RECOMMENDED HYDROSTATIC

TEST PROCEDURE
FOR BOILER
 RECOMMENDED HYDRO TEST PROCEDURE
INDEX
Sno Content Page
1 Introduction
2 Hydrostatic test Circuit
3 Test pressure
4 Pressure e gauges
5 Preparation for the test
6 Water quality

7 Water Filling in the pressure parts

8 Pressurizing the system
9 Hydrostatic testing
10 Depressurization of the pressure parts

11 Inspection of the boiler pressure parts after testing

Proceedings to prevent accidents and endangering of persons
12 during pressure test
13 Preservation of boiler after hydrostatic test

FIGURES
FIG 1 Hydro test limit Boiler water circulation system.
FIG 2 Hydro test limit super heater system.
FIG 3 Hydro test limit re heater system.
FIG 4 Hydro test limit boiler water circulation system and super heater system.

TABLES
TABLE 1 Typical hydro test pressure and test pressure gauge ranges
TABLE 2 Quality of water
TABLE 3 Water volume (typical for various capacity of units)

1. INTRODUCTION

Hydrotest on Boiler pressure parts are required to be carried out to ensure the boiler circuit (water
& steam circuit) is healthy & leak free. After the repair works following the tube failure or preventive
maintenance during long outages / annual overhauling, it is required for a hydrotest to ensure the
proper completion of repair jobs and the capability of Boiler pressure parts to withstand the
operating pressure during normal running condition.
This document provides a general guideline for carrying out hydrotest of Boiler pressure parts.

2. HYDROSTATIC TEST CIRCUIT

The hydrotest of boiler circuit (water & steam circuit) is broadly categorized into two parts
1. Water Circuit from ECO Feed Line NRV to riser tube connecting point at Boiler drum & Steam
Circuit from SH Connecting tubes to Main Steam Stop Valve.
2. Reheater Circuit from CRH Isolating Device to HRH Isolating Device.

3. RECOMMENDED TEST PRESSURE LIMITS:

The hydraulic test of the Boiler shall be carried out as follows:

(i) Boiler Drum, Economizers, Water walls, Super heaters at 1.25 times the design pressure.
(ii) Re heaters at 1.25 times the design pressure or at minimum 70 kg/sq.cm.

For 250 MW Boilers:

Design Pressure – 182.5 kg/cm2 (g)
Hydraulic Test Pressure for Water & Steam Circuit = 182.5 x 1.25 = 228.125 kg/cm2.
Hydraulic Test Pressure for Reheater Circuit = 70.5 kg/cm2.

Test Pressure gauge range for Water & Steam Circuit = 0-300 kg/cm2
Test Pressure gauge range for Reheater Circuit = 0-100 kg/cm2

For 500 MW Boilers:

Design Pressure – 209.0 kg/cm2(g)
Hydraulic Test Pressure for Water & Steam Circuit = 209.0 x 1.25 = 261.25 kg/cm2
Hydraulic Test Pressure for Reheater Circuit = 78.6 kg/cm2.

Test Pressure gauge range for Water & Steam Circuit = 0-300 kg/cm2
Test Pressure gauge range for Reheater Circuit = 0-100 kg/cm2

Subsequent hydrotest of Boiler Water & Steam Circuit is to be carried out at design pressure and
hydrotest of reheater circuit is to be carried out at minimum 70 kg/cm2 (g).

4. PRESSURE GAUGES

Two Nos of Pressure Gauges installed at Boiler Drum Floor elevation are required to be calibrated
and checked prior to hydrotest. All the pressure transmitters are required to be checked for error
free readings prior to start of hydrotest.

5. PRE-REQUISITES FOR CARRYING OUT HYDROTEST

a) Welding of pressure parts including valves & radiography test has been completed.
b) In case of welding of headers / critical piping / High alloy tube joints, all PWHT has been
completed & PWC returned by Boiler Maint.
c) Maintenance of all valves installed in the hydrotest Circuit from Boiler Feed Pump Discharge
to Main Steam Stop Valves has been completed.
d) Availability of CW/ACW/DMCW pumps (atleast one from each should be in service)
e) Availability of at least one BFP, Boiler Fill Pump & CEP.
f) Boiler is in completely drained condition.
 g) Feed Water System is lined up upto ECO Inlet.
h) All HP heaters are isolated & feed water 100% bypass valves are opened.
i) All safety valves to be gagged at 80% of set pressure.
j) All spring hangers (VSH & CLH) of critical piping are in locked condition.
k) The valves should be operated as per the “VALVE OPERATING DIAGRAM” prior to filling of
empty boiler.
l) For carrying out hydrotest of Re-heater circuit, install the isolating devices with replacing
pressure seal rings.

6. WATER QUALITY

Water to be used for hydrotest should be treated, as specified below. The water temperature should
be at ambient temperature but in no case less than 70°F (21°C).

