Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 1 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
SLNO
LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PERECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDICES
a) APPENDICES

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 2 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
STATUS
SL.NO
1.0

PLANT DETAILS:
Refer to procedure - I

2.0

OBJECTIVE:
Refer to procedure - I

3.0

PROPOSALS:

3.1

Auxiliary Boiler will be hydraulically tested at 1-5 times the design

pressure of the boiler Recommended Hydrostatic Test pressure :
37.5 Kg/Cm2

3.2

Chemically treated water as specified shall be filled in the boiler

and hydro test shall be conducted. (Refer 4-2)

4.0

SERVICES REQUIRED:

4.1

Two number of calibrated pressure gauge one at Drum level

and other near pressurizing pump to be installed for testing.
(Least count: Preferably 1 KSC)

4.2

Chemically treated water with 200 PPM of Hydrazene and PH

value of 9.5 to 10.0 shall be used for Hydraulic test.

4.3

Approximate quantity of DM water required for Hydraulic test is

around 50 tons.

4.4

Availability of L.T Power Supply, lighting etc.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 3 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
STATUS
SL.NO
5.0

SAFETY PRECAUTIONS:

5.1

Readiness of stair case, platforms, Hand rails and approaches as

decided jointly by BHEL & NTPC at site shall be ensured.

5.2

No person is allowed to enter the boiler house when the pressure

in the boiler is above the maximum operating pressure.

5.3

First aid Kits are available in the test area.

6.0

EMERGENCY PROCEDURES:

6.1

The testing team should be aware of the procedure to be followed

in case of accident involving personnel injury.

6.2

The testing team should be aware of the operating procedure of

fire extinguishers to be used for quenching fires.

6.3

A person is to be posted at emergency push button and

instructed that he should trip the pressuring pumps in the event of
emergency being notified to him by observers.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 4 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
SLNO
STATUS
7.0

STATE OF THE PLANT :

7.1

Erection of the Boiler pressure parts is complete as per drg. All

necessary welds completed, x-rayed and stress relieved. All FQA checks
as per approved Erection FQP completed.

7.2

All necessary valves including drain valves installed and closed.

7.3

All safety valves installed and hydrostatic plugs should be assembled

before commencing the test.

7.4

The drain valves and test valve in the calibrated standard test pressure
gauge sensing line must be open.

7.5

The isolating valves provided in all the other branching systems like SB
system tapping, SH spray connections, Pr. Gauges etc. have to be tightly
closed. Hydraulic test of SB system, SH spray system etc. is carried out
separately at specified pressures.

7.6

All vents necessary to prevent air entrapment during filling operation

such as superheater vents, drum vents etc. shall be open.

7.7

When valves are in tandem (double valves) both valves must be closed
during the hydrotest.

7.8

All the hangers in Boiler & piping system are set / locked as per
recommendation.

7.9

Keep the required peepholes / manholes door in furnace, open for

inspection during H.T.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 5 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
SLNO
STATUS
7.10

Ensure the availability of required quality of chemically treated DM

Water near the test area. (DM transfer Pump to be made use off for this
or an alternate method adopted for transporting DM water to Auxiliary
Boiler)

7.11

Ensure readiness of Boiler Fill pump or an alternative temporary pump

and tank system and their respective pipe connections to Boiler.
Ensure readiness of Boiler Pressurising Pump and its pipe connection
from temporary tank of sufficient capacity to a suitable input point at
Boiler bottom drain header.

7.12

7.13

Ensure lighting in all the areas where inspection is to be carried out

including inside of Boiler for effective checkup.

7.14

Ensure communication between drum level and pressurizing pump area

and other operating areas.
Boiler drain is suitably connected to storm water drain.

7.15
All connected pipelines (temporary) are welded.
7.16
Delivery line of pressurizing pump should be high-pressure seamless
pipe to withstand the required test pressure.

7.17

Temporary tanks should be of required capacity.

7.18

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 6 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
SLNO
STATUS
8.0
TEST METHOD
8.1

AIR TESTING THE PRESSURE PARTS

8.1.1

Before filling the boiler with water, an air tightness test is to be

performed to detect leakages due to valve left in open position, X-ray
plug forgotten, any cuts or guages etc. not observed by visual
inspection. This will reduce the DM water consumption, as well as time.

8.1.2

The boiler is to be pressurised not more than 2 kg/sq.cm (G).

8.1.3

Before admitting air, close drum manhole, isolating valves in drain

lines, branching lines and vent lines including the vent valves in SH and
drum, Drain and Test Valves in official pressure gauge etc.

8.1.4

Inspect for any leakage and attend the same.

