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ER. J.K.

BAGHEL ASSISTANT PROFESSOR

PURPOSE : To check the reliability of the boiler at higher pressure. Also statutory requirement yearly in presence of the boiler inspector. Recommended hydro test pr. for 250 MW boiler is 263 Kgs./cm2 and that for Reheater circuit is 70 Kgs./cm2.

To LTSH w w w SV - 01 SV - 03 SV - 02 VENT

Gauge Glass
Hydra Step

VENT

DRUM
Drain

Drain
DOWN COMMER Front Water Wall Right Side Water Wall Ext. Water Wall Left Side Water Wall Rear Water Wall DOWN COMMER

Chemical Dozing line

CBD EBD To IBD tank CBD sample line

LEFT

F R O N T

FURNACE
RIGHT

R E A R

ECO O/L HEADER E 024


c

ECO I/L HEADER

BOILER DRAIN HEADER

FEED CHECK VALVE


FEED WATER SAMPLE LINE

From Feed Control Station


Eco Filling Line

PROCEDURE Boiler Filling (using boiler fill pump) a) Line up boiler fill pump. b) Open filling line valves at low point drain for water wall and economizer .

c)

Open Drum and super heater vent valves

d) Close CBD, IBD and EBD valves, close sodium phosphate dozing line valve. Isolate Gauge glasses and Hydrasteps.

e) Isolate all the transmitters and instruments except drum pr gauge (range 400kgs/cm2).
f) Gage the drum and super heater safety valves, Spring loaded header supports.
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PROCEDURE

g)

Close the boiler outlet Valves along with their Equalizing valves.

h) Close the drain valves of all the Super heaters headers. i) Ensure that all men and materials are removed from boiler and also record clearance from concern erection/maintenance executive. Ensure sufficient water level in CST. Open suction valve and close the discharge valve of the fill pump, vent the pump completely. Start fill pump, allow to stabilize.

j) k)

l)

m) Gradually open the discharge valve fully and control valve slightly, allow the water to enter to the boiler slowly.
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PROCEDURE

n) While filling the boiler intermittently check CST level, pump performance. o) Meanwhile connect Reciprocating pump with Low point drain header with discharge valve closed and fill the water tank completely. p) As soon as the water comes out of the vents of economizer, super heaters, and drum, close them one by one. q) As soon as drum pr. Reaches around 10 KSC stop the fill pump. Close suction and discharge valve.

r)

Line up the reciprocating pump and start it.

PROCEDURE

s) t)

Gradually increase the pressure up to the prescribed limit (263 Kgs/cm2). Stop the reciprocating pump and check the boiler pressure parts thoroughly.

u) Any major/minor leakage should be marked. v) Reduce the pressure gradually by opening some drain.

w) Open drum, super heater economizer, LTSH vents.

x)

Drain the boiler completely.

QUALITY OF WATER A. D M WATER SPECIFICATIONS 1. 2. 3. 4. 5. 6. 7. 8. PH at 25oC Elect. Conductivity Total Hardness Total Silica Chloride ppm as Na Cl Sodium ppm as Na Organic matter General appearance heziness 7+_ 0.2 Less than 0.2 micro mho NIL Less than 0.02 ppm NIL Less than 0.003 0.2 ppm as on average Clear, free from odour, colour and
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B. QUALITY OF TREARED DM WATER OR TREATED CONDENSATE The DM water or condensate treated with 10 ppm of Ammonia and 200 ppm of Hydrazine to have pH value of approximately 10. C. QUALITY OF BOILER WATER

Total dissolved solids


Sp. Elect. Conductivity at 25oC Phosphate residual ppm PH at 250C Silica

25 ppm
50 micro mho 5-10 9.1 9.8 0.02 ppm in drum leaving steam

D. QUALITY OF FEED WATER Hardness PH at 250C NIL 8.8 9.2

Oxygen (max) ppm


Total Iron ppm Total Copper ppm Total CO2 Total silica ppm

0.007
0.01 0.005 max NIL 0.02

Sp. Electric conductivity


Hydrazine residual ppm Oil

0.3 micro mho


0.01 0.02 Not allowed
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WATER VOLUME Generating Surface 130 M3

Drum
Super Heaters Reheater Economizer Total

35 M3
95 M3 50 M3 25 M3 335 M3

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PRESANTATION BY ER. J.K.BAGHEL ASSISTANT PROFESSOR JIPT/TAMNAR, RAIGARH(C.G.) +91 7898905254 DATE:- 17-05-2012

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