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ECL/EPCM/PIPING - IBR

INDIAN BOILER
REGULATION
(IBR)

PRESENTED BY:

MANJUNATH SHET
SUDHIR PATIL
PRASHANT PATHADE
ECL/EPCM/PIPING - IBR

 Introduction
 Definitions
 What is IBR?
 What is IBR in Piping?
 What is IBR purview?
 Equipments under IBR Purview
 Submissions for IBR approval
 Certification of forms
 Material for Piping
 Working pressure calculations
 Submission of plans
 Inspection
 Testing

ECL/EPCM/PIPING - IBR
Introduction

 What is IBR?
Indian Boiler Regulations are the
standards in respect of materials,
design and construction, inspection
and testing of boilers and boiler
components for compliance by the
manufacturer's and users of boilers in
the country.

ECL/EPCM/PIPING - IBR
Definitions as per IBR
 “The Act” means Indian boiler Act 1923.
 “Controlling Authority” means chief inspector of boiler.
 “Chief inspector” means body responsible for the
administrating regulation throughout India and approve
any installation.
 “Inspecting Authority” means Authority to inspect items
and grant certificates in form II,III A, III B.
 “Competent authority” means authority recognize by
central boiler to issue certificate to welders.
 “Boilers” means any closed vessels exceeding 22.75 liters
capacity which is used expressly generating steam under
pressure and includes mountings and other fittings.
 “Economiser” means any part of feed pipe that is wholly or
partly exposed to the action of flue gases for the purpose
recovery of waste heat .
ECL/EPCM/PIPING - IBR
Introduction
 IBR consist of 15 chapters with 635 regulations as Indian Boiler
Regulations -1950
 These are statutory rules of the central government but administration
of this rules are at state level i.e. The separate authority is located at
in each capital except Jammu and Kashmir
 All disputes in this regards have to be referred to central boiler board
Delhi
 The Central Boilers Board, constituted under Section 28 of the Indian
Boilers Act 1923 ( 5 of 1923) is responsible for making regulations for
lying down the standards for materials, design, construction as well as
for registration and inspection of boilers
 These regulations are being updated regularly by amending them in
line with fast changes in boiler technology by the Central Boilers
Board.

ECL/EPCM/PIPING - IBR
Introduction
 What is IBR in Piping?

 Installation of steam pipe lines (coming under IBR


purview) are required to be approved by the IBR
authorities of the state in which same is located.
 The equipment and other piping item manufactured in
particular state shall be approved by the IBR authority of
the state in which it is located
 Fabrication and installation of piping coming under IBR
purview shall not be carried unless installation drawing in
proper format are required to approved by IBR authority

ECL/EPCM/PIPING - IBR
Introduction

 IBR drawing checklist( Form FL408) available shall be


used during presentation and checking of IBR drawing so
that IBR drawings are approved by the state IBR authority

 IBR drawings of fabrication shall always submitted to


IBR authority with either companies (ESSAR) standard
Drawings for IBR fabrication details or clients fabrication
drawings if available

 Following Regulations of IBR are Important for Piping


Steam pipes and Fittings - Regulations 343 to 374
feed pipes – Regulations 520 to 534
valves and mountings – Regulations 519 and 364

ECL/EPCM/PIPING - IBR
IBR purview

What comes under IBR purview?


Steam lines with condition mentioned below comes under IBR
purview

 Lines for which design pressure 3.5 kg/sq.cm and above.


 Line size above 10 inch. Having design pressure 1 kg/sq.cm and
above.
 Boiler feed water lines to steam generator.
 Condensate lines to steam generator and Flash drum

ECL/EPCM/PIPING - IBR
Schematic presentation of IBR Piping

ECL/EPCM/PIPING - IBR
Equipments coming under IBR purview

• Boiler
• Economiser
• Super heater
• de-super heaters
• steam receivers
• feed heaters
• separately fired super heaters
• separators
• De aerator
• flanges
• Valves
• mountings

ECL/EPCM/PIPING - IBR
Submissions for IBR approval

 Back flow diagrams or systems PID showing the steam


system to be approved
 Piping and instrumentation diagrams
 Piping specifications
 Pipe thickness calculations
 Branch reinforcement calculations
 List of equipments generating\using steam
 Stress analysis calculations & supporting details
 Standard drawing for utility stations and steam trap
assemblies

ECL/EPCM/PIPING - IBR
Submissions for IBR approval
Contd…………

 Fabrication detail drawing showing the welding details


 Line list
 Relief valve list
 IFC isometrics showing support, standard notes, references
system wise for final IBR approval
 Piping G.A. drawings may be submitted (instead of IFC
approval)

ECL/EPCM/PIPING - IBR
Approval for piping

For Pipes
 Memorandum of Inspection on Form I
 Inspection Authority's certificate of inspection during the constriction
on form II
 Certificate of manufacturers and test on form III-A signed by maker
and inspection authority shall be furnished. This form intended for use
by both pipe manufacturer and fabricator
For Tubes
certificate of manufacturer and test on form III-B signed by maker and
inspection authority shall be furnished this form is intended for use by
both tube manufacturer and fabricator

ECL/EPCM/PIPING - IBR
Approval for Piping
Contd…….

