THIS STANDARD IS: STD NO : 110-75-04

Updated INDEX : 4.9.2

DESIGN STANDARD DATE : 28 APR 2006
OWNER : 8157
PAGE : 1 OF 10

SUBJECT : HYDROSTATIC TESTING - NATURAL AND CONTROLLED CIRCULATION BOILERS

PURPOSE : To provide recommended hydrostatic test procedures.

REMARKS: This Standard to be effective immediately.

NOTES: 1. See Page 2 for Versions.

2. Standard No. 17-75, Index 4.9.2 has been incorporated into this Standard.

PROGRAM MANAGER
PREPARED BY: T. MISKELL STANDARDS ENGINEERING - 9390
MANAGER
APPROVED FOR CONTENT: D. CELLI FIELD OPERATIONS - 8157
PROGRAM MANAGER
APPROVED FOR PUBLICATION: T. MISKELL STANDARDS ENGINEERING - 9390

This document contains proprietary data and shall not be reproduced

or disclosed without the permission of ALSTOM Power Inc.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation STD NO : 110-75-04
Boilers INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 2 of 10

UNITS: „ ENGLISH; † METRIC; † BOTH; † NONE

PRODUCT LINES: CHECK THE PRODUCT LINES THAT THE STANDARD IS APPLICABLE TO
† ALL; „ A = CONTROLLED CIRC. BOILERS † H = HEAT RECOVERY STEAM GENERATORS (HRSG)
† B = SUPERCRITICAL BOILERS † P = PULVERIZERS – MILLING SYSTEM
„ C = VU40 AND VU60 BOILERS „ R = CHEMICAL RECOVERY BOILERS
„ E = FLUIDIZED BED BOILERS (CFB) † S = SERVICES (AFTER MARKET USE)
„ F = NATURAL CIRC. BOILERS (UTILITY)

Versions

Ver. 2 - Updated Standard format; revised

Paragraphs 1.1, 1.2, 1.4, 1.5.1,1.5.1b, 1.5.1c,
1.5.2, 1.5.3, 2.1.4d, 2.1.5, 2.2.4, 3.1, 3.1.1,
3.1.2, 3.1.2a, 3.1.2b, 5.1.3, 5.4.1; added
Paragraphs 1.5.1d, 1.5.1e, 2.1.9, 2.8, 3.1.2b,
4.6; deleted Paragraphs 4.3.2.1, 5.4.2 and
Attachment "B".

