IS I 1856· 1979•

Indian StandardSPECIFICATION FOR

CARBON STEEL CASTINGS FOR PRESSURECONTAINING PARTS SUITABLE FOR

HIGH TEMPERATURE SERVICE(FUSION WELDING QUALITY)

.: ~ ( Second Revision) t,e 2~~(~/~

..,. .

Q Copyright ~979

INDIAN STANDARDS INSTITUTIONMANAICBHAVAN. 9 BAHADUll SHAH ZAPAR MARO

NBW DELHI 110002

October 1979

Is : 2856 -1979

Indian StandardSPECIFICATION FOR

CARBON STEEL CASTINGS FOR PRESSURECONTAINING PARTS SUITABLE FO '~~~\.lJliof.

HIGH TEMPERATURE SERVICE.. :; ):(FUSION WELDING QUALITY) :: \\<iJ " .•..

( Second Revision)Steel Castings Sectional Committee, SMDC 20

Chairman Representing

Steelcast Bhavnagar Pvt Ltd, BhavnagarSHRI T. KUMARMembers

SHRI R. P. S. BURMEESHRI A. K. MALLIK (Alternate)

SHRI R. CHATURVEDI

Uni Abex Alloy Products Ltd, Thana

Tata Engineering & LocomotiveJamshedpur

Co

SHRI A. P. SINHA ( Alternate)DEPUTY CHIEF MECHANICAL Ministry of Railways

EN GIN E E R, CHITTARANJANL 0 COM 0 T I V E W 0 R K S,CHlTTARANJAN

JOINT DIRECTOR (WAGON) III,RESEARCH, DESIGNS&STANDARDSORGANIZATION,LUCKNOW ( Alternate I)

ASSISTANTDIRECTOR (MI),RDSO, MET INSP CELL,CHI'ITARANJAN (Alternate II)

SHRI P. K. GANGOPADHYAY Ministry of Defence (DGI )SHRI R. N. RAY (Alternate)

SHRI V. C. GOPALARAO Hindustan Shipyard Ltd, VishakhapatnamSHRI C. K. KURIAKOSE (Alternate)

SHRI S. MAJUMDAR Directorate General of Technical Development,New Delhi

SIfRI R. M. BALANI ( Alternate)SHRI B. V. PRABHU Heavy Engineering Corp Ltd, Ranchi

SHRI L. P. SINGH ( Alternate)( Continued on page 2 )

@ Copyright 1979INDIAN STANDARDS INSTITUTION

This publication is protected under the Indian Copyright Act (XIV of 1957) andreproduction in whole or in part by any means except with written permission of thepublisher shall be deemed to be an infringement of copyright under the said Act.

Ltd,

1S: 2856 - 197!>

( Continued from page I )

MembersSHRl C. M. PRASADSHRI P. P. RASTOGI

RepresentingCentral Boilers Board, BangaloreSteel Authority of India Ltd, Rourkela Steel Plant,

RourkelaSHRl S. CHOWHAN ( Alternate)

SHRI C. S. REDDY Bharat Heavy Electricals Ltd, HyderabadSHRI U. MOHAN RAO (Alternate I )SHRI C. VENKATARAMAN (Alternate II )

SHRI R. K. SRIVASTAVA Mukand Iron & Steel Works Ltd, BombaySHRI Z. M. BHATE ( Alternate)

SHRI K. M. TANEJA Directorate General of Supplies & Disposals (Inspec-tion Wing)

SHRI M. C. AICH ( Alternate)SHRI K. S. VAIDYANATHAN M. N. Dastur & Co Pvt Ltd, Calcutta

SHRI J. C. AGRAWAL ( Altemate)SHRI C. R. RAMA RAO, Director General, ISI (Ex-officio Member)

Director (Struc & Met)Secretary

SHRI SHANT! SWARUPDeputy Director (Metals), ISI

Panel for Steel Castings for Pressure Parts for High TemperatureService, SMDC 20: P3

