BOILER HYDRAULIC TEST AND PRESERVATION

PS: TSX: 262:00:11

NORTH CHENNAI THERMAL POWER LTD, 2 X600 MW

MPPGCL-MALWA, 2X600MW
RAYALASEEMA STAGE-IV-UNIT-6,1X600MW
KAKATIYA STAGE-II, 1X600MW

TECHNICAL SERVICES DEPARTMENT

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector - Southern Region
690, Anna Salai, Nandanam, Chennai 35

NORTH CHENNAI THERMAL POWER LTD, 2 X600 MW

MPPGCL-MALWA, 2X600MW
PROJECT
RAYALASEEMA STAGE-IV-UNIT-6,1X600MW
KAKATIYA STAGE-II,1X600MW
PROCEDURE

BOILER HYDRAULIC TEST AND PRESERVATION

PURPOSE OF
DOCUMENT

FOR EXECUTION / INFORMATION

DOCUMENT NO.

PS:TSX: 262:00:2011 /REV 00

DATE:23/12/2011

COPY NO:
ISSUED TO:

K.SELVARAJ

P.GOVINDARAJU

J .BALASUBRAMANIAN

DY ENGINEER

DGM

AGM/TSX

PREPARED

REVIEWED

APPROVED

TECHNICAL SERVICES DEPARTMENT

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR SOUTHERN REGION
CHENNAI 600 035
2

PROJECT SPECIFIC TECHNICAL DATA RELEVANT TO THE PROCEDURE

Water volume of different sections (approximate) is listed below.
Water Volume (Approx m 3)

System
Drum (FULL)

67

Circulating System

202

Economiser

114

Super Heater

220

Reheater

210

Total

813

Recommended Hydrostatic Test Pressures are

Stage - I A & IB

315.00 Kg/sq.cm 2

Stage - II

78.0 kg/sq.cm 2

QUANTITY OF CHEMICALS REQUIRED:

Stage I A & IB:
Ammonia

Hydrazine Hydrate :

300 Liters
600 liters

Stage II :
Ammonia

100 liters

Hydrazine Hydrate :

300 liters

CHEMICALS FOR WET PRESERVATION:

Ammonia
Hydrazine Hydrate

: 300 liters
:

600 liters
3

BOILER HYDRAULIC TEST AND PRESERVATION

SL.NO

LIST OF CONTENTS

1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PRECAUTIONS

6.0

EMERGENCY PROCEDURES

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

PRESERVATION OF BOILER

10.0

COMPLETION CRITERIA

11.0

APPENDICES

STATUS

a) LOG SHEETS.
b) DRAWINGS

1.0 PLANT DETAIL

a) The steam generator is an assisted circulation, Dry Bottom, Tangentially fired,
Balanced draught, Radiant Reheat type with direct pulverized coal fired Boiler.
The furnace consists of water and steam cooled tubes complete with down
corners, water and steam headers, bottom hoppers, drains, vents, sampling line
connections etc.
b) Super Heater section comprises drainable and non-drainable portions and
including safety valves, SH outlet stop valves with integral bypass valves, drains,
start up vents, nitrogen capping connections etc.
c) Water volume of different sections shall be referred for total water requirement.
Refer project specific technical data for water volume of different sections. Total
volume will be around 813 m3 .
2. OBJECTIVE:
a) To ensure healthiness of pressure parts.
b) To Preserve the boiler
3.0 PROPOSAL:
a) The Unit shall be hydraulically tested for conformation to IBR code requirements.
b) It is preferable to conduct the hydraulic test of the complete Boiler (except Reheat
section) in one stroke at the stipulated Hydraulic test pressure. If it is not possible
to accomplish this, the hydraulic test may be conducted in two sub stages.
c) Stage IA - Hydraulic Test of the drainable portion separately may be conducted at
1.5 times the design pressure. Suitable dummies shall be provided at LTSH outlet
link pipes. After completing the hydrostatic test for drainable portion, the system
will be drained and vented for drying and released for subsequent work.
d) Stage IB Later Hydraulic test for the entire system comprising both drainable
and non-drainable portions up to Boiler Stop valves is conducted at a pressure 1.5
times the design pressure.
e) Stage II This covers the Reheat sections i.e., cold reheat lines from Isolator,
Reheater and hot reheat line up to Isolator.
f) Air tightness test shall be performed before filling water in the Boiler (for carrying
out the hydraulic test). This is done to detect leakages due to valves left in open
position, forgotten gamma plugs, any cuts not observed by visual inspection

