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Blast Furnace

ESSAR-HAZIRA
FURNACE LEAK TEST
WITH COMP. AIR
STAGE I
(Draft)

CONTENTS

1. Introduction mandatory
2. Safety Precautions
3. Design Basis
4. Definition of area to be tested
5. Test Description
6. Leak test pre-checks
7. Leak Test procedures
8. Manning
9. Tools

1. introduction mandatory:
The aim of the test is to check the flanges and seals on the, Cold blast system,
Hot blast system, Bustle main, Furnace and Furnace top, dust catcher system up
to venturi-I at a pressure of 0.6kg/cm2 and the Clean gas mains at a pressure of
0.01 kg/cm2 and later up to 2.0kg/cm2
Compressed air blower will be used with the furnace pressure being controlled
using ASU valve operating supply position. The air will be exhausted to
atmosphere through the bleeders decided at ASU, furnace top and dustcatcher
The test will also allow the Commissioning Team to simulate the operation of the
various equipments involved and so check any operational features prior to blow
in. All designated Operation/mechanical/E&A must necessarily be nominated and
be prepared wrt their respective areas equipments.
It will also enable ESSAR personnel to familiarise themselves with the operation
of the equipment.
Complex and integrated pressure testing of ESSAR BF shall be done with cold
blast with furnace design test parameters taking from snort up to septum valves
via total GCP involving all operations of equipments after they are tested.
2. Safety Precautions
1. In order to prevent possible damage to the furnace lining the furnace top
bleeders will be set in automatic 0.15 kg/cm2 above the test pressure. The
bleeders will also be set to open if the pressure in the Pipe Mains & at
furnace top/dust catcher exceeds 0.15 kg/cm2.

2. In the event that the automatic system fails, the bleeder valves will be
opened in manual from the control desk.
3. In the event of the bleeders failing to operate, the ASU supply stopped
and bleed valve will be opened.
4. If all these operations fail, the blower will be shut down by signalling to the
compressor house.
5. All parties on site will be appraised about the location and timing of the
leak test.
6. Display signs Danger Pneumatic Leak Test in Progress to be installed
at strategic places and sirens to be given before start and after finish.
7. Clear outdoor areas of limited access zone of all unnecessary personnel.
And cordon the area with RED Ribbon as a safety precaution. Safety to
look after the safe measures.
8. Position watchers in strategic positions to keep unnecessary people out of
the limited access area.
9. Provide free and safe access to all joints to be inspected, during the leak
test.
10. To provide First aid and ambulance at site
11. If the leak test is done during the night, then lighting must be sufficient to
allow proper examination of the equipment.
12. Brief all personnel involved in the test.
13. Prior to the leak test carry out a visual inspection of the system to be
tested to ensure all parts are securely bolted, manhole covers are on etc.

14. Do not use any tools on any fittings whilst the system is under pressure.

3. Design Basis
The basic design data for leak test is detailed below:
1. Test Pressure
Furnace (Three tests)
1.

Approximately 0.1 kg/cm2 bleeders open and hold it for 15


min, after to determine major leaks

2.

0.4kg/cm2

3.

0.6 kg/cm2 and later 2.00 kg /cm2

Dust-catcher-up to venturi - I inlet:


0.01 kg/cm2 initially and so on.

2. Test Medium
Comp.Air from the compressor house will be used. Flowrate initially to be
1000 nm3/min and then to 2000 Nm3/minute.
3. Test Duration

Each Test 4 hours.


4. Bleeder Valve Settings
1.

0.25 kg/cm2

2.

0.55 kg/cm2

3.

0.85 kg/cm2

4.

and later with 2.25 kg / cm2

4. Definition of area to be tested

The following area will be tested for leaks.

Cold blast Main


Flange joints a n weld joints and man holes if any (Check stoves
heating not disturbed)

Hot Blast Valves and Branches, Hot Blast Main and Bustle Main.
Flange joints and manholes.

Tuyere Stocks
All Flange joints and seatings of tuyere, blow pipes and TC.

Furnace Proper
Welds on all furnace penetrations, all detection hole flanges and
all man holes and all thermocouples slots, probes/sampling slots
All Flange Joint and all cooling system washers and joints

Furnace Top
Furnace Top Valve Chest(goggle valve of BLT)
Bleeder Valves, man holes
Cone doors/Access doors/Hatch covers
Stockrod/Radar profile meters
Flanges
Uptakes, Offtakes and Downcomer and all liner plate bolts/nuts
and washers

Cyclone
Access doors
Flanges

Dust catcher
Access doors/manholes/bleeders
Flanges and all liner bolts and washers