ConvenerSHRI U. MOHAN RAO Bharat Heavy Electricals Ltd, Hyderabad

MembersSHRIS.L.ABHYANKAR

SHRI U. G. BHONSLE ( Alternate )SHRI D. K. DAS

SHRI L. P. SINGH (Alternate)DR KRISHAN LAL Bharat Heavy Electricals

SHRI K. RAMANA REDDY ( Alternate I )SHRI A. L. SURI i Altemate II )

SHRIM.S. R. V. PRASADSHRI D. K. SEHGAL

SHRI BALRAJ SETH (Alternate)SHRI A. SHANMUGASUNDARAM

Greaves Cotton & Co Ltd, GLED, Bombay

Heavy Engineering Corp Ltd, Ranchi

Ltd, Hyderabad

Steelcast Bhavnagar Pvt Ltd, BhavnagarLeader Engineering Works, JuJlundur

Sri Ramakrishna Steel Industries Ltd, Karamadai

2

IS: 2856 -1979.

Indian StandardSPECIFICATION FOR

CARBON STEEL CASTINGS FOR PRESSURECONTAINING PARTS SUITABLE FOR

HIGH TEMPERATURE SERVICE( FUSION WELDING QUALITY)

( Second Revision)O. FOR E W 0 R D

0.1 This Indian Standard ( Second Revision) was adopted by the IndianStandards Institution on 18 April 1979, after the draft finalized by theSteel Castings Sectional Committee had been approved by the Structuraland Metals Division Council.0.2 This standard was first published in 1964 and was revised in 1974.While reviewing the standard in the light of the experience gained duringthese years, the Sectional Committee has decided to issue the secondrevision modifying the chemical and the mechanical requirements to bringthem in line with the present practices being followed in this field.0.3 Carbon steel castings for valves, flanges, fittings, or other pressurecontaining parts for high temperature service and of quality suitable forassembly with other castings or wrought steel parts by fusion welding arecovered by this specification. The proper selection of the grade of thematerial for a specific application will depend upon design and serviceconditions, mechanical properties and high temperature characteristics.

0.4 In the formulation of this standard due weightage has been given tointernational co-ordination among the standards prevailing in differentcountries in addition to relating it to the practices in the field in this

c' country. This has been met by deriving assistance from the followingpublications:

BS: 1504: 1958 Steels for use in the chemical petroleum and alliedindustries. British Standards Institution.

ISO Rf831-1968 Rules for construction of stationary boilers.International Organization for Standardization.

ASTM Designation: A 216-77 (a) Specification for carbon-steelcastings suitable for fusion welding for high-temperature service.American Society for Testing and Materials.

3

en

IS: 2856 ·1979

0.5 For the benefit of the purchaser, an informative appendix (seeAppendix A) giving particulars to be specified while ordering for the steelcastings has been included.

0.-6 For the purpose of deciding whether a particular requirement of thisstandard is complied with, the final value, observed or calculated,expressing the result of a test or analysis, shall be rounded off in accordancewith IS: 2-1960*. The number of significant places retained in the roundedoff.value should be the same as that of the specified value in this standard.

t. SCOPE

1.1 This standard covers the requirements for fusion welding qualitycarbon steel castings for pressure containing parts suitable for hightemperature service not exceeding 425°C.

2. TERMINOLOGY

2.0 For the purpose of this standard, the following definitions shall apply.

2.1 Cast (Melt) - The product of anyone of the following:a) One furnace heat,b) One crucible heat, orc) A number of furnace or crucible heats of similar composition

mixed in a ladle or tapped in separate ladles and poured simulta-neously for making a casting.

2.2 Batch - A group of casting of one grade of material, cast from thesame melt and heat treated together under identical conditions.

3. GRADES

3.1 The castings shall be of two grades, namely, Grade 1 and Grade 2.

4. SUPPLY OF MATERIAL f(

4.1 General requirements relating to supply of steel castings shall conformto IS: 8800-1978t.

5. MANUFACTURE

5.1 The steel for the castings shall be made by electric arc or electricinduction or such other processes as may be agreed to between thepurchaser and the manufacturer.

*Rules for rounding off numerical values (revised).tTechnical supply conditions for steel castings.

