TRAINING

COMPETENT PERSONS FOR INSPECTION

&
CERTIFICATION OF BOILERS
Schedule for 2023

Gavade Institute of Nondestructive Testing & Training (GINDT)

710/3A Ground Floor, Swami Vivekananda Road, Angol, Belgaum - 590 006, Karnataka State, INDIA
 Walk-able Distance from 34 No. Marathi Government School Bus Stop:2minutes
Phone No.:+091-831-2484060, Fax No.:+091-831-2469074, Mobile No.:+091-9632916690
Email: gindtbelgaum@gmail.com , Website: www.gindt.org

Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org

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 PFD-Process or Block Flow Diagram of a typical Coal-Fired Thermal Power Plant/Station

In a coal based power plant coal is transported from coal mines to the power plant by railway in wagons or in
a merry-go-round system. Coal is unloaded from the wagons to a moving underground conveyor belt. This
coal from the mines is of no uniform size. So it is taken to the Crusher house and crushed to a size of 20mm.
From the crusher house the coal is either stored in dead storage( generally 40 days coal supply) which serves
as coal supply in case of coal supply bottleneck or to the live storage(8 hours coal supply) in the raw coal
bunker in the boiler house. Raw coal from the raw coal bunker is supplied to the Coal Mills by a Raw Coal
Feeder. The Coal Mills or pulverizer, pulverizes the coal to 200 mesh size. The powdered coal from the coal
mills is carried to the boiler in coal pipes by high pressure hot air. The pulverized coal air mixture is burnt in
the boiler in the combustion zone.

Generally in modern boilers tangential firing system is used i.e. the coal nozzles/ guns form tangent to a
circle. The temperature in fire ball is of the order of 1300 deg.C. The boiler is a water tube boiler hanging
from the top. Water is converted to steam in the boiler and steam is separated from water in the boiler
Drum. The saturated steam from the boiler drum is taken to the Low Temperature Superheater, Platen
Superheater and Final Superheater respectively for superheating. The superheated steam from the final
superheater is taken to the High Pressure Steam Turbine (HPT). In the HPT the steam pressure is utilized to
rotate the turbine and the resultant is rotational energy. From the HPT the out coming steam is taken to the
Reheater in the boiler to increase its temperature as the steam becomes wet at the HPT outlet. After
reheating this steam is taken to the Intermediate Pressure Turbine (IPT) and then to the Low Pressure
Turbine (LPT). The outlet of the LPT is sent to the condenser for condensing back to water by a cooling water
system. This condensed water is collected in the Hot well and is again sent to the boiler in a closed cycle. The
rotational energy imparted to the turbine by high pressure steam is converted to electrical energy in the
Generator.
Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org
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Examination will contain the following papers:

Paper Description Duration Marks

Open Book (IBR, 1950 & the Boilers Act, 1923) Multiple Choice 3 Hours 150 Marks
Duration
Questions (MCQ) & Descriptive Examination on Boiler Act and
Paper – I
Indian Boiler Regulations and their compliance &
Boiler Design Engineering
Paper – II Open Book, Multiple Choice Questions (MCQ) & Descriptive 3 Hours 150 Marks
Examination on Boiler Design, Manufacturing, Materials, Erection, Duration
Commissioning, Operation & Maintenance, Inspection &
Certification during manufacture or operations
and High Pressure Welding Inspection and Welder Qualification
130 Marks
Viva – Voce after passing the above examination

Schedule of Examination:
Date/Day Paper Timings Examination Marks
Morning Session Open book, Multiple Choice
Question & descriptive
09.30 a.m. to examination on Boiler Act and
Paper – I 150 Marks
12.30 p.m. (3 Hours) Indian Boiler Regulations and their
compliance & Boiler Design
Engineering
Paper – II Afternoon Session Open book, Multiple Choice
Question (MCQ) & Descriptive
02.00 p.m. to examination on Boiler Design,
05.00 p.m. (3 Hours) Manufacturing, Materials, Erection,
Commissioning, Operation & 150 Marks
Maintenance, Inspection &
Certification during manufacture or
operations and High Pressure
Welding Inspection
Viva – Voce Viva – Voce 130 Marks

Note: Examination Schedule to be obtained from the Central Boilers Board (CBB)

Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org

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Indian Boiler Regulations-1950

These Regulations shall apply to all boilers including those working on principles of natural circulation
and forced flow with no fixed steam and water line. Which are going to install in Indian, States
Jurisdiction the fabrication can be done at India or outside the India, then following criteria are apply.
For individual components or new constructed and assembled boilers.

