ST-1 BOILER HYDROTEST CHECKLIST DURING SHORT SHUTDOWN

UNIT: DT:
Sl no Status for Location Dept Normalisation
LOCATION: TURBINE SIDE Hydrotest required for BLU
1. CRH line manual drain before and after NRV (Atm drain) Open 0m ME NR
4NOS
2. MS line manual drains (Atm drain). 4NOS Open 0m ME NR

3. HRH line manual drains (Atm drain). 4NOS Open 0m ME NR

4. Hot Well normal and emergence makeup valves 8 + 2 + 1 Lineup 0m ME CI NR

EL
5. HPBP drain pot drain manual valve (HPBP 13/14/17/19) Close 0 m AFT ME Open for BLU
4NOS
6. CEP discharge to boiler fill line manual isolation valve Open 0m ME close after filling

7. MDBFP C Reheater spray isolation valves Close 8.5m ME

8. MDBFP C R/C CV air line disconnection (Air fail to open) 1+1 Open 8.5m ME CI Normalize

9. TDBFP A&B warm up isolation valves 2 + 2 Close 17.5m ME EL Open for BLU

Sl no Status for Dept Normalisation required

LOCATION: BOILER SIDE Hydrotest for BLU
5.5M BOILER FLASHTANK
1. RH drain header master drain (WDV 0153HV). Open ME NR (Not required)
2. SH drain header master drain (WDV 0151HV). Close ME NR
3. WW drain header master drain (WDV 0152HV). Close ME NR
4. Spiral WW inlet header drains (WDV109, Close ME NR
110,127,128,111,112,129,130) 8NOS
5. Boiler flash tank spray water line main & bypass valves 3 + 1 Close ME CI Open for BLU
LOCATION: 26M BOILER DRAIN HEAGER
6. Eco-1 (FW pipe) drain (WDV0099, 0100HV) 2NOS Open ME Close after filling
7. Eco-2 inlet header drain (WDV087, 088HV) 2NOS Open ME Close after filling
8. Spiral WW O/L header drains, 4nos(WDV101 to108HV) Close ME NR
9. Heat exchanger drains, 2nos (WDV89, 90,91,92HV) Close ME NR
LOCATION: 40M/43M/50M BOILER FRONT
10. HPBP warm up manual isolation valves, 4nos Close ME Open for BLU
11. HPBP upstream drain pot drains, 8nos(LHS / RHS) Close ME NR
12. HTRH I/L header drains (WDV57 to 60HV) 4NOS Open ME NR
13. HPBP spray line manual isolation valves, 2nos(LHS /RHS) Close ME Open for BLU
14. All ERV isolation valves. MS ERV 4NOS Close ME Open for BLU
LOCATION: 92M BOILER FRONT
15. Roof header vents, (WSE0723, 0724HV) 2NOS Open ME Close after filling
16. ITSH to Soot blowing manual isolation valves, 2nos. Close ME Close for BLU
LOCATION: 70M BOILER FRONT
17. HTSH manual vent valves (WSE0701, 702,703,704HV) 4NOS Open ME Close after filling
LOCATION: 12.5M BOILER FRONT
18. Boiler fill valves, 2nos (WDV0154, 157HV) Open ME Close after filling
19. RH SPRAY STATION 8 + 8 + 9 ME EL CI
20. HTSH SPRAY STATION 8 + 8+ 9 ME EL CI
21. ITSH SPRAY STATION 8 + 8 + 9 ME EL CI
IMPORTANT NOTE DURING HYDROTEST
 Open ANB slowly up to 15% to establish flow through Boiler, which is required to safe running of the BFP without
vibrations, and to control rate of pressure raise and safe suction flow of about 500t/hr.
 Rate of pressure raise: 2Ksc/ min
 Hold the boiler pressure at 140Ksc for safety valve gagging.
 Pressurize up to 210Ksc and hold it for 10min.
 Reduce the pressure to 85Ksc and hold it for checking any leakage.
 Take XT plot of separator and MS pressure.
 Rate of pressure drop during depressurisation is 3 to 5 Ksc /min.

