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BOILER HYDRAULIC TEST AND

PRESERVATION

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TESTING OBJECTIVE
To ensure healthiness of pressure parts.
To preserve the boiler after hydraulic
test is over.

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TEST METHOD
The hydraulic test is carried out in two stages:
Stage I : Hydro test at a pressure of 1.5 times the
design pressure. (313.5 kg/sq.cm for 500 MW).
It will cover the Drum, Down comers, Evaporator,
Economizer and all Super-heaters up-to Boiler stop
valves.
Stage II: (78.6 kg/sq.cm for 500 MW )
It will cover the Cold reheat lines from Isolator , Re-
heater and Hot reheat line up-to Isolator.
Air tightness test to be performed before water filling
(at 2 kg/sq.cm. (g)) to detect leakages due to valves
left in open position, forgotten gamma plugs, any
cuts not observed by visual inspection etc.
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TEST METHOD
It is preferable to do the hydraulic test of the
complete Boiler (except Re-heater section) in one
stroke. If it is not possible to accomplish this, the
hydraulic test may be conducted in two sub stages.
Stage IA - Hydraulic Test of the drainable portion only
at a press 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.
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.
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Water Volume of Blr Parts: 500MW

Sl. No. System Water Volume (Cu.M)
1. Drum 60
2. Circulating System 178
3. Economiser System 95
4. Super Heater System 167
5. Reheater 173
6. Total 673

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Hydraulic test & preservation

Chemically treated water is filled in the Boiler
and hydraulic test is conducted at 1.5 times
the design pressure.
After successful completion of Hydraulic test
Boiler is drained and chemically treated water
is again filled. The Boiler is kept pressurized
for wet preservation.

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Services Required
Pressure Gauges: At least two gauges: one at
drum level, and other near pressure raising
pump. Least count of gauge should be 1 KG/CM2
Availability of DM water:
Quantity: 1400 cu. meter.
pH: 9.5 to 10.0 by addition of Ammonia & Hydrazine
200PPM
Temperature: 20< T< 50 deg
Chemicals:
Ammonia :175 litres(stg.-I) + 125 litres(stg.-II)
Hydrazene : 550 litres (stg.-I) + 300 litres (stg.-II)
For Preservation: Ammonia: 200 litres + Hydrazine: 600
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SERVICES REQUIRED (Contd./-)

Pressurising pump (reciprocating type) : Head
600 Kg/cm2 & Discharge: 50LPM
Boiler fill pump.
Power supply for the motors
Flood lights and 24V hand lamps
Communications system e.g. as walkie-talkie
sets, telephones etc.
Ambulance near test area

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State of the Plant

Erection of the Boiler pressure parts is complete as per drg.
including all required Welding, S.R., NDT
All necessary valves including drain valves installed and closed
All safety valves installed and gagged as per recommendation.
The root valve of the calibrated standard test pressure gauge
impulse line must be open.
All manhole closure plates should be closed and bolted or
welded tight.
The isolating valves provided in all the other branching
systems like S/Blowing system tapping, SH spray connections,
Pr. Gauges etc. have to be tightly closed
All vents such as super heater link vents, economizer link
vents, drum vents etc. shall be open.
All the hangers in Boiler & piping system are set / locked as
per recommendation .
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State of the Plant(contd./-)

In CC pumps, installation of the rotating elements should
be deferred
Keep the required peepholes., manhole doors in furnace,
second pass area open for inspection during Hydro Test.
Ensure the readiness of Boiler Fill pump
Ensure the readiness of Boiler Pressurizing Pump
Sky climbers / Scaffolding arrangements are provided
inside the Boiler
Ensure communication between drum level and
pressurizing pump area and other operating areas.
All debries are removed manually from drum, buck stay
etc.
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Air testing of pressure parts & Piping

Before water filling an air pressurization test is
performed to detect leakages due to valve left in open
condition, missing RT plugs, any cuts etc.
Boiler /piping is pressurized with air up to 2 Kg/cm2(g).
Before admitting air all vents / drains are closed.
Boiler/ Piping are inspected & leakages, if any found are
attended.
After air leakage test, vent valves are left in open
condition.

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Water filling for Hydro test

Boiler system are filled with DM water
containing 200 ppm Hydrazine, PH= 9.5 to 10
through filling lines connected to boiler drain
header.
Confirmation of completion of filling of entire
system shall be done through vents.
Vents are closed after removal of air.
On completion of filling, the fill pump may be
stopped.
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HYDRAULIC TEST
Pressure is raised to 25Kg/cm2 and a thorough inspection is
done.
Rate of rise should not be more than 10 kg/sq.cm (g) per minute
up-to approx. 80% of the test pressure and should be 1 to 2
kg/sq.cm (g) per minute beyond that value.
The pressure is raised in steps and held for 10 minutes at 100 &
200 Kg/cm2
After reaching the test pressure the pressurizing pump is stopped
immediately & power supply to pump is cut off.
The Final test pressure held for half an hour in presence of
Inspection Authority.
During holding time the official test gauge pressure reading
should not drop noticeably
The average pressure drop during first 10 minutes of stopping
the pressuring pump should be less than 1 Kg/cm2.

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HYDRAULIC TEST
After 30 Min holding pressure is reduced to 50 Kg/cm2 and entire
pressure parts/ piping are checked.
Wherever valves are in tandem both valves should be checked for
passing one by one by keeping one valve closed and other open.
If leaks are found, release the pressure and drain the concerned
portion. After repairs the boiler is refilled & hydro test is
repeated.
The pressure parts shall be de-pressurized at a rate of 1 kg/ Sq.
cm/minute.
Vents should be opened when the system pressure reaches
2kg/sq.cm
After completion of the hydraulic test, an inspection of boiler
inside and outside is made to ensure that the boiler has
satisfactorily withstood the test
After satisfactory hydro test entire Boiler is drained & joint
protocol is signed for completion of Hydro Test.
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PRESERVATION OF BOILER
Purpose: To protect the internal surfaces from oxidation.
Boiler pressure raised to 5 10 kg/sq. cm at drum with
treated DM water containing 200 PPM of Hydrazine and
Sufficient amount of Ammonia to raise pH value of 10.0
to 10.5.
Drum water samples collected periodically say once in a
week or fortnight & tested for pH and hydrazine content.
Criteria for preservation of Boiler :
i) PH : Not less than 9.0
ii) Hydrazene Hydrate : Not less than 50 PPM
iii) Drum Pressure : Not less than 2 kg per sq. cm.
Alternatively, preservation can be done under Nitrogen
capping at 1.5 Kg/cm2 at vents of drum and Super
Heater.
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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 should
satisfactorily withstand such pressure without
appreciable leakage or undue deflection or
distortion of its pressure parts for at least 10
consecutive minutes

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