Doe No. Qua Date: TMBICMOTEIRE Hydrostatic test procedure 792012 Boiler Hydrostatic TestDoe No Qua Date TINBCMIOTARE Fiydrostalie test procedure Tm Table of Contents 1. Preliminary Work 1L1 Completion of all work 1.2, Terminal points 13 Temporary Equipments 1A.Chemicals Required 1.5.stimated Quantity of DM water required 1.6. Customer Inputs required 2. Hydrostati Test of Bolter : ee 2.1 Testing Pre-requisites 22. BCP fillpurging 23. Backwashing of soperhester, 2.4 Water Washing of Main Boiler 2.5.Water Filling 2.6 Pressrzation ‘3 Dewatering and Boiler preservation 3.1 De watering & Boiler Preservation 4, Annexare 41 Hydro Test pressure Char for Boller ‘42 Temporary Installation Scheme 43.8Hydeo test Scheme for Main Boiler 2Doc No, Qua TMBIOMOTETR Hydrostatic test procedure ‘7092012, 1. Preliminary Work 1.1 Confiem thatthe test procedure is established. Confirm that the all wos necessary for the hydrostatic test are complete, 1.2, TERMINAL POINTS : “The terminal points for Boiler Hydro test are shown below: UNDARY S.No. BOILER TAG No. scope __| conommion Blanking to i be done 500 mmm ater TP- Boiler feed water ine : trenuns _|01-BE-601 ‘MAIN STEM STOP VALVE ae, 2a BOILER LEFT SIDE STOP VALVE OrLBADIAADIO wo cose 2» | soWeR AIGHT SiOE STOP VALVE orsaosaaor 106 cose AUXILLARY STEAA ISOLATION VALVE 3_| FROM PrinaRy SH O/L HEADER susszoanoo1 uP. cose AUXILLARY STEAA ISOLATION BYPASS 4 [VALVE FROM PrivaRY SH O/L HEADER | sLaAz0M011 ue. cose SOOT BLOWER PCY (FROM BOILER ) 5_| INLET NoToR VALVE" oceotaaoot my chose Blanking to be done at TPOLBE. 607 and TP. 6 |woc tine zs 16 (01-BE-608 31Do No amu Date: TCMBICMIOTIRE | | Hydrostatic test procedure Oe 1.3. TEMPORARY OUIPMENTS: Prope all necessary equipment and materials for boiler as well as re heater hydrostatic test as shown below TEMPORARY EQUIPMENTS LIST 5.NO. eM SPECIFICATION. avy. REMARKS + [pressurize pump E 4 No.) ‘Tobe sufficient for As per 2__| TeNPORARY LINE AND VALVE test Annexure 4.2 ‘As per 3 | temporary Tank. a sno. | Annexure 4.2 Calibration certificate shall PRESSURE GAUGES be submited. HT PUNP DISCAHRGE (P62), {0-800 Kg/em2) 10. 4 [WSequsiNG UNE(eG 3) {0-800 Ke/em2) 0. NAN STEAM LINE BEFORE STOP VALVE (PG PG 5) 0-800 Kg/em2) 20, AIR LEAK AND NITROGEN PRESSURIZATION( PG 11) (0-10 Kg/em2) 110. 4Dow | Gm Date EMB/CMIO7SR Hydrostatic test procedure or.092012 1.4 CHEMICALS REQUIRED: ‘The Chemicals to be used during hyo test isa per below table: Chemical concent | estimated so ration in | quantity of Process Name _| “water” | waterim3) Remarks Backwashing of super | Hydrazine | 500 ppm 1. | heater ‘Ammonia [10pm | 175 |pHo-9.5 Water wathing of boiler | ydraxine_| 200 ppm 2_| (Purnace, Eco.) ‘Ammonia | 10ppm | 330 _|pH9- 9.5 Water filling and hydro | Hydrazine_| 500ppm_ 3 |testofmainboiter [Ammonia | 10 pom | 485 | p9-9.5 Hydrazine | 500ppm ‘Ammonia | 10 ppm ‘Ammonia | 10 ppm ‘Ammonia | 10 ppm 4_| ace Fi purge ‘ammonia _| 10 ppm pi -9.5, Neutralization of Double the amount of Drained water during | Bleaching hydrazine used with 100% 5._|eraining main boter™ [powder 435 | concentration s| 5, ESTIMATED QUANTITY OF DM WATER ‘The estimated quantity of DM water required during hydro test of main Bilr is 3000 m3 oiler approx.Doe No, Qua Date EMB/CMIO7SIRZ Hydrostatic test procedure (07.09.2012 1.6, CUSTOMER INPUTS REQUIRED, NO, TEM SPECIFICATION] QTY. REMARKS 1 CONDENSATE STORAGE TANK (C57 NO.