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IS : 2856 - 1979

(i. CHEMICAL COMPOSITION

.6.1 The ladle analysis of steel used for the two grades of castings whenanalyzed in accordance with the relevant part of IS : 228* shall conform tothe requirements given in Table I, .~~________________________________________________________________________________________________~/~~~t~ ~/II

TABLE 1 CHEMICAL COMPOSITION OF CARBON STEEL CAST1Nn·~({~"\.~~SUITABLE FOR IDGH TEMPERATURE SERVICE 1oloi ~\

(FUSION WELDING QUALITY) - •I \

CONSTITUENT ,..- ~~~~~ ~\ ~ 'Iti.Grade 1* Grade 2t . -.Percent Percent

••(1 ) (2) (3)

Carbon, Max 0'25 0'30Silicon, Max 0'60 0'60Manganese, Max 1'2 1'00Sulphur, Max 0'045 0'045Phosphorus, Max 0'040 0'040

*For each reduction of 0'01 percent below the specified maximum carbon content,an increase of 0'04 percent manganese above the specified maximum may be permittedup to a maximum of 1'40 percent.

tIf specifiedat the time of enquiry and order the requirements for carbon contents shallbe limited to 0'25 percent, .

6.1.1 In the interest of uniform welding, the following restrictions in the'concentration of unspecified alloying elements may be specified by thepurchaser:

Constituent Percent

Copper, MaxNickel, MaxChromium, MaxMolybdenum +

tungsten, MaxVanadium, MaxTotal content of these

unspecified elements, Max 1'00

6.1.2 Analysis for residual elements may be carried out when so specifiedby the purchaser.

0'500·500'400'25

0'03

*Methods of chemical analysis of steels ( second revision), ( Being issued in various parts ),

5

IS : 2856 -1979

6.2 The manufacturer shall carry out analysis from each cast of steel andshall supply certified cast analysis of a sample of the steel from each cast.

6.3 Product Analysis - The product analysis may be carried out from abroken tensile test piece or from a casting representing each melt.Drillings for analysis shall be taken not less than 6 mm beneath surfacesand in such manner not to impair the usefulness of any castings selected.The permissible variation in product analysis from the limits specified inTable I shall be as given in IS: 6601-1972*.

7. WORKMANSHIP AND FINISH

7.1 The castings shall be accurately moulded in accordance with thepattern or the working drawings supplied by the purchaser with the addi-tion of such letters, figures and marks as may be specified.

7.2 The purchaser shall specify the tolerances on all important dimensions.On other dimensions, tolerances specified in IS: 4897-1976t shall apply.

8. FREEDOM FROM DEFECTS

8.1 All castings shall be free from cracks and other defects that willadversely affect machining and utility of castings.

8.1.1 The castings shall not be peened, plugged or impregnated to stopleakages.

8.2 When necessary to remove risers by flame cutting, care shall be takento make the cut at a sufficient distance from the body of the casting so as toprevent any defect being introduced into the casting due to local heating.Any flame or arc cutting which may have to be done shall be carriedout before heat treatment.

8.3 In the event of any casting proving defective from foundry causes in thecourse of preparation, machining or erection, such castings may be rejected fnotwithstanding any previous certification of satisfactory testing and/orinspection.

9. FETTLING AND DRESSING

9.1 All castings shall be properly fettled and dressed, and all surfacesshall be thoroughly cleaned.

10. HEAT TREATMENT OF CASTINGS

10.1 All castings shall be supplied in the heat-treated condition.

*Permissible deviations in chemical composition for product analysis of steel castings.tDeviations for untoleranced dimensions and mass of steel castings (first revision).

6

IS : 2856 - 1979

10.1.1 Test bars shall be heat treated along with the castings theyrepresent.

10.2 The method of heat treatment and the relevant records of heattreatment shall be furnished to the purchaser, if so specified by the pur-chaser at the time of enquiry and order.