Clean gas main in let at Venturi-I


Access doors
Flanges

5. Test Description

5.1 First Leak Test


First leak test at 0.1 kg/cm 2. This is undertaken with all the bleeder valves open
for some time to flush and continue. This test enables major leaks to be

identified. Wind to the furnace is then safely isolated and any major leaks are to
be rectified. If no major leaks are identified, the Second Leak Test can follow
immediately provided personnel are clear of the Limited Access Area.
5.2 Second Leak Test
Second leak test at 0.3 kg/cm2 with the dust catcher to Venturi-I cone providing
the furnace back pressure and with bleeder valves closed. The furnace pressure
will be increased to 0.6 kg/cm2 and held for 15 minutes with personnel excluded
from the test area. After 15 minutes at 0.6 kg/cm2, the pressure will be reduced
back to 0.3 kg/cm2 and testing personnel will be given access to the area to
identify leaks. When leaks have been identified, wind to the furnace is then safely
isolated and the leaks are rectified.

5.3 Third Leak Test


Third leak test to 0 .6 kg/cm2 with dust catcher to Venturi-I cone providing the
furnace back pressure. The furnace pressure will be increased to 0.6 kg/cm2
gauge and testing personnel will be given access to the area to identify leaks.
When leaks have been identified, wind to the furnace is then safely isolated and
the leaks are rectified. The test is repeated until all leaks are eliminated and later
to proceed for 2.0kg/cm2 gradually.
6. Leak test pre- checks
6.1 Blast System & Stoves
1. Ensure the Cold Blast Main from the TOP to the Stoves is complete and
checked for internal debris.
2. Ensure the Hot Blast Main and Bustle Main are complete and checked for
internal debris.
3. The furnace snort valve is installed and fully commissioned/blanked.
4. The blower at ASU is fully operational.

5. The blower signalling is fully operational.


6. Ensure the stove valves and instrumentation are operable.
7. The Hot Blast Main tie rods are put in the correct position and all
manholes/all slots are to be closed and ensured.
8. Since stoves are on heating, check thoroughly and ensure the closures of
cold blast and hot blast valves perfectly in-order to safe guard heating
process and avoid untoward incident
9. Close the back draft valve.
10. Apply blanks only wherever necessary.

6.2 Furnace Proper


1. Both taphole outlet pipes to have a blanking plate, positioned outside the
furnace.
2. All furnace water systems to be commissioned and balanced as follows:

Staves operational/status isolated.


Tuyere High and Low Pressure operational/status isolated
Underhearth Cooling isolated.
Top Cone Shower Cooling isolated.

3. Furnace and hearth thermocouples to be operable.


4. Furnace stack pressure transmitters to be on.
5. All 4 above burden temperature probes to be installed
6. Close all bustle ring and blast main man holes/install thermocouple slots
are closed or installed with thermo couples
7. All down legs, tuyeres and tuyere stocks installed and checked for
obvious leaks. Ensure glass peep sights are installed.
8. Ensure that all furnace grout sockets /detection holes have been blanked/
plugged and welded.
9. Ensure the hearth thermocouple flanges have been checked for bolt
tightness.

6.3 Furnace Top


1. Ensure the Furnace Top goggle valve is open.
2. Ensure the upper seal valves are closed.
3. Ensure equalising and relief valves are closed.
4. Ensure mechanical stockrods are raised and isolated.
5. Ensure the radar/ Stockrods have the nitrogen purge on valves closed .
6. Ensure the Furnace top BLT isolated.
7. The N2 purging to the dome/up-takes are closed.
8. Ensure uptake pressure transmitters and thermocouples are operational.
9. Ensure the ignition lance isolation valve is closed, and the hydraulics
isolated.
10. The furnace top charging system isolation
11. All manholes and doors to be closed.
12. Furnace Top bleeders to be fully commissioned.
13. Ensure all platforms are thoroughly cleaned of any muck, scrap or
scaffolds etc.
6.4 Dust catcher-inlet of Venturi-I
1. Ensure all manholes are closed/ fully sealed
2. Ensure the purging isolation valves to the dust catcher and uptakes are
closed.
3. The furnace cutt-off valve, bleeder valves on cut off valve side and on raw
gas line side are to be fully commissioned. This are to be fully operable
in automatic and manual, with respect to the top pressure control.
4. Ensure all relevant manholes are closed.
5. Ensure all mains are inspected and debris removed.
6. shut-off valves/Goggle valve closed
7. Blank plate to be given at inlet venturi-I and Cone removal door open

7. Leak test procedure

7.1 First Leak Test


1. Close the snort valve (if included) or (ensure blank that side)\ close air supply
valve to the furnace.
2. All stoves are boxed/isolated completely and safe guarded with all precautions.
3. Open all 3 bleeder valves and dust catcher bleeders.
4. Top gas pressure regulation to be activated and set at 0.1 bar
5. Start the blower slowly open the blower valve and call for 1000-2000 Nm 3/minute
and snort/or any means to atmosphere for about 30 minutes.
6. open cold blast mixing main./ take cold blast to the furnace through mixer
valve/tuyere stock .
7.