Sl Status for Location Dept Normalisation

LOCATION: UCB Hydrotest required for BLU
1. Separator vents (UV610A/B) 2NOS Open 92m Close at 2ksc EL Open for BLU
2. ECO 1&2 vent valves (UV 603A/B, 604A/B) 4NOS Open 92/81m Close after filling
EL
3. RH vent valves (UV0201A/B) 2NOS Open 43m EL NR
4. Heat exchanger bypass valves (UV602A) Open 40m EL Close for BLU
5. Economizer I/L isolation valve (UV 601) Open 40m EL NR
6. ITSH drain valves (Uv1001A/B, 1002A/B) 4NOS Close 5.5m EL Open for BLU
7. MS drain before stop valves (UV1003A/B, Close 5.5m EL Open for BLU
UV1004A/B) 4NOS
8. MS stop valves with IBV (UV101A/B/C, Close 40m P/S off EL Open for BLU & P/S
UV102A/B/C) 6NOS off
9. HPBP valves (LBF 10/20/30/40) 4NOS Close 43m Local locking CI Open for BLU
10. HPBP warm up valves (LBF10/20/30/40AA001) Close 43m P/S off ME P/S normalise
4NOS
11. HPBP drain pot drains (HPBP13/14/17/19) 4NOS Close AFT P/S off EL Open for BLU
12. MS to APRDS isolation valves with IBV Close APRDS P/S off EL NR
(UV0101A/D) &B/E 4NOS
13. CRH to APRDS isolation valves with IBV Close APRDS P/S off EL NR
(UV0202B/E) &A/D 4NOS
14. ITSH to soot blowing isolation valves (ASB Close 92m P/S off EL NR
UV0001A/B) 2NOS
15. AA/AN/ANB isolation valves (CSC 0606A/0607A, Open 0m&D/A CV close & NR
0608A) 1 + 3NOS manual CI EL
16. CRH /HRH drains (CR024/025,HR011/013) 4NOS Open 0 mtr EL NR
17. TDBFP A&B discharge valves 2NOS Close 8.5m P/S off EL P/S normalise
PROTECTIONS TO BE BYPASSED
1. MDBFP tripping from separator level high high and no drainage. Normalise
2. AA/AN valves forced closing from condenser pressure high. Normalise
3. HPBP locking in close condition by C&I. Normalise
4. MDBFP-C R/C valve airline disconnection in open condition. Normalise
OTHER SYSTEMS READYNESS
1. LPBP ready (Control fluid pump in service).
2. Bottom ash hopper drained and circular manhole open.
3. ECW system in service (CLCW&DMCW).
4. Instrument air supply is available.
5. AA/AN/ANB oil supply units in service.
6. One CEP in service.
7. MDBFP C is available for service.
8. MS O/L steam temperature LHS/RHS (ST233/234) to be < 150deg., MS
header steam temp ST235<100°C, MS Y-piece 100% metal temp
BT212<100°C
 QUALITY OF WATER FOR HYDROTEST
1. Hydrazine >200ppm
2. Ammonia: Sufficient to obtain PH >10.5
3. Feed water temperature: >20deg
CIRCUIT VOLUMES
1. FW lines: 5.8 Cub meter, Economizer: 163 Cub meter, Evaporator: 97 Cub
meter, Separator: 8 Cub meter (Total 273.8Cub meter),
Con/CST/FST: 500/800/280 Cub meter.

HYDRO TEST VALVES STATUS

BOILER BMD EMD C&I OPRN REMARK
VALVES DEFECT
TOTAL /55 /55 /33 /
NO.S:
166

HYDRO TEST VALVES STATUS

TG VALVES TMD EMD C&I OPRN REMARK
TOTAL DEFECT
NO.S /19 /19 /5 /
53

BMD TMD
MANUAL V/V 78 29

ME-MECHANICAL
EL-ELECTRICAL
CI-C&I