Ver. 3 - Updated standard format; name

change to ALSTOM Power Inc. Revised Para.
1.5.1.c

Ver. 4 – Added paragraph 2.1.10 on Page 5

 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation
Boilers
1.0 General
1.1 After installation of all pressure
parts, Section I of the ASME Boiler and Pressure
Vessel Code requires that a boiler shall be
subjected to a hydrostatic pressure test. This will
be conducted at a test pressure of 1.5 times the
maximum allowable working pressure to be
stamped on the boiler. This is shown on the
Manufacturer's Data Report, Form P-3 or P-3A.
The limits of the ASME boundaries are shown on
the Pressure Part piping and instrument drawing.
1.2 The exact hydrostatic test process will
depend on local job site conditions. Since this
procedure is general in nature, it shall be
followed as conditions allow, in conjunction with
the subject Contract Instruction Manual.
1.3 The unit shall be hydrostatically
tested for conformance to ASME Code
requirements in two areas:
1.3.1 Primary Circuitry (Drums,
Economizers, Water Walls, Steam Cooled Walls,
Superheater).
1.3.2 Reheater(s).
1.4 Upon request, the Project Engineer
shall supply assistance or additional information
for hydrostatic testing.
1.5 Reports
1.5.1 Section I of the ASME Boiler and
Pressure Vessel Code states that the boiler
Manufacturer has the responsibility of assuring,
through proper certification, that all work
performed by him or others responsible to him
complies with all the code requirements including
design, construction, materials and
workmanship. When some portions of a
completed boiler unit are supplied by or worked
on by others not responsible to the Manufacturer,
the Manufacturer has the duty of obtaining from
STD NO : 110-75-04
INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 3 of 10
these other organizations their proper Code
certification covering such portions of work.
Regardless of any division of contractual
responsibilities, the Manufacturer has the duty of
compiling Code certification, covering all parts of
a field-assembled boiler and of preparing Master
Data Report Form P-3 or P-3A.
a. The completed boiler unit
includes all piping and piping components that
are covered by the ASME Boiler and Pressure
Vessel Code, Section I, Fig. 58.3.1.
b. When ALSTOM Power designs
and fabricates a boiler in accordance with the
ASME Code, it is our responsibility to register it
with the National Board.
c. An ASME Master Code Data
Report is assembled for each project. The report
consists of: Form P3A, Form P7 and Form P4
from the Fabricators. This package will be sent
from Windsor to the Site Manager prior to
hydrostatic testing. The Contractor who erected
the boiler must, after the successful site
hydrostatic test, sign the back of the P3A or P3
Forms in the "Certificate of Field Assembly
Compliance" block and have the site's Authorized
Inspector sign the "Certificate of Field Assembly
Inspection" block.
Note: To make it easier to identify the originals,
please sign in blue ink. The entire report is
returned to:
ALSTOM Power Inc.
2000 Day Hill Road
Windsor, CT 06095-0500
ATT: Project Quality Manager
d. When the completed report has
been received in Windsor, it will be reviewed by
our Authorized Inspector and the final signatures
will be affixed to the report. The nameplate will
then be stamped and sent to the site for
attachment to the boiler.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation
Boilers
e. The original ASME Master Code
Data Report will be filed with the National Board
and copies will be distributed, as required, by
QA.
1.5.2 The following information about
leaks during hydro test is to be reported
immediately to the Project Engineer in Windsor
both by phone and by TIR (Technical Information
Request).
a. Exact location of leak(s) -
component circuit, elevation, material, etc.
b. Description of leak(s) - in straight
tube, elbow, shop or field weld, torch cut where a
lug was removed, attachment weld, etc.
c. Magnitude of leak(s) - weep,
longitudinal crack, burn through, etc.
The Project Engineer will advise
QA and Projects of this information.
1.5.3 Upon completion, a written
Report of Inspection of the hydro test is to be sent
to the Project Engineer in Windsor. This report
shall include the leak information reported in
Paragraph 1.5.2.
1.5.4 Check List
Attachment "A", Hydrostatic Test
Water Sample, is to be completed by the Site
Manager and retained in the site QA file.
2.0 Test Preparation
2.1 Prior to hydrostatic testing, the
following items shall be inspected:
2.1.1 All debris shall be removed from
all pressure parts including headers and drums.
2.1.2 All necessary welds completed,
x-rayed and stress relieved.
STD NO : 110-75-04
INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 4 of 10
2.1.3 All necessary valves, including
drains, installed and closed.
2.1.4 All safety valves installed or
openings blanked off.
a. Safety valves shall not be
gagged at this time.
b. Check that hydrostatic test plugs
were installed where necessary and gags are
available and fit correctly.
c. Detailed instructions are
provided by the Manufacturers for hydrostatic
testing safety valves. These instructions must be
adhered to without change.
d. Power actuated pressure
relieving valves do not require gagging or
hydrostatic test plugs. However, special
precautions must be observed:
The power actuated pressure
relieving isolation valve must be in the full open
position.
The shut-off valve in the pressure
sending line from the header to the controller
must be closed to avoid damaging the controller.
The drain and test valve in the pressure sensing
line must be open.
2.1.5 All manhole closure plates and
header handhole caps closed and bolted or
welded tight. If special closure plugs must be
designed, contact the Project Engineer for
assistance.
2.1.6 All instrumentation isolated or
valved off.
Water columns and gauge
glasses must not be hydrostatically tested with the
boiler; they are designed for operating pressure
