BOILLR l\DRAULIC BOILLR l\DRAULIC

1LS1 AND 1LS1 AND

PRLSLRVA1ION PRLSLRVA1ION PRLSLRVA1ION PRLSLRVA1ION
1LS1ING OBJLC1IVL: 1LS1ING OBJLC1IVL:
1o ensure healthiness o pressure parts. 1o ensure healthiness o pressure parts.
1o presere the boiler ater hydraulic test is 1o presere the boiler ater hydraulic test is
oer. oer.
1LS1 ML1lOD 1LS1 ML1lOD
1he hydraulic test is carried out in two stages: 1he hydraulic test is carried out in two stages:
Stage Stage I : Hydro test at a pressure of J.S times the I : Hydro test at a pressure of J.S times the
design pressure. (at 3J3.S kg/sq.cm for S00 MW) design pressure. (at 3J3.S kg/sq.cm for S00 MW). It . It
wwill coer the Drum, Down comers, Laporator, ill coer the Drum, Down comers, Laporator,
Lconomizer and all Super Lconomizer and all Super--heaters up heaters up--to Boiler stop to Boiler stop Lconomizer and all Super Lconomizer and all Super--heaters up heaters up--to Boiler stop to Boiler stop
ales. ales.
Stage Stage II: (at 78.6 kg/sq.cm for S00 MW II: (at 78.6 kg/sq.cm for S00 MW,, wwill coer ill coer
the Cold reheat lines rom Isolator , Re the Cold reheat lines rom Isolator , Re--heater and lot heater and lot
reheat line up reheat line up--to Isolator. to Isolator.
Air tightness test Air tightness test to be perormed beore water illing ,at to be perormed beore water illing ,at
2 kg,sq.cm. ,g,, 2 kg,sq.cm. ,g,, to detect leakages due to ales let in to detect leakages due to ales let in
open position, orgotten gamma plugs, any cuts not open position, orgotten gamma plugs, any cuts not
obsered by isual inspection etc. obsered by isual inspection etc.
Water Volume of Water Volume of Blr Blr Parts:S00MW Parts:S00MW
Sl. No. System \ater Volume , Sl. No. System \ater Volume ,Cu.M Cu.M, ,
1. Drum 60 1. Drum 60
2. Circulating System 18 2. Circulating System 18
3. 3. Lconomiser Lconomiser System 95 System 95 3. 3. Lconomiser Lconomiser System 95 System 95
4. Super leater System 16 4. Super leater System 16
5. 5. Reheater Reheater 13 13
6. 1otal 63 6. 1otal 63
Hydraulic test & preservation Hydraulic test & preservation
Chemically treated water is illed in the Boiler Chemically treated water is illed in the Boiler
and hydraulic test is conducted at 1.5 times the and hydraulic test is conducted at 1.5 times the
design pressure. design pressure.
Ater successul completion o lydraulic test Ater successul completion o lydraulic test Ater successul completion o lydraulic test Ater successul completion o lydraulic test
Boiler is drained and chemically treated water is Boiler is drained and chemically treated water is
again illed. 1he Boiler is kept pressurized or again illed. 1he Boiler is kept pressurized or
wet preseration. wet preseration.
Serices Required Serices Required
Pressure Gauges: At least two gauges: Pressure Gauges: At least two gauges: one at one at
drum leel, and other near pressure raising pump drum leel, and other near pressure raising pump. .
Least count o gauge should be 1 KG,CM2 Least count o gauge should be 1 KG,CM2
Availability of DM water Availability of DM water::
Quantity: 1400 cu. meter. Quantity: 1400 cu. meter.
pl: 9.5 to 10.0 by addition o Ammonia & lydrazine pl: 9.5 to 10.0 by addition o Ammonia & lydrazine pl: 9.5 to 10.0 by addition o Ammonia & lydrazine pl: 9.5 to 10.0 by addition o Ammonia & lydrazine
200PPM 200PPM
1emperature: 20 1 50 deg 1emperature: 20 1 50 deg
Chemicals: Chemicals:
Ammonia Ammonia ::15 15 litres litres,stg. ,stg.--I, - I, - 125 125 litres litres,stg. ,stg.--II, II,
lydrazene lydrazene lydrate lydrate: : 550 550 litres litres ,stg. ,stg.--I, - I, - 300 300 litres litres ,stg. ,stg.--II, II,
lor Preseration: Ammonia: 200 lor Preseration: Ammonia: 200 litres litres - lydrazine: 600 - lydrazine: 600 litre litre
SLRVICLS RLQUIRLD ,Contd., SLRVICLS RLQUIRLD ,Contd.,--,,
pressurising pressurising pump ,reciprocating type, : lead pump ,reciprocating type, : lead
600 Kg,cm2 & Discharge: 50LPM 600 Kg,cm2 & Discharge: 50LPM
boiler ill pump. boiler ill pump.
power supply to the motors power supply to the motors power supply to the motors power supply to the motors
lood lights and 24V hand lamps lood lights and 24V hand lamps
communications system e.g. as walkie communications system e.g. as walkie--talkie sets, talkie sets,
telephones etc. telephones etc.
