Provide WBPDCL Approved Title Block as

per Approved CCP, R-06

Doc No. PS: CP:445: HA:TS010 Page no. 01 of 13
Rev No. 00
Effective Dt. 31/01/23

TABLE OF CONTENT
1.0 PLANT DETAILS

2.0 OBJECTIVES

3.0 PROPOSALS

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURES

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10.0 APPENDICIES

1. HYDROTEST PRESSURE
2. LOGSHEET AND DRAWING
3. HYDROTEST SCHEME
4. ANNEXURE

This procedure is the property of BHEL and is exclusively developed for the
commissioning of SAGARDIGHI STAGE II, 1x 660 MW project. This procedure
should not be used by any other person or firm without the written permission
of BHEL (Power Sector Eastern Region Technical Services) or put to any use
other than specified above. This document shall not be copied in any manner
unless authorized.

Digitally signed by Pratip Basak

DN: cn=Pratip Basak, o=DCPL,
ou=Power,
email=pratip.basak@in.dclgrou
p.com, c=IN
Date: 2023.05.18 15:24:47
+05'30'
Doc No. PS: CP:445: HA:TS010 Page no. 02 of 13
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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 Super heater section comprises drainable and non-drainable portions and includes
safety valves; SH outlet stop valves with integral bypass valves, drains, startup
vents, nitrogen capping connections etc.

1.3 Water volume of different sections are

System Volume (m3)

Economizer 210
Startup and circulation system 100
Superheater 160
Reheater 450

2.0 OBJECTTIVE

2.1 To ensure integrity of pressure parts circuits

2.2 To preserve the Boiler after the hydrostatic test is over.

3.0 PROPOSAL

3.1 The Unit will be hydraulically tested for conformation to Testing as per IBR and
ASME B31.1

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 1A-Hydraulic Test of the drainable portion (economizer, evaporator,
separator, separator storage tank, wet leg, warm keeping line, mixing sphere, BRP
suction & discharge lines, steam cooled roof, back pass wall, divisional SH inlet
link) is to be done. Suitable dummies shall be provided at SH platen inlet link
pipes. After completing the hydrotest of the drainable portion, the system will be

.
.
There is no Divisional SH in
the design. Is it SH Front
Platen Inlet header Link
(S-25b)? If so, then please
rectify with Tag no. for
avoiding confusions at site.
 Please include " dummies in
SH Front Platen inlet header
Link (s-25b) will be removed"
Doc No. PS: CP:445: HA:TS010 Page no. 03 of 13
Rev No. 00
There is no divisional SH.
Effective Dt. 31/01/23
Revise it as Front Platen
Also, LBA01AA011
SH(S-27), Rear Platen
SH(S-33), .Finish SH
and LBA02AA011
front(s-39), Finish SH drained and released for subsequent work.
Intermediate (S-39M), Finish
SH Rear (S-40)
3.4 Stage 1 B - Hydraulic test for the entire system comprising b o th drainable and
non- drainable portions (divisional SH, platen SH, Finishing SH) up to Main
Steam Stop valves (LBA01AA001 & LBA02AA001) is to be done.

3.5 Stage 2A-Main Steam Stop valves to HP Turbine stop valve (MAA11AA051 &
Please check, it will be MAA22AA051), HPBP valve (LBF11AA101 & LBF21AA101) inlet, APRDS
MAA21AA051
(ASV-20, LBG10AA002) till isolating valve/blank. Blank/blanking device to be
welded in u/s of HPBP valves and u/s of HP Stop Valve. Is it ASV-21?