11. MECHANICAL TESTS

11.0 The mechanical properties specified are those which are to beobtained from test bars cast either separately from or attached to thecastings to which they refer. The test values so exhibited, therefore, repre-sent the quality of steel from which the castings have been poured; they donot necessarily represent the properties of the castings themselves.

11.1 In the case of a special or large casting or in other cases, the purchasermay specify at the time of enquiry and order that the test bar bc castattached to the casting from which the mechanical tests are to beconducted. The purchaser shall show the size and the location of suchan attached test bar on the drawing, in the absence of which the manufac-turer may use his discretion in this regard.

11.1.1 Such a test bar shall not be detached from the casting untilthe heat treatment of the casting is over and it has been stamped bythe purchaser.

11.2 Tensile Test - The tensile test shall be carried out in accordancewith IS: 1608-1972*. The minimum tensile strength, yield strength (or0'5 percent proof stress), reduction in area and elongation shall be asspecified in Table 2.

B.2.1 Should a tensile test piece break outside the middle half of itsgauge length and the percentage of elong.ition obtained is less thanthat specified, the test may be discarded at the option of the manufacturerand another test made from the sample selected representing the same castand batch.11.3 Charpy V-Notch Irnpact Test - If specified by the purchaser atthe time of enquiry and order, the impact values when tested in accordancewith IS : 1757-19 74t shall be as specified in Table 2.

11.4 Bend Test - If specified by the purchaser at the time of enquiry andorder, the bend test shall be carried out in accordance with IS: 1599-1974!.Test pieces shall be capable of being bent cold without fracture to anangle of 90° round a former having a radius of 25 mm.

*Methods for tensile testing of steel products i first revision).tMethods of beam impact test (V-notch) on steel (first revision).tMethod for bend test for steel products other than sheet, strip wire and tube (first

revision) .

7

~et~•••••••••••••••••••••••••••••••••••••••• ~;

IS :2856 • 1979

TABLE 2 PROPERTmS OF CARBON STEEL CASTINGS SUITABLE FORHIGH TEMPERATURE SERVICE (FUSION WELDING QUALITY)

( Clauses 11.2 and 11.3 )

GRADE ULTIMATE YIELD ELONGATION, REDUCTION tIMPACT VALUETENSILE STRENGTH PERCENT OF AREA, CHARPY V-

STRENGTH Min MINIMUM PERCENT NOTCHMin ( GAUGE LENGTH Min Min

t:;j-MPa* MPa* So Jt

(1 ) (2) (3) (4) (5) (6)

1 500 280 20 35 202 500 250 20 35 20

*IMPa = 1 N/mm2 = 1 MN/m2 = 0-1020 kgfjrnm",

t1J = IN.m = 0'1020 kgf.m.

11.4.1 Bend test pieces shall be of suitable length; convenient for themachine in which they will be bent, and shall have either a diameter of25 mm or a rectangular section of 25 X 20 mm. The edge of the rectangulartest piece shall be rounded to a radius of not more than I:5 mm andthe test shall be made by bending the test piece over the thinner section.

12. ELEVATED TEMPERATURE PROPERTIES

12.1 The minimum values for ratio of 0'2 percent proof stress at elevatedtemperatures (Et) to the specified minimum ultimate tensile strength atroom temperature (R) shall be as givcn below:

Temperature °C 250 275 300 325 350 375 400 425EtfR 0'40 0'38 0'36 0'34 0-33 0'32 0'31 0'30

12.2 If required by the purchaser and specified in the enquiry and order,the manufacturer shall either:

a) certify that the castings have the properties as specified in 12.1, orb) Hot-test the material at the temperature stated in the order, in

which case 02 percent proof stress values obtained shall benot less than those calculated on the basis given in 12.1.

13. NON·DESTRUCTIVE TESTS

13.1 Non-destructive testing may be applied by agreement between thepurchaser and the manufacturer, in which case it shall be clearly specifiedin the enquiry and order.

8

IS : 2856 • 1979

14. HYDRAULIC TESTS

14.1 If specified by the purchaser at the time of enquiry and order,castings shall be pressure tested in a manner agreed to between the purcha-ser and the manufacturer.