Ambulance near test area Ambulance near test area
State of the Plant State of the Plant
Lrection o the Boiler pressure parts is complete as per Lrection o the Boiler pressure parts is complete as per drg drg
including \elding, S.R., ND1 including \elding, S.R., ND1
All necessary ales including drain ales installed and closed All necessary ales including drain ales installed and closed
All saety ales installed and hydrostatic plugs should be All saety ales installed and hydrostatic plugs should be
assembled beore commencing the test assembled beore commencing the test
1he root ale o the calibrated standard test pressure gauge 1he root ale o the calibrated standard test pressure gauge
impulse line must be open. impulse line must be open.
All manhole closure plates ,except drum manhole and header All manhole closure plates ,except drum manhole and header All manhole closure plates ,except drum manhole and header All manhole closure plates ,except drum manhole and header
hand hole caps, should be closed and bolted or welded tight. hand hole caps, should be closed and bolted or welded tight.
1he isolating ales proided in all the other branching systems 1he isolating ales proided in all the other branching systems
like S,Blowing system tapping, Sl spray connections, Pr. like S,Blowing system tapping, Sl spray connections, Pr.
Gauges etc. hae to be tightly closed Gauges etc. hae to be tightly closed
All ents necessary to preent air entrapment during illing All ents necessary to preent air entrapment during illing
operation such as super heater link ents, economizer link ents, operation such as super heater link ents, economizer link ents,
drum ents etc. shall be open. drum ents etc. shall be open.
All the hangers in Boiler & piping system are set , locked as per All the hangers in Boiler & piping system are set , locked as per
recommendation recommendation
State of the Plant(contd./ State of the Plant(contd./--))
In CC pumps, installation o the rotating elements should be In CC pumps, installation o the rotating elements should be
deerred deerred
Keep the required peepholes., manhole doors in urnace, second Keep the required peepholes., manhole doors in urnace, second
pass area open or inspection during l.1. pass area open or inspection during l.1.
Lnsure the readiness o Boiler lill pump Lnsure the readiness o Boiler lill pump Lnsure the readiness o Boiler lill pump Lnsure the readiness o Boiler lill pump
Lnsure the readiness o Boiler Lnsure the readiness o Boiler Pressurising Pressurising Pump Pump
Sky climbers , Scaolding arrangements are proided inside the Sky climbers , Scaolding arrangements are proided inside the
Boiler Boiler
Lnsure communication between drum leel and pressurizing Lnsure communication between drum leel and pressurizing
pump area and other operating areas. pump area and other operating areas.
Boiler drain is suitably connected to storm water drain. Boiler drain is suitably connected to storm water drain.
All All debries debries are remoed manually rom drum, buck stay etc. are remoed manually rom drum, buck stay etc.
Air testing of pressure parts & Piping Air testing of pressure parts & Piping
Beore water illing an air pressurization test is Beore water illing an air pressurization test is
perormed to detect leakages due to ale let in perormed to detect leakages due to ale let in
open condition, missing R1 plugs, any cuts etc. open condition, missing R1 plugs, any cuts etc.
Boiler ,piping is pressurized with air up to 2 Boiler ,piping is pressurized with air up to 2
Kg,cm2 ,g,. Kg,cm2 ,g,. Kg,cm2 ,g,. Kg,cm2 ,g,.
Beore admitting air all ents , drains are closed. Beore admitting air all ents , drains are closed.
Boiler, Piping are inspected & leakages, i any Boiler, Piping are inspected & leakages, i any
ound are attended. ound are attended.
Ater air leakage test, ent ales are let in open Ater air leakage test, ent ales are let in open
condition. condition.
Water filling for Hydro test Water filling for Hydro test
Boiler system are illed with DM water Boiler system are illed with DM water
containing 200 containing 200 ppm ppm lydrazine, Pl~ lydrazine, Pl~ 9.5 9.5 to 10 to 10
through illing lines connected to boiler drain through illing lines connected to boiler drain
header. header. header. header.
Conirmation o completion o illing o entire Conirmation o completion o illing o entire
system shall be system shall be done done through ents. through ents.
Vents are closed ater remoal o air. Vents are closed ater remoal o air.
On completion o illing, the ill pump may be On completion o illing, the ill pump may be
stopped. stopped.
l\DRAULIC 1LS1: l\DRAULIC 1LS1:
Pressure is raised to 25Kg,cm2 and a thorough inspection is done. Pressure is raised to 25Kg,cm2 and a thorough inspection is done.
Rate o rise should not be more than 10 kg,sq.cm ,g, per minute Rate o rise should not be more than 10 kg,sq.cm ,g, per minute
up up--to approx. 80 o the test pressure and should be 1 to 2 to approx. 80 o the test pressure and should be 1 to 2
kg,sq.cm ,g, per minute beyond that alue kg,sq.cm ,g, per minute beyond that alue..
