PROCEDURE FOR HYDRO TEST OF BOILER

Boiler specification
Boiler water volume : 550 m
3
Total water req for hydro test : 500 m
3
Primary system : 440 m
3
DMST cap : 300 m
3
Boiler fill pump :
Chemicals use
ydra!i"e : #00ppm
$mmo"ia %0ppm
H!raulic test pressure
Primary system : %&5'(&P) %&5'%*&+* Mpa )#*&,-Mpa
RE"UIRE#E$TS FOR THE HYDRO TEST
.eed water pumps / 0/#00m head / #0o1s
Booster pump / % 32sc3mi"
4hemicals
%& ydra!i"e / #00ppm
#& $mmo"ia / %0ppm
Temporary ta"2 / %%m
3
Temporary li"2s /
Safety 5alve 6a7s / 3 "o1s
Pressure 6au7e / 0/40 Mpa %"o
0/%0Mpa %"o
CHEC%S FOR HYDRO TEST
8"sure all the errectio" a"d weldi"7 related to pressure parts is completed&
0o wor2 is pe"di"7
$ll the valves for steam a"d water pipi"7 should 9e i"stalled correctly&
Temporary facilities1 which are i"stalled duri"7 errectio"1 shall 9e removed a"d
clea"ed&
Prior to hydrostatic test 1 hydrostatic test plu7s must 9e i"stalled o" drum safety
valves:%0$6%0$$%*%/%*3; a"d super heater valves :%0<B$#0$$%*%/%*#; =0
accorda"ce with safety valve ma"ufacturer i"structio"&
Two cali9rated pressure 7au7es :0/45mpa;shall 9e used for hydro test &o"e
pressure7ua7e shall 9e located at the hydrostatic test pump a"d the other o"e shall
9e located at the hi7hest elevatio" i&e steam drum of the 9oiler pressure parts&
The systems for feedi"7 water1 9oosti"7 pressure1 drai"i"7 water 1all pipes which
are required for hydraulic test should 9e i"stalled properly&&
$ll the pro9lems to 9e ide"tified a"d solved 9efore duri"7 hydraulic test&
Pressure 7au7es for hydraulic test shall 9e cali9rated a"d completely i"stalled&
Safety precautio"s to 9e ta2e"
ydraulic test to 9e do"e u"der =B> re7ulatio"
Temporary systems comprisi"7 of ta"21 pressuri!i"7 pump a"d its dischar7e li"e
co""ected to 9oiler pressuri!i"7 poi"ts is complete a"d ready for operatio"&
PROCEDURE FOR HYDRO TEST
4lose the followi"7 valves
Eco i&l isolation / %0<$B4%$$00%/00#
<TS outlet li"2
Before starti"7 the filli"7 pump1 the delivery valve to 9e closed a"d the suctio"
valve 2ept ope"ed& The" ope" the dischar7e valve 7radually for filli"7 9efore
stoppi"7 the pump1 dischar7e valve should closed&
Before starti"7 the pressuri!i"7 pump it should 9e e"sured that the dischar7e
valve 2ept ope"&
The fill pump is feedi"7 the water to the temporary ta"2 a"d the feed water pump
feed the water to the pressure parts throu7h distri9utio" header drai" to the
9ottom ri"7 header to water walls drum 1<TS =3< T? <TS ?3< a"d also fill
throu7h the 84? =3< 8$D8> D>$=01 to 84? ?3< 8$D8> T? D>@M
?pe" the followi"7 valves
o Steam drum ve"t /%0$6#%$$50%/50#1
%0$6##$$50%/50#1
o 84? ?3< header <=0A ve"t M=5/$1B/ %0$4%0$$50%/50#/3 0o1s
$ll drai"s valves 1 i"strume"t root valves drum level 7au7e isolatio" valves T?
B8 4<?S8D
.ill the 9oiler throu7h feed water pump u"til as steady stream of the water over
flows from the steam drum ve"t valve :%0$6#%$$50%/50#; $0D 84?
8$D8> ?3< <=0AS 580T 5<5
The" chec2i"7 of the filli"7 of the e"tire system shall 9e do"e throu7h the ve"ts&
8"sure air eBhausts a"d water flows without air 9u99les1 close ve"t valves& stop
the fill pump&
(he" pressure reached to 3 2sc e"sure air ve"ti"7 completed&
4lose the steam drum ve"t valve :%0$6#%$$50%/50#; $0D 84? 8$D8>
?3< <=0AS 580T 5<5
Pressuri'in( the s!stem
The pressure shall 9e raised up 9y mea"s of pressuri!i"7 pump :9ooster pump;
The pressure shall 9e i"creased at a rate of "ot more tha" 32sc3mi" up to %*&+*
Mpa a"d record eBpa"sio"s& $"d also chec2 for lea2s
>aise the pressure to the hydrostatic test pressure #*&,- Mpa close presuri!i"7
pump outlet valve&
The pressure is held for #0 mi" duri"7 the holdi"7 time the official test 7au7e
pressure readi"7 shall "ot drop "oticea9ly&
The hydraulic test pressure readi"7 will 9e ta2e" from the cali9rated sta"dard test
pressure 7au7e located at the drum level&
The test pressure is the" reduced to "ot less tha" the maB allowa9le wor2i"7
pressure %*&+* Mpa C chec2 the whole pressure parts
& $fter accepta"ce 9y i"spector of qualifyi"7 the test 1the pressure is released&
=f lea2s are fou"d it will 9e "ecessary to release the pressure a"d drai" these
portio"s& Ma2e the repairs a"d refill the u"it as me"tio"ed a9ove a"d repeat
hydraulic test

