Certifying the world's largest heat recovery boilers

Client: Larsen & Toubro Heavy Engineering, Oman

Application: Ten sets of heat recovery boilers, high-pressure steam drums and associated high-pressure piping 

Project scope: IBR certification of boilers, third-party inspection of associated components

L&T Heavy Engineering in Oman was contracted to fabricate 10 heat recovery boilers for SCHMIDTSCHE SCHACK, Arvos Group, in Germany. The boilers are designed for the Reliance pet coke gasification project in India, a $4.6 billion USD expansion of the Jamnagar refinery, which is the largest refinery in the world. 

As befits a project of this scale, the boilers are believed to be the largest of their kind as well, weighing 630,000 kilos each and measuring more than 45 metres in length. Each has an accompanying set of high pressure steam drums and high pressure piping. 

EN-ISL-2015-HTHR-Boiler_630

Because they will be installed in India, the equipment needs to comply with the Indian Boiler Regulations (IBR). IBR is the legal requirement for boilers in India and failure to gain compliance could result in the rejection of the boilers upon arrival in India.

Lloyd’s Register Energy is one of the largest providers of IBR certification services globally, and has a long-standing relationship with L&T in India as its preferred inspection provider for more than 50 years.

Business challenge for L&T

L&T constructed the boilers using one of the most modern techniques in the world for fabrication, coupled with modern project monitoring systems and the latest technologies for non-destructive testing (NDT).

These new techniques presented a challenge for L&T with regard to the IBR. The Regulations are complex and typically more difficult to meet than other international pressure equipment requirements, especially when using new and innovative procedures.

How Lloyd's Register Energy helped

Using our global expertise with the IBR and pressure equipment, we helped L&T:
  • Develop an NDT procedure to use TOFD (time of flight diffraction)
  • Set up critical welding procedures and welder requirements
  • Set up best fabrication techniques

Lloyd's Register Energy surveyors knew that L&T’s use of these innovative techniques would need approval from IBR authorities in India. Due to our strong relationship with the Central Boilers Board, we were able to directly contact the authorities to clear the use of these techniques beforehand. 

By ensuring the procedures received the appropriate clearance, we helped our client avoid incurring hundreds of thousands of dollars in time and project delays.

A ground-breaking success

During the handing-over ceremony for the first two sets, L&T Heavy Engineering chairman Y.S. Trivedi appreciated our work, calling the boilers the most critical equipment L&T has fabricated in Oman so far. SCHMIDTSCHE SCHACK project director Erik Ullrich called the achievement a lifetime memory for all contributors and stakeholders.