3.6 Stage 2B-This covers the total Reheat circuit comprising CRH lines starting from
CRH NRV (LBC10AA051), tap off lines (Aux Steam, HPH 8, Deaerator pegging
& TDBFP) from CRH lines up to first isolation valve, HPBP valve downstream
line, Reheater, hot reheat lines up to IP Stop Valves (MAB11AA051&
MAB21AA051), LPBP valves (MAN52AA161 & MAN55AA161)inlet. Blanking
device/blank shall be welded in CRH NRV, u/s of IP Stop Valves, u/s of LPBP
1. Will RH Isolating Device RHI-1 and RHI-2 be also installed for the hydrotest?
valves and d/s of HPBP valves. 2. If yes, please state how the rest of CRH piping from the RH Isolating Devices to
CRH-NRV and downstream of HPBP be taken into service for hydrotest.
3.7 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.

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

3.9 After completion of Stage 1A Hydrostatic test the Boiler will be drained and after
completion of Stage 1B Hydrostatic test the Boiler will be kept under preservation.
Procedure for Stage 2A and 2B after
4.0 SERVICES REQUIRED. hydrotest?

4.1 PRESSURE GUAGUES

During testing at least two properly calibrated standard test pressure gauges of
suitable range calibrated from a NABL accredited or equivalent laboratory (with
calibration certificate) are to be used to monitor pressure in the system.

4.2 Availability of DM Water

Approximate quantity of DM water required for Hydraulic Test is 2000 m3.

Temperature of DM water should be between 21C to 49C. pH should be between
9.2-9.6 (by addition of Ammonia).

4.3 DM water parameters

.
.
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Effective Dt. 31/01/23

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The DM water having Specific conductivity: < 0.3 µS/cm & pH: 6.8-7.3 will be
used for hydro test. Testing of DM Water?

4.4 CHEMICALS

Chemicals required for whole process (1A, 1B, 2A&2B) of hydrotest including
preservation of boiler& non drainable coils is 800 liters of Ammonia.

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

(a) 600 Kg/cm2 (minimum) & 30 LPM (minimum).
, This hydro test pump can be
also utilized as chemical dozing pump.
Please mention DC
4.6 Availability of Boiler fill pump. hand lamps and
also numbers.
4.7 Availability of Temporary tanks and temporary dosing pumps.

4.8 Availability of flood lights and 24V hand lamps.

4.9 Availability of reliable communications system such as walkie-talkie sets,

telephones etc.
4.11 Availability of proper illumination
4.12 Site free from scraps and debris.
4.10 Availability of Fire Tender and Ambulance near the test area.

5.0 SAFETY PREACAUTIONS

5.1 Readiness of stair-cases, platforms, hand rails, approaches etc. 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 50 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.

.
.
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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.

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. Please include "There shall be no pending scope of reworking or rewelding or
ND testing in the circuits which are considered to be hydro tested."

7.2 Filled & signed copies of FQPs and Erection Protocols with exceptions highlighted
are handed over to the commissioning group.
Does this mean that the all the manholes in the sections to be
7.3 Effective communication facility is available
hydrotestedbetween Separator
will remain closed? If so, it willfloor,
not meet clause 7.13,
moreover for observations, all manholes to be kept open.
pressurizing pump area and other operating areas.

7.4 Boiler drain is suitably connected to plant/temporary neutralizing pit.

7.5 All debris removed manually from all pressure parts, backstays etc.

7.6 All manhole closure plates and header hand hole caps in the sections to be hydro
tested are closed and bolted or welded.

7.7 All safety valves are mounted, and hydrostatic test plugs are installed where
necessary and gags are fitted correctly.

7.8 All hangers in Boiler and piping system are locked.

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

7.10 All branch system like soot blowing, SH/RH spray is isolated at root valves
(Hydraulic test of soot blower system, SH/RH spray system is carried out
separately or along with main boiler. Blank is welded in feed line just u/s of NRV
(LAB91AA401). please add the relevant drawing no. (TP-DG-445-BMG-
A003)
7.11 All drains, vents, sampling, dozing, pressure/level instrumentation impulse taping
root valves are installed. Drain, dozing, instrumentation tapping and sampling
tapping valves are isolated at root valves.