g) DM water shall be used for conducting drainable portion as well as non drainable
hydraulic test.
h) The hydrostatic test pressure shall be 1.5 times the design pressure
i) Recommended Hydrostatic Test Pressures are: (Refer project specific data for
correct values)
j) After completion of Stage IA Hydrostatic test the Boiler shall be drained and after
completion of Stage IB Hydrostatic test the Boiler shall be kept under
preservation.
4. SERVICES REQUIRED
a)

PRESSURE GAUGES: During testing at least two properly calibrated standard

test pressure gauges of suitable range are to be used. One of the gauges is mounted
at drum floor and the other near pressurising pump. The least count of the gauge
should preferably be 1kg /cm2.

b)

DM WATER: DM water of quality specified below containing 200 PPM of

hydrazine and having pH between 9.5 and 10.0 by addition of adequate quantity of
ammonia shall be used for Hydraulic test.
pH at 250 C

: 7 + 0.2

Conductivity

: < 0.2 mho/cm

Total hardness

: Nil

Total Silica

: < 0.02 ppm

Chloride

: Nil

Sodium

: 0.003 ppm

5.0 SAFETY PRECAUTIONS:

a) Readiness of stair-cases, platforms, hand rails, approaches etc., as decided jointly
by BHEL & customer at site in advance, should be ensured.
b) 24V lamps should only be used for internal inspection of the Boiler.
c) Delivery line of pressurising pump should be high pressure seamless pipe to
withstand the required test pressure.
d) 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 being raised. Medical
assistance should be readily available.

6.0 EMERGENCY PROCEDURES:

a) The testing team should be aware of the procedure to be followed in case of
accidents causing injury to personnel.
b) The testing team should be aware of the operating procedures of fire
extinguishers.
c) A person is to be posted at emergency push button and should have the
instruction to trip the pressurising pumps in the event of emergency being notified
to him by observers.
7.0 STATE OF THE PLANT :
a) Erection of the Boiler pressure parts is complete as per drawing. All necessary
welding jobs are complete, stress relieved and x-rayed. All Quality checks as per
approved Erection FQP are also complete. No welding including attachment
welding on tube will be allowed subsequently.
b) Filled & signed copies of FQP and Erection Protocols with exceptions highlighted
have been handed over to the testing group.
c) All necessary valves including drain valves installed and kept closed.
d) All safety valves are installed and hydrostatic plugs assembled before
commencing the test.
e) The root valves of the calibrated standard test pressure gauge impulse line are
open.
f) The isolating valves provided in all the other branching systems like Soot Blowing
system tapping, SH &RH spray connections, Pressure Gauges etc. are tightly
closed. Hydraulic test of Soot blowing system, SH & RH spray system etc. is
carried out separately at specified pressures.
g) All vents necessary to allow venting of entrapped air during filling operation such
as super heater link vents, economiser link vents, and drum vents etc. are open.
h) All the hangers in Boiler & piping system are set / locked as per recommendation.
i) Installation of the rotating elements of CC pumps should be deferred until the
hydraulic test of the Boiler has been completed. The pump casings must be
blanked off during the test.
j) Required peepholes & manholes doors of furnace and second pass are kept open
for inspection during Hydraulic test.
k) DM storage tank is ready for receiving and storing required quantity of DM water.
7

