The document discusses engineering and administrative controls as well as the Indian Boiler Regulations. It describes how a hazard control program works and the main types of controls, including engineering controls like process control, isolation, and ventilation. It also outlines some common administrative controls like training, procedures, maintenance, and signage. Finally, it provides an overview of the Indian Boiler Regulations, including what they cover and their history stemming from a boiler explosion in 1863.

1. Industrial safety engineering
(Department of mechanical engineering)
SEMINAR TALK ON
ENGINEERING AND ADMINISTRATIVE CONTROLS
AND
INDIAN BOILER REGULATIONS
GUIDED BY: SUBMITTED BY:
DR R.PRAKASH Y. SANDEEP RAO
MECHANICAL ENGG.DEPT 211223019

2. CONTENTS:
ENGINEERING AND ADMINISTRATIVE CONTROLS
 WHAT IS A HAZARD CONTROL PROGRAM?
 WHEREARE CONTROLS NEEDED?
 HOW DO I KNOW WHAT KIND OF CONTROL IS
NEEDED?
 WHATARE MAIN WAYS TO CONTROLA HAZARD?
 HIERARCHY OF CONTROLS
 ADMINISTRATIVE CONTROLS
 EXAMPLES OF ADMINISTRATIVE CONTROLS
 ENGINEERING CONTROLS
 PROCESS CONTROL
 ISOLATION & ELOSURE
 VENTILATION
I. INDIAN BOILER REGULATIONS(IBR)
 WHAT IS IBR?
 LAMONT BOILER
 THERMAL POWER PLANT
 WHAT DOES IBR COVER?
 CONTENTS - CHAPTER WISE
 VARIOUS REGULATIONS
 IBR INSPECTION

3. ENGINEERINGCONTROLS
&
ADMINISTRATIVE CONTROLS

4. A hazard control program consists of all steps necessary to protect
workers from exposure to a substance or system, the training and the
procedures required to monitor worker exposure and their health to
hazards such as chemicals, materials or substance, or other types of
hazards such as noise and vibration.
 A written workplace hazard control program should outline which
methods are being used to control the exposure and how these
controls will be monitored for effectiveness.
W
HATIS A HAZARDCONTROLPROGRAM?

5. Controls are usually placed:
 At the source (where the hazard
"comes from").
 Along the path (where the hazard
"travels").
 At the worker.
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1%2F&psig=AOvVaw1UHan73m01ZGpLBIRIu1zB&ust=1602746921778000&source=images&cd=vfe&ved=0CAYQtaYDahcKEwiQr-u1y7PsAhUAAAAAHQAAAAAQDg

6. HOWDOI KNOWW
HATKINDOFCONTROLIS NEEDED?
Selecting an appropriate control is not always easy. It often involves doing a risk
assessment to evaluate and prioritize the hazards and risks. In addition, both
normal and any potential or unusual situations must be studied. Each program
should be specially designed to suit the needs of the individual workplace. Hence,
no two programs will be exactly alike.
Choosing a control method may involve:
 Evaluating and selecting temporary and permanent controls.
 Implementing temporary measures until permanent (engineering) controls can be
put in place.
 Implementing permanent controls when reasonably practicable.
For example, in the case of a noise hazard, temporary measures might require
workers to use hearing protection. Long term, permanent controls might use
engineering methods to remove or isolate the noise source.

7. The main ways to control a hazard include:
 Elimination (including substitution): remove the hazard from the workplace, or substitute (replace)
hazardous materials or machines with less hazardous ones.
https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.ccohs.ca%2Foshanswers%2Fhsprograms%2Fhazard_control.html&psig=AOvVaw1UHan7
3m01ZGpLBIRIu1zB&ust=1602746921778000&source=images&cd=vfe&ved=0CAQQtaYDahcKEwiY4eKeyrPsAhUAAAAAHQAAAAAQEw

8.  Engineering Controls: includes designs or modifications to plants, equipment, ventilation systems, and
processes that reduce the source of exposure.
 Administrative Controls: controls that alter the way the work is done, including timing of work, policies
and other rules, and work practices such as standards and operating procedures (including training,
housekeeping, and equipment maintenance, and personal hygiene practices).
 Personal Protective Equipment: equipment worn by individuals to reduce exposure such as contact with
chemicals or exposure to noise,abrasive particles & other hazardous materials.
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9. HIERARCHYOFCONTROLS
The idea behind this hierarchy
is that the control methods at
the top of graphic are
potentially more effective and
protective than those at the
bottom. Following this
hierarchy normally leads to
the implementation of
inherently safer
where the risk of
systems,
illness or
injury has been substantially
reduced.