Gradually open the snort valve/air supply valve until fully open so that Blower to
deliver 2000 Nm3/min.cold blast /air will pass to atmosphere through the
bleeders. This will enable the majority of the leaks to be checked.

8. Check will be physically done by putting on the indicated points a solution

of water and soap (or equivalent) so that bubbling due to leaks will be
easily seen. Leaking point will be registered on the relevant paper sheet
and the leaking point will be marked with red paint.
9. During the same period, eliminate all possible leaks not requiring a

reduction of blast pressure. Once one leak is eliminated, the same must
be deleted from leaking points paper sheet and red paint must be
removed. For leakages not to be fixed during this operation follow point
no. 10.
10. After the leak test close the snort valve to the furnace and close the stove
valves until the leaks are fixed.
11. Check for leak free closing of bleeders. By opening and closing them in

sequence for short periods.

7.2 Second Leak Test


1. Snort valve/air supply valve closed to the furnace.
2. All stoves are boxed/isolated completely and safe guarded with all
precautions.
3. Open all 3 bleeder valves and dust catcher bleeders.
4. Start the blower and slowly open the blower valve and call for 1000-2000
Nm3/min. Snort/bleed to atmosphere for 10 minutes.
5. Open cold blast mixing main./ take cold blast to the furnace through mixer
valve/tuyere stock .
6. Gradually open the snort valve/air supply valve to the furnace.
7. Close each bleeder at one minute intervals. Bleeder relief set to 0.55
kg/cm2.
8. Close the bleeders at top/DC gradually in manual until 0.3 kg/cm2 furnace
top pressure is achieved.
9. When the furnace top pressure has been achieved, check the pressure at
dust catcher and at inlet of venturi-I is ok.
10. Check for furnace, furnace top, uptakes, down comer and dust catcher
plant leaks.
11. When the leak checks are completed close the snort valve/air supply
valve to the furnace and box Stoves. Leaks are to be then fixed/rectified.

7.3 Third Leak Test:

1. Snort valve /air supply valve closed to the furnace.


2. All stoves are boxed /isolated completely and safe guarded with all
precautions.
3. Ensure all 3 bleeder valves open and dust catcher bleeders
4. Start the blower and slowly open the blower valve and call for 1000 2000 Nm3/min. Snort /open air to atmosphere for 10 minutes.
5. Gradually open the snort valve/air supply valve to the furnace.
6. Close each bleeder at one minute intervals. Bleeder relief set from 0.85
kg/cm2 to 1.5 2.25 kg/cm2 later gradually.

7. Close the bleeders at top/DC until 0.6 kg/cm 2 furnace top pressure is
achieved wrt to supply/stop air to furnace to maintain the top pressure by
controlling.
8. When the furnace top pressure has been achieved check the pressure is
ok at fce top, uptakes and DC
9. Check for furnace, furnace top, up takes, down comer, DC up to gas
cleaning plant inlet(venturi I) leaks.
10. When the leak checks are completed, close the snort valve/air supply
valve to the furnace.
11. Furnace to continue with the dry out.
The operation of the top pressure/furnace pressure will be observed
particularly and closely during the following :
Opening and closing the bleeders.

Opening and closing the snort valve/air supply valve /vent.


Like wise the repeat of 3rd leak

testing to be done up to the

achieving the top pressure at 2.00 kg/cm2 with all step by step
rectifications.
8. Manning
The more people available to carry out the location and repair of leaks the better
- they must however be properly supervised and be provided with sufficient tools
to carry out the work.
-The labour should be arranged into small groups with a responsible supervisor
in charge of each group.
These groups should be located as follows:

LOCATION
Cold Blast main
Under the Casthouse
Floor
Tuyere Platform
Bustle Main

SUPERVISOR/ENGNR
1
1

NUMBER OF PEOPLE
10
10

1
1

10
5

Furnace Stack Platforms


Furnace Top Platforms
Bleeder Platform
Hot Blast Main
Gas Cleaning Plant /
venturi-I
Down comer and Dust
catcher

2
1
1
1
1

20
10
5
5
5

10

The allocated supervisor should study his area before the start of the leak
tests to identify potential leak points and list any special tools.

9. Tools
Each supervisor should have an adequate supply of soapy water solution and
squeezy bottles to locate the leaks; different colour paint or chalk to identify
leaks, then paint to delete the marks when the leak is repaired.

Spanners and tools to repair leaks should be available. Also portable lights
( Hand torches should be available, particularly in areas such as below
tuyere level.