= SCP-SITE-BG-05 Form of Construction Organization & Design ( Construction Proposal, Construction Instruction ) for Review and Approval Serial NoCP-T3109-Cons-022 Project Item. PLTU 1 Jawa Barat 3X330MW | Contract Code | SPC-IKT-HT-C-008-2007 INDRAMAYU Unit Project Item | Boiler Unit Project Code Part Project Item | Boiler pressure part Part Project Code Tol) SCP Project Department We herewith submit in faith where of Procedure for Hydroulic ‘Test of Boiler Pressure Part Construction Organization =, Construction Proposal = Construction Instruction for your review and approval. ‘Attachment: - Organization Chart , Equipment and Plan Manpower, Lifting Plan, Sketch Preassembly Construction Contractor’ Legal Representative : Ags Sib}gyo ‘Comments of Project Department: Panels Construction Manager: Construction Management in Charge: Professional Engineer: QUQC Engineer: Safety Manager: ‘The Form that filled in by contractor is in triplicate, of which must be kept on file each by JMK SCP JO ProjectSCP-SITE-BG-06 Form of Unit (Part) Project Commencement for Approval Serial No: P-T-3109-Cons-012 Unit Project Item] Boiler Unit Project Code Part Project Item | Boiler pressure part Part Project Code ‘To: SCP JO Project Department Be kindly informed that the project PLTU 1 Jawa Barat 3X330 MW Indramayu undertaken by ‘our company is in fully ready for commencement. It is scheduled to be commenced on 20 Jan 2009. Your prompt approval is highly appreciated. Yes No NoNecd 1 Have received Design Drawing provided by SCP JO Project Dept.(A.B status) 2.Clearly aware of design drawings and technical requirements. 3.On-site organization structure has been set up and working staffs are deployed in site. 4.Construction Machinery and Instruments have been mobilized into the site. 5. Water & electrical power supply furnished,road, communication in good co 6.Equipment & materials already mobilized into site through being well exai 7.Construction Organization & Design c Construction Proposal Construction Instruction m have been published after being approved. moo Attachment tions d. 4) Organization & Design (Construction Proposal,Construction Instruction). =o 0 b) Organization structure chart, working staffs list, and copies of qualification certificates. =o 0 ©) Lists of machineries and testing instruments.( Items, Qualities, Performance): Permit Copies of travelling heavy machineries(10t and over), Permit copies of stationary heavy machineries.(10t and over), Copies of Certificates of Testing and measuring instruments. 4) Statement of drawing, power supply, road, communication and others. Contractor = PETruba Jaya En, y a Personnel in change: (/Mujiono 2009/01/20 Comments of Project Dept : Construction Superintendent: Professional Engineer: ‘The Form that filled in by contractor is in duplicate, of which must be kept on file each by SCP JO Project Department and Contractor.BTA = Procedure for Hydrostatic Test DOCUMENT NO. : of Boiler Pressure Part for P-T3109-CONS-022 3X330 MW Steam Power Generation [T5syep DATE? Indramayu pec2s08 UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager 1ofii 00 | | | Procedure for Hydrostatic Test | of Boiler Pressure Part for 3X330 MW Steam Power Generation Indramayu { | DOCUMENT NO: P-T3109-CONS-022 | : | ORIGINATED BY REVIEWED BY APPROVED | DISTRIBUTION BY ~ SDCC Original cA | =e - CNEEC eee. Ville Copy set lan = Originator: Mujiono, e Paryaman Copy Area Manager ns Manager SMR inager BRIEF OF REVISION. REV | ISSUED EFFECTIVE No. DATE. DATE. | © | Bec.25,2008 | Dec,25,2008 |Procedure for Hydrostatic Test of Boiler Pressure Part for 3X330 MW Steam Power Generation Indramayu DOCUMENT NO. : P-T3109-CONS-022 ISSUED DATE : Dec 25, 08 UNIT ISSUING: ‘APPROVED BY : PAGE | REVISION Construction Site Manager 2of 14 00 TABLE of CONTENT No Description Page | 4 | Cover | tofat Ha: | Table of Content i Hi 2ofit | 3 Scope Bort. | 4: Purpose : 3ofi1 | 5 Responsibility 3 of 11 6 Test Scope 3 of 11 7 Testing Prerequisites 4 of 11 8 Test Preparation Sof 14 9 Test Procedure 7 of 11 10 Basic of Acceptance 10 of 11 14 Preservation after the test 10 of 11 12 Repair ‘| 1001 13 Inspection 11 of 11 14 Safety 11 of 11 15 Record 11 of 11 16 Attachment 11 of 11 a |Procedure for Hydrostatic Test DOCUMENT NO. : ruta of Boiler Pressure Part for P-T3109-CONS-022 3X330 MW Steam Power Generation [ISSUED DATE: —*| Indramayu Bee Oe UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager 3 of 11 00 1.0 SCOPE 2.0 3.0 4.0 This procedure covers the hydrostatic testing of boiler pressure part, Boiler Internal Piping for Indramayu 3 x 330 MW Coal Fired Steam Power Plant Project. PURPOSE This instruction serves as guide in hydrostatic testing of the above scope. This is also to satisfy the contract technical requirement, boiler manufacturer's requirement, reference Codes and standard as well as government regulations. RESPONSIBILITIES 3.1 The Boiler Area Manager shall make sure that this instruction is implemented at site. 3.2 The Boiler Superintendent and engineers are responsible for implementation of this instruction. He has to check that requirement in Hydrostatic test are properly adhered to as indicated in this instruction. 