Presentation on IBR

1. Applicability of IBR in a Process Plant

2. Indian Boiler Regulation
❖ Indian Boiler Regulations first publication came in 1923.
❖ The provision for consulting and providing regulatory power
and authority to Central Boilers was made in Indian Boilers
Amendment Act 1937.
❖ Full fledged First IBR published in 1950
❖ The current version of these regulations is known as Indian Boiler
Regulation1950with amendments up to 22nd February 2015.

3. THE BOILERS ACT, 1923

4. THE BOILERS ACT, 1923

5. IBR Regulation Scope
◼ Indian Boiler Regulation usually referred as IBR is a set of
standards that regulates :
• Materials
• Design
• Construction
• Inspection and testing of boilers and boiler components
◼ It is mandatory for the manufacturer and users of boiler in
India to follow this regulation and obtain approval from Chief
of Boilers of concern state on steam generation and
distribution parts and piping systems.

6. Identification of Equipment
falling under IBR

7. IBR Regulation Scope
Following is the list of equipment which may fall under IBR if
these are in steam service:
❖ Boilers along with the feed piping starting from feed pump
❖ Full Steam piping
❖ Steam receivers
❖ Heat exchangers or any other process equipment using
steam under pressure (but no full condensation)
❖ Separators, steam traps, evaporators and similar where steam
is generated

8. Equipment which need to be compliant with IBR
❖ Any closed vessel with capacity more than 25 litres which
is exclusively used for generating steam under any pressure
for process.
❖ This includes mounted fittings, isolation valves, safety
valves, which are wholly or partially under pressure even
when steam is shut off.
❖ Any vessel (steam user ) where condensate goes to flash
drum for steam generation and is not open to atmosphere
shall come under IBR .
❖ All steam users equipment where the outlet condensate
piping is connected to IBR equipment

9. Equipment which do not fall under IBR
❖ Following equipment will not fall under IBR:
o Where outlet condensate is drained to atmosphere or
flashed to atmospheric pressure (like the case of a
Deaerator operating at pressure 1.05 kg/cm2 ) and steam
is vented (without isolation).
o In case of steam turbine even if the condensate is
connected to IBR equipment, the steam turbine is not
covered under IBR.
❖ The IBR spec - break in such cases is done at last isolation
valve on the steam line upstream of equipment.

10. Piping systems that fall under IBR:
❖ All steam and condensate line for which the design pressure
exceeds 3.5 kg/cm2.
❖ All steam and condensate line greater than pipe ID 254mm for
which the design pressure exceeds 1 kg/cm2.
❖ All steam and condensate line interconnecting IBR pressure
vessels
❖ Boiler feed water pipelines from BFW pump to boiler.

11. Generally piping in following conditions are
designed as per IBR

12. Special piping attached to Pressure Vessels
These shall be controlled by
IBR piping laws (i.e. if pipe size is less than 254mm and
pressure less than 3.5 Kg/cm2, it will not come under IBR)
❖ Steam tracing piping
❖ Heating coils and heating tubes in tanks.
❖ Steam jacketed piping.

13. Pressure Temperature and Hydrotest categories of
piping class

14. All steam economizers and steam super
heaters come under IBR

15. Discharged condensate from any equipment,
connected to flash vessels falls under IBR

16. Few examples of Materials
specifications as per IBR

17. Materials
recommendations as per IBR
❖ IBR specifies the metallurgical restrictions and properties
to be used for pressure parts.
❖ It also specifies the minimum stress values and
mechanical properties of materials to be used.
❖ The selection of materials as per any Code ( ASME or
Indian) is required to take care of such requirements.

18. Typical Material Specification as per IBR

19. Typical Material Specification as per IBR

20. The procedure for IBR approval

21. Procedure for IBR approval
❖ IBR packages preparation ( drawing + calculation)
❖ Inspection fees to be paid for IBR approvals
❖ Drawings and calculations for divisional boiler inspector.
❖ Fabrication can start when the drawing is in the approval stage.
❖ After drawing approval, welder qualification and approval.
❖ Equipment material identification and stamping by boiler
inspector
❖ During fabrication, NDT approval from IBR
❖ Hydrotest witness and approval, by IBR inspector

22. Certification Forms
❖ The material should be used with an IBR stamp.
❖ IBR material must come with Form IIIA, B and C
certificate.
❖ Inspection and testing certification as per Form IV-A ,
❖ Recertification of welders (Form XII and XIII)

23. Special Design requirement for equipment
under IBR
1. Equipment top most point must have adequately sized
vent valve & bottom most point must have a drain
valve.
2. Exchangers shell side or channel side having steam must
comply to above requirement.
3. All flange gaskets must be metallic (SS spiral wound or
corrugated metal or ring)
4. All pressure parts design thickness calculations to comply
with IBR given formula and correlations. Irrespective of
the secondary design code and standard.

24. Special requirement for equipment under IBR
1. CS nozzle necks minimum thickness 3/8”
2. CS must have a corrosion allowance of 1/16” for all
carbon steel and low alloy steel items
3. All weld joints of pressure parts, or tube to tube sheet
joints must be as per IBR
4. All heat treatment and NDT requirements to be
complied as per IBR.
5. All metal metallurgy to be in compliance with IBR

25. Thank you