For other items


For all other items like fittings, flanges, valves, traps etc. A
certificate of manufacturer and test on form III-C signed by
maker and inspection authority in respect of boiler
mountings and pipe fittings shall be furnished this form is
intended to both for manufacturer and fabricators

ECL/EPCM/PIPING - IBR
FEED PIPES

 Feed-pipe ─

 Means any pipe or connected fittings wholly or partly


under pressure through which feed-water passes
directly to a boiler.

 Every reference to a steam pipe or steam pipes shall be


deemed to include also a reference to feed pipe or feed
pipes respectively.
MATERIAL SELECTION

 As per Regulation 521 to 523 the material of feed pipe is :

 Cast-iron pipe:
The cast iron feed pipe will not be accepted for working
pressure over 200psi (pound per square inch) or 245º F.

 Copper pipe :
It is solid drawn and not exceed 8 inch external diameter
and may be used for working pressure not exceeding
350psi or 300º F.

 Steel pipe
Design Pressure

 Design Pressure for Feed Piping –

The design pressure shall be the maximum


pressure generated in overcoming friction and other losses
in the feed piping under ordinary working conditions, or
the maximum pressure which can be generated by the
boiler feed pumps unless special provision is made to
prevent that pressure being communicated to the pipe line.
Working Pressure calculations for feed pipes

 As per Regulation 522 –


 For cast iron pipe ,
W. P. = 130 (t-6)
d
where,
t= Thk of thirty second of inch
d= External dia of pipe in inch
 For copper pipe ,
W. P. = 60 (t-3)
d
where,
t= Thk in hundred of inch
d= External dia of pipe in inch.
Calculation of pipe wall thickness

 As per Regulation-350

P*D
T= + C
2 S*E + P

where
P = Design Pressure
D = OD of pipe
S = allowable working stress
E = joint efficiency
C = Corrosion allowance
T = thickness of pipe
INSPECTION OF FEED PIPE

 As per Regulation 534(A) –

 Feed pipes shall be inspected and hydraulically tested before


erection in place, and the hydraulic test pressure shall be not
less than twice the working pressure of the economiser.
If the Inspector is satisfied with the test, the pipes
may be erected.

 At subsequent inspection or at any other time, the Inspector


may make an external inspection of feed pipes and if found
in an unsatisfactory condition he shall report the matter to the
inspector who may require the pipes to be hydraulically
tested.
HYDRAULIC TEST

 Procedure for Hydraulic Test ─


( Regulation 527 )
Every economiser for registration shall be
hydraulically tested in the presence of an Inspector to 1½
times the working pressure. Hydraulic tests of economisers
at subsequent examination shall when required by the
Inspector, be made after the inspection. The test pressure to be
applied to economisers at subsequent examinations shall be
from 1¼ to 1½ times the working pressure of the economisers.
During the test, all parts externally and in the flues shall be
noted for leakage.
SUBMISSION OF PLAN OF FEED PIPE

 As per Regulation 534(B)─


 Plans of feed pipes shall be submitted with the prescribed
fee to chief inspector before construction
 The fees for scrutiny of plans and particulars of the material,
design and construction of feed pipes at the time of
commencement is Rs. 30 for 30 meters of piping.
 For any such fitting like feed water heater, the fees shall be
equal to which feed pipes is attached subject to a maximum
of Rs. 1500.
 The fees for scrutiny of lay-out plans of feed pipes shall be
Rs. 20 for 30 meters of piping or part thereof, subject to a
minimum of Rs. 50 exclusive of fitting like feed water
heater for any such fitting like feed water heater, the fee
shall be Rs. 510 for each such fitting.
STEAM PIPE

 “Steam-pipe” means any pipe through which steam passes


from a boiler to a prime-mover or other user or both, if –

 The pressure at which steam passes through such pipe


exceeds 3.5 Kilograms per square centimeter above
atmospheric pressure; or

 Such pipe exceeds 254 millimeters in internal diameter;


and includes in either case any connected fittings of a
steam-pipe.
MATERIAL SELECTION

 As per Regulation 344 ─


 The pipes shall be made from steel made by an Open Hearth of
Electric process or by any of the oxygen process.
 Hot finished seamless pipe may be made of Bessemer Steel.
Bessemer Steel shall not be used for pressure exceeding
21 Kg/cm² or temp. exceeding 260ºC.
 When used for temp. exceeding 399 deg. The steel shall be of
non- segregated or fully skilled type.
 carbon and alloy steel pipe shall not be used for design temp.
exceeding those given in table 2.
 For designed temp. over 427ºC. Special precaution shall be
taken to ensure that the surface condition of the pipe is suitable
for these requirement.
CONTD……

Max
Max
Permissible
Material Method of manufacture permissible Form
working
Temp. (oC)
pressure

Cold drawn seamless No restriction 454

Hot finished seamless No restriction 454


Straight, bents or
Carbon steel
Fittings
Butt welded (max bore 102 mm) 21 kg/ cm2 260