11.  Training: Workers should be trained to
identify hazards, monitor hazard exposure,
and safe procedures for working around
the hazard. Additionally, employees should
know how to protect themselves and their
co-workers.
 Procedures: The steps in a job process
may need to be rearranged or updated to
keep the worker for encountering the
hazard. Developing standardized safe
work practices is an important step.
https://www.google.com/url?sa=i&url=http%3A%2F%2Fwww.sustained-quality.com%2Fsmart-safety-increases-productivity-
time%2F&psig=AOvVaw3ot8WZah37fD7cJ5NcfhbO&ust=1602748149610000&source=images&cd=vfe&ved=2ahUKEwiHsZ-
izLPsAhXCj0sFHRhIDl8Qr4kDegUIARCeAQ
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does-osha-stand-
for&psig=AOvVaw3ot8WZah37fD7cJ5NcfhbO&ust=1602748149610000&source=images&cd=vfe&ved=2ahUKEwiHsZ-
izLPsAhXCj0sFHRhIDl8Qr4kDegQIARA8

12.  Maintenance:
known to be
Having a maintenance
for machines
can keep everything running
schedule
hazardous
smoothly and safely. Preventive
maintenance will address any equipment
issues before they become a problem.
 Housekeeping: Sustaining a clean and
clutter-free space will greatly reduce the
risk of injury and can minimize the severity
of an accident.
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maintenance.jpg&imgrefurl=https%3A%2F%2Fwww.creativesafetysupply.com%2Fglossary%2Fadministrative-controls%2F&tbnid=JkTNglw48sVEOM&vet=12ahUKEwj_u-
LYx7PsAhXQmUsFHRl4BiAQMygpegUIARD4AQ..i&docid=X3_0RlvP87oCTM&w=792&h=800&q=engineering%20and%20administrative%20controls&ved=2ahUKEwj_u-
LYx7PsAhXQmUsFHRl4BiAQMygpegUIARD4AQ
https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.ccohs.ca%2Foshanswers%2Fhsprograms%2Fhazard_control.html&psig=
AOvVaw3ot8WZah37fD7cJ5NcfhbO&ust=1602748149610000&source=images&cd=vfe&ved=2ahUKEwiHsZ-
izLPsAhXCj0sFHRhIDl8Qr4kDegUIARCEAQ

13.  Signs: Wall signs and floor signs can be posted or installed to enforce administrative controls.
Visual cues can remind workers which areas are prohibited from entering, when breaks need to
be taken to limit heat exposure, and much more.

14.  Engineering controls are methods that are built into the design of a plant,
equipment or process to minimize the hazard.
 Engineering controls are a very reliable way to control worker exposures as
long as the controls are designed, used and maintained properly.
 The basic types of engineering controls are:
i. Process control.
ii. Enclosure and/or isolation of emission source.
iii. Ventilation.

15. PROCESS CONTROL
 Process control involves changing the way a job activity or process is done to reduce the risk.
Monitoring should be done before and as well as after the change is implemented to make
sure the changes did, in fact, control the hazard.
Examples of process changes include to:

16. ENCLOSUREANDISOLATION

17. ENCLOSUREANDISOLATION
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110j.htm&psig=AOvVaw1UHan73m01ZGpLBIRIu1zB&ust=1602746921778000&source=images&cd=vfe&ved=2ahUKEwj_u-LYx7PsAhXQmUsFHRl4BiAQr4kDegUIARClAQ
https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.oshatrain.org%2Fcourses%2Fmods%2F751m
3.html&psig=AOvVaw1UHan73m01ZGpLBIRIu1zB&ust=1602746921778000&source=images&cd=vfe&ved=0
CAcQtaYDahcKEwiY4eKeyrPsAhUAAAAAHQAAAAAQDA

18. VENTILATION
A local exhaust ventilation system consists of these basic parts:
 A hood that captures the contaminants generated in the air (at the source).
 Ductwork (exhaust stack and/or recirculation duct) that carries the contaminated air to the air cleaning
device, if present or to the fan (away from the source).
 A fan which draws the air from the hood into the ducts and removes the air from the workspace. The fan
must overcome all the losses due to friction, hood entry, and fittings in the system while producing the
intended flow rate.
 Air cleaning devices may also be present that can remove contaminants such as dust (particulates), gases
and vapours from the air stream before it is discharged or exhausted into the environment (outside air),
depending on the material(s) being used in the hood.