SCHE#E FOR HYDRO TEST
There are two ways to fill the 9oiler:
%/ Throu7h eco i"let header drai"&
#/ Throu7h dow" comer distri9utio" header drai"&
Throu(h ECO inlet heaer rain:
The DM water from the temporary stora7e ta"2 is pumped i"to 84? i"let header
drai" throu7h feed water pumps&
The DM water from the 84? i"let header drai" flows throu7h the 8co"omi!er
coils a"d the" throu7h the 84? ha"7er tu9es i"let headers a"d the" flows throu7h
the 84? ha"7er tu9es a"d fi"ally to the 84? ha"7er tu9es outlet header &
.rom the 84? ha"7er tu9es outlet header water flows to the 9oiler drum throu7h
3 outlet li"2s&

Throu(h Do)ncomer istri*ution heaer rains:
The DM water from the temporary stora7e ta"2 e"ters i"to the dow"comer
distri9utio" header drai"s&
.rom there it flows i"to the 9ottom headers of the waterwalls throu7h the
fur"ace supply tu9es&
.rom the waterwalls the DM water rises a"d flows i"to the upper waterwall
headers&
.rom here the water flows to the drum throu7h upriser tu9es&
=" case of fur"ace rear water wall the DM water from the Bottom header
flows i" to the >ear waterwall a"d the" throu7h the >ear a"7er tu9es a"d
.ur"ace >ear arch&
.rom the >ear ha"7er tu9es the water flows i"to the >ear ha"7er tu9es outlet
header a"d fi"ally to the 9oiler drum throu7h the outlet li"2s a"d from the
fur"ace rear arch the water flows i"to scree" tu9es a"d the" to the outlet
header a"d fi"ally to the drum throu7h outlet li"2s&
Drum to Bac+pass ,alls:
The DM water from the Drum flows i"to the .ur"ace roof i"let header throu7h
the li"2s& .rom here it flows i"to the fur"ace roof a"d the" to the outlet header&
$"other li"2 from the .ur"ace roof i"let header flows i"to the 9ottom header of
Bac2pass 8DT side wall at > fi"ish&
.rom the .ur"ace roof outlet header the DM water e"ters i"to the Bac2pass upper
left a"d ri7ht wall headers& .rom here the water flows throu7h the walls a"d
fi"ally to the Bac2pass 9ottom ri"7 header&
$lso the water from the Bottom header of Ba2pass 8DT sidewall at > fi"ish
rises throu7h the Bac2pass 8DT side walls a"d e"ters i"to the upper eader a"d
from there it flows to the Bac2pass upper left a"d ri7ht wall headers&
The water from the Bac2pass 9ottom ri"7 header rises throu7h the Bac2pass fro"t
a"d rear wall& .rom the Bac2pass fro"t wall it flows i"to the upper header a"d
the" throu7h the Bac2pass roof wall a"d fi"ally e"ters i"to the <TS i"let header
throu7h upper rear walls&
Mea"while the water from the Bac2pass rear wall rises a"d e"ters i"to the <TS
i"let header throu7h the lower rearwall&
$"other li"2 from the Bac2pass fro"t 9ottom header e"ters i"to the Bac2pass
8DT side wall at S fi"ish i"let header from where it rises throu7h the 8DT side
walls a"d to the outlet headers from where it fi"ally Eoi"s i"to the Bac2pass upper
fro"t wall header&
0ow the water from the <TS i"let header flows throu7h the <TS coils a"d the"
fi"ally to the <TS outlet header which completes the primary circuit for
FD>? T8ST&