IBR Services

Thanks to, over 2 decades of rich experience in IBR work, Celsun undertake Boiler approvals, Boiler consultancy & Liasoning contracts, for steam boiler plants, all over the India. The Indian Boiler Authorities strictly enforce the requirements of IBR, refusing site installation or assembly of any materials that are not correctly certified to the Indian Boiler Regulations. Compliance with IBR is confirmed via certification on relevant IBR forms issued and/or endorsed by Competent Persons of an Inspecting Authority recognized by the Central Boilers Board - India.

We have executed over 100 projects involving design, consultancy, supervision & IBR related work. Renewed boiler OEM’s such as Thermax & Forbes Marshall are our regular clients. You can contact us for following services:

• Consultancy on green field boiler Project

• Design of Boiler Plant & steam piping

• Organizing visit of Inspector & Supervision of inspection.

• Assistance in Boiler Registration

• Assistance in Drawings correction & approvals

• Assistance in getting provisional order for firing

• Assistance in Registration Number engraving

• Assistance in organizing & supervising Steam test

• Stress analysis

Boiler Plant 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.

Hydraulic Test:

Hydraulic test of boilers & various components like Drums, Headers, piping, tubular products at works. Hydraulic test of boilers at site after erection and for renewal of certificate for use of boiler. Venting, Test pressure, Number of calibrated gauges, Holding time, method of Inspection, Maker’s stamp as stipulated in regulation.

Inspection & Certification:

• Stages of Inspection during manufacture of Boiler/Boiler Components, different forms and their applicability. Fees for approval of drawings/design, inspection during manufacture, erection, registration.

• Calculation of heating surface area of boilers and its components

• Exemptions as per Act.

Field installation and registration

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 non destructive examination. Evaluation of field welds by RT, UT, MT or PT or by combination.

Heat Treatment where applicable method for local HT and controls - Witnessing final Hydraulic test before thermal insulation, water quality and temperature, 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

Requirements for Registration of boilers.

Repair and Renewal of Certificate for use of Boilers.

Procedure for Inspection and repair of Installed Boilers & Steam pipes.

Consultancy on 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 examination, Conducting laboratory examination on tube samples for erosion / corrosion, creep damage, 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 mountings, 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.