only. They must be valved off and the drain
valves opened.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation
Boilers
2.1.7 All vents necessary to prevent air
entrapment during filling opened (such as
superheater link vents, economizer link vents,
drum vents, etc.).
2.1.8 All gamma ray or radiographic
openings have their plugs installed and seal
welded.
2.1.9 The blanking off plates for the
circulating pumps, when used, are installed.
a. We do not recommend that
the boiler water-circulating pump (BWCP)
be installed during the initial ASME Code
hydrostatic test. If the pumps are
installed, contact the Project Engineer or
Standards Engineering for special
instructions.
b. If the unit does not have
suction valves, the BWCP's shall not be
installed until the ASME Code hydrostatic
test has been completed.
2.1.10 All spring and constant support
hangers and supports must be blocked to avoid
overextending and potential damage due to the
additional water weight from pressure parts
being completely filled for the hydrostatic tests.
Refer to Standard 76-75 and Drawing B-983-0300.
This applies to all Pressure Part Constant and
Variable supports as well as Boiler and Non-
Boiler external Piping.
For all non- pressure part
constant and variable supports, the stops are to
be released This applies to components such as
coal piping and ductwork.
2.2 Test Gauges
2.2.1 Two calibrated pressure gauges,
with current calibration tags, shall be used for the
hydrostatic test.
Pressure gauges used for the test
shall be checked for calibration at the job site.
Do not rely on any calibration performed before
shipment.
STD NO : 110-75-04
INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 5 of 10
2.2.2 One gauge shall be located at
the hydrostatic test pump.
2.2.3 One gauge shall be located
near the highest elevation of the boiler for test
pressure.
2.2.4 A connection shall be provided
for the Inspector's test gauge. A check with the
local Inspector(s) can verify if this is a technique
to be used.
2.3 Air Testing Pressure Parts
2.3.1 Testing the pressure parts with
air prior to filling may reduce filling time and
water wastage. This will aid in locating any cuts
or gouges not observed by visual inspection.
2.3.2 Smaller leaks can be detected by
using sonic testing devices.
2.3.3 The air pressure used for testing
shall not exceed 25 psi.
2.3.4 The air should be filtered and
free of oil prior to entering the unit.
3.0 Filling
3.1 The Contract Documents will state
who has the responsibility to provide the properly
treated water at the specified temperature for the
hydrostatic test.
3.1.1 Type of Water
Refer to Contract Instruction
Manual for details. If water of the following
quality is not available, contact the Project
Engineer who will obtain assistance in
determining what quality is acceptable.
a. All Non-Drainable Areas
Fill with condensate or
demineralized water, containing 10 PPM of
ammonia and 200 PPM of hydrazine, with a
solution of pH value of approximately 10.0.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation
Boilers
b. Drainable Superheater and
Reheater
Fill with condensate or
demineralized water containing 10 PPM of
ammonia and 200 PPM of hydrazine, with a
solution of pH value of approximately 10.0. If
not available, fill with water specified in
Paragraph 3.1.1.c, except that no chlorine may
be present in this water.
c. Remainder of Boiler Unit
Fill with condensate type water
or, if not available, with a clean source of filtered
water containing 10 PPM of ammonia and 200
PPM of hydrazine, with a solution of pH value of
approximately 10.0.
3.1.2 The water temperature during
hydro testing shall be no less than 70o F per
Section I of the ASME Boiler and Pressure Vessel
Code.
a. Following the intent of the Code,
the steam drum metal temperature shall be not
less than 70o F prior to or during the hydrostatic
test.
b. For safety purposes during
inspection, the metal temperature should not
exceed 120o F.
3.1.3 Responsibility for furnishing
temporary connections for filling and draining
the boiler will be dictated by the Contract
Documents.
3.2 The Erecting Contractor will decide
the best location for filling and pressurizing the
unit.
3.2.1 The sequence of filling the non-
drainable areas will be dictated by the design of
the boiler. Generally, fill the superheater
through a suitable outlet connection (such as
final superheater outlet header drain or vent)
until all elements are filled and the water
overflows into the steam drum. Close
superheater fill connection.
STD NO : 110-75-04
INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 6 of 10
3.2.2 Proceed filling the unit through
the normal filling connections. The unit can be
filled either through the economizer feedline or
through the water wall lower drums. Filling the
unit simultaneously from top and bottom is not
recommended, since this will greatly increase air
entrapment. If the unit is filled through the
economizer, the economizer recirculating line
valve should be in the wide-open position which
will facilitate filling and minimize air entrapment.
3.3 The use of a vacuum pump can help
substantially in speeding up the filling time for a
boiler.
3.3.1 A vacuum pump will also help to
partially evacuate air from many areas where it
might be trapped when using normal filling
procedures.
3.3.2 The following general
procedures shall be incorporated when using
vacuum assist filling.
a. All boiler vents must be
connected to a common manifold to pull a
vacuum on all circuits of the boiler at the same
time.
b. In order to minimize the amount
of water pulled into the vacuum, the manifold
must be connected to an inverted "J" pipe of
sufficient height to cause the water to go to
saturation. The vacuum pump should be
connected to the end of the inverted "J" pipe.
c. Open all valves in the vent
manifold system.
d. Close all other valves not
necessary for filling the unit.
e. Turn on the vacuum source and
start filling the boiler with water. Care must be
exercised to minimize the amount of water
