Erection and commissioning of steam boilers is a highly specialized activity that involves precise engineering, quality workmanship, and adherence to international safety standards. The process ensures that the boiler is installed, aligned, and operated to deliver maximum efficiency, reliability, and safe performance. The scope of erection includes unloading, handling, assembling, welding, mounting of auxiliaries, piping, instrumentation, and alignment of all structural and mechanical components.
Commissioning involves systematic pre-checks, hydro testing, refractory lining, safety valve setting, calibration of instruments, and trial runs. This ensures smooth start-up, optimized fuel combustion, safe pressure build-up, and stable steam generation. The ultimate objective is to hand over a fully functional, efficient, and safe boiler system to the client, ready for continuous industrial operation.
Technical Highlights
1. Pre-Erection Activities
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Site preparation, leveling, and foundation checks.
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Verification of civil works for boiler foundations, columns, and load points.
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Material inspection, documentation review, and layout planning.
2. Boiler Pressure Parts Erection
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Unloading and positioning of main boiler components such as drums, headers, water walls, and super-heaters.
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Precision welding of pressure parts with radiography/UT testing as per IBR/ASME standards.
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Alignment of coils, tube banks, and steam lines.
3. Structural & Non-Pressure Parts Erection
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Fabrication and installation of boiler support structures, platforms, ducts, and casings.
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Fixing of refractory lining and insulation for heat retention and safety.
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Erection of chimneys, ducts, and flue gas handling systems.
4. Auxiliaries & Accessories Installation
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Mounting of burners, air-preheaters, economizers, feed water pumps, ID/FD/PA fans.
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Installation of fuel handling systems (coal, oil, gas, biomass).
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Integration of ash handling, soot blowing, and dust collection systems.
5. Piping & Instrumentation
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Fabrication and laying of HP/LP steam and water pipelines.
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Hydrostatic pressure testing as per statutory requirements.
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Calibration and installation of pressure gauges, temperature sensors, safety valves, and control systems.
6. Electrical & Control Systems
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Installation of MCC panels, control systems, and DCS/PLC integration.
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Testing of interlocks, alarms, and safety trip systems.
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Power cabling and earthing of electrical equipment.
7. Commissioning & Performance Trials
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Pre-commissioning checks including leak tests, flushing, and lubrication.
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Boiler light-up, gradual heating, and refractory drying.
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Safety valve setting and load trials up to rated capacity.
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Efficiency measurement, flue gas analysis, and combustion tuning.
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Performance guarantee tests as per client and statutory norms.
Key Features & Benefits
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Compliance with IBR / ASME / ISO standards for quality and safety.
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Skilled workforce with expertise in heavy equipment erection and welding.
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Precision alignment and testing for long-term reliability.
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Optimized fuel-to-steam conversion for maximum efficiency.
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Safe operation with automated interlocks and protections.
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On-time commissioning ensuring faster plant readiness and productivity.
