IS I 1856 1979

Indian Standard
SPECIFICATION FOR CARBON STEEL CASTINGS FOR PRESSURE CONTAINING PARTS SUITABLE FOR HIGH TEMPERATURE SERVICE (FUSION WELDING QUALITY)

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( Second Revision)
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Q Copyright ~979

INDIAN

STANDARDS

INSTITUTION

MANAICBHAVAN.

9 BAHADUll SHAH ZAPAR MARO NBW DELHI 110002

October 1979

Is : 2856 -1979

Indian Standard
SPECIFICATION FOR CARBON STEEL CASTINGS FOR PRESSURE CONTAINING PARTS SUITABLE FO '~~~\. lJliof. HIGH TEMPERATURE SERVICE.. :; ): (FUSION WELDING QUALITY) :: \\<iJ " ...

( Second Revision)
Steel Castings Sectional Committee,
Chairman
SHRI T. KUMAR Steelcast

SMDC 20

Representing
Bhavnagar Pvt Ltd, Bhavnagar Ltd, Thana Locomotive Co Ltd,

Members
SHRI R. P. S. BURMEE SHRI A. K. MALLIK (Alternate) SHRI R. CHATURVEDI SHRI A. P. SINHA ( Alternate) DEPUTY CHIEF MECHANICAL EN GIN E E R, CHITTARANJAN L 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 SHRI R. N. RAY (Alternate) SHRI V. C. GOPALARAO SHRI C. K. KURIAKOSE (Alternate) SHRI S. MAJUMDAR SIfRI R. M. BALANI ( Alternate) SHRI B. V. PRABHU SHRI L. P. SINGH ( Alternate) Uni Abex Alloy Products Tata Engineering Jamshedpur of Railways &

Ministry

Ministry Hindustan

of Defence Shipyard

(DGI

Ltd, Vishakhapatnam of Technical Development,

Directorate General New Delhi Heavy Engineering

Corp

Ltd,

Ranchi

( Continued on page 2 )
@ Copyright 1979 INDIAN STANDARDS INSTITUTION

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

1S: 2856 -

197!>
Representing
Central Boilers Steel Authority Rourkela Board, Bangalore of India Ltd, Rourkela Steel Plant,

( Continued from page I ) Members

SHRl C. M. PRASAD SHRI P. P. RASTOGI

SHRl S. CHOWHAN ( Alternate) SHRI C. S. REDDY Bharat Heavy Electricals Ltd, Hyderabad SHRI U. MOHAN RAO (Alternate I ) SHRI C. VENKATARAMAN (Alternate II ) SHRI R. K. SRIVASTAVA Mukand Iron & Steel Works Ltd, Bombay SHRI Z. M. BHATE ( Alternate) SHRI K. M. TANEJA Directorate General of Supplies & Disposals (Inspection 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! SWARUP Deputy Director (Metals), ISI

Panel for Steel Castings for Pressure Parts for High Temperature Service, SMDC 20: P3
Convener
SHRI U. MOHAN RAO Bharat Heavy Electricals Ltd, Hyderabad

Members
Greaves Cotton & Co Ltd, GLED, Bombay SHRIS.L.ABHYANKAR SHRI U. G. BHONSLE ( Alternate ) Heavy Engineering Corp Ltd, Ranchi SHRI D. K. DAS SHRI L. P. SINGH (Alternate) Ltd, Hyderabad DR KRISHAN LAL Bharat Heavy Electricals SHRI K. RAMANA REDDY ( Alternate I ) SHRI A. L. SURI i Altemate II ) Steelcast Bhavnagar Pvt Ltd, Bhavnagar SHRIM.S. R. V. PRASAD Leader Engineering Works, JuJlundur SHRI D. K. SEHGAL SHRI BALRAJ SETH (Alternate) Sri Ramakrishna Steel Industries Ltd, Karamadai SHRI A. SHANMUGASUNDARAM

IS: 2856 -1979.

Indian Standard
SPECIFICATION FOR CARBON STEEL CASTINGS FOR PRESSURE CONTAINING PARTS SUITABLE FOR HIGH TEMPERATURE SERVICE ( FUSION WELDING QUALITY)

( Second Revision)
O. FOR EW 0 R D
0.1 This Indian Standard ( Second Revision) was adopted by the Indian Standards Institution on 18 April 1979, after the draft finalized by the Steel Castings Sectional Committee had been approved by the Structural and 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 during these years, the Sectional Committee has decided to issue the second revision modifying the chemical and the mechanical requirements to bring them in line with the present practices being followed in this field. 0.3 Carbon steel castings for valves, flanges, fittings, or other pressure containing parts for high temperature service and of quality suitable for assembly with other castings or wrought steel parts by fusion welding are covered by this specification. The proper selection of the grade of the material for a specific application will depend upon design and service conditions, mechanical properties and high temperature characteristics. 0.4 In the formulation of this standard due weightage has been given to international co-ordination among the standards prevailing in different countries in addition to relating it to the practices in the field in this country. This has been met by deriving assistance from the following publications: BS: 1504: 1958 Steels for use in the chemical petroleum and allied industries. 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-steel castings suitable for fusion welding for high-temperature service. American Society for Testing and Materials.

c'

en

IS: 2856 1979

0.5 For the benefit of the purchaser,

an informative appendix (see Appendix A) giving particulars to be specified while ordering for the steel castings has been included.

