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 697.6m
2
. 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.