7.12 In boiler start up scheme, all lines will be included for hydro test e.g., wet leg,
High Water Limit (HWL)line up to blanking plates (shown in attached scheme),
warm keeping line up to isolation valves , Mixing sphere and BRP suction and
discharge line will be included in the hydro test scheme.
.
.
 Doc No. PS: CP:445: HA:TS010 Page no. 06 of 13
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7.13 All peephole / manhole doors are open in furnace & second pass.

8.0 METHOD

8.1 AIR TESTING OF THE PRESSURE PARTS (only for Stage 1A&1B)

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 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.

Procedure?
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 1A & 1B.

The circuit is filled with DM water using Boiler Fill pump and Ammonia is dosed Please include a
schematic in this
such that pH 9.2-9.6. Hydrotest pump connection is done provided in Furnace document.(Typ.)
Lower Front header drain (Ref TP-DG-445-BMG-A006). Confirmation of
completion of filling of the entire system is done through the vents. The vent
valves are closed and opened several times to allow venting of entrapped air till
How pH value
would be
steady stream of water overflows from the vents. Boiler fill pump is stopped.
ensured? (Typ.)
8.2.2 STAGE 2A

Filling with Ammoniated DM water (pH 9.2-9.6) through temporary connections

to either (MSP-101 or MSP-103) & (MSP-102 or MSP-104) (Ref Drawing no. PE-
DG-445-100-N101) from Boiler Fill pump or any other DM water source.
Confirmation of completion of filling of the entire system is done through the
vents. But since these lines do not have any vent any of the Pressure transmitter
points may be used for that. Suitably hydrotest pump line may be fitted in the
filling line. Specify

If MS stop valves are opened and the hydrotest is performed simultaneously

. with Stage-1B, then the Boiler side vent valves may be used. Please clarify
whether this Hydrotest will be separately done upto MS Stop valve and if so,
then why it is not done together with Stage-1B.
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8.2.3 STAGE 2B

The Re-heat circuit with DM water having pH 9.2-9.6 through a temporary fill line
connected to CRH drain (CRHV103,104) Ref drwg no. PE-DG-445-100-N101.
Confirmation of completion of filling of the entire system is done through the
vents. The vent valves are closed and opened several times to allow venting of
entrapped air. Suitably hydrotest pump line may be fitted in the filling line.

8.3 PRESSURING THE SYSTEM. Mention the

pressure at which
8.3.1 Pressure is raised with the help of pressurizing pump. this checking will
be done.
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. Blanking plates d/s of HWL (High Water Limit) isolating valves and NRVs
should be checked for passing, if any, by observing downstream during
pressurization of the boiler. Checking of valves must be at the design pressure or
below.

8.3.3 The pressurization & depressurization curves are attached.

8.3.4 After reaching the test pressure the pressurizing pump is stopped immediately and
power supply to the pump is cut off.

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.

8.4.2 The test pressure will be held as per IBR and ASME.

8.4.3 The pressure is then reduced to less than 50 kg/cm2 and the entire pressure parts
are checked. Any drain may be used for reducing the boiler pressure. It is ensured
that personnel inspecting is equipped with proper illumination device, safety
equipment, and clothing and safety goggles.

8.4.4 If leaks are found, then pressure is released and concerned section drained. After
repairs the Boiler is refilled and the hydraulic test repeated.

Please mention the value of static

head correction in kg/cm2

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

Exact location of the leak(s) Component, circuit, elevation, material etc.

Description of the leak(s) Straight tube, elbow, shop or field weld etc.
Magnitude of the leak(s) Seeping, sweating, longitudinal cracks etc

8.5 DEPRESSURISATION OF PRESSURE PARTS

8.5.1 The pressure parts shall be de-pressurized as per IBR and ASME.

8.5.2 While releasing the pressure the vents should be opened when the system pressure
falls to around 7 Kg/cm2 to prevent creation of vacuum in the system.

8.6 HYDROSTATIC TEST PROTOCOL

After successful completion of the Hydraulic Test a joint protocol is signed

between BHEL & WBPDCL.

