CFW PRESENTATION

GROUP NO:28
TOPIC:

TESTING OF PIPE PLATES ,

BOILERS , This Photo by Unknown Author is licensed under CC BY-SA-NC

DRUMS AND TANKS.

OVERVIEW:
Introduction
Significance of testing
Different testing procedures.
I. Air leakage testing
II. Hydrostatic pressure testing
III. Gas distribution test
IV.Boiler light up etc……
Conclusion
 INTRODUCTION

OBJECTIVE OF TESTING:
• It is the systematic procedure used
after the installation , making the
equipment for safe smooth and reliable
operation.
• It help in the working of these
equipment at high pressure and
temperature without failure.
This Photo by Unknown Author is licensed under CC BY-SA
Different Testing
Procedures:
1. Air leakage test
2. Hydrostatic test
3. Gas distribution test
4. Boiler light up
5. Safety valve floating
6. Steam blowing of critical piping
7. Coal firing

This Photo by Unknown Author is licensed under CC BY-SA-NC

 Why testing?
 To verify proper functioning of the equipment/system after
installation; and
 To verify that the performance of the installed
equipment/systems meet with the specified design intent
through a series of tests and adjustments.
To capture and record performance data of the whole
installation as the baseline for future operation and
maintenance.
 Air Leakage Test:
It is an installation activity
Conducted before hydrostatic test
Test ensures that the erection of
pressure parts is completed.
Air is introduced into the boiler pressure
parts at very high pressure (aprox. 8ksc).
Later entire boiler pressure parts are
checked manually for leakage.
And it’s rectified thereafter.
Figure 1: Air leakage test
equipment
 Hydrostatic
pressure Test:
 Used for boilers, drums, pipes
etc..
 Conducted just after air leakage
test
 The test consist of:
Filling the boiler with water
Pressurizing the water
Why water?
Easily available liquid
Non toxic and no waste
Figure 2: Apparatus created
for hydrostatic test Almost incompressible
This Photo by Unknown Author is licensed under CC BY-SA
 It is conducted to ensure zero
leakage.

The
procedure:
In this test, water is filled from the
bottom most portion using high
capacity filling pump.
After ensuring full flow of water
through the vents , the vents are
closed.
Pressurization is done by an
external pump installed near the
drain header.
Pressure gauge is installed in order
to measure the pressure.

This Photo by Unknown Author is licensed under CC BY-SA

Diagrammatic representation of hydrostatic
test in boilers:

Figure:3
 GAS DISTRIBUTION TEST
It affects the collection efficiency since high velocity would
result in reentrainment(already collected particles).
It is conducts inside electrostatic precipitator during plant
shut down.
The flow concentration can be adjusted with the help of
diverters placed on G.D. screens.
An inlet transition nozzle and gas screens are used at the
entrance to reduce the gas velocity and evenly distribute it
across ESP cross section
 BOILER LIGHT UP
LDO(light diesel oil) is used
to light up the boiler.
Its ignition temperature is
very less compare to HFO and
coal.
To take LDO we have to
purge boiler for 5 minute

Figure 4: Boiler
Light up set up
 SAFETY VALVE
FLOATING:
• They are used to designed set pressure
before allowing the boiler to go for
commercial operation.
• It is located on boiler steam drum, and will
automatically open when pressure of inlet
side of valve increases past the present
pressure.
• In high pressure, spring loaded safety valves
are popular. Springs are selected to have
high repeatability on set pressure.
• The torsion bar safety valve are used by
some boiler designer.
Figure 5: Safety Valve In
Steam Blowing Of Critical Piping:
The blowing of steam through piping to remove debris from the pipe,
cleaning steam lines to an steam turbine, cleaning plant expansion lines
or new installs. To steam blow a pipe requires steam to blow through
the pipe.
APPLICATIONS:
 Steam blowing is one of the important commissioning activities at
boiler and turbine side of thermal power plant.
 It allows boilers and pipe lines to ensure that during normal operation
on adhering material in the superheaters, re-heaters and steam
pipelines
COAL FIRING:
There are two methods for firing coal as a fuel.
One is solid fuel firing boiler. It has two parts-1.Hand firing
2.Mechanical stroke firing
Second is pulverized firing fuel firing.
Hand firing-it is operated in smaller size boiler. It is used to drive coal
engine locomotive in past.
Mechanical stroke firing-when fuel(coal) is put into steam boiler
furnace by means of mechanical strokes.
FIGURE 6: COAL FIRING IN BOILER
 CONCLUSION
• All pipework, vessels and boilers shall be clean up thoroughly before
subject to inspection, both internally and externally.
• All associated pipework, fitting and valves shall be completely
drained after hydraulic test and shall be blown with compressed air to
remove any trace of water and dirt.
• After being dried, the pipework, fitting and valves shall be flushed
with oil to prevent rusting.
• Certain tests will be carried out on different systems of the
installation during construction to ensure their suitability for
operating at the design conditions. Certificates of such tests have to
be issued together with certificates of any work tests
 THANK YOU
PRESENTED BY:
JYOTHI JAYAKUMAR
KIRAN KUMAWAT
RAJ RAJESHWARI