CFB Boiler / A 320 tph – Soda

Sanayii A.Ş

CFB Boiler / A 320 tph – Soda Sanayii A.Ş

BOILER HYROSTATIC PRESSURE TEST PROCEDURE

Elaborated by: EFOR

Approved by Supplier Issue date: Effectivity:

guarantor:

Approved: Name: Function: Date: Signature:

EFOR Ayhan ALTINTAŞ Site Manager

RAFAKO

SODA

Revision: Rev:0

Date: 30.01.2014

COMPANY: EFOR

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REVISED L I S T

No. Elaborated Reason for the change Garant Effectivity

change Signature New lists Canceled lists Signature datum

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CONTENTS

Page

1.0 SCOPE 4

2.0 PURPOSE 4

3.0 RESPONSIBILITY 4

4.0 TESTING 4

5.0 NONCONFORMANCE CONTROL 8

6.0 RECORD 8

7.0 ATTACHMENTS

Enclosure 1- HYDROSTATIC TEST REPORT

Enclosure 2- LIST OF TESTED PIPELINES

Enclosure 3- LIST OF TESTED VALVES

Enclosure 4- PRESSURE TEST SCHEMA

Enclosure 5- PRESSURE_TEST_DIAGRAM

Enclosure 6- MERSİN SODA TEST SAFETY GUIDELINES

1 SCOPE

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This procedure describes the requirements for the hydrostatic test process for standard
items which are fabricated in accordance with EN 12952 water tube boiler standart.

2 PURPOSE

Throughout this Standard the following dated and undated standards/codes are
referred to. These referenced documents shall, to the extent specified herein,
form a part of this standard. For dated references, the edition cited applies. The
applicability of changes in dated references that occur after the cited date shall
be mutually agreed upon by the Company and the Vendor. For undated
references, the latest edition of the referenced documents (including any
supplements and amendments) applies.

1) EN 12952-6 10.2
2) EN 13445-5

3 RESPONSIBILITY

3.1 The QA/QC Inspector shall be responsible for preparing the Pressure Instructions
(Hydrostatic Test Report) for each item. The Hydrostatic Test Instructions shall be approved
by the QA/QCM.

3.2 QA/QC Inspector assigned by the Manufacturing Department shall be responsible for the
preparation of the hydrostatic test, including cleaning and performance of the test in
accordance with the procedure and instructions.

3.3 The QA/QC Inspector shall be responsible for the monitoring of the test and inspection after
full pressurization, and recording the test results.

4.1 Preparation

4.1.1 After completion of the final closure seam and prior to the hydrostatic test, inside of the item
to be tested shall be thoroughly cleaned.

4.1.2 Prior to start of test the QA/QC Inspector shall verify that all the other Code activities (except
pressure test) are completed and each item is identified with a manufacturing serial number.
This verification shall be accomplished by reviewing the applicable steps of the Inspections
that are properly signed-off and dated and any Noncorformance Report has been closed-out.
The QA/QC Inspector shall also check the preparation of the equipment and the device
which will be used prior to the test as follows:
1) Range of pressure gauges,
2) The calibration label attached to the pressure gauges to assure that the gauges have
been calibrated and are within the calibration due date,
3) The valves and pipe for connection with gauges and the pump.

4.1.3 All openings, except test medium inlet and vent openings shall be closed using proper plugs,
caps or other suitable means.

4.1.4 Supports for hydrostatic test, if used, must be placed properly to ensure a safe test. In order
to inspect all the weld joints, no supports shall be placed on or over weld joints of the item.

4.2 Test Gauge

4.2.1 Location
When items are to be hydrostatic tested, to pressurize the gauge without intervening valves,
it shall be connected to the item directly with dial gauges readily visible to the operator
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controlling the pressure throughout the duration of pressurizing and testing. One pressure
gauge shall be located on top of the item.

4.2.2 Range
Pressure indication gauges to be used in testing shall preferably have dials graduated over a
range of about double the intended maximum pressure, but in no case shall the range be
less than one and half (1½) and no more than four(4) times of that pressure.

4.2.3 Calibration
All gauges to be used shall be calibrated with master gauge and recalibrated at least once in
every twelve (12) months.

4.3 Test Fluid

The potable water shall be used as a test medium, unless otherwise specified.

4.4 Test Temperature

The test pressure shall not be applied until the item and its contents are about the same
temperature. The test fluid temperature shall not be less than 20° C.

4.5 Filling the fluid

4.5.1 Vents shall be provided at all high points of the item, where it will be possible to purge the air
pockets while the item is being filled.

4.5.2 The item will be filled with fluid by any suitable low pressure filling lines, while venting through
the pressure vent in the upper most nozzle.

4.5.3 Before applying pressure, the test operator shall check the test equipment to assure that all
low pressure filling lines and other accessories shall not be subject to the test pressure and
have been disconnected or isolated by valves or other suitable means.

4.6 Application of Pressure

4.6.1 The pressure in the item shall be increased steadily until the required test pressure is in
accordance with EN 12952 requirements and / or customer specifications. When the test
pressure is reached, the valve on the pump shall be shut off.

4.6.2 The test pressure shall not be less than EN 12952 requirement and greater than 90% of the
item’s yield strength at test temperature.