getting into the vacuum pump.
3.4 As the unit fills, periodically check for
leaks.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation
Boilers
3.5 Vents shall be closed after a steady
stream of water overflows from the vents.
Note: When valves are in tandem (double
valved), both valves must be closed for the hydro
test.
4.0 Hydrostatic Testing
4.1 Start hydro pump and raise pressure
to 80% of the pressure stamped on the lowest
safety valve setting. Hand tighten safety valve
gags per the Manufacturer's recommendations.
4.2 Pressure readings during the test will
be taken from the pressure gauge at the high
point of the boiler.
4.3 The Erecting Contractor will decide
on the equipment to be used for the hydrostatic
testing of the unit.
4.3.1 When the boiler feed pump has
been used for filling, the operating pressure of
the pump may be used to partially pressurize the
boiler.
4.3.2 High pressure pumps shall then
be used to obtain the test pressure.
4.4 Hydro Testing the Primary Circuitry
4.4.1 The primary circuitry will be
tested at 1.5 times the maximum allowable
working pressure.
a. Start hydro pump and raise the
pressure to 80% of the pressure stamped on the
lowest safety valve setting. Hand-tighten safety
valve gags per the Manufacturer's
recommendations.
b. Raise the pressure to the
hydrostatic test pressure.
The pressure shall be under
proper control at all times so that the required
test pressure is never exceeded by more than 6%.
STD NO : 110-75-04
INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 7 of 10
Close visual inspection is not
required during this stage.
c. The hydrostatic test pressure is
then reduced to not less than the maximum
allowable working pressure, after the maximum
pressure has been noted and agreed to by the
Inspector.
4.5 Hydro Testing the Reheater(s)
4.5.1 The reheater(s) shall be
pressurized at 1.5 times the maximum allowable
working pressure of the reheat sections.
a. Paragraphs 1.0 through 4.0 are
applicable for preparing to hydro test the
reheater.
b. For the actual hydro, follow the
procedures listed in Paragraphs 4.4.1a, 4.4.1b
and 4.4.1c.
4.6 Inspection
4.6.1 Reduce the hydrostatic pressure
to the agreed upon specific working pressure for
the boiler or the reheater respectively.
4.6.2 Ensure that all personnel doing
the inspection are equipped with appropriate
illumination devices, safety equipment, clothing
and safety goggles. High pressure water jets and
chemicals can cause injury.
4.6.3 It is recommended that the
inspection teams work in pairs especially in
conditions where inspections are not visible from
boiler walkways or inside of the boiler walls.
4.6.4 The areas of the boiler pressure
parts to be inspected should be divided up to the
respective inspection teams. It is suggested that
the Field Weld Data Summary sheets be given to
each inspection team so that all welds inspected
can be noted.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation
Boilers
4.6.5 Unless there are significantly
large leaks during the test, complete an entire
inspection of the unit, noting all areas of actual
and suspected leakage. Suspected tube leaks
should be marked using a non-water soluble
marker such as a paint stick.
4.6.6 If repairs are to be required,
shut down the hydrostatic pump, release the
pressure, remove the safety valve gags an drain
down the boiler to an elevation below the
indicated repair location if possible.
4.6.7 When repairs have been
completed, the entire unit should be re-tested
using the test procedure until no leaks are found.
At this time, the test pump should be isolated.
The boiler should be re-inspected for any leaks.
There may be some pressure variation due to
temperature changes or leaking valves. When
the Authorized Inspector is satisfied with the
results, release the test pressure and drain the
boiler.
4.7 Releasing Test Pressure
4.7.1 Upon completion of either the
primary circuitry or reheater test, or if leaks are
found, it will be necessary to release the
pressure.
a. When valves are in tandem
(double valved), test pressure should be released
at a moderate rate with the outboard valve, while
the inboard valve is opened wide. This is to
prevent the valve seat of the pressure side valve
from being damaged.
b. Gag pressure on safety valves
should be released when hydrostatic test pressure
is 85-90% of the pressure on the lowest set valve
per the Manufacturer's recommendations.
4.7.2 Drain the areas necessary to
make the repairs.
STD NO : 110-75-04
INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 8 of 10
4.7.3 Make the required repair(s).
4.7.4 Refill the unit per Paragraph 3.2.
4.7.5 Re-hydro per Paragraph 4.0.
5.0 Post Hydrostatic Test Procedure
5.1 The local job conditions and contract
specifications will dictate what laying-up
procedures are necessary for the boiler.
5.1.1 This may include protection of
non-drainable areas from freezing and a
possible nitrogen blanket on the drainable areas
of the boiler.
Caution: When nitrogen is used, thorough
ventilation is essential before entering boiler
drums.
5.1.2 When the boiler is laid up with
water in it, the water must meet the criteria in
Paragraph 3.1.1
5.1.3 Laying-up is normally the
Customer's responsibility. When the Contractor
is responsible, it is a joint Projects and Field
Operations responsibility.
5.2 Draining the Boiler
5.2.1 Open the boiler vent valves and
drain all drainable sections of the boiler.
5.2.2 If wet lay-up is to be used, fill the
unit with hydrazine and ammonia treated water
per the Contract Instruction Manual to
overflowing at the drum vents. Introduce
nitrogen through the drum vent to pressurize the
unit approximately 3-5 psi.
5.2.3 Since there is generally some
time delay between the hydrostatic test and the
initial boiling out and acid cleaning of the unit,
the water level should not be allowed to remain
at operating level.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation STD NO : 110-75-04
Boilers INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 9 of 10