Indian Boiler Regulations, 1950 deals with the following:

 General and Standard requirement of Boilers

 Materials for construction of Boilers-Plates, Pipes, Forged Fittings, Castings and Welding Electrodes
 Working pressure to be allowed for various pressure containing parts of Boiler
 Requisite mounting and fittings of Boilers
 Steam Pipes and fittings
 Registration/Erection and Inspection of Boilers and Pipe lines
 Safety of person inside boilers during new construction and in-service inspection of Boilers
 Economisers, Feed Pipes and Feed Water Heaters
 Registration/Erection and inspection of economiser
 Shell type Boilers of Welded construction
 Qualification Test for Welders – WPQ as per IBR
 Review of WPS-Welding Procedure Specification, as per ASME, BPVC Section-IX
 Qualification Test for PQR-Procedure Qualification Records, as per ASME, BPVC Section-IX
 Small Industrial Boilers
 Feed Water for Boiler
 Boiler Blow down unit and Pumps
 Fees for Registration/Erection and Inspection of Boilers and related activities
 Different types of Forms for Registration/Erection and Inspection of Boilers and Boiler mounting
accessories

When ASME Code Stamp – “S” is applicable by the Code then following standards are used.

ASME Boiler and Pressure Vessel Code, Section I: Rules for Construction of Power Boilers

ASME Boiler and Pressure Vessel Code, Section VIII, Division 1: Rules for Construction of Pressure Vessels

ASME Boiler and Pressure Vessel Code, Section IX: Welding and Brazing Qualifications

2021 ASME Boiler and Pressure Vessel Code, Section V: Nondestructive Examination
+
Indian Boiler Regulations-1950

Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org

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Repairs and alterations of boilers and pressure vessels

The National Board of Boiler and Pressure Vessel Inspectors Codebook, popularly known as the NBIC
(National Boiler Inspection Code), has a long history of setting jurisdictional standards in North America;
and, it is the only standard recognized worldwide for in-service inspection, repairs and alterations of
boilers and pressure vessels.

It is divided into four volumes or parts.

The parts of NBIC Edition: 2021 are listed below.

Document No. NBBI NB 23
Document Year: 2021

Part 1 : Installation — This Part provides information and guidance to ensure all types of pressure-
retaining items are installed and function properly. Installation includes meeting specific safety criteria
for construction, materials, design, supports, safety devices, operation, testing, and maintenance.

Part 2 : Inspection — This Part provides information and guidance needed to perform and document
inspections for all types of pressure-retaining items. It includes information on personnel safety, non-
destructive examination, tests, failure mechanisms, types of pressure equipment, fitness for service, risk-
based assessments, and performance-based standards.

Part 3 : Repairs and Alterations — This Part provides information and guidance to perform, verify, and
document acceptable repairs or alterations to pressure-retaining items regardless of code of
construction. Alternative methods for examination, testing, heat treatment, etc., are provided when the
original code of construction requirements cannot be met. Specific acceptable and proven repair
methods are also provided.

Part 4 : Pressure Relief Devices — This Part provides information and guidance to perform, verify, and
document the installation, inspection, and repair of Pressure Relief Devices, including a supplemental
section that contains specialized information, such as pressure margins, recommended repair practices,
and test stand design details.

