Comm/ JB No 0993/C3
Rev 00 01/ 28.06.13
Isgec Heavy Engineering Ltd
SECTION 3 – HYDRAULIC TEST
3.1 Purpose
Hydraulic test in a boiler is carried out to
check leakages of pressure parts and
prove the strength of the boiler at a
pressure greater than the working
pressure of the boiler, and is carried out
at following stages:-
On completion of erection.
On completion of repair of boiler
pressure parts.
On completion of annual overhaul.
At the request of statutory authority
to fulfill the statutory requirement.
3.2 Preparation for Test
Check that all tools, equipment and
loose items have been removed from
drums and manifolds.
Check that all NDT activities and Post
weld heat treatment wherever
applicable after Boiler pressure parts
welding have been completed.
Check that all drums manholes and
manifolds inspection caps are tightly
sealed.
Close all stop valves, drain valves and
blow down valves. Wherever double
isolation valves are provided close the
second valve.
Remove all safety valves and fit blank
flanges for flanged type Safety valves.
For Welded safety valves, hydro test
plugs are to be installed ensuring that
correct plug is fitted as per
identification. For test taken at
working pressure hydraulic plugs
need not be provided.
Open all air release valves.
Isolate all the instruments except the
test pressure gauge.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
These isolated instruments or equipments
must be vented to atmosphere to prevent
any built up of pressure.
Calibrated pressure gauges are required to
be connected on the boiler steam drum.
Dial pressure gauge used in testing shall
preferably have dials graduated over their
entire range of about double the intended
maximum test pressure, but in no case
the range shall be less than 1.5 times of
test pressure. The Calibrated pressure
gauges size must be greater than 150 mm.
Ensure the availability of the sufficient
quantity of DM water as per the
requirement for hydro test (approximately
3 times of boiler water holding capacity).
Check boiler filling pump/boiler feed
pump is ready in all respect for boiler
water filling.
Check all hanger tie rods, pipe supports
and locking arrangement are placed as per
drawing.
Check that constant load hangers, spring
loaded hangers are locked in position with
locking pin. Check that all temporary
supports are removed.
Hydraulic test is to be carried out up to
the root valves of mountings.
Check that Proper lighting, approach
platforms and communication systems are
ready.
Pressure Parts must not be covered with
insulation for first hydro test.
Temporary water filling connection with
proper supports must be complete.
Two sets of drum and other important
gaskets must be kept ready as spare.
Check all buck stays and seismic supports
are installed as per drawing.
Ensure that all attachment welding with
pressure parts is complete including fin to
tube and anchors to pressure parts.
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Isgec Heavy Engineering Ltd
Hydraulic test should be carried
out on boiler in cold condition.
Sudden changes in temperature
caused by filling a hot boiler with
relatively cool water will cause
thermal stresses, leading to
serious damage. The
temperature of the water used as
a medium of pressure testing
shall not be less than 20 0C and
not greater than 50 0C, 40 0C is
an ideal.
NOTE:
Hot condition : Furnace temperature
more than 200deg C
Warm condition: Furnace temperature
60 deg to 200 deg C.
Cold condition: Furnace temperature
less than 60 deg C.
3.3 Procedure of Hydro-test
Start filling boiler by means of boiler
filling pump from lowest point
possible i.e. through economizer
bottom header drain or water wall
drain. Maintain boiler feed water pH
between 9.5 to 10.5 and oxygen
scavenger to 200 ppm. If the boiler is
required to be idle after the hydrotest
(There is a long gap between hydrotest
and boiler firing), it is suggested to
preserve the boiler. In that case the
pH of the DM water to be maintained
between 10.5 to 11.0 and Oxygen
scavenger to 200 ppm.
As boiler fills, operate all blow down
and drain valves to prove them clear.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C3
Rev 00 01/ 28.06.13
Close air vents of economizer, water wall
top header, drum, super heater in
sequence, when water starts coming out
freely without air.
