67. [ Pressure Vessels of Plants. [Substituted by Notification No. 4(a) 3-81-LAB-XVI, dated 28-5-1981.]
(1)Interpretation-(a)"design pressure" means the maximum pressure that a pressure vessel or plant is designed to withstand safety when operating normally;(b)"maximum permissible working pressure" is the maximum pressure at which a pressure vessel or plant is permitted to be operated or used under this rule;(c)"plant" means a system of piping that is connected to a pressure vessel and is used to contain a gas, vapour of liquid under pressure greater than the atmospheric pressure and includes that pressure vessel;(d)"pressure vessel" means an unfired vessel that may be used for containing, storing, distributing, transferring, distilling, processing or otherwise handling any gas, or liquid under pressure greater than the atmospheric pressure and includes any pipe line fitting or other equipment attached thereto or used in connection therewith; and.(e)"competent person" means a person who is, in the opinion of the Chief Inspector, capable by virtue of his qualification, training and experience conducting a thorough examination and pressure tests, as required on a pressure vessel or plant, and of making a full report on its condition.(2)Exceptions. - Nothing in this rule shall apply to-(a)[ deleted;](b)vessels made of ferrous materials having an internal maximum permissible working pressure not exceeding 1 Kg/sq. cm. (15 Lbs./ sq. inch.);(c)steam boilers, steam and feed pipes and their fitting coming under the purview of Indian Boilers Act, 1923 (V of 1923);(d)metal bottles or cylinders used for storage of transport of compressed gases or liquified or dissolved gases under pressure covered by the Gas Cylinder Rule, 1940 framed under the Indian Explosives Act, 1884 (IV of 1884);(e)vessels is which internal pressure is due solely to the static head of liquid;(f)vessels with a nominal water capacity not exceeding 500 liters connected in a water pumping system containing air that is compressed to serve as a cushion;(g)vessels for unclear energy applications;(h)refrigeration plant having a capacity of 3 tons or less or refrigeration in 24 hours; and(i)working of cylinders of steam engines or prime mover feed pumps and steam steps; turbine casings; compressor cylinders; steam separators of dryers; steam stramers; steam; de-super heaters; oil seed operators; air receivers for fire sprinkler installations; air receivers; of monotype machines provided the maximum working pressure of the air receiver does not exceed 1.33 Kg. f/ cm 2 (20 Lbs/ sq. in) and the capacity 84.95 liters (3 cu.ft.); air receivers electrical breakers; air receiver of electrical relay; air vessels on pumps pipe/coils, accessories of instruments and appliances such as cylinders and piston assemblies use for operating relays and interlocking appear of guards; vessels with liquids subjected to static head only; and hydraulically operating cylinders other than any cylinder communicating with an air loaded accumulator.(3)Design and construction. - Every pressure vessel or plant used in a factory-(a)shall be properly designed on sound engineering practice;(b)shall be of good construction, sound material, adequate strength and free from any patent defects; and(c)shall be properly maintained in a safe condition :Provided that the pressure vessel or plant in respect of the design and construction of which there is an Indian standard or a standard of the country of manufacture or any other law or regulation in force, shall be designed and constructed in accordance with the said standard, law or regulation, as the case may be, and a certificate thereof shall be obtained from the manufacturer or from the competent person which shall be kept and produced on demand by an Inspector.(4)Safety devices. - Every pressure Vessel shall be fitted with-(a)suitable safety valve of other effective pressure relieving device of adequate capacity to ensure that the maximum permissible working pressure of the pressure vessel shall not be exceeded. It shall be set to operate at a pressure not exceeding the maximum permissible working pressure and when more than one protective device are provided, only one of the devices need be set to operate at the maximum permissible working pressure and the additional device shall be set to discharge at a pressure not more than 5 per cent in excess of the maximum permissible working pressure;(b)a suitable pressure gauge with a dial range not less than 1.5 times the maximum permissible working pressure, easily visible and designed to show at all times correct internal pressure and marked with a prominent red mark at the maximum permissible working pressure of the pressure vessel;(c)a suitable nipple and globe value connected for the exclusive purpose of attaching a test pressure gauge for clerking the accuracy of the pressure gauge referred to in clause (b) of this sub-rule;(d)a suitable stop valve or valves by which the pressure vessel may be isolated from other pressure vessel or plant or source of supply of pressure such a stop valve or valves shall be located as close to the pressure vessel as possible and shall be easily accessible; and(e)a suitable drain cock or valve at the lowest part of the pressure vessel for the discharge of the liquid or other substances that may-collect in the pressure vessel :Provided that it shall be sufficient for the purposes of this sub-rule if the safety value or pressure relieving device, the pressure gauge and stop valve are mounted on a pipe-line immediately adjacent to the pressure vessel and where there is a range of two or more similar pressure vessel served by the same pressure load one set of such mounting need be fitted on the pressure load immediately adjacent to the range of pressure vessels, provided they can not be isolated.(5)Pressure reducing devices. - (a) Every pressure vessel which is designed for a working pressure less than the pressure at the source of supply or less than the pressure which can be obtained in the pipe connecting the pressure vessel with any other source of supply, shall be fitted with a suitable automatic device to prevent the minimum permissible working pressure of the pressure vessel being exceeded;(b)To further protect the pressure vessel in the event of failure of the reducing value or device, at least one safety value having a capacity sufficient to release all the steam, vapour or gas without undue pressure rise as determined by the pressure at the source of supply and the size of the pipe connected the source of supply, shall be fitted on the low pressure side of the reducing valve.