15. SAMPLING

15.1 The methods of sampling the steel castings for the purpose of chemicalanalysis and mechanical tests including retest shall be in accordance withIS: 6907-1973*.

16. REPAIR OF CASTINGS

16.1 Unless otherwise specified by the purchaser on the enquiry and order,castings may be rectified by the welding without the previous permission ofthe purchaser.

16.1.1 All repairs by welding shall be carried out in accordance with theprocedure laid down in IS: 5530-1969t.

16.2 If castings have been subjected to non-destructive testing byagreement between the purchaser and the manufacturer, the castings shallbe re-examined in the area of repair following any rectifying operation per-formed on the castings.

17. MARKING

17.1 Each casting shall be legibly marked with the following:

a) The number of identification mark by which it is possible to tracethe melt and the heat treatment batch from which it was made,

b) Grade of the casting,

c) The manufacturer's initial or trade-mark, and

d) Other identification marks in accordance with the agreementbetween the purchaser and the manufacturer.

17.2 By agreement between the purchaser and the manufacturer, castingscomplying with the requirements of this standard shall, after inspection, belegibly marked with an acceptance mark.

*Methods of sampling steel castings.+Code of procedure for repair and rectification of steel castings by metal arc welding

prOCeSS.

9

IS : 2856 - 1979

17.2.1 The castings may also be marked with the ISI CertificationMark.

NOTE - The use of the ISI Certification Mark is governed by the provisions of theIndian Standards Institution ( Certification Marks) Act and the Rules and Regulationsmade thereunder. The ISI mark on products covered by an Indian Standard conveysthe assurance that they have been produced to comply with the requirements of thatstandard under a well-defined system of inspection, testing and quality control whichis devised and supervised by ISI and operated by the producer. ISI marked productsare also continuously checked by ISI for conformity to that standard as a furthersafeguard. Details of conditions under which a licence for the use of the ISICertification Mark may be granted to manufacturers or processors, may be obtainedfrom the Indian Standards Institution.

APPENDIX A( Clause 0.5)

INFORMATION TO BE SUPPLIED BY THE PURCHASER

A-I. BASIS FOR ORDER

A-I.I While placing an order for the purchase of steel castings covered bythis standard the purchaser should specify the following:

a) Material specification;b) Drawing or reference number of the pattern (if supplied by the

purchaser), along with a copy of the drawing;c) Tests required;d) Whether the cas lings are to be inspected and tested m the

presence of the purchaser's representative;e) Condition of delivery;f) Any special requirements; andg) Test reports, if required.

10

INDIAN STANDARDSONSTEEL CASTINGS

IS:276-1978

1030-19742644-19792707-19732708-19732856-1979

Austenitic manganese steel castings ( third revision)Carbon steel castings for general engineering purposes (second revision)High tensile steel castings (second revision)Carbon steel castings for surface hardening (first revision)1·5 Percent manganese steel castings (first revision)Carbon steel castings suitable for high temperature service (fusion weldingquality) (second revision)Steel castings for ship's structure (first revision)Steel castings for marine engines and boilersAlloy steel castings for pressure containing parts suitable for high temperatureservice (first revision)Corrosion resistant alloy steel and nickel based casting for general applications(first revision)Comparison of Indian and overseas standards for steel castingsSteel castings for high magnetic permeability (first revision)Heat resistant alloy steel castingsOne percent chromium steel castings for resistance to abrasion (first revision)Deviations for untoleranced dimensions and mass of steel castings (first revision)Steel castings for case carburizingFerritic steel castings for use at low temperatures (first revision)Cast alloy steel grinding mediaPermissible deviations in chemical composition for product analysis of steelcastingsFerritic and austenitic steel castings for high-temperature serviceLow alloy steel castings suitable for pressure serviceCode of inspection of surface quality of steel castings" for valves and fittings( visual method)Technical supply conditions for steel castings

2985-19732986-19643038-1974

3444-1978

4331-19674491-19794522-19684896-19764897-19764898-19684899-19766079-1971660~-1972

7806-19757899-19758092-1976

8800-1978

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