When boiler is full of water and all air
vents have been closed, inspect boiler at
full water level condition for any leak. If
leak observed- stop the test, repair it. If no
leak found proceed for pressure rising to
50 % of working pressure. Observe the
rate of pressure drop by stopping the
pump; pressure drop rate should not be
appreciable. In case pressure drop is high
check and correct. Raise pressure slowly
to desired hydro test pressure. Rate of
pressure increase must not exceed 50 psig
(3.5 kg /cm2g) per minute. Test pressure
should never exceed by more than 6 % of
required test pressure.
When filling the boiler with the
feed pump ensure that the
discharge pressure does not fall
below its normal operating
pressure. This is required to
avoid overloading of pump. This
can be done by throttling the
flow at the discharge stop valve.
Maintain boiler feed water pH
between 9.5 to 10.5 (10.5 to 11
if boiler is to be preserved),
water quality as per contract &
Oxygen scavenger to 200 ppm
Do not weld any pressure parts
or attachments to pressure parts
with water inside the tubes.
For a newly erected boiler, the test
pressure shall be maintained for
maximum 30 minutes at 1.5 times
maximum allowable working pressure of
drum / design pressure of drum (201
Kg/Cm2(g) for this boiler) and then
pressure shall be reduced to maximum
Section 3, Page 2

Isgec Heavy Engineering Ltd
allowable working pressure and
maintained at sufficient time to permit
close visual inspection for leakage of
pressure parts. Carry out a thorough
examination on all boiler parts under
pressure, mark locations of leaks /
sweats. The pressure should be
monitored at the boiler drum
elevation.
3.4
NOTE:
Boiler must be hydro tested to 1.5
Times maximum allowable working
pressure (design pressure of the
drum) only for first time after
completion of erection (As per
Relevant Code requirement). All
subsequent hydro tests must be
done at normal working pressure at
Superheater outlet to avoid any
undue stresses on boiler unless
there is any specific requirement
given by statutory/ inspection
authority.
Cyclic Hydraulic test is adopted to
detect weak joints which do not get
exposed in normal hydraulic test.
After the pressure is raised to hydro
test pressure, reduce the pressure
below working pressure to about 75%
of working pressure. Again the
pressure is raised to the test pressure.
This is repeated for three times. A
thorough inspection is done after
three cycles to detect any leaks.
Reduce the pressure gradually by
crack opening the drain valves/ vent
valves till the boiler reaches 5 Kg/Cm2
and then open all the vent valves. Do
not keep any drain open below 5
Kg/Cm2 pressure till all vents are
opened. Further drain the boiler to
sufficiently low level to allow leaks /
sweats to be rectified.
Refill and pressurize the boiler as per
the procedure out lined above. Re-
check for leaks and repeat as often as
is necessary until all leaks are
stopped.
1 X 80 TPH CFBC Boiler
M/s. PT Tereos FKS, Indonesia
Comm/ JB No 0993/C3
Rev 00 01/ 28.06.13
If Hydro test is found satisfactory and
Boiler is required to be preserved, then
slowly depressurize the boiler by opening
a suitable vent till the pressure reduces to
about 10 kg/cm2. Close all drains and
vents and maintain the pressure of 3 to 10
kg/cm2 during the idle period.
Action after the Test
In case of welded safety valves, remove
hydro test plug and reinstall the normal
Safety valve seat after depressurizing and
draining the boiler. In case of flanged
safety valves, refit the valves.
Reinstate instruments that have been
sealed off for the test.
The drained water should never be reused.
If Boiler is under preservation, check the
level of oxygen scavenger and water pH
weekly. Oxygen scavenger level should not
fall below 100 ppm and pH should not fall
below 10.5. When pressure falls to about 3
kg/cm2, again raise the boiler pressure to
10 Kg/Cm2 and maintain this throughout
the idle period. If pH or oxygen scavenger
level falls below the desired level, boosting
of chemical may be done and checked. If it
is not possible to boost the levels to
desired value, boiler must be fully drained
and the process shall be repeated using
fresh water having the desired chemical
levels.
Boiler should always be filled
with treated water as specified
in Contract. Filling the boiler
with untreated water will cause
internal damage, corrosion to
the pressure parts.
Section 3, Page 3