8.1.5

After completing the air tightness testing keep vent valves in SH drum
and drain and test valves in official pressure gauge in open position.

8.2

TEMPORARY
BOILER
FILL
PRESSURISING
PUMP, WITH
CONNECTING PIPELINES.

PUMP,
THEIR

TEMPORARY
TEMPORARY

8.2.1

Check for correct direction of rotation of pumps.

8.2.2

Open air vent of the Pressurising Pump during start-up

8.2.3

Check weather a correct fuse is introduced in the circuit to avoid

damages to the motors of these pumps.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 7 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
SLNO
STATUS
8.2.4

Before starting the filling pump, the delivery valve to be closed and the
suction valve kept open. Then open delivery valve gradually for filling.
Before stopping the pump, delivery valve should be closed.

8.2.5

Before starting the pressurising pump it should be ensured that the

delivery valve is kept open.

8.3

FILLING THE SYSTEMS

8.3.1

The boiler Drum, bank tubes and Superheaters are filled through filling
lines connected to the boiler drain header.

8.3.2

Confirmation of completion of filling of the entire system shall be done

through the vents.

8.3.3

Close and open the vent valves several times in order to allow venting
of entrapped air.

8.3.4

Stop the fill pump.

8.4

PRESSURISING THE SYSTEMS

8.4.1

The pressure shall be raised up by means of pressurising pumps.

8.4.2

The pressure shall be increased at a rate of not more than 10kg/sq.cm (g)
per minute upto approximately 80% of the test pressure and by 1 to 2
kg/sq.cm (g) per minute beyond that value.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 8 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
SLNO
STATUS
8.4.3

Raise the pressure to the hydrostatic test pressure. The pressure shall be
under proper control at all times. The pump operator and the responsible
person watching the official test gauge must have constant contact.
When the test pressure is reached, the responsible person watching the
test gauge shall give orders to stop the test pumps immediately and to
cut off the electric connections.

8.4.4

The test pressure is held for about 10 minutes. During the holding time
the official test gauge pressure reading shall not drop noticeably.

8.5

HYDRAULIC TEST

8.5.1

The hydraulic test pressure reading will be taken from the caliberated
standard test pressure guage located at the Drum level.

8.5.2

After the hydraulic test pressure has been noted, the test pressure is then
reduced to not less than the maximum allowable working pr. and the
whole pressure parts checks will be carried out.

8.5.3

If leaks are found, it will be necessary to release the pressure and drain
these portions. Make the repairs and refill the unit as mentioned above
and repeat hydraulic test.

8.5.4

Details of the leaks noticed during Hydraulic Tests are to be furnished as

given below for better understanding:
a)

Exact location of leak(s) component circuit, Elevation, materials

etc.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 9 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
SLNO
STATUS
b) Description of leak(s) such as straight tube elbow, shop or field
weld, torchcut, where a lug was removed and attahcment weld etc.
c) Magnitude of leaks-seeping/sweating,
longtitudional crack.
8.6

leaks,

burn

through,

DEPRESSURISATION OF THE PRESSURE PARTS

8.6.1

The pressure parts shall be depressurised at the rate of 1 kg/ Sq. cm /

minute.

8.6.2

While releasing the pressure, the vents should be opened when the
system pressure reaches 1kg/sq.cm to prevent creation of vacumm in the
system.

8.7

INSPECTION OF THE BOILER PRESSURE PARTS AFTER

TESTING

8.7.1

After completion of the hydraulic test, an inspection of boiler inside and

outside is made to ensure that the boiler has satisfactorily withstood the
test.

8.7.2

After satisfactory completion of Hydro test, entire Boiler system is

drained.

8.8

HYDROSTATIC TEST PROTOCOL

8.8.1

A joint protocol by BHEL & NTPC to be made after the successful

completion of Hydraulic Test.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0031

Sheet 10 of 10
NTPC Ref no SIM/0/TS/3/31
Plant area: BOILER (AUXILIARY)
PROCEDURE FOR COMMISSIONING OF AUXILIARY BOILER (HYDRAULIC TEST)
STATUS
SL.NO
9.0

COMPLETION CRITERIA;
The test pressure in the official pressure gauge is held for 10
minutes ( or for a duration decided by Inspection authority) in
presence of Inspection authority. The Boiler shall satisfactorily
withstand such pressure without appreciable leakage or undue
deflation or distortion of its pressure parts.

10.0

APPENDICES:
Refer to Procedure

- I

Procedure for commissioning of

Auxiliary Boiler.

Signatures
NTPC

BHEL

PROCEDURE FOR COMMISSIONING OF

AUXILIARY BOILER (HYDRAULIC TEST)