Note: Shall to be consider here as a “Mandatory Requirements” in this context

Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org

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 Annexure- I
SYLLABUS
Paper: 1 - Boiler Act, Indian Boiler Regulations and their compliance and Boiler Design Engineering
(Three hours, Open Book (IBR, 1950 & the Boilers Act, 1923), Multiple Choice Question &
Descriptive Examination)

Boiler Act and Indian Boiler Regulations:

Salient Features of Boiler Act 1923 (as amended) and Indian Boiler Regulations, 1950 (as amended).

Water tube boilers: Classification of boilers- Natural circulation, Forced circulation, Fluidized Bed Combustor
Boiler (FBC), Circulating Fluidized Bed Combustor Boiler (CFBC), Waste heat boiler or WHRB-Waste Heat
Recovery Boilers, Chemical recovery boilers, Cycles for Steam Power Plants.

Once through boilers, Supercritical boiler and Ultra-supercritical boiler functions and differences, advantages
and disadvantages.

Solar Boilers, unfired boilers including thermic fluid boilers Water circuit and steam circuit.
Fire tube boiler: Shell type boilers – Horizontal and Vertical boiler, Various types of furnaces, Furnace heat
release rates for solid fuel and Oil fired Boilers, Methods of various attachments in Shell and furnaces.

Boiler Design and Engineering :Design calculation methods – factors to be considered in designing a boiler,
boiler layout, pressure part arrangement, pressure and temperature drops across the boiler - temperature
control methods, High temperature properties (Hot yield, creep) of steel and design criteria for ascertaining
permissible stress and maximum temperature for use of each grade of steel - Design calculation to ascertain
maximum working pressure of parts, tubes exposed to hot gases connecting pipes, headers, pipes and drums,
ligament efficiency, method of compensation for opening, method of attachment of tubes and branch pipes,
Longitudinal Stress, bending moment etc., weld coefficient.

Elements of feed water heaters –Design and construction including tube expansion methods.

Design & working pressure calculations for shell type boilers, ligament efficiency, end plates
/ tube plates, tube design, furnace design, method of compensation for openings, stay rods, gussets, stiffeners,
pressure circle calculations etc.

Various boiler mountings and auxiliaries like fusible plugs, safety valves, safety valve selection criteria and
capacity calculation, electromatic safety valves, drum level indicators, selection of feed water pumps etc.
Boiler components, piping, fitting, steam receivers, valves, steam traps, new materials.

Criteria for adopting Pressure reducing and de-superheating stations (PRDS), Feed water control system, Tees,
elbows, bends and fittings.
Metal temperature calculations for various sections of boiler. MDMT - Minimum design metal temperature and
this temperature is stamped on the vessel nameplate.
Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org
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 Paper – 2 - Boiler Design, Manufacturing, Materials, Erection, Commissioning, Operation
and Maintenance, Inspection & Certification during manufacture or operations and High
Pressure Welding Inspection
(Three hours, Open Book (IBR, 1950 & the Boilers Act, 1923), Multiple Choice Question &
Descriptive Examination)

Boiler Design
All aspects of boiler design included.

Materials
Classification of materials, Classification of steels, boiler materials, basic metallurgy, weldability of materials,
plates , pipes, tubes, casting and forgings of boiler quality and welding electrodes, process of steel
manufacturing, chemical composition, mechanical properties, tolerances, knowledge on equivalent
international materials used in boiler manufacture ,well known steel
/forge/foundry/ pipe / tube maker etc requirements, procedures, inspection and testing to be done in the
absence of well-known recognitions, new materials.
Construction and workmanship

Welding- Welding procedure, Welders Qualification, Initial Qualification & renewal for welders, Conditions
under which requalification test is required, tests to be done on plate/Pipe & Tube for Initial and
requalification, Essential variables. Tube Welding and Tube to Tube Sheet Welding in Heat Exchangers.

Welding processes : SMAW, GTAW, GMAW, SAW, FCAW, GMAW, Combination welding, Plasma, Flash butt
welding, Induction Pressure welding, etc., welding consumables and their classification, welding engineering
(joint design, fit-up, weld & welding symbols), reinforcement requirements, weld defects unique to each
weld-fit-up process and their acceptance norms, methods & norms for weld repairs.
Welding Consumables - initial/periodic check tests on consumables as per IBR.