N OTE

I. After completion of work in pressure parts / attending leakage/ as per requirement, Boiler
to be subjected to pressure tests using water at no less than ambient temperature, but in no
case less than 210 C. The intent of this limitation is to reduce the risk of brittle fracture,
because , steel is more prone to brittle fracture when temperature slides below transition
temperature.
II. During testing, the temperature of water should in no case exceed 49°C.
III. It is recommended to use demineralized or condensate quality water of specified purity.
IV. For Quality of Treated water, Boiler water and Feed water, Refer Table - 1.
V. For super heater and re heater (drainable and non-drainable sections) treated condensate
or demineralized water can also be used. The treatment shall include 1O ppm ammonia and
200 ppm hydrazine. This treated water will have a pH value of approximately 10.
VI. The use of fill water treated with solid chemicals should be avoided. Deposits of solid
materials in super heaters and re heaters are detrimental from heat transfer and corrosion
point of view. Super-heaters and re heaters containing stainless steel tubing are particularly
vulnerable to stress corrosion cracking in the presence of chemicals as caustics and
chlorides.
VII. In the case of 500 M.W. or more capacity Unit Boiler, the Boiler Water Circulation pumps are
to be filled with condensate or demineralized water before putting water into the Boiler for
testing of Boiler with Boiler circulating water pumps.

7. WATER FILLING IN THE SYSTEMS

a) Before taking water in to the system proper line up of the filling lines are to be ensured.
b) The empty boiler is to be filled up by using Boiler Fill Pump only.
c) All the drains of boilers are to be tightened properly.
d) The water should be taken into the superheater circuit through superheater drain valves.
In no case water entry into super heater should be permitted through the drum. This is to
prevent carry over of suspended impurities into the super heater.
e) The isolating valves provided in all the other branching systems like Soot Blower System
tapping, SH spray connections, Pressure gauges etc., have to be closed tightly.
f) During filling of the Boiler all vents as super heater link vents, economizer link vents, drum
vents etc. should be kept open till the water pressure developed is at 2 kg/cm2.
g) After observing the water coming out from the vents, close the vents one by one. The order
of vents to be closed – (i) Drum Vents (ii) SH Roof Header O/L vents (iii) SH Desh Link Vents
(iv) Platen to FSH Link Vents (v) Eco Link Vents (vi) SH Start Up Vents
h) Close and open the vent valves several times in order to allow the entrapped air to vent
out. When valves are in TANDEM (Double valve) both valves must be closed during the
 hydro test.
i) Raise the pressure to 6-7 kg/cm2 by means of boiler fill pump. Close all the manual drain
valves through which filling was being carried out.
j) Check that no water is coming out of any vent, MS/CRH/HRH atmospheric drains and
IBD/UFT drains.
k) The reheater circuit is to be filled up through the atmospheric drains provided in the CRH
lines(Upstream of Isolating Device of CRH). Temporary piping is to be laid from atmospheric
drain to spare tapping point of Boiler fill line (near Boiler Blow Down Header).

8. PRESSURIZING THE SYSTEMS

a) The pressure shall be raised up by means of Boiler Feed Pumps.

b) Increase the pressure slowly at a rate of not more than 10 kg/cm2 per minute by operating
BFP scoop.
c) Safety valves to be gagged at around 70% of the pressure to which the low set valve is
adjusted, by the Boiler Maint. Personnel., Hold the pressure till drum & superheater safety
valves gagging has been completed.
Under no circumstances, cold gagging of safety valves shall be carried out.
d) The pressure is to be raised at a rate of not more than 10 kg/cm 2 per minute upto
approximately 80% of the test pressure and by 1 to 2 kg/cm2 per minute beyond that value.
e) 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 radio-telephonic contact.

9. HYDROSTATIC TESTING

a) The hydraulic test pressure reading will be taken from the official pressure gauge located at
the highest point and by control room data in the presence of the Engineer in charge.
b) Hold the boiler pressure at desired value (as stated above) for 5 mins. The drop in pressure
should not exceed 1 kg/cm2.
c) Reduce the pressure to 100 kg/cm2 and hold the pressure to allow removal of gags by Boiler
Maint. personnel.
d) Further reduce the pressure to around 50 kg/cm2 and hold the pressure till internal
inspection for leakages has been completed by Boiler Maint. personnels.
e) lf 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 hydrostatic test.

Details of the leaks noticed during Hydraulic Tests are to be furnished as given below for
better understanding:
 Exact location of leak(s) component circuit, Elevation, materials etc.
 Description of leak(s) such as straight tube elbow, shop or field weld, torch cut,
where a lug was removed and attachment weld etc.
 Magnitude of leaks-weeping/ sweating, leaks, burn through, longitudinal crack.

