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Boiler Hydro Test by R K Jaint PDF
Boiler Hydro Test by R K Jaint PDF
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TESTING OBJECTIVE
• To ensure healthiness of pressure parts.
• To preserve the boiler after hydraulic
test is over.
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TEST METHOD
• The hydraulic test is carried out in two stages:
• Stage – I : Hydro test at a pressure of 1.5 times the
design pressure. (313.5 kg/sq.cm for 500 MW).
It will cover the Drum, Down comers, Evaporator,
Economizer and all Super-heaters up-to Boiler stop
valves.
• Stage – II: (78.6 kg/sq.cm for 500 MW )
It will cover the Cold reheat lines from Isolator , Re-
heater and Hot reheat line up-to Isolator.
• Air tightness test to be performed before water filling
(at 2 kg/sq.cm. (g)) to detect leakages due to valves
left in open position, forgotten gamma plugs, any
cuts not observed by visual inspection etc.
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TEST METHOD
• It is preferable to do the hydraulic test of the
complete Boiler (except Re-heater section) in one
stroke. If it is not possible to accomplish this, the
hydraulic test may be conducted in two sub stages.
• Stage IA - Hydraulic Test of the drainable portion only
at a press 1.5 times the design pressure. Suitable
dummies shall be provided at LTSH outlet link pipes.
After completing the hydrostatic test for drainable
portion, the system will be drained and vented for
drying and released for subsequent work.
• Stage IB – Later Hydraulic test for the entire system
comprising both drainable and non-drainable portions
up to Boiler Stop valves is conducted at a pressure 1.5
times the design pressure.
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Services Required
• Pressure Gauges: At least two gauges: one at
drum level, and other near pressure raising
pump. Least count of gauge should be 1 KG/CM2
• Availability of DM water:
• Quantity: 1400 cu. meter.
• pH: 9.5 to 10.0 by addition of Ammonia & Hydrazine
200PPM
• Temperature: 20< T< 50 deg
• Chemicals:
• Ammonia :175 litres(stg.-I) + 125 litres(stg.-II)
• Hydrazene : 550 litres (stg.-I) + 300 litres (stg.-II)
• For Preservation: Ammonia: 200 litres + Hydrazine: 600
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HYDRAULIC TEST
• Pressure is raised to 25Kg/cm2 and a thorough inspection is
done.
• Rate of rise should not be more than 10 kg/sq.cm (g) per minute
up-to approx. 80% of the test pressure and should be 1 to 2
kg/sq.cm (g) per minute beyond that value.
• The pressure is raised in steps and held for 10 minutes at 100 &
200 Kg/cm2
• After reaching the test pressure the pressurizing pump is stopped
immediately & power supply to pump is cut off.
• The Final test pressure held for half an hour in presence of
Inspection Authority.
• During holding time the official test gauge pressure reading
should not drop noticeably
• The average pressure drop during first 10 minutes of stopping
the pressuring pump should be less than 1 Kg/cm2.
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HYDRAULIC TEST
• After 30 Min holding pressure is reduced to 50 Kg/cm2 and entire
pressure parts/ piping are checked.
• Wherever valves are in tandem both valves should be checked for
passing one by one by keeping one valve closed and other open.
• If leaks are found, release the pressure and drain the concerned
portion. After repairs the boiler is refilled & hydro test is
repeated.
• The pressure parts shall be de-pressurized at a rate of 1 kg/ Sq.
cm/minute.
• Vents should be opened when the system pressure reaches
2kg/sq.cm
• 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
• After satisfactory hydro test entire Boiler is drained & joint
protocol is signed for completion of Hydro Test.
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PRESERVATION OF BOILER
• Purpose: To protect the internal surfaces from oxidation.
• Boiler pressure raised to 5 – 10 kg/sq. cm at drum with
treated DM water containing 200 PPM of Hydrazine and
Sufficient amount of Ammonia to raise pH value of 10.0
to 10.5.
• Drum water samples collected periodically say once in a
week or fortnight & tested for pH and hydrazine content.
• Criteria for preservation of Boiler :
• i) PH : Not less than 9.0
• ii) Hydrazene Hydrate : Not less than 50 PPM
• iii) Drum Pressure : Not less than 2 kg per sq. cm.
• Alternatively, preservation can be done under Nitrogen
capping at 1.5 Kg/cm2 at vents of drum and Super
Heater.
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COMPLETION CRITERIA
• The test pressure in the official pressure gauge
(Calibrated standard test pressure gauge) is
held for 30 consecutive minutes in presence of
Inspection Authority. The Boiler should
satisfactorily withstand such pressure without
appreciable leakage or undue deflection or
distortion of its pressure parts for at least 10
consecutive minutes
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