Electric resistance welded No restriction 454

Straight, bents or
Cast Steel Castings No restriction 454
Fittings
Cold drawn seamless and Straight, bents or
Molybdenum Steel No restriction 624
castings Fittings

Chromium Cold drawn seamless and hot Straight, bents or


No restriction 621
Molybdenum Steel finished seamless Fittings

Not allowed
Solid Drawn upto and including for Straight, bents or
Copper 12.6 kg/ cm2
127 mm. dia. Superheated Fittings
steam
Working pressure Calculation for steam pipes

 As per Regulation 350 ─

 For Steel pipe :


On the basis of outside diameter,
W. P. = 2fe (t-c)
D-t +c
On the basis of inside diameter,
W.P. = 2fe (t-c)
D+t-c where,
f= allowable stress
D= outside dia. Of pipe
e= efficiency factor
c= 0.75
CONTD…….

 For Cast Steel pipe (Regulation 351):

W. P. = 200 S
D-t
where,
t = Minimum thk.
D = External dia.
S = Allowable working stress.
c = 0.64 cm (0.25 inch)
CONTD…..

 For Copper pipe (Regulation 352):

W.P. = 2S (t-1.5D-c )
D

where,
t= minimum thickness
D= outside dia. of pipe
S= max permissible design stress
CONTD……

 Maximum Design Stress Value of ‘S’ for Copper pipes :─


(in kg per sq. mm)

For temp. 60ºC 121ºC 149ºC 177ºC 207ºC


Not exceeding

Max Design 4.9 4.31 3.5 2.66 1.75


Stress
INSPECTION OF STEAM PIPES

 As per Regulation 395 –


 Steam pipe shall be inspected and hydraulically tested before
erection in place, in test pressure to be that prescribed in the
standard conditions for steam pipes.
 The Inspector may make an external inspection of the steam
pipes and for this purpose may require a part of the lagging at
the flanges to be removed.
If pipes are found in an unsatisfactory condition he shall
report the matter to the Chief Inspector, who may require the
whole of the lagging to be removed and may require any pipe or
pipes to be hydraulically tested.
The test pressure at such hydraulic test shall not be less than
1½ times the working pressure of the boiler.
PREPARATIONS FOR INSPECTION

 Regulation 376─
 At every examination of boiler or the grant of renewal of a
certificate, the boiler shall be empty and thoroughly clean in all its
parts.
 Provision shall be made for the removal of lagging or brick-work
or other concealing part and for the drilling of plates, and for
verifying the pressure gauge and safety valve dimensions and
weights.
 All smoke tubes, exterior of water tubes, smoke boxes, and
external flues shall be swept clean.
 Provision shall be made for the effective disconnection of all
steam and hot water communication with another boiler under
steam.
 In the case of forced flow and forced circulation types of boilers,
provisions shall be made for checking that proper circulation is
maintained through all sections of the circuit by the flow of water.
PREPARATIONS OF HYDRAULIC TESTS
(As per Regulation 378)

 The chest of all mounting subject to steam pressure shall be in


place and shut tight or blank flanged.
 The safety valves should invariably be removed and the chest
opening blank flanged.
 The attachment for the Inspector's pressure gauge shall be in
order.
 All doors shall be properly jointed and tightened up. The boiler
shall be completely filled with water, care being taken to allow
all air to escape.
 When a boiler is hydraulically tested for the first time, it shall be
entirely cleared of lagging or brickwork, at subsequent tests the
lagging or brick work, or portions thereof, shall be removed if
required by the Inspector.
PROCEDURE FOR HYDRAULIC TESTS

 Regulation 379 ─

 Subject to regulation 381(e), every boiler shall be hydraulically


tested after erection at site in presence of the Inspector to 1.25
times the maximum working pressure.

 If all components of the boiler in the manufacturer's premises


have not been tested hydraulically as per regulation 268, the test,
on completion, shall be taken to 1.5 times the maximum working
pressure.
CONTD……

 The temperature of the water used as medium of pressure


testing shall not be less than 20°C and greater than 50°C.

 The test pressure shall be raised gradually under proper


control at all times so that it never exceeds by more than
6% of the required pressure and maintained for 30 minutes
whereupon the pressure shall be reduced to maximum
allowable working pressure and maintained for sufficient
time to permit close visual inspection for leakage of
pressure parts.
SUBMISSION OF PLAN OF STEAM PIPE

 As per Regulation 394 ─


 Plans of steam pipes shall be submitted with the prescribed
fee to the Chief Inspector before construction.
 The fees for examination of plans and the particulars of
materials, design and construction of steam pipes before
the commencement at the rate of Rs. 30 for 30m of piping
or part thereof, subject to a minimum of Rs. 50.
 For any fittings like de-superheater, steam receivers,
separators and flanges, the fees shall be Rs. 150 for each
category of such identical fitting.
 The fees for examinations of lay out plans of steam pipe
shall be Rs. 20 per 30 meters of piping or part thereof,
subject to a minimum of Rs. 50.
ECL/EPCM/PIPING - IBR

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