5.2.4 Units not equipped with e. Samples should be sent to the

superheater or reheater outlet stop valves should Project Engineer in Windsor with a memo stating
have these outlets isolated by means of blank the sources of the hydrostatic test water used in
flanges so that a small positive nitrogen pressure filling the superheater and any chemical
can be applied. additions made to it.

5.3 Freeze Protection 5.5 Flexitallic Gaskets

5.3.1 If there is a chance of freezing, ALSTOM Power normally supplies,

the water in the drainable circuits in the boiler as contract material, 3 complete sets of drum
must be displaced with nitrogen and the unit can manholes.
be laid up under nitrogen pressure.

Temporary heating equipment

should be provided to keep the non-drainable
(superheater, reheater) sections above freezing
temperature. When external heating is being
applied, the unit should never be left unattended.

5.4 Water Sample

5.4.1 The ALSTOM Power Site

Manager has the responsibility of obtaining a
sample of the hydrostatic test water. See
Attachment "A".

a. The sample should be taken

from some portion of the non-drainable sections
of the superheater and reheater.

b. Suitable locations include the

superheater or reheater header drains or vents.

c. The sample of at least 1/2

gallon should be taken in a clean plastic bottle
which has been rinsed 3 times in the water being
sampled.

d. Precautions should be taken

against contamination from external sources.
Samples will be analyzed from external sources.
Samples will be analyzed for chlorides, so
particular care should be taken to prevent
contamination from the skin.
 SUBJECT: Hydrostatic Testing - Natural and Controlled Circulation STD NO : 110-75-04
Boilers INDEX : 4.9.2
DATE : 28 APR 2006
OWNER : 8157
PAGE : 10 of 10

Attachment "A"
Hydrostatic Test Water Sample

Customer ______________________________ Contract No. _____________________

Location _______________________________ Unit No. _________________________

*Source of Hydrostatic ____________________ Date of Hydro ____________________

Fill Water Date of Boil-Out __________________

Chemical Added to Fill Water Quantity Added

1. ____________________________ _______ppm or_____________lbs/103lbs H2O________

2. ____________________________ _______ppm or_____________lbs/103lbs H2O________

3. ____________________________ _______ppm or_____________lbs/103lbs H2O________

Method of Chemical Addition: 1. _________________________________________

2. _________________________________________

3. _________________________________________

**Source of Sample
____________________________________________________________________________________

Nitrogen Pressure Maintained between Hydro and Boil-Out _____ Yes _____ No

Same Taken By _________________________________ Date ________________

* Complete Description of Source - Example: City of Albany, zeolite softened; well water, demineralized;
station condensate; e-c.

** Source of Sample - Example: Superheater outlet header drain, superheater intermediate pendant inlet
header drain, horizontal superheater inlet header drain, etc.

Precaution: If sampling water from horizontal superheater, make certain that the same water is used to fill
this section as was used in the pendant sections. If not, take the sample from the location representative of
the water in non-drainable pendant sections.