts have not taken place resulting in saving of fuel and also expenditure incurred in tube replacement.   

C.     Boiler Accident caused by overheating of furnace due to sludge accumulation in the narrow space between the furnace and shell. 

A fire tube boiler installed in a rice mill was thrown to a distance of about 50 feet from its original foundation caused by jet action due to sudden failure of furnace. After investigating the accident it was found that the furnace was overheated due to accumulation of sludge between the furnace and shell, this is in turn due to improper blowing down operation. 

D.    Boiler accident due to Tube Failure caused by erosion. 

A Water tube boiler installed at M/s Davanagere Cotton Mills Ltd., Davanagere was failed due to erosion of front bork tube due to excessive Silica content in fuel. Due to the sudden discharge of hot contents from the failed portion which resulting in death of three persons who were standing in front of the fire hole door, due to scald. The Department advised the management to provide proper refractory lining on such sensitive portion to overcome erosion.