Heat Treatment
Preheating, Post heating and Post weld heat treatment, Criteria for application of PWHT for Shells, Drums,
Headers, piping, Tubular products, method of loading, calibration of furnaces and measuring instruments,
soaking temperature / time, Rate of heating / cooling . Loading and Unloading Heat Treatment witnesses.

Different process adopted in welding of tubes, pipes, Shells, Visual Inspection of welds, reinforcement
requirements, acceptance norms for weld defects, norms & method for weld repairs.
Destructive Testing (DPA-Destructive physical analysis) : Mechanical Testing
Ultimate Tensile Testing, Impact Testing, Bend Test, Hardness Test, Macro Test of Weld and Micro Test of Weld
Non-destructive Testing: Mandatory NDT requirements for various welds on tubes, pipes, headers and
drums, Qualification of NDE personnel.
PT- Liquid Penetrant Testing
Principles of liquid penetrant process, Lighting for liquid penetrant testing Materials for liquid penetrant
testing, Testing of materials, Interpretation/Evaluation, Factor affecting indications, Indications from
discontinuities, Procedures, Codes/Standards/Specifications. Non relevant indications.
Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org
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MT- Magnetic Particle Testing
Characteristics of magnetic fields and equipments, Technique/Calibrations, Selecting the proper
method of magnetization, Magnetic particle test indications and interpretations, Procedures,
Codes/Standards/Specifications. Non relevant indications.

RT-Radiographic Testing
Principles Radiographic imaging, Sources for radiation, Techniques / Calibration, Imaging considerations, Image
Quality Indicator (IQI), Density of material, Viewing of radiographs, Judging radiographic quality, Interpretation
and Evaluation: Radiographic appearance of discontinuities, Non-relevant indications, Film artifacts, Film
identification and correlation of the weld, Procedures, Codes/Standards/Specifications. X and Gamma Ray.

UT-Ultrasonic Testing
Principles, Equipment/Materials, Pulse/echo instrumentation, Calibration blocks, Techniques/Calibrations, Use
of all types of probes, Calibration(electronic and functional), Interpretation and Evaluations: Evaluation of base
metal, product forms, Evaluation of weldments, Variables affecting test results, Procedures,
Codes/Standards/Specifications.

VT-Visual and Optical Testing: Visual Inspection of Welds and measuring Instruments for inspection

PMI - Radioscopy Test (Fluoroscopy) - refer in next page No.10 of 11.

Field installation and registration of Boilers

Review of document of boiler parts as received and correlation to the corresponding part - Verifying the
qualification of welders, NDE personnel etc, review and remedial action, Inspection during field installation
w.r.t parts identification, Weld setups, Welding and NDE - non destructive examination. Evaluation of field
welds by RT, UT, MT or PT or by combination. VT-Visual and Optical Testing of Welds, prior to Radiogrpahy.

Heat Treatment where applicable method for local HT and controls - Witnessing final Hydraulic test before
thermal insulation, water quality and temperature, PSV-Safety Valve set / reset pressure, discharge capacity,
Safety valve set pressure and discharge capacity for waste Heat Boiler with auxiliary firing, Water level
indicator and use of remote Water level indicator, Steam pipe lines cold / hot condition flexibility and hanger
settings, Verification of instruments to measure metal temperature, Steam temperature and pressure,
Protection of boilers through burner management system (Fuel cut off systems, flame scanner and trips ,
interlocks etc.).

Documentation for registration of boilers.

Inspection & Certification:
Stages of Inspection during manufacture of Boiler/Boiler Components, erection and use of different IBR forms
and their applicability, Memorandum of Inspection or registration Book (Form I) and its salient features.
Requirements for Registration of boilers.

