WORK PROCEDURE

FOR
Boiler Hydraulic Test

PT, Poosan Heavy Industries Indonesia

ClREBON COAL FIRED POWER PLANT

PROJECT

Document No : TO7119-UT00-P1HA-740025
WP NO : WP-M-025

16. Mar. 2010

Date I Prepared by
Reviewed by
Mech. General Manager
Approved by
Site Representative

Cirebon Coal Fired Power Plant Project

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PT. Daosan Heavy Industries
Indonesia
WORK PROCEDURE DATE : 3/17/2010
PAGE : 20f 11
I I

BOILER HYDRAULIC TEST

Table of Contents

Hydraulic Teat Procedure

1. Objective

2. Application Scope

3. Guidance

4. Work Procedure

5. Attachments

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BOILER HYDRAULIC TEST

- -

1.0 Objective

This work procedure is aimed at performing hydraulic test and repairing defects and
damages in accordance with the related code until assuring an airtight on all pressure
parts and main pipes of boiler.

2.0 Application Scope

This work procedure is applied to perform all hydraulic tests for boiler pressure parts
and main pipes( superheater, reheater, all systems)

2.1 High Pressure Parts : Water Pipes + Boiler High Pressure Parts + Main Steam
Pipes

2.2 Low Pressure Parts : Low Temperature Reheater pipes + Reheater +

High Temperature Reheater Pipes

3.0 Guidance

Hydraulic tests for boiler pressure parts and main pipes pressure parts would be
performed in accordance with this work procedure.

4.0 Work Procedure

4.1 Requirements for Hydraulic Test

4.1.1 Pressure for Hydraulic Test

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BOILER HYDRAULIC TEST

Unit : kglcd
I Max. Working
Pressure Parts Test Pressure Remark
Pressure

Max. Working
Pressure x 1.5
( HDR at Super
heater Outlet)
Max. Working
I Low Pressure Parts 53 80
Pressure x 1.5

~ ( HDR at Rehe
ater Outlet)

% Hydraulic Test by Maximum working pressure (1.5 times allowable working

pressure) according to ASME B&PV Code

4.1.2 Temperature Requirements

4.1.2.1 Filling Water Requirement

Use demi water (above PH 10) added hydrazine and ammonia but following items
should be satisfied.

Filling and pressurization should be done as quickly as possible so that

the temperature of water inside of the furnace keeps more than 20 "C
during hydraulic test.

After pressurization, If the terr~peratureof water inside of the furnace goes down
below 20 "Cduring holding time or inspection, proceed the remaining test
continuously.

4.1.3 Other Requirements

Check tightening condition of all hangers

4.2 Boiler Requirements

4.2.1 Volume of Boiler Filling Water

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BOILER HYDRAULIC TEST

Step Part Unit Volume Remark

High Pressure m' 634,395 Boiler

1 Step
Low Pressure 1n3 114,800 Boiler

High Pressure m' 65,000 BOP

1 Step
Low Pressure m3 195,000 BOP

4.2.2 Chemical Requirements

1) Hydrazine(35%): mixing ratio(Uton) 0.571 W o n , 200PPM,

2) ammonia(28%): mixing ratio(Uton) 0.036 W o n , 10 PPM

4.2.3 Diagram of Boiler Hydraulic System: Already Submitted to CEP

4.3 Detailed Process of Hydraulic Test

4.3.1 Preparations

1) Instrument Setting & Inspection

(1) Pressure Gauge (The precision of the test pressure gauge should be not
less than first grade)

O Quantity
D For High Pressure (Pressurization): 2 EA (0- 500 kglc11f.g)
D For Low Pressure (Pressurization): 2 EA (0 - 100 kg1cd.g)

D For Water Filling: 1 EA (0 - 30 kglc1d.g)

O Install Location
D For High Pressure: TIG BOP Heater 8 Outlet, Boiler Outlet

D For Low Pressure: Boiler Inlet, TIG BOP Inlet

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BOILER HYDRAULIC TEST

D Pump Exit For Filling Water Transfer

(2) Gauge for Measuring Temperature

Quantity: 3 EA

a Temperature Range: 0 - 50°C

@ Install Location :