l) Boiler Fill pump, Pressurising pump, other temporary pumps and tanks of required
capacity are ready with their respective pipe connections to Boiler.
m) Adequate lighting for effective checking of all the areas including inside the Boiler
is available.
n) Effective communication facility is available between Drum floor, pressurising
pump area and other operating areas.
o) Sky climbers / Scaffolding arrangements are provided inside the Boiler.
p) Boiler drain is suitably connected to storm water drain/ DM plant neutralizing pit..
q) All debris are removed manually from upper and lower drums (Ring headers),
buck stays etc.,
8.0 METHOD OF CONDUCTING HYDRO TEST
8.1 AIR TESTING THE PRESSURE PARTS
a) Before filling the boiler with water, an air tightness test is to be performed to detect
leakages due to valve left in open condition, missing X-ray plugs; any cuts etc. not
observed by visual inspection. This will reduce the DM water consumption and
time as well.
b) Boiler is to pressurised with air up to 2 kg/sq.cm 2
c) Boiler is inspected and leakages, if any found, are attended.
d) After completing the air tightness test vent valves are left in open position.
8.2 FILLING OF THE SYSTEM FOR HYDROSTATIC TEST
Stage IA & IB
a) The boiler water circulation system, economiser and Super-heaters are filled with
DM water through boiler fill pump and injecting ammoniated hydrazine water
simultaneously using hydro test pump. The same HYDRO TEST PUMP
(Pressurising pump) is used for pressurisation after ensuring filling the
boiler without any air entrapment by adopting techniques mentioned in 8.2 b
to c. Economiser recirculation line valves should be in wide-open position.
b) Confirmation of completion of filling of the entire system is done through the vents.
c) The vent valves are closed and opened several times to allow venting of
entrapped air.
d) On completion of filling the fill pump may be kept running in recirculation to supply
water to pressurising pump tank.
8

Stage II
a) The Reheater circuit is filled with DM water containing 200 ppm hydrazine and pH
9.5 10.0 (with ammonia) through fill line connected to boiler drain header. At the
same time chemical dosing is injected by hydro test pump as shown in the
scheme.
b) Isolators provided in the CRH & HRH lines should be kept in position and perfect
closing is ensured.
c) Confirmation of completion of filling of the entire system is done through the vents.
d) The vent valves are closed and opened several times to allow venting of
entrapped air.
e) On completion of filling the fill pump may be kept on recirculation to facilitate filling
of pressurising pump inlet tank
8.3. PRESSURISING THE SYSTEMS
a) Pressure is raised with the help of pressurising pump
b) 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.
c) The pressure is raised up to 25 Kg/cm 2 and a thorough inspection of the Boiler is
done. For Stages IA & IB the pressure is raised in steps and held for 10 minutes at
100 & 200 Kg/cm2. The rate of rise of pressure should not be more than 10
Kg/cm2 per minute up to approximately 80% of the test pressure and should be 1
to 2 Kg/cm2 per minute beyond that value.
d) After reaching the test pressure, maintain/hold the pressure for 30 minutes.
8.4 HYDRAULIC TEST
a) The hydraulic test pressure reading is taken from the calibrated standard test
pressure gauge mounted near the pressurising pump with necessary correction
for the height of the Drum and simultaneously from the gauge mounted at a safe
location at Drum floor as per requirement of the statutory Inspection Authority.
b) The test pressure is maintained for 30 consecutive minutes in presence of
Inspection Authority.
c) The pressure is then reduced to 50 Kg/cm 2 and the entire pressure parts are
checked.

d) If leaks are found, it will be necessary to release the pressure and drain the
concerned portions. After the repairs the Boiler is refilled and the hydraulic test is
repeated.
e) Details of the leaks noticed during Hydraulic Tests are recorded as given below for
better understanding:

Exact location of leak(s) component circuit, Elevation, materials etc.

Description of leak(s) - straight tube, elbow, shop or field weld, torch-cut,

removed lug, attachment welds etc.

Magnitude of leak(s) - seeping/sweating, leaks, burn through, longitudinal

crack etc.