( AN) 2 [soWeR FLL PUMP, 41NO. CON.) isparF eID 3} sover Fu une s7o00-2144-2 FOR DRAIN PIT OF BOILER FLASH TANK [NEUTRALIZATION 4 | DRAIN PIT & WATER DISPOSAL to. | OF DRAINED waTER SYSTEM DURING HYORO. rest 2. Hydrostatic Test of Main Boller The hydro test pressure for the main boiler = 408 kglem2 (9) ‘The various activities tobe performed: 2.1. Testing Pre requisite: «+ Check the pressure pats o be hyd tested have been erected in altspect and clearance to conduct hyo test has boon obtined frm all concomed «+ Please ensure that belore commencement ofthe tes, no works going on nso the boler Clearance Cariiate’ shall be signed off by al pares before the tos, ‘+ Proper iluination i avaiable around the bolle, insde boller and areund temporary Syston, «+ Proper communication systom is avaiable. «+ Safely checks have boon carried out as per HSE gudalin. ‘+ Scatfoing, ahs, and repair tools re tobe ready atthe ime of hysstatictatng «+ Allpumps tal poration must be ensured ‘+ Required quanti of chomicals(Hydrazine & Ammonia) shal be ada in CST (Condensate storage Tank) manualy and re-crculated for proper ming before fling the water to bei.Doe No Quu Da EMBICMOTSR Hydrostatic test procedure 7092012 ‘+The tomperature of Dk water tobe uted shoud be maintained between 20°C and sore, + BP Ail purge water wil be reqied upto the ight up of bole 2.2. BCP fil purging ‘Baller circulating pump (BCP) casing along with ts motor need to be erected as per the procedure commanded by BCP supplier Porto bole fling, BCP fifpurge system i o be commissioned and BCP should be filed {28 per filngprocadure recommended by BCP supper Since permanent filpurge may not ba ready during boer hydro tet, a temporary BCP {purge Ine Isto be connected rem Botor i ina to permanent BCP fang ine coming fom condensate pump, sm shouldbe kept ON dur purge 8 2.3 Backwashing of Superhester Tho Tetlary super heater & secondary super heater are to be back fished wth hydrazinated DM water( Hydrazine =600 ppm , pH=9~8.5) til the turbid i less than 10, pm and chorne less than 0.2 ppm at Sampling points(S) shown in attached Annexure 6.4 24 Water washing of main boiler: ‘Simarly the economizer, water wall and back pass wil be fished with OM water (ydrazine= 200 ppm, pH=5-8.5) The fushng willbe completed unt diferent turbidity | not more than 10 ppm and C! in water is not more than 0.2 pom at Samping points(S) hav in attached Annexure 43 5. Water iting Now the bole is filed wth hyérazinated OM water( Hydrazine =500 ppm. pH=9-2.5) ‘During fing, monitor ail the vents and ensure that al ar entapment has 2een completlyDoe No Qua Date EMBICMOTIRE Hydrostatic test procedure ‘7092072 8) released and the lest cult is completly filed with water. Mer proper ar vating lose the vent vate, 2, Pressurzation Inia pressurize the boll using bor fil pump to maximum possible pressure, Thereafter further pressurizing wil be done using temporary pressuring pump. The recommended pressurizing rate shuld be 2— 3 Kalem2 per minute as per attached Annexure - Hydro test pressure chart ‘+ Once the test pressure is achieved, Koop the system under tes pressure for 30 ‘inue and then decrease the pressure to operating pressure. Chck the system ‘horoughiy + During de pressurizing of Boller, reduce the pressure through the reccul Valve in the pressurizing pump or the drain valves. The rate of pressure ocroased shall be 35 Kglem2 por minutos per attached Anrewure-6.1. After the pressure reaches 35 Kglem2 open the ar vents one by one or daiing the boiler, required ‘Thereafter boler may be preserved as por the baller preservation procedure 3. De-watering and Boiler preservation 3.1. Dewatering After the successful completion of Boller hycrostatic test, boiler may te preserved or ‘rained as per site requirement. ‘The waste wator dischargod from the boller shall be treated in neutralizing pit for proper neutralization of boiler discharge before disposal of the same.oo No Qua Date TMBCMTOTIRE Hydrostatic test procedure Trova HYDRO TEST PRESSURE CHART deol “es nesuunE Men) 9)* oo ay —— a Se = eee = | came me