3.3. The Boiler Supervisor is responsible for the arrangement of all processes involved in the execution of hydrostatic test. He has to make sure that ‘standard code practice is applied accordingly. 3.4 The Welding Superintendent and Welding Supervisor shall make sure that all welding directiy on pressure retaining parts are completed. 3.5 The QA/QC personnel in charge of hydrostatic test are responsible in assuring that the requirement in this procedure are properly implemented and followed. They have to make sure that all NDTs and hot works on pressure retaining Parts are completely executed before the test. They have to make all pertaining records ready and available for review by all parties concerned. They have to perform hydrostatic testing in process inspections. They have to prepare pertinent records after the test. TEST SCOPE Considering the different pressure ratings, the hydrostatic test is divided in two systems namely primary system (superheating system) and secondary system (reheater system). 4.1 Primary System. This is consists of Economizer inlet header, economizer system, steam drum, water-cooled wall system, Down comer, Riser pipes, CP wall panels and superheater as well as associated inter connecting piping, drains, blow down, Venting, chemical dosing, feed water & desuperheated water piping & valves.DOCUMENT NO. : Procedure for Hydrostatic Test of Boiler Pressure Part for P-T3109-CONS-022 3x330 MW Steam Power Generation [TSsyED DATE : indramayu Dec 25, 08 UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager 4of ii 00 5.0 4.2 The test boundary for the Superheater system should be until hydrostatic test blind plate located in Economizer inlet header to Superheater outlet valve number 10 LBA80 AA801. Secondary System. This is consists of reheater inlet header, Primary reheater snake tube, Secondary reheater elements and reheater outlet header, drains, Safety valve & valves. The boundary shall be from cold reheat valve number 10 LBC70 A801 to hot reheat outlet valve number 10 LBB80 AA8O1 The blind valve was designed at the Final RH outlet, RH inlet header and Final SH outlet; therefore it is regarded that the blind valves of the main steam, reheat hot pipe and cold pipes and boiler proper shall be identified as their boundary of hydraulic test. Refer to the attached flow diagram for the boundary detail of each system. TESTING PREREQUISITES SL 5.2 5.3 5.4 5.5 5.6 a 5.8 All the welding fixing parts on the boiler wall, such as the fin on the tube of heating surface or pressure part, sealing part, antiseptic device, fixture, insulation nail, Soot blower nozzles, inspection hole as well as the tapping point of I & C elements etc, shall be completely installed. After the hydro test, no welding work is permitted on the boiler pressure part. All the temporary stiffening parts, lifting lugs or the other steel welded on heating surface and pressure parts for lifting and transportation have been removed, and smoothly ground. The hangers and rods of boiler proper must be completely installed and adjusted to ensure the balance force and tension is carried on. Housekeeping is done in boiler area particularly on top of boiler, stairway, platform, ground level, furnace, Eco hopper, corner water wall, superheaters, reheaters, economizer, etc. All hot works including PWHT on pressure retaining parts have been done & completed. All NDTs have been completed & documented. Punch listing prior to testing has been done; punch killing completed & documented. All records pertaining to pressure retaining part erections have been completed & ready available for review.