D SIH, RIH, LINE

D DEMI.WATER TANK

2) Communication Facilities

(1) Cable Quantity: 1 Lot

Location: Main Control Center (PUNIP Location),

The Highest Location (Pressure Gauge) Pressure Checking Location

(2) Wireless Quantity : About 1OEA

Location : Main Control Center(PUMP Location) and Inspection Team

3) Inspector and Recorder Positioning

Location Positioning Status: Scheduled to make later

4) All sorts of valves operation list

Operation List sorted by time and location : Scheduled to make later

5) Water Supply System for Hydraulic Test

Refer to Boiler Hydraulic Test System Diagram

7) Primary Equipments Specification

Pump Quantity Pressure(kg1ad) Volurne(ll1~1Hr)

FILI-ING PUMP 1 20 100

PRESSURE PUNlP 1 500 0.3

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BOILER HYDRAULIC TEST

8) Equipments setting and working status confirmation before final test

(1) Remove all lifting lugs on all pressure parts like tube bundle, header, etc to prevent
material defects and Perform penetrant tests on the parts where lifting lugs
removed.

(2) Check completion status of pressure parts installation, welding, non-destructive

test and heat treatment and etc.

(3) Check completion status of all sorts of thermocouple, fin, thermowell, casing plate
and etc.

(4) Check the condition of the temporary pipes.

(5) Check preparations for night work.

(6) Check status of MSV, CRV and NRV.

(7) Check bypass valves

(8) Check tightening of all sorts of hangers.

(9) Check all sorts of drain valves and vent valves related hydraulic test.

(10) Check all sorts of sampling and chemical injection systems.

(1 1) Check shutting off of terminal points.

4.3.2 Preliminary Test

Perform air leak test on all welded points using air applying 0.5 kglcm' pressure
(Air compressor requirement: Max. pressure 8 kglci~f)

4.3.3 Hydraulic Test

(1) Preparations

@ FILI-ING PUMP SETTING

PRESSURE PUNlP SETI-IIVG
@ ALL VALVES OPENING CHECK

(2) WATER FILI-ING STEP

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BOILER HYDRAULIC TEST

O Chemical Treatment

O Water Filling

O High Pressure Parts

D FILLING SYSTEM

DEMI. WATER STORAGE TANK -+FILLING PUMP -+ MS-MV-03(CRV WARM

LlNE UP LINE) ON MAlN STEAM LlNE AND N0.8 HEATER OUTLET (START-
UP CONNECTION V045) WILL BE USED

D FILLING METHOD

FILLING PIPE will connect to MS-MV-03 VALVE on MAlN STEAM LINE and
START UP CONNECTION LlNE and perform filling water fully into HIGH
PRESSURE PARTS and STEAM PIPES using BOILER FILLING PUMP.

D WATER FILLING FOR HYDRO TEST

-After flushing, when certain overflows occur in each vent valve by filling again,
close all valves and apply a pressure up to about 10 Kg1cd.g

- After filling, when the pressure reaches about 10 kg/cd.g, stop the filling pump
and close the filling line valve.

@ Low Pressure Parts

D FILLING SYSTEM

DEMI. WATER STORAGE TANK -+FILLING PUMP 4 CR-MV-03(AUX.STEAM

HEAD SUPPLY LINE) ON HOT REHEAT DRAIN LlNE AND CRP DRAIN LlNE

D FILLING METHOD

- For filling reheater system, the temporary filling pipes will be connected from the
filling pump to the CR-MV-03 on the HOT R/H LlNE and the CRP DRAIN LlNE
and fill water fully into the reheater and the high & low temp. pipes.

D SYSTEM FLUSHING

If overflow occurs in each vent, stop the boiler filling pump and perform system
flushing by opening boiler drain valves.

D WATER FILLING FOR HYDRO TEST

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BOILER HYDRAULIC TEST

-After flushing, when certain overflows occur in each vent valve by filling again,
close all valves and apply a pressure up to about 10 Kg/cm2.g

- After filling, When the pressure reaches about 10 kg/cm'.g, stop the filling pump
and close the filling line valve.