8.5. DEPRESSURISATION OF PRESSURE PARTS

The pressure parts shall be depressurised at the rate of 2 Kg/cm 2 per minute
a) While releasing the pressure the vents should be opened when the system
pressure falls to around 2 Kg/cm2 to prevent creation of vacuum in the system.
8.6. INSPECTION OF THE 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.
8.7. HYDROSTATIC TEST PROTOCOL
After successful completion of the Hydraulic Test, a joint protocol is signed
between BHEL & Customer.
9.0 PRESERVATION OF BOILER
Preservation of Boiler is done to protect the internal surfaces from oxidation..
Water wall, Drum & Super heater system
a) The Boiler is pressurised to 5 10 Kg/cm 2 with hydrazine and Ammonia treated
DM water containing 200 ppm of Hydrazine and sufficient quantity of Ammonia to
have pH value to 10.0 to 10.5 and retained at this value for preservation.
Approximately 1.5 liters of Hydrazine hydrate (80% concentration) per 100 tons of
water to make it 10ppm, for 200ppm 30 liters for 100 tons.
b) Drum water samples can be collected periodically say once a week or fortnight,
depending on the pressure holding worthiness of the system, tested for pH and
hydrazine content. Sampling point will be low point drain.

10

c) In case, the sample water does not meet the criteria for preservation of Boiler the
same is to be boosted up using Boiler fill pump and dosing arrangement and at
the same time venting sufficiently through the air vents in the top level of the
boiler.
d) No welding shall be carried out on pressure parts when the system is under
preservation or the system is filled.
e) Alternatively, preservation can also be done under nitrogen capping at 0.5 Kg/cm 2
by admitting nitrogen through vents of Drum and Super heaters.
Reheater system
a) Reheater system should also be preserved using treated DM water containing not
less than 200 ppm of Hydrazine and sufficient quantity of ammonia to have pH
value of 10.0 10.5 or by Nitrogen capping at 0.5 Kg/cm 2.
b) Reheater system should be filled through drain. Perfect isolation of the Reheater
circuit from Turbine should be ensured before pressurizing.
10.0 COMPLETION CRITERIA;
The test pressure in the official pressure gauge (Calibrated standard test
pressure gauge) is held for 30 consecutive minutes in presence of Inspection
Authority. The Boiler shall satisfactorily withstand such pressure without
appreciable leakage or undue deflection or distortion of its pressure parts for at
least 10 consecutive minutes

11

BOILER HYDRAULIC TEST

LOG SHEET NO. 1(CHEMICAL ADDITION)
PROJECT:
UNIT

DATE :

ACTIVITY: BOILER HYDRAULIC TEST

STAGE

QTY OF CHEMICALS
ADDED IN LITRE
DATE

TIME
AMMONIA
LITRES

BHEL

HYDRAZINE
HYDRATE
LITRES

ANALYSIS VALUE
AFTER DOSING
POINT
N2H4
pH
CONCEN.
ppm

CUSTOMER

12

LOG SHEET NO. 2(PRESURISATION)

PROJECT:
UNIT

DATE :

ACTIVITY: BOILER FILLING & PRESSURISATION & DEPRESSURISATION

STAGE

S.NO

BHEL

DATE

TIME

PRESSURE
HYDRO TEST
PUMP
DRUM
OUTLET in
ground level

REMARKS

CUSTOMER
13

LOG SHEET NO. 3 (PRESERVATION)

PROJECT :
UNIT

DATE :

ACTIVITY : BOILER PRESERVATION

CHEMICALS ADDED:

CHEMICAL VALUES ACHIEVED: ACHIEVED

i) Ammonia
ii) Hydrazene Hydrate

S.NO

i) pH
:
ii) Hydrazene :

SAMPLE
COLLECTED AT
SH VENT
DATE

BHEL

TIME

N2H4
CONCEN
.
ppm

SYSTEM
PRESSURE

CHEMICAL ADDED
AMMONIA
LITRES

N2H4
LITRES

CUSTOMER
14

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