19. VENTILATION
• The design of a ventilation system is very
important and must match the particular
process and chemical or contaminant in use.
Expert guidance should be sought. It is a very
effective control measure but only if it is
designed, tested, and maintained properly.
• Because contaminants are exhausted to the
outdoors, you should also check with your
local environment ministry or municipality for
any environmental air regulations or bylaws
that may apply in your area.
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AOvVaw1UHan73m01ZGpLBIRIu1zB&ust=1602746921778000&source=images&cd=vfe&ved=0CAQQtaYDahcKEwiY4eKeyrPsAhUAAAAA
HQAAAAAQEw

20. INDIAN
BOILER
REGULATIONS
(IBR)

21. WHAT IS IBR?
 IBR is Indian Boiler Regulations, which was created in 15th September 1950 in
exercise of the powers conferred by section 28 & 29 of the Indian Boilers Act. The Indian
Boilers Act was formed in 1923, 23rd February to consolidate and amend the law relating
to steam boilers.
History
 A tragic boiler explosion in Calcutta in 1863 was the origin of the Indian Boiler Regulation.
 A bill was passed by the Bengal Council in 1864 calling for the inspection of steam boilers
in and around Calcutta. Other Indian provinces followed, and eventually the country
decided on one uniform set of regulations and passed The Indian Boilers Act in 1923. The
regulations would cover not only inspections, but also the conditions for material
procurement. The Central Boilers Board was formed as a result of an amendment in
1937. The latest version of the law is known as the Indian Boiler Regulation, 1950.
Amendments are issued from time to time.

22. LAMONT BOILER

23. STEAM POWER PLANT LAYOUT

24. WHAT DOES THE IBR COVER?
The IBR covers the design, fabrication, inspection, testing and certification of
boilers or any boiler part including feed piping and fittings or vessels attached
thereto Boiler components, i.e.
 Steam piping
 Feed piping
 Economizers
 Super heaters
 Valves, including safety valves
 Any mounting or fitting or any external or internal part of a boiler which is subjected to pressure
exceeding 1 Kg/cm square gauge
 Steam receivers, separators, steam traps, accumulators and similar vessels
 Heat exchangers, converters, evaporators and similar vessels in which steam is generated
 Materials, e.g. forgings, castings, tubes, pipes, plates, welding consumables

25. CONTENTS - CHAPTER WISE
>
>
PRELIMINARY
CHAPTER - I
(Regulations)
> CHAPTER - II
(Electric-Resistance-Welded Steel Boiler And Super-Heater Tubes
For Design Metal Temperatures Not Exceeding 454°C (850°F)
> CHAPTER - III
(Boiler Tubes Subject To External Pressure)
> CHAPTER - IV
(Regulations For Determining The Working Pressure To Be Allowed
On Various Parts Of Boilers Other Than Fusion Welded And
Seamless Forged Drums.)
> CHAPTER - V
(Fusion Welded And Seamless Forged Drums For Water Tube Boilers
And Super Heaters)
> CHAPTER - VI
(Requisite Mountings, Fittings and Auxiliaries)
> CHAPTER - VII
(Boiler And Super Heater Tubes, Headers And Other Pressure Parts
Tubes)
> CHAPTER - VIII
(Steam-PipesAnd Fittings)
> CHAPTER - IX
(Regulations For The Registration Of Boilers And Inspection Of
Boilers And Steam-Pipes)
> CHAPTER - IX A
(Safety Of Persons Inside Boilers)
> CHAPTER - X
Electrode Boilers (General Requirement)
> CHAPTER - XI
Standard Conditions For The Design And Constgruction Of
Economizer, Feed Pipes, Feed Heaters And Other Similar Vessels
(Economizers)
> CHAPTER - XII
(Shell Type Boilers Of Welded Construction)
> CHAPTER - XIII
(Qualification Tests For Welders Engaged In Welding Of Boilers And
Steam-Pipes Under Construction, ErectionAnd FabricationAt Site In
IndiaAnd In Repairing Boilers And Steam-Pipes By Welding)
> CHAPTER - XIV
(Regulations made under clause (a) and (aa) of section 28 of the Act)
Small Industrial Boilers (General)
> CHAPTER - XV
(Feed Water For Boiler)
> APPENDIX

26. CHAPTER : II
Reg. 9
M AT E R I A LS O F CO N ST R UC TI O N
S T E E L PLATES, RIVETS, SEC T I O N A N D BARS IN C A R B O N S T E E L
Process of manufacture
(a)Steel for plates shall be made by the open hearth, electric furnace or basic oxygen process or any other process which gives steel
having equivalent specified properties.
(b)General deoxidation practice shall be appropriate to the type of steel used, particularly where the deoxidation practice influences the level of
the elevated temperature properties of steel.
(c) Rimmed steels may be permitted only for riveted drums or shells made of plates having a nominal thickness upto 20 mm.
(d) Plates of carbon steel shall conform to one of the following four grades of tensile strength:-
(i)37 to 45 kgf/mm2
(ii)42 to 50 kgf/mm2
(iii)47 to 56 kgf/mm2
(iv)52 to 62 kgf/mm2
(e) Semi-killed steel may be used for plates in C and C-Mn steel with an upper limit of the tensile strength not exceeding 56 kg /mm2 and with
thickness not exceeding 50mm under service temperature condition 0-450°C.