8.7 INSPECTION OF BOILER PRESSURE PARTS AFTER TESTING

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

8.8 PRESERVATION OF BOILER

8.8.1 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.

8.8.2 The Boiler is pressurized to 5-10 Kg/cm2 with Ammonia treated DM water
containing sufficient quantity of Ammonia to have pH value of 9.2-9.6.

8.8.3 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.
Sampling is done from low point drain.

8.8.4 If welding work needs to be carried out on pressure parts when the system is under
preservation, then boiler shall be drained however it should be ensured than non-
drainable portion is preserved with Ammoniated DM water.

. How to ensure? Where from

. samples to be collected and
tested weekly? How NH3 to
be dosed further if pH is not
found to be adequate?
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Effective Dt. 31/01/23

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9.0 COMPLETION CRITERIA

Completion criteria will be as per BBR and ASME Section i.

10.0 HYDROTEST PRESSURES This will be 72 kg/cm2. Refer to Boiler

Pressure parts arrangement & HSA
Stage 1A,1B&2A =1.5 x Design Pressure calculations.
=1.5 x 294.8 kg/cm2
= 442.2 kg/cm2

Stage 2B =1.5 x Design Pressure

=1.5 x 68.5 kg/cm2
=102.75 kg/cm2

LOG SHEET

Project: Date:
Unit:
Activity: Boiler Filling, Pressurization and De-pressurization
Stage:
Sl. No. Activity Dt/Time Pressure Remarks
At Boiler Fill Pump At pressurizing At topmost point
Discharge pump discharge of the pressure
parts

BHEL WBPDCL

.
 Hydrostatic Test Pressure rise vs Time ( Stage 1A,1B &2A)

500

442.2 442.2
450
30 min hold time
400

350 Rate of pressure rise is 1-2 kg/cm2 per min above 350 kg/cm2
HYDROSTATIC TEST PRESSURE ( Kg/cm2)

350

300 300
300
5 min hold time

250
200 200
200
5 min hold time

150 Rate of pressure rise is 10 kg/cm2 per min up to 350 kg/cm2

100 100
100
5 min hold time

50

0
0
0 20 40 60 80 100 120 140 160 180 200
TIME ( MIN)
 Hydrostatic Test Pressure rise vs Time ( Stage 2B)
120

102.75 30 min hold time

102.75

100
HYDROSTATIC TEST PRESSURE ( Kg/cm2)

Rate of pressure rise is 1-2 kg/cm2 per min above 80kg/cm2

80
80

Revise the value

60 as stated earlier.
50 50

10 min hold time

40
Rate of pressure rise is 5 kg/cm2 per min up to 80kg/cm2

20

0
0
0 10 20 30 40TIME ( MIN)50 60 70 80 90
 Hydrostatic Test Pressure drop vs Time ( Stage 1A,1B & 2A)

500

442
450
412

400 382 De-pressurization rate is 1 kg/cm2 per min

352
350
HYDROSTATIC TEST PRESSURE ( KSC)

322
294.8
300
262

250 232

202
200
172

142
150
112

100 82

All boiler inspection is to be done below 50 kg/cm2 52

50
22
0
0
0 50 100 150 200 250 300 350 400 450 500
TIME ( MIN)
 Hydrostatic Test Pressure drop vs Time ( Stage 2B)

120

102.75

100
92.75

De-pressurization is done at the rate of 1 kg/cm2 per min

82.75
HYDROSTATIC TEST PRESSURE ( KSC)

80
72.75
68.5
62.75

60
52.75
All boiler inspection to be done below 50 kg/cm2

42.75

40
32.75

22.75

20
12.75

0
0
0 20 40 60 80 100 120
TIME ( MIN)
 Please include Blank position
circuit for Stage 1A, 1B, 2A and 2B
seperately

Also show the blanking position for HP stop vlve, IP

stop valve, CRH NRV, HPBP (both u/s & d/s) and
LPBP for stage-2A and 2B