PROCEDURE FOR BOILER HYDRO TEST AND PRESERVATION

DOCCUMENT NO: BHEL:PW: TSX:916: B: BLR: CP/01

PROJECT: MSPGCL BHUSAWAL UNIT # 6 (660 MW).

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector - Western Region
TECHNICAL SERVICES DEPARTMENT
345, SHREEMOHINI COMPLEX, KINGSWAY, NAGPUR – 440 001
PROJECT MSPGCL BHUSAWAL UNIT #6 (660 MW).

PROCEDURE BOILER HYDRO TEST AND PRESERVATION

DOCUMENT NO. BHEL:PW:TSX:916:B:BLR:CP/01

AMIT KUMAR
DIPAK GAIKWAD S. MANDAL
SHRIVASTAVA
SR. MANAGER / TSX SR. MANAGER / TSX GM / TSX
PREPARED REVIEWED APPROVED

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector - Western Region
TECHNICAL SERVICES DEPARTMENT
345, SHREEMOHINI COMPLEX, KINGSWAY, NAGPUR – 440 001
MSPGCL Sheet 1 of 13
BHUSAWAL
U#6 (660 MW) BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01

Plant Area: BOILER

BOILER HYDRAULIC TEST AND PRESERVATION

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURES

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 PRESERVATION OF BOILER

10.0 LOG SHEETS

APPENDICES
MSPGCL Sheet 2 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

1.0 PLANT DETAILS

1.1 The steam generator is a top supported, sliding pressure supercritical boiler. The furnace
consists of welded spiral wound water walls, water wall lower headers, intermediate
headers, straight (upper) water wall panels, water wall outlet headers, risers, drains, vents,
sampling line connections etc. The separator is of welded construction with all its safety
valves, mountings, fittings and all accessories. This boiler is assisted by one Boiler
recirculation pump complete with drive motor, high pressure cooler, lubricating system,
purge and fill system.

1.2 Superheater section comprises drainable and non-drainable portions and includes safety
valves, SH outlet stop valves with integral bypass valves, drains, start up vents, nitrogen
capping connections etc.

1.3 Water volume of different sections are:

System Water Volume (Approx m3)

Economiser 200
Separator 20
Furnace 120
Super heater System 95
Re-heater Syatem 440
Start up system 25
Total 900

2.0 OBJECTIVE

2.1 To ensure integrity of pressure part & circuits.

2.2 To preserve the Boiler after the hydrostatic test is over. (Preservation may not be possible
till the completion of installation of Boiler Recirculation Pump and removal of hydro test
plugs from the safety valves).
MSPGCL Sheet 3 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

3.0 PROPOSAL

3.1 The Unit will be hydraulically tested for conformation to IBR code requirements.

3.2 It is preferable to do the hydraulic test of the complete Boiler (except Re-heater section) in
one go at the stipulated Hydraulic test pressure. If it is not possible to accomplish this, the
hydraulic test may be conducted in two sub stages.

3.3 Stage I A - Hydraulic Test of the drainable portion to be conducted at a pressure 1.5 times
the design pressure. Suitable dummies shall be provided at SH platen inlet link pipes. After
completing the hydrostatic test for drainable portion, the system will be drained and vented
for drying and released for subsequent work.

3.4 Stage I B – 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.

3.5 Stage II - This covers the total Reheat circuit comprising CRH lines starting from CRH
NRV, tap off lines emanating from CRH lines upto first isolation valve, HPBP valve
downstream line, Reheater, hot reheat lines up to IVs, LPBP lines up to LPBP valves.

3.6 Air tightness test shall be performed before filling water in the Boiler (for carrying out the
hydrostatic test). This is done to detect leakages due to valves left in open position, forgotten
gamma plugs, any cuts not observed by visual inspection etc.

3.7 Chemically treated water (as specified) shall be used for conducting hydrostatic test.

3.8 The hydrostatic test pressure will be 1.5 times the design pressure.

3.9 Recommended Hydrostatic Test Pressures are

2
Stage – IA & IB :403.95 Kg/cm
2
Stage – II : 96.45 Kg/cm
3.10 After completion of Stage IB Hydrostatic test the Boiler shall be kept under preservation.
MSPGCL Sheet 4 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

4.0 SERVICES REQUIRED

4.1 PRESSURE GAUGES

4.1.1 During testing at least two properly calibrated standard test pressure gauges of suitable range
calibrated from a NABL accredited laboratory are to be used. One of the gauges is mounted
at separator floor (stage IA) / Super heater outlet header (stage IB) / Final RH outlet (Stage
II).

