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BHEL - Hydro Test Procedure

Boiler Hydrotest Manual

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Rajagopal Ganapathy
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4K views18 pages

BHEL - Hydro Test Procedure

Boiler Hydrotest Manual

Uploaded by

Rajagopal Ganapathy
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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RECOMMENDED HYDROSTATIC TEST PROCEDURE @ roaree) Bharat Heavy Electricals Limited Revised as on: 01.08.2011 10. “ 12 13, 44 6 16. FiG4 FIG.2 FIG.3 FIG. FIG. TAB 1 TABLE OF CONTENTS GENERAL LIMITS OF HYDROSTATIC TEST TEST PRESSURE PRESSURE GAUGES: PREPARATION FOR THE TEST WATER QUALITY AIR TESTING THE PRESSURE PARTS FILLING PUMP AND PRESSURISING PUMP WiTH TEMPORARY CONNECTED PIPELINES FILLING THE SYSTEMS PRESSURISING THE SYSTEMS HYDROSTATIC TESTING DEPRESSURISATION OF THE PRESSURE PARTS INSPECTION OF THE BOILER PRESSURE PARTS AFTER TESTING PROCEEDINGS TO PREVENT ACCIDENTS AND ENDANGERING OF PERSONS DURING PRESSURE TEST HYDROSTATIC TEST REPORT PRESERVATION OF BOILER AFTER HYDROSTATIC TEST FIGURES HYO. TEST LIMIT BOILER WATER CIRCULATION SYSTEM HYD. TEST LIMIT SUPERHEATER SYSTEM HYD. TEST LIMIT REHEATER SYSTEM HYD. TEST LIMIT BOILER WATER CIRCULATION SYSTEM AND SUPERHEATER SYSTEM SILICA IN BOILER WATER RELATIONSHIP WITH DRUM PRESSURE TABLES TYPICAL HYD. TEST PRESSURE AND TEST PRESSURE GAUGE RANGES TAB2 QUALITY OF WATER TAB 3 WATER VOLUME (TYPICAL FOR VARIOUS CAPACITY OF UNITS) 10 2.0 3.0 4.0 GENERAL ‘After installation of all pressure parts, the unttis subjected to the required initial Hydrostatic Proseure taste. The exact Hydrostatic test procedure to be followed depends on local job site condilions. The procedure outlined below is general in nature. LIMITS OF HYDROSTATIC TEST 2.1 Main boiler with water circulation eystem (trom feed check valve inlet to drum) wiln SH saturated conn.tubes blanked), Ref. Fig. 1 22 SHSYSTEM From drum (with SH saturated conn.tubes blanked) to MS stop valve, (Ref. Fig. 2) 2.3. RH SYSTEM RH inlet neader to RH outlet header. (Suitably blanking the RH inlet & outlet headers with the isofating devices if provided or by means of blank langes) Ref. Fig. 3. TEST PROCEDURE ‘The Unit shal be hydre-tested for conformation to 18RCode requirement in two areas () Primary Cireuitary Drums, Econamisers, Waterwalls, Superneatars at one and hal times the design prescure - and (i) Reheaters at one and half times the cesign pressure of at minimum 70 kg/sa.cr (g) NOTE Itis preferable to do the hydro test at one stroke at the stipulated hydro test presstre indicated in the pressure part arcangement drawing, Hf itis not possible to accomplish this the nyaro fest may be conducted twice, once for drainabie portion and another including non drainable partion at the stipulated hydro test pressure (officlal test 1% times the design pressure). Incase site would prefer to conduct @ hydro test at 2 lower pressure prior fo bifcial nyéro test fre same may be done once at the design pressure. For the site hydrostatic pressure respective BOILER pressure part arrangement drawing has to be referred PRESSURE GAUGES During testing, atleast three property calibrated pressure gauges are to be located one at ‘drum level, one at operating floor level and one near pressure raising pump. “The indicator of the pressure gauges selected should have atleast 6” dial wilh dials graduated duera range of double the intencee maximum test pracedure, out in no caso the range be Ieee than ‘¥times that pressure. The pressure gauges should be calibrated as per FOA- F-18 of FQA systems manual. For typical “Test Pressure Gauge Range” Refer Table 1 - “TYPICAL HYD. TEST PROCEDURE AND TEST PRESSURE GAUGE RANGES" 5.0 6.0 PREPARATIONS FOR THE TEST Prior to Hydrostatic testing, the following items should be inspected. vi vii xi All necessary welds completed, x-rayed and stress relieved. All necessary valves including drain valves instailed and closed. All satety valves installed and hydrostatic plugs, should be assembled before commencing the test. All debris shall be removed menvally from all pressure prts including headers and drums “The drain valve and test valve in the official calibrated pressure gauge sensing tine must be open. Ail manhole closure plates (except drum manhole) and header handhole caps should ‘be closed and bolted o welded tight. ‘The isolating valves provided in all the other branching systems like SB System tapping, SH spray connections, Pr gauges etc, have to be closed tightly. All vents necessary to prevent air entrapment during filing operation such as ‘superheater link vents, economiser link vents, drum vents ete., shall be kept open When valves are in TANDEM (Double valved) both valves must be closed during the hydrotest. In 800 MW Units, if the boiler circulating pumps are of the sub-merged motor or canned motor