(6)Pressure vessel or plant being taken into use. - (a) No new pressure vessel or plant shall be taken into use in a factory after coming in force of this rule unless it has been hydrostatically tested by a competent person at a pressure, at least 1.3 times the design pressure and not pressure vessels or plant which has been previously used or has remained isolated or idle for a period exceeding 2 months or which has undergone alterations or repairs shall be taken into use in a factory unless it has been thoroughly examined by a competent person externally if practicable and has been hydrostatically tested by the competent person at a pressure which shall be 1-5 times the maximum permissible working pressure :Provided, however, that the pressure vessel or plant which is so designed and constructed that it cannot be safety finned with water or liquid or is used in service where even some traces of water cannot be tolerated, shall be pneumatically tested at a pressure not less than the design pressure or the maximum permissible working pressure as the case may be :Provided further that the pressure vessel or plant which is lined with glass shall be tested hydrostatically or pneumatically as required at pressure not less than the design pressure or maximum permissible working pressure as the case may be.Design pressure shall be not less than the maximum permissible working pressure and shall take into account the possible fluctuations of pressure during actual operations.(b)No pressure vessel or plant shall be used in a factory unless there has been obtained from the maker of the pressure vessel or plant or from the competent person a certificate specifying the design pressure or maximum permissible working pressure thereof, and stating, the nature of tests of which the pressure vessel or plant and its fittings (if any) have been subjected and every pressure vessel or plant so used in a factory shall be marked so as to enable it to be indemnified as to be the pressure vessel or plant to which the certificate relates and the certificate shall be kept available for perusal by the Inspector;(c)No pressure vessel or plant shall be permitted to be operated or used at a pressure higher than its design pressure or maximum permissible working pressure as shown in the certificate.(7)Service test and examination. - Every pressure vessel or plant in service shall be thoroughly examined by a competent person-(a)externally, once in every six months;(b)internally, once in every twelve months;if by reason of the construction of a pressure vessel or plant, a thorough internal examination is not possible, this examination may be replaced by a hydrostatic test which shall be carried out once in every two years :Provided that for a pressure vessel or plant process which can not be frequently opened, the period of internal examination may be extended to four years; and(c)hydrostatically tested once in every four years :Provided that in respect of pressure vessel or plant with thin walls such as sizing cylinder made of copper or any other non-ferrous metal periodic hydrostating test may be dispensed with subject to the conditions that the requirements laid down in sub-rule (8) are fulfilled :Provided further that when it is impracticable to carry out thorough external examination of any pressure vessel or plant every six months as required by clause (a) or if owing to its construction and use a pressure vessel or plant can not be hydrostatically tested as required in sub-rule (b) of this clause thorough external examination of the pressure vessel or plant shall be carried out atleast once in every two years, and atleast once in every four years a thorough systematic non-destructive test like ultrasonic test for metal thickness or other defects of all parts the failure of which might lead to eventual repture of the pressure vessel or plant shall be carried out.(d)the hydrostatic test pressure to be carried out for the purposes of this rule shall be 1.25 times the design pressure or 1.50 times the maximum permissible working pressure vessel whichever is less.(8)Thin walled pressure vessel or plant. - (a) In respect of any pressure vessel or plant of thin walls such as sizing cylinder made of copper or any other non-ferrous metal the maximum permissible working pressure shall be reduced at the rate of 50% of the original maximum permissible working of pressure for every years of its use after the first five years and no such cylinder shall be allowed to be continued to be used for more than twenty years after it was first taken into use;(b)If any information as to the date of construction, the thickness of walls, or maximum permissible working pressure is not available, the age of such pressure vessel or plant shall be determined by the competent person in consultation with the Chief Inspector from the other particulars available with the manager;(c)Every new and second hand pressure vessel of plant or thin walls to which repairs likely to affect its strength, or safety have been carried out, shall be tested before use to atleast 1-5 times its maximum permissible working pressure.(9)Report by competent person. - (a) If during any examination any doubt arises as to the ability of the pressure vessel or plant to work safety until the next prescribed examination the competent person shall enter in the register his observations, findings, and conclusions with other relevant remarks with reasons any may authorise the pressure vessel or plant to be used and kept in operation subject to a lowering of maximum permissible working pressure, or to more frequent of special examination or test, or subject to both of these conditions;(b)A report of the result of every examination or test carried out shall be completed in the prescribed Form No. 9 and shall be signed by the person making the examination or test, and shall be kept available for perusal by the Inspector at all hours when the Factory or any part thereof is working;(c)Where the report of any examination under these rules specified any condition for securing the safe working of any pressure vessel or plant, the pressure vessel or plant shall not be used unless the specified conditions is fulfilled;(d)The competent person making report of any examination under this Rule, shall within seven days of the completion of the examination sent to the Inspector a copy of the report in every case where the maximum permissible working pressure reduced or the examination shows that the pressure vessel or plant or any part thereof can not continue to be used with safety unless certain repairs are carried out or unless any other safety measure is taken.(10)Application of other laws. - (a) The requirements of this Rule be in addition to and without any prejudice to and not in derogation of the requirements of any other law in force;(b)Certificates or reports of any examination or test of any pressure vessel or plant to which sub-rules (7) to (9) do not apply, conducted or required to be conducted under any other law in force and other relevant record relating to such pressure vessel or plant, shall be properly maintained as required under the said law and shall be produced on demand by the Inspector.]
