PROTOCOL FOR INSPECTION OF IBR VALVES

IBR Inspection Protocol

Sl. No. Inspection Stages
1 One month advance intimation to be submitted in the form of
"Inspection Request Letter" tantative date of inspection.

2 Inspection dates to be settled in consultation with IBR

inspector.

3 Inspection of Forgings/ Casting prior to start machining but

along with original MTC. Inspection to be recorded in Form E
and shall be sign-off by IBR inspector.

4 Stage Inspection for verification of weld fittment and edge

preparation. Inspection to be recorded in Form E and shall be
sign-off by IBR Inspector.

5 Visual Checking of finish welding. Inspection to be recorded in

Form E and shall be sign-off by IBR Inspector.

6 Welding is permitted to perform only by the welder having

being qualified by IBR Authority.

7 Welding Electrode and Filler Rods of respective batch shall

have valid IBR periodical approval certificate issued to
electrode manufacturer. In absence of the same electrode shall
be tested and certified from local IBR laboratory.

8 PWHT as applicable to be done from a furnace duly approved

by IBR authority on the basis of periodical calibration.

9 Radiography Test to be done on welding of 5% valve and RT

films are to be checked and certified by IBR laboratory

10 Visual, Dimensional & Hydro-Pneumatic Testing on 10%

complete valves randomly selected from the batch lot.
Inspection Report to be documented in IBR Form E and shall be
sign-off by the IBR Inspector. The same will be submitted to
local IBR office for necessary verification and sign by Joint
Director. The document shall be obtained in original from IBR
office. It may take 3/7 days time.

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11 verification of valid calibration status of pressure gauges

installed in testing bench.

12 Periodical verification of calibration certificate of gauges.

13 Review and verification of documents as mentioned below.

14 Final Certification in IBR Form IIIC shall be submitted against

receipt of Original IBR Form E. IBR Form IIIC duly signed by
manufacturer's represenative, HOD, IBR Inspector and
respective Boiler Director shall be received in duplicate. It may
take 10/ 15 days time.

Following Documentation are mandatory for IBR Inspection

Serial No. Title of Documents
1 Form E for Forging Inspection duly signed by IBR Inspection
authority.

2 Updated Stock Card showing cumulative balance as on date of

Inspection

3 IBR Approved Drawings for the offerred Items

4 Stage Inspection Form E for Welding.

5 Valid Welder's Qualification Certificate from IBR Laboratory

5 PWHT Graphs duly reviewed, accepted and signed by

manufacturer's representative. The graph shall mention the
item details, heating rate, soaking heat, soaking time, rate of
cooling in line with WPS, Material specification.

6 RT Film verification Report.

7 Form E for Final Inspection.

7 IBR Form IIIC

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Action
To be submitted to IBR Inspector at local IBR office.

To meet IBR Inspector at local IBR office on Monday of every week for
finalisation of weekly inspection schedule.

Stock Card mentioning Description, Size, Class, Material, Heat Code to be

be maintained till stock last.

IBR inspector will verify.

IBR inspector will verify.

IBR inspector will verify.

IBR inspector will verify.

IBR inspector will verify.

RT Films are to be submitted to IBR Lab and obtain reports of RT film

verification.

IBR inspector will witness the test.

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IBR inspector will physically varify the status.

IBR Inspector will verify the calibration certificate.

IBR Inspector will sign off the Form E.

IBR Form IIIC to be obtained from IBR office with in 10/15 days from the
date of submission.

Document Routing
To be submitted along with documents to local IBR office.

To be made available for verification by IBR Inspection Authority.

To be submitted along with documents to local IBR office.

To be submitted along with documents to local IBR office.

To be made available for verification by IBR Inspection Authority. May be

submitted on demand

To be submitted along with documents to local IBR office. The Graphs shall
duly signed by IBR Inspector.

To be submitted along with documents to local IBR office.

To be submitted along with documents to local IBR office.

To be reviewed endorsed and submit to QC dept.

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