“Procedure for Hydrostatic Test | DOCUMENT NO. : of Boiler Pressure Part for P-T3109-CONS-022 Indramayu Dec 25, 08 UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager Sof il 00 6.0 oa 5.10 5.11 5.12 s.13 5.14 5.19 5.20 5.21 5.22 All weld joints and weld attachment areas shall be left uninsulated and exposed for examination during test. Equipment not subjected to pressure test shall be disconnected from the system or isolated by blank or valve or plug. The main boiler safety valve and other safety valve are all blocked; economizer inlet header, attemperature, spray water piping, drain and vent are all isolated from not tested areas using valve or blind plate. All valves included in the test boundary will be tagged open/close as per test requirement. Temporary water filling line and pressurizing line shall be flushed and in service leak tested before water delivery into the systems. The pressurizing line should undergo hydro testing to assure that the line has the capacity to carry the pressure of the system while in hold, The quality of chemical demineralized water shall be acceptable with the qualified report, and enough amount of water shall be prepared for hydraulic test at least 30003. The expansion indicator / Pressure gauge have been mounted properly according to the instruction on the drawings and adjusted to 0 positions. Min 2 nose pressure gauge for each system. Check the expansion clearance and its position of boiler proper whether it meets the requirements of designed drawings or not. All temporary pipelines to be used in water filling are flushed and checked as safe for operation. All permanent equipments to be used for water filling are inspected and documented. All parties (Contractor, Client, and Owner) are convinced and agreed that the systems are ready for hydrostatic testing. Clearance Certificate shall be signed off by all parties before the test. TEST PREPARATION 6.1 Equipment a. Filling Pump: Temporary Transfer pump shall be used to transfer water from 1500m? tank at WTP to Boller area, and Filling water pump with total head 100m 150kw shall be used for filling the boiler troughs Bank Manifold drain. 3X330 MW Steam Power Generation ISSUED DATE :DOCUMENT NO. : P-T3109-CONS-022 | Procedure for Hydrostatic Test of Boiler Pressure Part for 3X330 MW Steam Power Generation ar ISSUED DATE : Derameys Dec 25, 08 UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager 6 of 11 00 b. — Pressurizing Pump: 750 bar 25 liter/min capacity. c. Temporary water line: Schematic diagram is attached d. Air Compressor: specification to be informed later e. Pressure Gauge 500 kg/cm? ‘An indicating gauge, visible to the person controlling the pressure applied, shall be connected to pressure parts. The location for the primary system shall be in steam drum and the other one is close to the pressure pump. For the secondary system, the location of the pressure gauge shall be at the reheater outlet and the other one shall be close to the pressure pump. The hydrostatic head on the gauge shall be considered such that the test pressure is achieved at the top of the boiler. Dial pressure gauges to be used in testing shall preferably have dials graduated over their entire range of about double the intended maximum test pressure, but in no case shall the range be less than 1.5 times that pressure. The spacing between graduations shall be such that the inspector and the person controlling the test shall be able to determine when the required test pressure has been applied. Test gauges shall be accompanied with valid calibration certificates and should be equipped with snubber to keep hammering from affecting the gauge calibration. f. Communication All communication between the boiler contro! station and the hydro-pump station will be by walkie-talkie on Truba special channel. There will be a second radio at each station for back up. g. Tools and Scaffolding Scaffolding, lights, and repair tools are to be ready at the time of hydrostatic testing. h. Compressed Air Air Pressure used for testing prior to the Boiler hydro-test shall not exceed 0.3 Mpa to be kept for a minimum of 1 hour for air tightness test. i. Demineralized WaterDOCUMENT NO. : P-T3109-CONS-022 ISSUED DATE : Procedure for Hydrostatic Test _ rata) of Boiler Pressure Part for 3X330 MW Steam Power Generation Indramayu Dec 25, 08 UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager 7 of 11 00 This type of water is to be used for hydrostatic test to be produced from permanent water treatment plant. Or Supplied by client. j. Drainage Boiler drain line shall be routed to main pipes of intermittent blow down and drain pipe then to be connected with temporary piping going to waste water pond. 7.0 TEST PROCEDURE 7.1 Pneumatic Test In order to find any serious leakage as early possible the primary and secondary system shall be connected temporarily before hydro test. The same temporary line intended for hydrostatic testing will be used for air test. The system shall be filled with compressed air at a pressure of 0.3 MPa, It shall be held for a minimum period of 1 hour for air tightness test and check. Leakage shall be checked by listening to the sound and by spraying soap solution. 