Involvement of Directorate of Boilers in

Power Plant Renovation & Modernization

Project Site

Date: 10.07.2014
RANENDRA CHAKRABORTY
Directorate of Boilers

Directorate of Boilers is a Statutory Body acting in accordance

with the provisions of the Boilers Act-1923 and the Indian Boilers
Regulation and the rules made there under. It is a technical
Directorate which mainly deals with the material, design,
construction, erection, inspection and certification of Boilers
under construction and in use.
Main Functions of the Boiler Directorate

1. Scrutiny and approval of design, material and drawings of boilers.

2. Inspection and certification of boilers under construction.

3. Inspection of boilers during Registration/Erection.

4. Annual inspection and certification of boilers while in use.

5. Destructive and Non-Destructive testing of parts of boiler.

6. To conduct Boiler Operation Engineers’ Exam.

7. To conduct First Class Boiler Attendants’ Examination.

8. To conduct Second Class Boiler Attendants’ Examination.

9. Certification of IBR Welders.

10. To conduct Remnant Life Assessment of boilers.

11. Transfer of ownership formalities.
12. Registration of boilers as per IBR-1950.
13. Welders’ Training Centre.
14. Approval of repairer and erector of boiler.
15. Approval of manufacturer of pressure parts of boilers, mountings and fittings.

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Sequence of IBR Activities at Erection site

1. Approval of Scope & Drawings

A write up with detail scope to be submitted to Directorate of Boilers along with

GA drawing for approval.

All erection drawing need to be submitted for scrutiny and subsequent approval
from Directorate of Boilers.

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2. Dry Inspection

a) Shutdown the plant in which renovation will be taken place.

b) Application to be submitted to Directorate of Boilers for Dry Inspection

of the boiler.

3. Approval of Erector

a) After approval of scope of work and erection drawings, application

to be submitted for Erector Approval.

b) Erector approval is required before commencing of any dismantling work.

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4. Ground Inspection of Pressure Parts

Ground Inspection of Pressure Parts to be conducted before starting

of Erection.

All original IBR inspection certificates are require during ground inspe
ction.

5. Welder Qualification for Pressure Part Welding

Welder Qualification test to be conducted at site in presence of IBR

Inspecting Authority.

Pressure part welding can be started only after welder qualification.

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6. Material Compatibility

For replacing an existing material with a different material, Material

Compatibility Chart to be submitted to IBR for approval. Following things
to be consider in material compatibility chart

1. Material description.
2. Material specification old and new.
3. Design temperature.
4. Allowable stress values at design temperature for old and new materials.
5. OD X Thickness of the material for old and new.
6. Minimum design thickness of the material for old and new.
7. Provided thickness of the new material.
8. Creep Rupture values at 100000 hours for old and new material.
9. Supply condition of the new materials.
10. Oxidation temperature.

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7. Stage Inspection
IBR inspecting authority will witness the following during stage inspection:

a) Fit up of pressure part weld joints.

b) Weld visual.
c) Non-destructive test.
d) PMI inspection.
e) Fiberscopic inspection(if require).

8. Hydro test of Boiler

After completion of all stage inspection and acceptance of all radiography

films, clearance of hydro test will be given by IBR inspecting authority.

IBR inspecting authority will witness the hydro test and will give final acceptance.

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