10. DEPRESSURISATION OF THE PRESSURE PARTS

The pressure parts shall be depressurized at a depressurization rate of 1 kg/cm2/ minute.
While releasing the pressure, the vents should be opened when the system pressure reaches
1 kg/cm2 to prevent creation of vacuum in the system.
11. INSPECTION OF THE BOILER PRESSURE PARTS AFTER TESTING
 After completion of the hydraulic test, the Engineer in charge shall carefully examine the
boiler inside and outside to ensure satisfactory execution of the test.
 Passing of Main Steam Stop Valves, MS line drains, IBD & CBD drain valves.
 Passing of any vent / drain valves in boiler side, drum manholes, valve glands etc.

12. PROCEEDINGS TO PREVENT ACCIDENTS AND ENDANGERING OF PERSONS DURING PRESSURE

TEST

 Due to the fact that during the pressure test the boiler and boiler house area are under an
increased risk of danger, special safety precautions have to be taken to prevent accidents.
These arrangements are made by the Boiler maintenance personnel according to the
instructions of the EIC.
 During the period of raising, holding and releasing the test pressure, the entry to the boiler
house is prohibited for all persons not participating in the pressure test. Works at the
pressure parts or in the direct neighborhood are not permitted.
 All agencies working on the site must be notified of the pressure test in writing. No claim
based on the restriction or stopping of work will be accepted.

13. PRESERVATION OF BOILER AFTER HYDROSTATIC TEST

I. There is generally some time delay between hydrostatic test and subsequent Boiler light up.
Hence, the unit should be kept under preservation for protecting the internal surfaces from
oxidation.

II. In case there is a need to preserve the boiler, drain the boiler completely (water & steam
circuit). Fill the unit with hydrazine and Ammonia treated DM water containing 300 ppm
hydrazine and 10 ppm Ammonia with a pH value of 10.0 to 10.5 till it overflows at vents.

III. The unit should be kept under nitrogen cover with a pressure of 1.5 kg/sq.cm. In the absence
of nitrogen capping facility the unit should be pressurized with the aid of a fill pump to 5
kg/cm2 and the pressure to be maintained.

IV. Samples can be collected periodically say once a week or fortnight, depending on the
pressure holding worthiness of the system, tested for pH and hydrazine content.

V. In case the sample water does not meet the criteria for layup water, the conditioning system
shall be operated as to restore the required composition.

VI. No welding shall be carried out on pressure parts when the system is under preservation or
the system is filled with water.

TABLE - 1
 QUALITY OF WATER
Sno 1. DEMINERALISED WATER (SPECIFICATION)
1 pH at 25°C 7 ± 0.2
2 Electrical Conductivity at 25°C Less than 0.2 Michromhd/cm
3 Total Hardness(Ca + Mg) PPM CaC03 Nil
4 Total Silica Less than 0. 02
5 SiO2 PPM
6 Chloride PPM as NaCl Nil
7 Sodium PPM as Na Less than 0.003
8 Organic matter Mgm, KMnO4 Should be free in any case should not
exceed 0.2 PPM on an average.
9 General Appearance Clear: Free from odour, colour and
Haziness. No Glittering to tyndal effect

2. QUALITY OF TREATED DM WATER OR TREATED CONDENSATE

The DM water or Condensate treated with 10 PPM ammonia and 200 PPM hydrazine to have a pH
value of approximately 10.

TABLE : 2

QUALITY OF BOILER WATER

Drum operating pressure 126-165 166-180 181-205
kg/sq.cm. (g)

Total Dissolved Solids - max (ppm) 50 25 15

Specific Electrical Conductivity

100 50
at 25°C (S/m) 30
Phosphate Residual (ppm) 5-10 5-10 2-6

pH at 25°C 9.1-9.8 9.1-9.8 9.1-9.6

Silica (max.) (ppm) To be controlled on the basis of silica in

boiler water and drum pressure
relationship (Fig.1) to maintain less than
0.02 ppm in the steam leaving the drum
 TABLE - 3

WATER VOLUME (TYPICAL FOR VARIOUS CAPACITY OF UNITS)

120 MW 200/210 MW M3 250 MW 500 MW

SYSTEM
M3 M3
M3

1. Water Wall Surfaces 70.4 126.5 130.0 160.0

2. Drum 21.1 37.0 35.0 60.0
(Full) (Full) (Full) (Full)
3. Economizer 30.0 30.0 25.0 135.0

4. Super heater
(Drum to SHO Header) 47.0 95.0 95.0 145.0
5. Re heater 15.0 43.0 50.0 220.0

6. Total 183.5 331.5 335.0 720.0

 HYDRO TEST LIMIT BOILER
WATER CIRCULATION SYSTEM

FIG.1
HYDRO TEST LIMIT BOILER
SUPER HEATER SYSTEM
FIG.2
HYDRO TEST LIMIT BOILER RE HEATER SYSTEM

FIG.3