4.6.3 Unless otherwise specified on the manufacturing drawing holding time at test pressure shall
be at least ten (30) minutes.

4.6.4 After the pressure has been maintained for longer than the minimum holding time, the
pressure shall be reduced to a value about maximum allowable working pressure.

4.6.5 Test pressure must be Pt=1,43 x Ps (EN 13445-5 10.2.3.3.1-2)

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4.7 Safety Precautions

4.7.1 Signs are to be displayed at an area closed-off, indicating that hydrostatic test is under
progress. Only the authorized personnel shall be near the item during testing.

4.7.2 During pressurization, the hydrostatic test personnel shall stand clear off the nozzle by
staying off the ropped area.

4.8 Inspection

4.8.1 At the pressure described in paragraph 4.6.4, inspection for leakage or other visible defects
shall be made by QA/QC personnel on the whole body of the item; particularly all the joints
and connections, and all regions of high stress, such as head knuckles, region around
openings and thickness transition sections.
4.8.2 The visual inspection shall be performed by the QA/QC Inspector.

4.9 Emptying the item

4.9.1 After completion of the hydrostatic test, vents and drains shall be opened to remove all the
fluid in the item. Shop air may be used to force the evacuation.

4.9.2 After all the fluid is drained, the item shall be checked for inside cleanness and finally
inspected on the external surface for out-of-roundness or other defects.

4.10 EN 12952

The test pressure to be used on water-tube boiler components and complete boiler
assemblies shall be determined in accordance with EN 12952-3:2001,5.7.4.

The hazards involved in pressure testing shall be considered by the manufacturer and
adequate precautions shall be taken.

NOTE 1: Since it is necessary to avoid the risk of repeated over-pressurization, it is

recommended that, prior to the witnessed hidrostatic test, a preliminary examination of the
water-tube boiler or component should be carried out at the maximum allow-able pressure
for the purpose of identifying any significant leaks.

NOTE 2: Care should be taken to ensure that the complete pressure envelope, its supports
and its foundations are capable of withstanding the total load that will be imposed upon them
during the pressure test.

Water shall be used as the pressurizing agerıt.The quality of the waier used shall be such as
to prevent both corrosion and any residue of injurious solids.

The completed water-tube boiler, and any components which are required to be
hydrostatically tested before assembly into the water-tube boiler, shall be tested with a water
at a temperature such that the risk of freezing is avoided. The temperature of the water used
for the pressure test shall be selected by the manufacturer taking into account the risk of
brittle fracture of the pressure parts, but in any case the temperature selected for the
pressure test shall not exceed 50 °C.

The water-tube boiler, or component being tested, and their connections shall be vented, or
evacuated, to prevent the formation of air pockets. However, small pockets of trapped air
may remain after fiiling, and the procedure with regard to these shall be based on the
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manufacturer's own proven practices which shall ensure that, the safety of the boiler is not
impaired.

All temporary tubes, connections and blanking devices shall be designed to withstand the
appropriate test pressure.

No component undergoing pressure testing shall be subjected to any form of shock loading,
e.g. hammer testing, thermal shock, or rapid pressure changes.

The full test pressure shall be maintained for 30 min for completed water-tube boilers and
large components, and for an appropriately lesser time for smaller components.

Prior to close examination, the test pressure shall be reduced to not less than the maximum
allowable pressure.

Pressure parts which have been repaired following the hydrostatic test shall again be
hydrostaticalıy tested in accordance with 10.2, after completion of ihe repair and any
required post-weld heat treatment and non-destructive examination, unless otherwise
agreed. Such an agreement shall be based on the manufacturer's own proven prac- tices
which shall ensure that, the safety of the boiler is not impaired.

4.11 EN 13445

For a vessel according to testing group 1 , 2 and 3 the test pressure shall be not less than
that determined by the following:

Pressure of vessels under test shall be gradually increased to a value of approximately 50 %

of the specified test pressure, thereafter the pressure shall be increased in stages of
approximately 10 % of the specified test pressure until this is reached. The required test
pressure shall be maintained for not less than 30 min. At no stage shall the vessel be
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approached for close examination until the pressure has been positively reduced by at least
10 % to a level lower than that previously attained. The pressure shall be maintained at the
specified close examination level for a sufficient length of time to permit a visual inspection
to be made of all surfaces and joints.

Acceptance criteria

During the proof test the vessel shall show no signs of general plastic yielding. Local
deformation which is identified by visual inspection and which is cause for concern shall be
referred to the designer for reconciliation against the design specification. During the proof
test no leaks are permitted from the pressure envelope.

4.12 PNEUMATIC TESTING

lf hydrostatically testing can not be performed then pneumatic test shall be applied and
referenced standart paragraphs shall be followed.

5. NONCONFORMANCE CONTROL

5.1 If visual defects occur, such as leaks, cracks and other defects, they shall be identified and
handled in accordance with Section 7 of the EFOR Quality Manual (EFOR QM Ed.1)

5.2 Any leaks that are present shall be eliminated, then the item shall be re-tested.

6. RECORD

6.1 The QA/QC Inspector shall record the results of hydrostatic test using the Hydrostatic Test
Report which shall be reviewed and approved by the QA/QC Inspector.

6.2 If the result of the test is acceptable, the QA/QC Inspector shall sign and date the Pressure
Test Report.

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