4.2 AVAILABILITY OF DM WATER

Chemically treated DM water having pH between 9.5 and 10.0 by addition of adequate
4.2.1 quantity of Ammonia shall be used for Hydraulic test.

4.2.2 During testing the temperature of water should be above 210C but should not exceed 49
0
C.

4.2.3 Approximate quantity of DM water required for Hydraulic Test is 950 m3.

4.3 CHEMICALS
Stage IA & IB
Ammonia : 300 litres

Stage II
Ammonia : 200 litres

4.4 AVAILABILITY OF CHEMICALS FOR PRESERVATION

Ammonia : 25% Min as NH3
(Not less than 10 ppm Ammonia so as to have pH value of 9.0 - 10.0 )

4.5 Availability of reciprocating type pressurizing pump (H and Q of the pumps):

(a) 600 Kg/cm2, 30 LPM and (b) 600 Kg/cm2, 50 LPM

4.6 Availability of reciprocating type chemical injecting pump of 600 Kg/cm2 & 12 LPM.
Alternatively, hydrotest pump can be utilized as chemical dozing pump.

4.7 Availability of Boiler fill pump.

MSPGCL Sheet 5 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

4.8 Availability of power supply to the motors of these pumps.

4.9 Availability of Temporary tanks, Temporary fill pumps and dosing pumps.

4.10 Availability of flood lights and 24V hand lamps.

4.11 Availability of reliable communications system such as walkie-talkie sets, telephones etc.

4.12 Availability of Fire Tender and Ambulance near the test area.

5.0 SAFETY PRECAUTIONS

5.1 Readiness of stair-cases, platforms, hand rails, approaches etc., as decided jointly by BHEL
& MSPGCL at site in advance, should be ensured.

5.2 24V lamps should only be used for internal inspection of the Boiler.

5.3 Delivery line of pressurizing pump should be high pressure seamless pipe to withstand the
required test pressure.

5.4 While raising the pressure for the first time no individual should be allowed to enter the
Boiler house when the pressure in the Boiler is above 25 Kg/cm2.

5.5 Medical assistance should be readily available.

6.0 EMERGENCY PROCEDURES

6.1 The testing team should be aware of the procedure to be followed in case of accidents
causing injury to personnel.

6.2 The testing team should be aware of the operating procedures of fire extinguishers.

6.3 A person is to be posted near emergency push button and should have the instruction to trip
the pressurizing pump in the event of emergency being notified to him by observers.

7.0 STATE OF THE PLANT

7.1 Erection of the Boiler pressure parts is complete as per drawing. All necessary welding jobs
are complete, stress relieved and X-rayed. All gamma plugs are seal welded. All Quality
checks as per approved Erection FQP are also complete. No welding including attachment
welding or welding on tube will be allowed subsequently.
MSPGCL Sheet 6 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

7.2 Copies of FQPs and Erection Protocols with exceptions highlighted are Filled & signed.

7.3 Effective communication facility is available between Separator floor, pressurizing pump
area and other operating areas.

7.4 Sky climbers / Scaffolding arrangements are provided inside the Boiler.

7.5 Boiler drain is suitably connected to storm water drain / DM plant neutralizing pit.

7.6 All debris removed manually from all pressure parts, buck stays etc.

7.7 All manhole closure plates and header hand hole caps are closed and bolted or welded tight.

7.8 All safety valves are installed and hydrostatic test plugs are installed where necessary and
gags are fitted correctly.

7.9 Verify that all hangers in Boiler and piping system are set and locked.

7.10 Boiler Recirculation Pump casing is blanked off with the blank plate supplied (Impeller and
motor are not erected).

7.11 All branch system like soot blowing, SH & RH spray are isolated at root valves (Hydraulic
test of sootblower system, SH & RH spray system are carried out separately). Blank is
welded in feed line to economizer just after NRV.

7.12 All drain, vent, sampling, dozing, pressure/level instrumentation impulse tapping root valves
are installed. Drain, dozing, instrumentation tapping and sampling tapping valves are
isolated at root valves.