27. Reg. 10
M AT E R I A LS O F CO N ST R UC T I O N
S T E E L PLATES, RIVETS, SEC T I O N A N D BARS IN C A R B O N S T E E L
Chemical Analysis
(a) The steel shall not contain more than 0.05 per cent of sulphur or phosphorus.
(b)A sulphur print test shall be taken from the material of each charge used for rivet bars for the purpose of ensuring that sulphur segregates are
not concentrated in the core. The stage in manufacture at which this test is made shall be at the option of the Steel-Maker.
(c)When the material is required for flame cutting and/or welding, the carbon content shall not exceed 0.30% and special precautions shall be
taken when the carbon content exceeds 0.26%.
When steels are intended for service temperatures over 700°F the silicon content shall be not less than 0.10% or alternatively, the material shall
pass the proof test for creep quality of carbon steel plates of boiler quality.
(d)Plates having thickness of 12 mm and less than that, not intended for hot forming, can be supplied in unnormalized or as rolled
condition subject to the condition that the code of manufacture provides for the same. For plates having thickness more than 12mm, not intended
for hot forming, shall be supplied in the normalized conditions:
Provided that the normalizing may be exempted if it is demonstrated by the manufacturer that equivalent properties can be produced by the rolling
subsequent cooling.
NOTE:- The boiler manufacturer may, if he so wishes order a check analysis.

28. Reg. 331
FUSIBLE PLUGS
General
1)Fusible plugs shall be of sufficient height and fitted in such a position as to give early protection to all parts of the boiler liable to damage by the direct
application of furnace heat in the event of shortness of water.
2)On boilers having wet back reversing chamber, a minimum of two fusible plugs shall be fitted; one on the crown of the reversing chamber and the other
on one of the tube plates. On boilers not having Wet back reversing chamber, at least one fusible plug shall be provided on the front end tube plate. The
plug shall be fitted in such a way that in the event of fusion of the plug, the pressure inside the boiler shall push the pellets out.
Note: - For example : In Lancashire Boilers the fusible plugs should be in the crowns of the furnaces from 12 inches to 18 inches in front of the brickwork
fire bridge.
Reg. 332
Type
Fusible plugs shall consist of an outer body with a central conical passage the smallest part to be not greater than 1/2 inch for plugs suitable for pressure
up to 100 lbs. per sq. in. and not greater than 3/8 inch for plugs for pressures exceeding 100 lbs. per sq. in. The passage shall be closed by a plug
secured by an annual lining of fusible alloy so that the plug may drop clear if the lining melts.
The portion of the body carrying the fusible metal should preferably be detachable from the base to allow of easy replacement without removing the
whole fitting from the boiler.
Reg. 333
Material
The non-fusible portions of the plug shall be of bronze except where the nature of the boiler water precludes the use of a non-ferrous material. The
fusible metal shall be an alloy melting readily at a temperature not less than 150º F in excess of the saturated steam temperature at the maximum
permissible working pressure of the boiler.

29. A TYPICAL IBR INSPECTION INCLUDES THREE STAGES

30. CASE STUDY:
 BACKGROUND:
The NTPC power plant explosion was a boiler explosion that occurred on 1
November 2017 at a newly commissioned 500-megawatt unit of the Feroze Gandhi
Unchahar coal-fired power plant. The plant is operated by government-
owned National Thermal Power Corporation (NTPC) Limited, in Unchahar, Uttar
Pradesh, India.[3] The explosion killed 32 people who may have been cleaning ash
from the boiler's interior.
The investigation highlighted several critical aspects contributing to the accident.
Maintenance issues were indentified, indicating that the boiler had not undergone
proper maintenance procedures , leading to the accumulation of ash and the eventual
blockage caused the pressure to build up inside the boiler, leading to the explosion.
According to a statement released by NTPC, "there was sudden abnormal sound at
20 m. elevation and there was an opening ... from which hot flue gases and steam
escaped, affecting the people working around the area”.

31. NTPC BOILER EXPLOSION:

32. • https://oshwiki.eu/wiki/Engineering_controls
• https://www.creativesafetysupply.com/glossary/administrative-controls/
• https://www.cdc.gov/niosh/topics/hierarchy/default.html#:~:text=Engineering%20controls%20
are%20favored%20over,in%20contact%20with%20the%20worker.
• https://www.ccohs.ca/oshanswers/hsprograms/hazard_control.html#:~:text=Administrative%
20Controls%3A%20controls%20that%20alter,%2C%20and%20personal%20hygiene%20pra
ctices).
• https://thermodyneboilersblog.wordpress.com/2017/04/07/what-are-the-indian-boiler-
regulations/#:~:text=IBR%20is%20Indian%20Boiler%20Regulations,law%20relating%20to%
20steam%20boilers.
• https://dipp.gov.in/sites/default/files/boiler_rules_updated/index1.htm

33. THANK YOU