ISGEC John Thompson

SECTION-3

HYDRAULIC TEST
 ISGEC John Thompson

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:
a. On completion of erection.
b. On completion of repair of boiler pressure parts.
c. On completion of annual overall.
d. At the request of boiler inspector to fulfill the statutory
requirement.

3.2 PREPARATION FOR TEST

1. Check that all tools, equipment and loose items have been
removed from drums and manifolds.
2. Check that all drums, manholes and manifolds inspection
caps are properly joined and tightly sealed. Drum internals
need not be fitted for test done before steam blowing /
chemical cleaning.
3. Close all stop valves, drain valves and blow down valves
where double isolation is possible close both valves. Single
isolating valves must be blanked off.
4. Remove all safety valves and fit blank flanges for flanged
type Safety valves. For Welded valves, safety valves gags are
kept ready. Gagging to be done after raising the pressure to
60% of the working pressure.
5. Open all air release valves.
6. Close all valves to equipment and gauges, which are not
designed for, or intended to be subjected to, the pressure to
be applied. Such instruments or equipment must be
vented to atmosphere to prevent any build up of pressure.
7. All panel pressure gauges must be calibrated by dead
weight tester and correctly connected.
8. Calibrated pressure gauges are required to be connected
near the drum.
9. Check the water supply Check boiler filling pump/boiler
feed pump is ready in all respect for boiler water filling.

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 ISGEC John Thompson
10. Check that all temporary pipe support locks have been
removed. Check all hangers, pipe support and locking
arrangement is placed as per drawing.
11. Hydraulic test to be carried out up to the root values of
mountings.
12. Proper lighting, approach platforms and communication
system are ready.
13. Pr. Parts must not be covered with insulation
14. Temporary water filling connection must be complete.

CAUTION:
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. Water used must be as near as possible at the
temperature of the boiler pressure parts temperature &
difference should not be more then 50 deg.

NOTE:
Hot condition : Boiler bank flue gas exit
temperature more than 200deg
Warm condition : Boiler bank flue gas exit
temperature 60 deg to 200 deg.
Cold condition : Boiler bank flue gas exit
temperature less than 60Deg.

3.3 APPLYING THE TEST

CAUTION:
 When filling the boiler with the feed pump, it is important
to avoid overloading the drive motor, by ensuring that the
discharge pressure does not fall below its normal operating
pressure. This is best done by throttling the flow at the
discharge stop valve.
 Maintain boiler water pH between 8.5 to 10.5 & hydrazine
to approximately 150 ppm

a. Start filling boiler by means of boiler filling pump from

lowest point possible i.e. through economizer header
water wall drain. Maintain boiler water pH between 8.5
to 10.5 and hydrazine to approximately 150 ppm.
b. As boiler fills, operate all blow down and drain valves to
prove them clear.
c. Close air vents of economizer, drum, super heater in
sequence, when water free of entrained air issues from
them.

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 ISGEC John Thompson
d. When boiler is full of water and all air vents have been
closed, inspect boiler in designated area at full water
level condition for any leak. If leak observed- stop the
test, repair it. If no leak found proceed for pressure
raising to 50% of working pressure. Observe the rate of
pressure drop by stopping the pump, pressure drop rate
should not be more 1-2 kg/cm2 /min. Raise pressure
slowly to 1.5 times of design pressure. Rate of pressure
increase must not exceed 50 p.s.i.g. (3.5 kg /cm2g.) per
minute.
Note : Boiler must be hydro tested to 1.5 Times design
pressure only for first time test after completion of
erection as per IBR requirement. All subsequent
hydro tests must be done at design pressure to avoid
any undue stresses on boiler unless there is any
specific requirement given by boiler inspector.
e. Maintain test pressure for at least 15 mins. Carry out a
thorough examination on all boiler parts under
pressure, mark locations of leaks/sweats.
f. Release pressure slowly and drain boiler to sufficiently
low level to allow leaks/sweats to be rectified.
g. 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 to the satisfaction
of the inspecting authority.
3.4 ACTION AFTER THE TEST
NOTE: In pendant type non-drainable superheaters
DEMINERALISED water with Hydrazine added of 300
p.p.m & pH more then 9.5 to be used. These may than
be left filled after the test.
 In case of welded safety valves, remove gag from all safety
valves. Gags to be removed when boiler pressure has come
down to 60% of the working pressure. In case of flanged
safety valves, refit the valves.
 Remove gauges specially fitted for test.
 Reinstate instruments that have been sealed off for the
test.
CAUTION
Boiler should always be filled with treated water as specified in
Technical data sheet. Filling the boiler with untreated water will
cause internal damage, corrosion to the pressure parts.

Section #3 PAGE 3 of 3