7.13 In boiler start up scheme, all lines will be included for hydrotest e.g., wet leg, High Water
Limit (HWL) line up to first isolation valve towards flash tank, warm keeping line up to
isolation valves, Mixing sphere and BRP suction and discharge lines will be included in the
hydro test scheme.
MSPGCL Sheet 7 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

8.0 METHOD

8.1 AIR TESTING OF THE PRESSURE PARTS

8.1.1 Before filling the boiler with water, an air tightness test is performed to detect leakages due
to valve left in open condition, X-ray plug forgotten, any cuts etc. not observed by visual
inspection. This will reduce the DM water consumption and time as well.

8.1.2 The air should be filtered and free from oil and dust prior to entering the unit. Boiler is
pressurized with air up to 2 Kg/cm2 (G).

8.1.3 Before admitting air manholes, isolating valves in drain lines, branching lines and vent lines
including the vent valves in SH link, economizer link and separator link, drain and test
valves in official pressure gauge etc. are closed.

8.1.4 Boiler is inspected and leakages, if any found, are attended.

8.1.5 After completing the air tightness test, vent valves are left in open position.

8.2 FILLING OF THE SYSTEM FOR HYDROSTATIC TEST

8.2.1 Stage IA & IB

8.2.1.1 The evaporator, separator, economizer and superheaters are filled with Ammoniated dosed
DM water of pH 9.5-10.0 (dosed to 10+ ppm with Ammonia) through filling lines connected
to the boiler drain header. At the same time chemical dosing is done by temporary dosing
pump or hydro test pump.

8.2.1.2 Confirmation of completion of filling of the entire system is done through the vents.

8.2.1.3 The vent valves are closed and opened several times to allow venting of entrapped air till
steady stream of water overflows from the vents.

8.2.1.4 Boiler fill pump is stopped.

MSPGCL Sheet 8 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

8.2.2 Stage II

8.2.2.1 The Re-heat circuit comprising CRH, RH, HRH, LPBP and downstream line of HPBP valve
is filled with Ammoniated dosed DM water of pH 9.5-10.0 (dosed to 10+ ppm with
Ammonia) through a temporary fill line connected to CRH drain.

8.2.2.2 Hydrotest devices are installed in CRH NRV, IV, LPBP valves otherwise blank plate is
welded. Blank plate is welded in HPBP valve downstream line. Tap off lines emanating
from CRH line are isolated at first isolation valve.

8.2.2.3 Confirmation of completion of filling of the entire system is done through the vents.

8.2.2.4 The vent valves are closed and opened several times to allow venting of entrapped air.

8.2.2.5 On completion of filling the fill pump is stopped.

8.3 PRESSURISING THE SYSTEMS

8.3.1 Pressure is raised with the help of pressurizing pump.

8.3.2 Wherever valves are in tandem, both the valves should be checked for passing one by one.
All the drain valves, vent valves and NRVs should be checked for passing, if any. HWL (
High Water Limit) isolating valves and NRVs should be checked for passing, if any, by
observing downstream open end during pressurization of the boiler.

8.3.3 The pressure is raised up to 25 Kg/cm2 and a thorough inspection of the Boiler is done. For
Stages IA & IB the pressure is raised in steps and held for 10 minutes at 100 & 200 Kg/cm2.
For Stage II the pressure is raised in steps and held for 10 minutes at 25 & 50 Kg/cm2. The
rate of rise of pressure should not be more than 5 Kg/cm2 per minute up to approximately
80% of the test pressure and should be 1 to 2 Kg/cm2 per minute beyond that value. The test
pressure shall never be exceeded by more than 6%.

8.3.4 The safety valve gags are hand-tightened at 80% of pressure of lowest safety valve set
pressure

8.3.5 After reaching the test pressure the pressurizing pump is stopped immediately and power
supply to the pump is cut off.
MSPGCL Sheet 9 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

8.4 HYDRAULIC TEST

8.4.1 The hydraulic test pressure reading is taken from the calibrated standard test pressure gauge
mounted near the pressurizing pump with necessary correction for the height of the topmost
pressure part of boiler and simultaneously from the gauge mounted at a safe location at
topmost floor as per requirement of the Statutory Inspection Authority. Instrument will have
valid calibration certificate.