1he pressure is raised in steps and held or 10 minutes at 100 & 200 1he pressure is raised in steps and held or 10 minutes at 100 & 200
Kg,cm2 Kg,cm2
Ater reaching the test pressure the pressurizing pump is stopped Ater reaching the test pressure the pressurizing pump is stopped
immediately & power supply to pump is cut o. immediately & power supply to pump is cut o. immediately & power supply to pump is cut o. immediately & power supply to pump is cut o.
1he linal test pressure held or hal an hour 1he linal test pressure held or hal an hour in presence o in presence o
Inspection Authority. Inspection Authority.
During holding time the oicial test gauge pressure reading should During holding time the oicial test gauge pressure reading should
not drop noticeably not drop noticeably
1he aerage pressure drop during irst 10 minutes o stopping the 1he aerage pressure drop during irst 10 minutes o stopping the
pressuring pump should be less than 1 Kg,cm2. pressuring pump should be less than 1 Kg,cm2.
l\DRAULIC 1LS1: l\DRAULIC 1LS1:
Pressure reduced to maximum allowable working pressure and Pressure reduced to maximum allowable working pressure and
maintained or suicient time to permit close isual inspection o maintained or suicient time to permit close isual inspection o
whole pressure parts whole pressure parts
Ater 30 Min holding pressure is reduced to 50 Kg,cm2 and entire Ater 30 Min holding pressure is reduced to 50 Kg,cm2 and entire
pressure parts, piping are checked. pressure parts, piping are checked.
\hereer ales are in tandem both ales should be checked or \hereer ales are in tandem both ales should be checked or
passing one by one by keeping one ale closed and other open. passing one by one by keeping one ale closed and other open.
I leaks are ound, release the pressure and drain the concerned I leaks are ound, release the pressure and drain the concerned I leaks are ound, release the pressure and drain the concerned I leaks are ound, release the pressure and drain the concerned
portion. Ater repairs the boiler is reilled & hydro test is repeated. portion. Ater repairs the boiler is reilled & hydro test is repeated.
1he pressure parts shall be de 1he pressure parts shall be de--pressurized at a rate o 1 kg, Sq. pressurized at a rate o 1 kg, Sq.
cm,minute. cm,minute.
Vents should be opened when the system pressure reaches Vents should be opened when the system pressure reaches
2kg,sq.cm 2kg,sq.cm
Ater completion o the hydraulic test, an inspection o boiler inside Ater completion o the hydraulic test, an inspection o boiler inside
and outside is made to ensure that the boiler has satisactorily and outside is made to ensure that the boiler has satisactorily
withstood the test withstood the test
Ater satisactory hydro test entire Boiler is drained & joint protocol Ater satisactory hydro test entire Boiler is drained & joint protocol
is signed or completion o lydro 1est. is signed or completion o lydro 1est.
PRLSLRVA1ION Ol BOILLR PRLSLRVA1ION Ol BOILLR
Purpose: 1o protect the internal suraces rom oxidation. Purpose: 1o protect the internal suraces rom oxidation.
Boiler pressure raised to 5 Boiler pressure raised to 5 -- 10 kg per sq. cm at drum with 10 kg per sq. cm at drum with
treated DM water containing 200 PPM o lydrazine and treated DM water containing 200 PPM o lydrazine and
Suicient amount o Ammonia to raise pl alue o 10.0 to 10.5 Suicient amount o Ammonia to raise pl alue o 10.0 to 10.5
is illed till it oerlows rom ents . is illed till it oerlows rom ents .
Drum water samples collected periodically say once in a week or Drum water samples collected periodically say once in a week or Drum water samples collected periodically say once in a week or Drum water samples collected periodically say once in a week or
ortnight & tested or pl and hydrazine content. ortnight & tested or pl and hydrazine content.
Criteria or preseration o Boiler : Criteria or preseration o Boiler :
ii, Pl : Not less than 9.0 , Pl : Not less than 9.0
ii, ii, lydrazene lydrazene lydrate : Not less than 50 PPM lydrate : Not less than 50 PPM
iii, Drum Pressure : Not less than 2 kg per sq. cm. iii, Drum Pressure : Not less than 2 kg per sq. cm.
Alternatiely, preseration can be done under Nitrogen capping Alternatiely, preseration can be done under Nitrogen capping
at 1.5 Kg,cm2 at ents o drum and Super leater. at 1.5 Kg,cm2 at ents o drum and Super leater.
COMPLL1ION CRI1LRIA COMPLL1ION CRI1LRIA
1he test pressure in the oicial pressure gauge 1he test pressure in the oicial pressure gauge
,Calibrated standard test pressure gauge, is held ,Calibrated standard test pressure gauge, is held
or 30 consecutie minutes in presence o or 30 consecutie minutes in presence o
Inspection Authority. 1he Boiler should Inspection Authority. 1he Boiler should Inspection Authority. 1he Boiler should Inspection Authority. 1he Boiler should
satisactorily withstand such pressure without satisactorily withstand such pressure without
appreciable leakage or undue delection or appreciable leakage or undue delection or
distortion o its pressure parts or at least 10 distortion o its pressure parts or at least 10
consecutie minutes consecutie minutes