India’s Boiler safety gets a digital upgrade

Remote monitoring capabilities allow operators to oversee boiler performance without being physically present, minimising exposure to hazardous environments and ensuring consistent adherence to safety standards.

The recent technological advancements, particularly in digital monitoring and the Industrial Internet of Things (IIoT), have become integral to the safety of boilers in India. These innovations support automation, real-time monitoring, predictive maintenance and regulatory compliance, significantly reducing operational risks. Additionally, the push for renewable energy in the country and stricter environmental standards have led to enhanced safety protocols for boilers in hybrid and waste-to-energy facilities. Integrating automated safety interlocks, remote shutdown systems, and thermal imaging further reinforces emergency preparedness and early fault detection, ensuring safer and more reliable boiler operations across industries.

Moreover, in response to the growing industrial demands and the need for enhanced safety in India, the government amended the Indian Boiler Regulations (IBR) in 1950 in October 2024. It has introduced the Boilers Act 2025, repealing the 1923 Act. This has strengthened compliance measures for boiler operations. Annual inspections by authorised boiler inspectors or third-party competent persons recognised by the Central Boiler Board (CBB) are now mandatory to ensure boiler systems’ continued safety, efficiency and legal operation. 

Satbir Singh Cheema shares how the combination of recent regulatory measures and innovative approaches has made the boiler industry safer and, thereby, more efficient to operate. Let us hear him.

How do CBB regulations and IIoT integration enhance boiler safety, compliance and environmental monitoring?

As per Central Boilers Board (CBB) guidelines by Indian Boiler Regulations, 1950, with the latest amendments and The Boiler Bills, 2024, all Boilers are inspected by an authorised Boiler inspector or 3rd party competent persons recognised by CBB annually before issuing the renewal license to operate the Boiler in the following year.

Based on inspection, necessary corrective actions/ testings/ overhaulings are officially conveyed to the boiler owner to compile within the stipulated time frame. Upon implementation, IBR grants a license renewal.

Digital monitoring and IIoT are increasingly integral to Boiler safety compliance in India, aligning with recent regulatory initiatives (The Boiler Bill, 2024) and technological advancements. With the help of these platforms, automation and remote operations can be integrated into the Boiler system, ensuring its safety and reliability. Automation in boiler systems reduces human error by managing operations and safety protocols. Remote monitoring capabilities allow operators to oversee boiler performance without being physically present, minimising exposure to hazardous environments and ensuring consistent adherence to safety standards.

Additionally, IIoT enables continuous monitoring of critical boiler parameters such as temperature, pressure and emissions through interconnected sensors. This real-time data collection facilitates early detection of anomalies, allowing for predictive maintenance strategies that preempt failures and reduce downtime. Such proactive approaches enhance operational safety and efficiency.

Moreover, the Indian government mandates the installation of Online Continuous Emission Monitoring Systems (OCEMS) for high-pollution industries. These systems, integrated with IIoT technologies, provide real-time data to the Central and State Pollution Control Boards, ensuring adherence to environmental regulations and enabling swift corrective actions in case of higher emissions.  

How has the government’s renewable energy push influenced boiler safety protocols in hybrid and waste-to-energy power plants?

The Indian government is pushing for renewable energy integration, and this has significantly influenced safety protocols for boilers operating in hybrid power plants and waste-to-energy (WtE) facilities. WtE plants, which often utilise incineration processes, produce flue gases that require stringent treatment. The Ministry of New and Renewable Energy (MNRE) mandates the implementation of comprehensive air pollution control systems to treat these emissions. Additionally, the resultant ash from incineration must be processed appropriately before disposal or utilisation in construction materials.

Adopting digital monitoring and Industrial Internet of Things (IIoT) technologies has become integral to boiler safety. These systems enable real-time monitoring of critical parameters such as temperature, pressure and emissions, facilitating early detection of anomalies and predictive maintenance strategies. In response to fire incidents, authorities have emphasised implementing necessary fire prevention measures. These include installing temperature monitoring and water spraying systems and ensuring the availability of fire safety equipment and training for workers.

How do PLC/DCS-based automated safety interlocks and remote shutdown systems enhance boiler safety during critical operational anomalies?

Automated safety interlocks are integral to modern boiler systems, ensuring that operations are halted automatically when unsafe conditions are detected. Through the Programmable Logic Controller/DCS Distributed Control System (PLC/DCS), automated safety interlocks, such as emergency stoppage of Boilers with low water levels, high pressure/temperature, drought in furnace, etc., are integrated to ensure emergency shutdown of Boilers. This provides rapid response to anomalies, minimising the risk of accidents.

The safety guidelines emphasise the need for consistent checks and upkeep of all process safety interlocks and emergency switches to ensure their reliability during critical situations. Remote shutdown systems allow operators to deactivate boiler operations from a distance, providing an added layer of safety, especially in hazardous scenarios. These systems are designed to be quick-acting and are often integrated with emergency shutdown (ESD) protocols.

How does the Industrial Internet of Things (IIoT) improve boiler monitoring, maintenance and overall efficiency in industrial operations?

The Industrial Internet of Things (IIoT) enables continuous monitoring of essential boiler parameters like temperature, pressure and emissions using a network of interconnected sensors. This real-time data collection supports the early detection of irregularities, enabling predictive maintenance that helps prevent equipment failures and minimises unplanned downtime. By addressing potential issues before they escalate, IIoT-driven solutions enhance operational reliability, improve safety standards and optimise overall system performance. This proactive approach extends the lifespan of boiler components. It ensures greater energy efficiency and cost-effectiveness in industrial operations, making IIoT a vital tool for modern boiler management and maintenance strategies.