8.4.2 The test pressure is held for 30 consecutive minutes in presence of Inspection Authority.

8.4.3 The pressure is then reduced to 50 Kg/cm2 and the entire pressure parts are checked. It is
ensured that personnel inspecting are equipped with proper illumination device, safety
equipment, clothing and safety goggles. If leaks are found then pressure is released and
concerned section drained. After repairs the Boiler is refilled and the hydraulic test repeated.

8.4.4 Details of the leaks noticed during Hydraulic Tests are recorded as given below for better
understanding:

- Exact location of leak(s) - component, circuit, elevation, material etc.

- Description of leak(s) - straight tube, elbow, shop or field weld, torch-cut, removed lug,
attachment weld etc.
- Magnitude of leak(s) - seeping, sweating, leaks, burn through, longitudinal crack etc.

8.5 DEPRESSURISATION OF PRESSURE PARTS

8.5.1 The pressure parts shall be de-pressurized at the rate of 1 Kg/cm2 per minute.

8.5.2 While releasing the pressure the vents should be opened when the system pressure falls to
around 2 Kg/cm2 to prevent creation of vacuum in the system.

8.6 INSPECTION OF BOILER PRESSURE PARTS AFTER TESTING

8.6.1 After completion of the hydraulic test a thorough inspection of boiler from inside and
outside is done to ensure that the boiler has satisfactorily withstood the test. After
satisfactory completion of Hydro test entire Boiler system is drained

8.7 HYDROSTATIC TEST PROTOCOL

8.7.1 After successful completion of the Hydraulic Test a joint protocol is signed between BHEL
& MSPGCL.
MSPGCL Sheet 10 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

8.8 COMPLETION CRITERIA

8.8.1 The Test Pressure in the official pressure gauge (Calibrated standard test pressure gauge) is
held for 30 (Thirty) consecutive minutes in presence of Inspection Authority. The Boiler
shall satisfactorily withstand such pressure without leakage or undue deflection or distortion
of its pressure parts.

9.0 PRESERVATION OF BOILER

9.1 After successful completion of Stage IB Hydrostatic test the Boiler is preserved for
protecting the internal surfaces from oxidation. Prior to preservation the BRP erection is
completed and hydro test plugs removed from the safety valves.

9.2 The Boiler is completely filled so as to overflow through the vents with Ammonia dosed
treated DM water containing not less than 10 ppm of Ammonia so as to have pH value of
9.5-10.0 and retained at this value for preservation. Then Boiler is pressurized to 5-10
Kg/cm2.

9.3 Boiler water samples are collected periodically, say, once a week or fortnight, depending on
the pressure holding worthiness of the system and tested for pH.

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

9.5 In case of fall in chemical level in boiler, same is boost up using Boiler fill pump and dozing
arrangement and at the same time venting sufficiently through the air vents in the top level
of the boiler.

.
MSPGCL Sheet 11 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

BOILER HYDRAULIC TEST

LOG SHEET NO. 1

PROJECT : DATE :

UNIT :

ACTIVITY : BOILER HYDRAULIC TEST – CHEMICAL ADDITON

STAGE :

CHEMICALS ADDED:

CHEMICAL VALUE
DATE TIME QUANTITY
ADDED ACHIEVED
MSPGCL Sheet 12 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

BOILER HYDRAULIC TEST

LOG SHEET NO. 2

PROJECT : DATE :

UNIT :

ACTIVITY : BOILER FILLING, PRESSURISATION & DEPRESSURISATION

STAGE :

PRESSURE
S. No. ACTIVITY DATE / AT BOILER AT SEPARATOR REMARKS
TIME AT PRESSURISING
FILL PUMP LEVEL / Final SH
DISCHARGE PUMP DISCHARGE / RH outlet
MSPGCL Sheet 13 of 13
BHUSAWAL BHEL Ref No : BHEL:PW:TSX:916:B:BLR:CP/01
U#6 (660 MW)
Plant Area: BOILER
BOILER HYDRAULIC TEST AND PRESERVATION

BOILER HYDRAULIC TEST

LOG SHEET NO. 3

PROJECT : DATE :

UNIT :

ACTIVITY : BOILER PRESERVATION

CHEMICALS ADDED: CHEMICAL VALUES ACHIEVED:

i) Ammonia : i) pH :

S. SAMPLE SYSTEM PRESSURE

No. DATE TIME COLLECTED pH BEFORE AFTER
AT PRESSURIZATION PRESSURIZATION
403.95