HYDROSTATIC TESTING

CIRCULATING FLUIDIZED BED UNITS

After installation of all pressure parts, except those omitted during chemical cleaning (see
Chemical Cleaning Procedures), the unit is subjected to the required initial hydrostatic test of 11/2 times the unit design pressure. Depending on insurance requirements, hydrostatic test of
pressure parts repairs are commonly made at the normal operating pressure or the design
pressure.
Hydrostatic test procedures depend to a great extent on local conditions and provisions. Procedures
for initial hydrostatic testing must be in accordance with Boiler Code requirements. Specific initial
hydrostatic testing procedures can be supplied, if necessary, by this Company's Construction
Services Department. The following basic rules should always be followed:
PRELIMINARY
1.

Before starting to fill the waterwalls and superheater make sure all drums and headers are
cleared of foreign material. Close all drains. Open all vents normally used when filling the unit
(such as superheater link vents, economizer link vents, drum vents).

2.

Prior to any hydrostatic test above the normal operating pressure, hydrostatic test plugs
must be installed in all safety valves in accordance with manufacturer's instructions. If the
hydrostatic test pressure is at or below the normal operating pressure it may be sufficient
to merely gag the safety valves. Refer to safety valve manufacturer's instructions.

FILLING
1. Fill the superheater (See Fill Water Below) through a suitable outlet connection (such as the
final superheater outlet header drain or vent) until all elements are filled and the water
overflows into the steam drum.
2.

Cease filling through the superheater outlet connection when the water overflows into the
steam drum. Close superheater fill and vent connections.

3.

Proceed filling the boiler (See Fill Water Below) through the normal filling connections.

4.

Keep filling until water overflows from the drum vents. Then close all vents.
FILL WATER

It is the responsibility of the customer to provide properly treated water, as specified below, at
ambient temperature but in no case less than 70 F (21 C). If the proper type of water is not
available the Manager of Technical Support, Windsor Construction Services should be contacted
for further information. Once the superheater has been filled, take water samples from each
available superheater vent or drain and analyze them to verify the absence of contamination.

Type of water to be used:

A.

Superheater (Drainable and nondrainable sections): Fill with treated

condensate or treated demineralized water (See Note). The treatment shall
include 10 ppm ammonia and 200 ppm hydrazine. This treated water will have
a pH value of approximately 10.
NOTE: Demineralize or condensate quality water is defined as containing no
more than 1ppm identifiable solids and essentially a zero
concentration (or lowest detectable level) of organic material.
CAUTION: The use of fill water treated with solid chemicals should be avoided.
Deposits of solid materials in superheaters can be detrimental from
heat transfer and corrosion standpoints. Superheaters containing
stainless steel tubing are particularly vulnerable to stress
corrosion cracking in the presence of such chemicals as caustics
and chlorides.

B.

Remainder of boiler unit: Fill with treated condensate or treated demineralized

water or, if not available, with a clean source of filtered water treated with 10
ppm ammonia and 200 ppm hydrazine.

HYDROSTATIC TESTING

1.

Apply hydrostatic test in accordance with Boiler Code requirements.

CAUTION: Hydrostatic test pressure should not be applied to the boiler if the
metal temperature of pressure parts is below 70 F (21 C).

POST HYDROSTATIC TEST PROCEDURES

1.

Introduce nitrogen through the drum vent to pressurize the unit to approximately 3-5
psi (21-34 kPa).

2.

Remove all hydrostatic test plugs and gags from the safety valves prior to starting up
the unit.
NOTES:

1. Since there is generally some time delay between the hydrostatic test and

the initial boiling out and acid cleaning of the boiler, the unit should remain
full
of water, air should not be allowed to enter.
2. If there is a chance of freezing, the water in the drainable circuits can be
displaced by nitrogen and the unit can be laid-up under nitrogen pressure.
Temporary heating equipment should be provided to keep the
nondrainable
superheater elements above freezing temperature.