4.3.4 Pressurization
Refer to the attachment of the boiler hydraulic test time-pressure diagram

(1) Pressurization Ratio and Depressurization Ratio

6)High Pressure Parts

D When pressurizing: 0 - 180 kglcm': Max. 10 k g / d M i n
180 - 410 kglcm' : Max. 2 kg/cm'/Min

D When depressurizing: 410 - 180 kglcm' : Max. 2 kg/cul'/lVlin

180- Okg/cd :Max. lOkg/cuflMin

@ L o w Pressure Parts

D When pressurizing : 0- 45 kg/cm' : Max. 10 kglcm'lMin,

45 - 80 kglc~o': Max. 2 kg/cm'/Min,

D When depressurizing : 80 - 45 kg/& : Max. 2 kg/cm'/Min,

45 - 0 kg/cd : Max. 10 kg/cm'/Min

4.3.5 Inspections during the test

(1) lnspection Parts

0All welding points on each part of the boiler

@ Leakage of valves
@ Parts mentioned in the boiler expansion record and deflection change as stage.
(2) lnspection Period

Cil High pressure parts

D After filling water, check all parts which have leakage possibility when
-
pressurizing 100 270 kg/cni and If no leakage has been found, pressurize
them up to final pressure. when pressure goes up more than 270kg/clu',
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BOILER HYDRAULIC TEST

approaching around the pressure parts shall be restricted and perform an

inspection according to the test curve during depressurization.

D After 30-minutes holding at 410 kglcd, depressurize and perform reinspection

in detail at 273 kglcm'

% If a problem occurs while pressurizing, stop pressurizing and check again.

@ Low Pressure Parts

D After filling water and 30-minutes holding at 80 kglcm', depressurize up to 53
kglcd and perform detailed inspection at 53 kglcd.

(3) Measures against Leakage during Test

If a leakage on the welding part is terrible, stop the test immediately and bring
back to original condition and re-test after repair works.

4.3.6 Test Record

Refer to attached record form (Temperature, Pressure, Deflection)

(1) Pressure Record

@ pressure recording at intervals of 2 minute

D GAUGE ON THE TOP
D GAUGE ON THE BOTTOM

(2) Temperature Record

4.3.7 Depressurization

(1) High Pressure Parts

When the hydraulic test has been finished, open the drain valves. depressurize
with less than 2 kglcd per minute until the pressure reaches at 180 kg/& and
apply 10 kglcd per minute when pressure is less than 180 kglcln'.

(2) Low Pressure Parts

When the hydraulic test has been finished, open the drain valves. depressurize
with less than 2 kglcuf per minute until the pressure reaches at 45 kglcmi and
apply 10 kglclu' per minute when pressure is less than 45 kglcmf.

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BOILER HYDRAULIC TEST

(3) After depressurizing, open the vent valves on the top of the boiler and drain
off water inside of the boiler.

4.3.8 Boiler Draining

If draining is needed, open all the air vent valves first and drain off water to
prevent a vacuum in the boiler.

4.4 Procedure after Test

Confirm the water inside of the boiler has been drained off and then, remove
moisture completely using oil-less-air and inhibit corrosion holding low humidity
by blowing instrument air into the boiler continuously before chemical cleaning.

5.0 Attachments

1) Hydraulic Test Time-Pressure Diagram (High Pressure)

2) Hydraulic Test Time-Pressure Diagram (Low Pressure)
3) Temperature Record
4) Pressure Record (High Pressure)
5) Pressure Record (Low Pressure)
6) Boiler Expansion Record
7) High Pressure Parts Hydraulic Valves List (Scheduled to make later)
8) Low Pressure Parts Hydraulic Valves List (Scheduled to make later)

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Attachemnt #3

Temperature Record
(Air Leak Test, Hydrostatic Test)

T I : Atmospheric Temperature T2 :

NOTE T3 :

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Attachment #4

Pressure Record
(Air Leak Test, Hydrostatic Test)

I
NOTE P I : #8 Heater Outlet P2 : Separator Outlet

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Attachment #5

Pressure Record
(Air Leak Test, Hydrostatic Test)

I
NOTE P I : HOT RIH LINE Inlet P 2 : Cold Reheater Line Inlet

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Attachment #6

BOILER EXPANSION RECORD

(Hydrostatic Test)

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