7.2 Hydrostatic Testing a. Water Quality Ph value at supplied water will be checked before filling to the system, Ph> 10- 10.5 b. Testing Pressure Based on the boiler manufacturer's requirement, the testing pressure is as follows; Primary System: Boiler drum design pressure is 20.5, Test pressure is 30.8MPa Secondary System: Reheater design pressure is 5.34, Test pressure is 8.01MPa ca Water Filling Sequence . Demineralized water will be taken from the demin water tank. ‘Temporary pipe line and transfer pump shall be used to transfer the water up to Boiler area.UNIT ISSUING: Construction _ | DOCUMENT NO. : P-13109-CONS-022 ISSUED DATE = Dec 25, 08 PAGE REVISION Sof il 00 Procedure for Hydrostatic Test of Boiler Pressure Part for 3X330 MW Steam Power Generation Indramayu APPROVED BY : Site Manager Filling water pump with total Head 100m shall be use for filling the Boiler trough the bank manifold and Economizer drain for Primary system, to HCP FW lower header and RH inlet header for Secondary system. Temporary water filling lines (includes the permanent drain header to boller blow down tanks which will be used for filling as well as draining of the test system) and pressurizing lines shall be in service leak tested and flushed before transferring test water in to the circuit or commencement of pressurizing. Pressure test of the temporary line that will be bounded by test circuit shall be separately hydro tested. Visual check shall be done on temporary water filling lines. Temporary power supply complete with appropriate control panel shall be provided, to supply power and control the transfer pump, Filling water pump. Check the pumps electrical connections, control panels and lubrication prior to running. Trial run of the pumps shall be done before the test. Sampling of water shall be taken before filling of boiler and recorded before ‘commencement of filling. All vents shall be kept open and hoses to be connected to convey venting spill to the drain funnel which is connected through the permanent drain header. Open water-feed valves of the temporary system and all vents, and shutdown all the primary valves, and then start up filling water pump to fill water into boiler. Normally, the temperature of filling water shall be taken 20-70°C, the temperature difference between filling water and the wall of steam drum shall not exceed 28°C. During the time of water feeding, all pressurized parts shall be checked for leakage. If found, the handling shall be made immediately, after fixed and the feeding shall be continued. Until 2-3 minutes overflow of all vents happened, it is confirmed that boiler has been filled fully; the vent valves can be closed and stop feed water pumping and shutdown feed water valve. The super heater and the reheater outlet shall be interconnected by pipeline with appropriate valves in order to fill and pressurize both systems systematically. This line will be isolated if each system at the time of pressurizing.Procedure for Hydrostatic Test DOCUMENT NO. : of Boiler Pressure Part for P-13109-CONS-022 3X330 MW Steam Power Generation [TSSUED DATE: ae Dec 25, 08 UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager 9 of 11 00 d.— Pressurizing Monitor all the vents and ensure that all air entrapment has been completely released and the test circuit is completely filled with water. Close vents one by one as filling continues, the hydro filling pump continues till the pressure gage register a pressure of about 3 Kg/cm?(at_ steam drum) and then the filling stops. * Check the electrical connections of pressure pump. Proper lubrication shall be done when required. . Trial run shall be done on the plunger pump before pressurizing begins. + Pressurizing plunger pump will be started and pressurizing will be through drain valve of feed water lines. * Keep the pressure rate at 0.3 MPa/min. * Secondary System . Continue pressurizing up to 10% of reheater design pressure 5.34 MPa, stop pressurizing and fully check the system for any abnormality. . Close the valves interconnecting the secondary and primary system located at super heater (main steam) line and reheater outlet (hot reheat) line. * When no sign of abnormality is observed, continue pressurizing the secondary system up to design pressure 5.34 MPa. * Stop pressurizing and check again. * When no sign of abnormality is observed, continue pressurizing up to the test pressure 8.01 MPa. . Keep the system under test pressure for 20 minutes and then decrease the pressure to design pressure. Check the system thoroughly. * Primary System * When the secondary system is checked by all parties as qualified, open the vent valve of reheater, check and confirm the valves in between super