0.-6 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS: 2-1960*. The number of significant places retained in the rounded off.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 quality carbon steel castings for pressure containing parts suitable for high temperature service not exceeding 425C. 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, or c) A number of furnace or crucible heats of similar composition mixed in a ladle or tapped in separate ladles and poured simultaneously for making a casting. 2.2 Batch - A group of casting of one grade of material, cast from the same 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

4.1 General requirements relating to supply of steel castings shall conform to IS: 8800-1978t. 5. MANUFACTURE 5.1 The steel for the castings shall be made by electric arc or electric induction or such other processes as may be agreed to between the purchaser and the manufacturer.
*Rules for rounding off numerical values (revised). tTechnical supply conditions for steel castings.

IS : 2856 - 1979

(i. CHEMICAL COMPOSITION

.6.1 The ladle analysis of steel used for the two grades of castings when
analyzed in accordance with the relevant part of IS : 228* shall conform to

the requirements given in Table I, .~~ ~/II ___________________________________________________________________________ ~/~~~t~

TABLE 1 CHEMICAL COMPOSITION OF CARBON STEEL SUITABLE FOR IDGH TEMPERATURE SERVICE (FUSION WELDING QUALITY)
CONSTITUENT ,..~~~~~

CAST1Nn~({~"\.~~
1oloi ~\

I ~\ ~ \

'Iti.

Grade 1* Percent
(1 ) (2)

Grade 2t Percent
(3)

. -.

Carbon, Max Silicon, Max Manganese, Max Sulphur, Max Phosphorus, Max

0'25 0'60 1'2 0'045 0'040

0'30 0'60 1'00 0'045 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 permitted up to a maximum of 1'40 percent. tIf specified at the time of enquiry and order the requirements for carbon contents shall be 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 the purchaser:
Constituent Copper, Max Nickel, Max Chromium, Max Molybdenum tungsten, Max Vanadium, Max Total content of these unspecified elements, Max Percent 0'50 050 0'40 0'25 0'03 1'00

6.1.2 Analysis for residual elements may be carried out when so specified by the purchaser.
*Methods of chemical analysis of steels ( second revision), ( Being issued in various parts ),

IS : 2856 -1979 6.2 The manufacturer shall carry out analysis from each cast of steel and shall 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 a broken tensile test piece or from a casting representing each melt. Drillings for analysis shall be taken not less than 6 mm beneath surfaces and in such manner not to impair the usefulness of any castings selected. The permissible variation in product analysis from the limits specified in Table I shall be as given in IS: 6601-1972*.

7. WORKMANSHIP AND FINISH 7.1 The castings shall be accurately

moulded in accordance with the pattern or the working drawings supplied by the purchaser with the addition of such letters, figures and marks as may be specified. shall apply.

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

8. FREEDOM FROM DEFECTS 8.1 All castings shall be free from cracks and other defects that will
adversely affect machining and utility of castings.

8.1.1 The castings shall not be peened, plugged or impregnated

leakages.

to stop

8.2 When necessary to remove risers by flame cutting, care shall be taken
to make the cut at a sufficient distance from the body of the casting so as to prevent any defect being introduced into the casting due to local heating. Any flame or arc cutting which may have to be done shall be carried out before heat treatment. 8.3 In the event of any casting proving defective from foundry causes in the course of preparation, machining or erection, such castings may be rejected notwithstanding any previous certification of satisfactory testing and/or inspection. f

9. FETTLING AND DRESSING 9.1 All castings shall be properly fettled

shall be thoroughly cleaned. and dressed, and all surfaces

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).

IS : 2856 - 1979 10.1.1 Test bars shall be heat treated

represent. along with the castings they

10.2 The method of heat treatment

and the relevant records of heat treatment shall be furnished to the purchaser, if so specified by the purchaser at the time of enquiry and order.

11. MECHANICAL TESTS 11.0 The mechanical properties specified are those which are to be obtained from test bars cast either separately from or attached to the castings to which they refer. The test values so exhibited, therefore, represent the quality of steel from which the castings have been poured; they do not necessarily represent the properties of the castings themselves. 11.1 In the case of a special or large casting or in other cases, the purchaser
may specify at the time of enquiry and order that the test bar b c cast attached to the casting from which the mechanical tests are to be conducted. The purchaser shall show the size and the location of such an attached test bar on the drawing, in the absence of which the manufacturer may use his discretion in this regard.