type, installation of the rotating elements should be defared until the hycrostatic test of the unit has been complated. The pump casings must be blanked off during the test Joint Inspection protocol prior to Hydrostatic Testing of Boiler prepared by FQA also to be duly filed up. (FQA-07-00-00-L-17 (a) WATER QUALITY 61 Itis the responsibility of the customer to provide properly treated water, as specified below at ambient temperature but in no case less than 70°F (21°C) NOTE The temperature limitation for hydrostatic testing is 70°F or 21°C. The important point is that the hydrostatic pressure should cit be applied when the water is less than this mit. It does not make any difference if the water is heated externally or once it has been pumped in ‘o the boiler. ‘The easiest way to achieve and maintain proper hydrostatic temperature in cold weather is with an external steam supply. The full water is heated with @ direct contact heater and the temperature is maintained by using the steam coil air heater, For a new project whare no steam is available, It is advised to consider electric 62 63 64 65 66 67 68 heaters or fuel fired space heaters. “The best method of maintaining non-crainable portion above freezing temperature is by use of steam air heater. M/s.CE too had good success with fuel fired space heaters. For this the unit should be completely insulated and lagged, During testing, the temperature of water should in no case exceed 49°C. It is recommended to use demineralised or condensate quality water of specified purity for both drainable and non-drainable portions (REFER NOTE BELOW) For Quality of Treated water, Boiler water and Feed water, Refer Table - 2 During initial hydraulic test, one may expect some laaks requiring draining, repairing and refiling, So it will be in order fo use, initially fitered water free from chlorine for drainable portions only. It is necessary that the filtered water is clezr, free from suspended and colloidal impurities with a restriction of the total dissolved contents to 100 ppm. However, filtered water should not be used for Lay Up work even for drainable portions. For non-drainable portions only demineralised or condensate quality water should be used. For superheater and reheater (drainable and non-drainable sections) treated condensate or demineralised water can also be used. The treatment shalt inciude $0 ppm ammonia and 200 ppm hydrazine, This treated water wit have a pH value of approximately 10. The use of fil water treated with solid chemicais should be avoided. Deposits of solid materiais in superheaters and reheaters are detrimental from heat transfer and corrosion point of view. Super-heaters and reheaters containing stainless steel tubing are particularly vulnerable to stress corrosion cracking in the presence of chemicals as caustics and chlorides. In the case of 500 M.W. Unit sets, the boiler water circulation pumps aré to be filled with condensate or demineralised water before putting water into the boiler for testing boiler with boiler circulating water pumps. NOTE Detmineralised or condensate quality water is defined as containing no more thant ppm identifiable solids and essentially & zero concentration (or lowest detectable level) of organic materials. ‘After chemical cleaning, steam blowing and lay up of the units, if situation warrants tc do hydraulic testing of the pressure parts usage of treated DM water or trealed condensate is only recommended. For quality of treated OM water REFER TABLE-2. 7.0 AIR TESTING THE PRESSURE PARTS ms Betore filing the boiler with water an air tightness test is to be performed to detect 72 73 74 75 Jeakages due to vaive left in open position. x-ray plug forgotten, any cuts or gauges etc., not observed by visual inspection. This will reduce the DM water consumption, as well as time. ‘The air shouid be filtered and free from oll and dust prior to entering the unit Tha boiler is to be pressurised not more than 2 kg/sq.cm.g) Before admitting air, close all the manhole doors including drum manhole, handhole plates, isolating valves in drain tines, branching lines and vent tines including the vent valves in SH dink, eco. link and drum link, Drain and Test Vaives in official pressure gauge etc., ‘After completing the air tightness testing keep the drum man hole, vert valves in SH links. etc , link and drum fink and drain and test valves in official pressure gauge in open position. 