heater and reheater as closed until the pressure on primary system reaches 10% of the design pressure of the steam drum20.5 MPa. * Check the system for any sign of abnormality. * Reroute the temporary pressurizing on primary system and start pressurizing until the pressure reaches design pressure of the steam drum.Procedure for Hydrostatic Test of Boiler Pressure Part for 3X330 MW Steam Power Generation DOCUMENT Ni P-T3109-CONS-022 ISSUED DATE : Indramayu Dec 25, 08 UNIT ISSUING: APPROVED BY : PAGE | REVISION Construction Site Manager 10 of 11 00 8.0 10.0 11.0 * Stop pressurizing and check again. * When no sign of abnormality is observed, continue pressurizing up to the test pressure of 30.8MPa. Stop pressurizing pump, and close the valve of pressurizing outlet. + Keep the system under test pressure for 20 minutes and then decrease the pressure to the design pressure at 20.5MPa. Check the system thoroughly. * Slowly open the vent valves until the pressure reaches 0.3 to 0.5 MPa. Control the pressure decreasing rate at 0.3MPa/min. BASIS OF ACCEPTANCE Keeping the test pressure in 20 minutes, the pressure of hydro test shall be reduced down to the design rated pressure for overall inspection. During the period of inspection, the pressure shall be held and there should not be any sign of any leakage, deformation and crack on all the welding joints, manholes, flanges and valves. If the test is acceptable, the hydrostatic test certificate shall be signed by all parties involve in the test. PRESERVATION AFTER THE TEST As recommended by the Client, test water shall remains in the system; the water shall be kept on the boiler with the pressure of 0.3 to 0.5 MPa. Monitoring Log shall be maintained. REPAIR. If any leakage is observed during water filling; the filling shall be stopped and the repair shall proceed as per repair procedure established and approved at site between the by all parties concerned. If any leak is observed during pressurizing, the pressurizing shall stop. The pressure shall be released at a permitted rate and the water shall be drained to a level where repair is permissible. INSPECTION. 11.1 DEPNAKER as government representative shall be invited to witness and certify the hydrostatic testing. Invitation shall be given on time.Procedure for Hydrostatic Test DOCUMENT NO. : frat of Boiler Pressure Part for P-T3109-CONS-022 3X330 MW Steam Power Generation ISSUED DATE : Indramayu Dec 25, 08 UNIT ISSUING: APPROVED BY : PAGE Construction Site Manager 11.2. For inspection convenience of PLN/ SCP-JO / PT. TJE the entire test area has been divided into different zones. Each zone will be manned by a team consisting of 2 to 4 inspectors. Each one of them will be equipped with walkye talkie to immediately report any abnormality found or observed. 11.3. Once satisfactory inspections have been completed pressure will be released preservation shall proceed. 12.0 SAFETY. Safety Requirement is follows; . The area of test shall be barricaded when the pressurizing starts. . Only authorized personnel will be permitted to enter the test zone. . Only trained personnel will be allowed to handle the chemical. . Any treated water drains will be securely collected in the retention basin and treated before disposing to others defined areas. 5. Not any hammering allowed during pressurizing. awe 13.0 RECORD Pressure test certificate shall be prepared and sign off immediately by concerning party after the inspection. 14.0 ATTACHMENT . Organization Chart . Schematic diagram of temporary lines (see attachment ) Pressure test boundary for primary and secondary system . Pressure time diagram BwneTruts RECORD OF BOILER PRESSURE TEST 7-3109-188-4-12-4-1P-0t reject nar Witainaya Goa Fixed Seam Power Pant Pc} SKIGO MW West ava Core China National Ete! Eeuirent Csporston Contactar PT, Tube Jaya Enpincesng soon Bee Y te siro oe ig a og fe t 0 ion 0 min | Time Minato nore TeST RESULT AO%FomOESIGNPRESSURE 0.534 MPa/ 75.26 PB) Clacceeraeee DESIGN PRESSURE 5.44 Mar 7588 i ‘esr PREssuRE 88 wear 12212001 (restores ACTUAL PRESSURE Pa Dave oF TESTED Prepared by Checked by Agproved by Approved by Prue ser J0 oepnncen ae DateRECORD OF BOILER PRESSURE TEST 1-3109-188-1-12-1-1P-01 Cent “China Nationa Electra! Equipment Corporation, Contractor: PT. Tube Jaya Engineering wb T8100 9075 MPa Test Pressure Pressure MPa 10% From DP (2.55 MPa Pressure Keeo 0.5 MPa Time / Minute Nore vest nesucr {0% From DESIGN PRESSURE: 265 Ma/ 362 Pa Chocerraate DESIGN PRESSURE: 205 MPa/ 2911 Pa Dresecreo TEST PRESSURE + 30.75 MPa/ A374 ACTUAL PRESSURE. MPa/ Pl DATE OF TESTED Prepared by Checked by “Approved by Approved by ere scp 10 Pr PUN mk DePNAKER, Date Date ‘aie Date