Repair and Renewal of Certificate for use of Boilers:

Procedure for Inspection and repair of Installed Boilers & Steam pipes.
Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org
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Boiler Operation and Maintenance
Chemical requirements of feed water, Boiler water, steam quality for low, medium pressure, high and super-
critical Boilers, sampling methods, test method, Carryover, scale and sludge, scaling of fireside of heating
surfaces, steam contamination and its control, prevention of deposit formation in boiler units, corrosion of
heating surfaces, Start & stop sequence, operation procedure, critical boiler parameters, alarms and
annunciations, contingency action plan, safety precautions.

Boiler emergencies – How to handle

Boiler explosions – Reasons and Preventions

Boiler repairs – Methods and procedure, Failure analysis

Thick walled component repair at site – Precautions and limitations, Preheating and post heating, Post Weld
Heat Treatment

Maintenance schedule – shutdown maintenance, procedure, safety precautions, work permit system,
restarting procedure , acid cleaning, hydraulic test, light up of boiler, commissioning
Data acquisition and analysis – Broad idea, importance Boiler inspection periodicity, methods, procedure

In-service periodic inspection

Review mandatory requirements of operating boilers, Procedures for conducting periodic hydraulic test of
operating boilers, Elements of mode of failures of metals, Assessment of condition of boilers: - Review past
record of boilers w.r.t. failures, outages, repairs / replacements of pressure parts, Visual inspection of external
& internal surfaces for visible damages, loss of metal by erosion/corrosion, condition of tube supports, spacers
etc., fire side scaling, ash/slag fouling, Boilers with record of frequent failures may require detailed
investigation by conducting NDE using Dye penetrant / magnetic particle test for detecting cracks or UT to
determine thickness of tubes or cracks in dissimilar welds / fillet / butt weld cracking or RT in-situ metallurgical
examination, Conducting laboratory examination on tube samples for erosion / corrosion, creep damage,
hydrogen embrittlement, Stress Corrosion Cracking, Oxygen pitting, Oxidation, fire side fouling, water side
deposits and need for chemical cleaning etc., Authorization for repairs & replacement, Verifying the condition
of safety valves, water level gauges and other mounting, instruments for measuring temperature and pressure
and fire protection systems and interlocks, Isolation of steam and water circuits in battery of boilers and other
safety measures.

Remnant Life Assessment (RLA) of boilers

Criteria for R L A – Tests required for various boiler components, Evaluation methods for remaining life.

Fuel – Air – Gas system

Basics knowledge in the areas like Primary fuels, principles of combustion, chemistry of combustion, pulverized
coal fired furnaces, fuel oil and gas fired furnaces, controls and instrumentation and their effect on boiler
functioning. Isolation of Fuel/Flue Gas during inspection.

Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org

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 Layout and Sketches
Layout and Sketches of boilers & boiler components, steam & feed water circuits and their parameters.

Customer Complaints after installation of Boilers

Customer complaint understanding based on the various problems faced by boilers during operation, various
Corrosion and Damage Mechanisms affecting boilers.

Metallurgy, Corrosion and Damage Mechanisms affecting boilers

 Condensate Corrosion
 CO2 Corrosion
 Flue Gas dewpoint Corrosion

Positive Material Identification (PMI) is a fast and non-destructive testing (NDT) method for verifying the chemical
composition of metals and alloys. PMI can be used to verify that supplied materials conform to the proper
standards and specifications.

Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org

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 COURSE REGISTRATION FORM

Course Name: Competent Persons for Inspection & Certification of Boilers

Course Date: From to

Candidate Name to be appear in Certificate:

Designation:

Educational Qualification:

Address for Correspondence:

PIN:

Telephone No: Mobile No:

E-mail:

Employer Name:

Employer Address:

PIN:

Telephone No: Mobile No:

E-mail: Website:

Course Fees: Examination Fees:

Amount in Words:

Enclosed D.D./Cheque No. Drawn on Date:

Bank Name:

Cheque/D.D. to be drawn in favor of

Please Provide the E-Transfer details on separate sheet, and attached to this filled in form.

Signature:
Date:
Name of Candidate: GINDT Approved for this Batch

Gavade Institute of Nondestructive Testing & Training (GINDT) gindtbelgaum@gmail.com , www.gindt.org

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