11.1.1 Such a test bar shall not be detached from the casting until the heat treatment of the casting is over and it has been stamped by the purchaser. 11.2 Tensile Test - The tensile test shall be carried out in accordance with IS: 1608-1972*. The minimum tensile strength, yield strength (or 0'5 percent proof stress), reduction in area and elongation shall be as specified in Table 2. B.2.1 Should a tensile test piece break outside the middle half of its gauge length and the percentage of elong.ition obtained is less than that specified, the test may be discarded at the option of the manufacturer and another test made from the sample selected representing the same cast and batch. 11.3 Charpy V-Notch Irnpact Test - If specified by the purchaser at
the time of enquiry and order, the impact values when tested in accordance with 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 and order, 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 an angle 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) .

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IS : 2856 1979
TABLE 2 PROPERTmS OF CARBON STEEL CASTINGS SUITABLE FOR HIGH TEMPERATURE SERVICE (FUSION WELDING QUALITY)
( Clauses 11.2 and 11.3 )

GRADE

ULTIMATE TENSILE STRENGTH Min MPa*

YIELD STRENGTH Min MPa* (3) 280 250

ELONGATION, PERCENT MINIMUM ( GAUGE LENGTH

t:;jSo (4)

REDUCTION OF AREA, PERCENT Min

tIMPACT VALUE CHARPY VNOTCH Min Jt

(1 ) 1 2 *IMPa t1J

(2) 500 500

(5) 35 35

(6)

20 20
= 0-1020

20 20

1 N/mm2

1 MN/m2 kgf.m.

kgfjrnm",

IN.m

0'1020

11.4.1 Bend test pieces shall be of suitable length; convenient for the machine in which they will be bent, and shall have either a diameter of 25 mm or a rectangular section of 25 X 20 mm. The edge of the rectangular test piece shall be rounded to a radius of not more than I: 5 mm and the 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 temperatures (Et) to the specified minimum ultimate tensile room temperature (R) shall be as givcn below: Temperature C 250 275 300 325 350 375 400 EtfR 0'40 0'38 0'36 0'34 0-33 0'32 0'31
at elevated strength at 425 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, or b) Hot-test the material at the temperature stated in the order, in which case 02 percent proof stress values obtained shall be not less than those calculated on the basis given in 12.1. 13. NONDESTRUCTIVE TESTS 13.1 Non-destructive testing may be applied by agreement between the purchaser and the manufacturer, in which case it shall be clearly specified in 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 purchaser and the manufacturer. 15. SAMPLING 15.1 The methods of sampling the steel castings for the purpose of chemical analysis and mechanical tests including retest shall be in accordance with IS: 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 of the purchaser. 16.1.1 All repairs by welding shall be carried out in accordance with the procedure laid down in IS: 5530-1969t. 16.2 If castings have been subjected to non-destructive testing by agreement between the purchaser and the manufacturer, the castings shall be re-examined in the area of repair following any rectifying operation performed 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 trace the 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 agreement between the purchaser and the manufacturer. 17.2 By agreement between the purchaser and the manufacturer, castings complying with the requirements of this standard shall, after inspection, be legibly 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.

IS : 2856 - 1979 17.2.1 The castings may also be marked Mark. with the ISI Certification

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

APPENDIX
( Clause 0.5)
INFORMATION TO BE SUPPLIED

A
BY THE PURCHASER

A-I. BASIS FOR ORDER A-I.I While placing an order for the purchase of steel castings covered by this 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; and g) Test reports, if required.

10

INDIAN

STANDARDS

ON
STEEL CASTINGS IS: 276-1978 1030-1974 2644-1979 2707-1973 2708-1973 2856-1979 2985-1973 2986-1964 3038-1974 3444-1978 4331-1967 4491-1979 4522-1968 4896-1976 4897-1976 4898-1968 4899-1976 6079-1971 660~-1972 7806-1975 7899-1975 8092-1976 8800-1978 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) 15 Percent manganese steel castings (first revision) Carbon steel castings suitable for high temperature service (fusion welding quality) (second revision) Steel castings for ship's structure (first revision) Steel castings for marine engines and boilers Alloy steel castings for pressure containing parts suitable for high temperature service (first revision) Corrosion resistant alloy steel and nickel based casting for general applications (first revision) Comparison of Indian and overseas standards for steel castings Steel castings for high magnetic permeability (first revision) Heat resistant alloy steel castings One 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 carburizing Ferritic steel castings for use at low temperatures (first revision) Cast alloy steel grinding media Permissible deviations in chemical composition for product analysis of steel castings Ferritic and austenitic steel castings for high-temperature service Low alloy steel castings suitable for pressure service Code of inspection of surface quality of steel castings" for valves and fittings ( visual method) Technical supply conditions for steel castings

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