8.0 FILLING PUMP & PRESSURISING PUMP WITH TEMPORARY CONNECTED PIPELINES: at 82 1. Check for correct direction of rotation. ii, Open air vent of the pump during start-up. ji Check motor current at no load as well as at full load conditions, Check whether a cortect fuse is introduced in the circuit to avoid damages to the motor. Iv. Before starting the filing pump, the delivery vaive to be closed and the suction valve kept opened. Then open delivery valve gradually for filing, Before stopping the pump, delivery valve should be closed. v. Before starting the pressurising pump it should be ensured that the delivery vatve is kept open, Connected pipelines (temporary) i Should all be welded, il. Delivery line of pressurising pump should be of high pressure seamless pipe to withstand the required test pressure. ‘il Mixing tank should be of required capacity. iv. Flow regulating valves, drain vaives, overflow lines should be provided with the mixing tank, 9.0 FILLING THE SYSTEMS a1 i. The boiler water circulation system is filed through filing lines connected to the doiter drain head or and eco. filling ines (in higher capacity boilers]. if the unit is filled through the economiser recirculating line valve should be in the vide open position ii, As the water raises upto the drum manholes, the later shall be tightly closed 92 93 and boiler filing shal! be completed lil, Then checking of the filing shall be done through the vents. iv. Close and open the vent valves several times in order to allow the entrapped air to vent out. v. Slop the fil pump and let water lay for some hours. Inno case water entry into superheater should be permitted through the drum, This is to prevent carry over of suspended impurities into the superheater Fill the superheater and reheater with the quality of water indicated under point 6.5 per SH drain header and Rt+drain header respectively unti! alt the elements are filled and the water overtiows through the vent vaives. CAUTION 1. fits decided to do the hydraulic pretest of boiler water circulating system and superheaters at the same time, treated DM water /condansate only should be used. The SH connection tubes in the drum need not be plugged in this case. Take care of point No. 9.2. Also refer Fig. 4 2. The water temperature during hydrostatic test should be ambient temperature: but in no case tess than 21°C. 10.0 PRESSURISING THE SYSTEMS 11.0 104 10.2 10.3 10.4 The pressure shall be raised up by meens of test pumps. ‘The pressure shall be increased at a rate of not more than 10 kg/sq.cm.(g) per rminute upto approximately 80% of the test procedure and by 4 to 2 kg/sq.cm.(9) Per minute beyond that value. Raise the pressure to the hydrostatic test pressure, The pressure shall be under proper control at all times. The pump operator and the responsible person watching the official test gauge must have radio-telephonic contact. When the test pressure is reached the responsible person watching the test gauge shall give orders to stop the test pumps immediately and to cut off the electric connections. The test pressure is held for about haif an hour. During the holding time the test cauge pressure reading shal! not drop noticeably. HYDROSTATIC TESTING 4 12 11.3 The hydraulic test pressure reading will be taken from the official pressure gauge located at the highest point in the presence of the inspector. ‘Alter the hydraulis test pressure has been noted and agreed by the Inspector, the hydrostatic test pressure is then reduced to not less than the maximum allowable ‘working pressure and the whole pressure parts checks will be carried out. IF leaks are found, it will be necessary to release the pressure and drain these portions, Make the tepairs and refill the unit as mentioned above and repeat hycrostatic test. 11.4 Details of the leaks noticed during Hydraulic Tests are to be furnished as given below for better understanding: 2. Exact location of leak(s) component circuit, Elevation, materials ete, b. Description of leak(s) such as straight tube elbow, shop or fieid weld, torchcut, where a lug was removed and attachment weld etc. c. Magnitude of leaks-weeping/sweating, leaks, burn through, longitudinal crack, 12.0 DEPRESSURISATION OF THE PRESSURE PARTS 12.1. The pressure parts shall be depressurised at a depressurisation rate of 1 kg/cm. sq/ minute, 42.2. While releasing the pressure, the vents should be opened when the system pressure reaches 1 kg/sq.cm to prevent creation of vacuum in the system. 13.0. INSPECTION OF THE BOILER PRESSURE PARTS AFTER TESTING 13.1. Atter completion of the hydraulic test, the inspector shall carefully examine the boiler inside and outside and satisfy himself that it has satistactory with-stocd the test. 13.2. To enable the inside inspection of the boiler, the interior has to be equipped with suitable scaffolding for inspecting the elements, walls, tubes and welds. 14.0 PROGEEDINGS TO PREVENT ACCIDENTS AND ENDANGERING OF PERSONS DURING PRESSURE TEST 141 Due to the fact that during the pressure test the boiler and boiler house area are under an increased risk of danger, special safety precautions have to be taken to prevent accidents. These arrangements are made by the erection and commissioning services according to the instructions of the site management. 14.2. During the period of raising, holding and releasing the test pressure, the entry to the oiler house is prohibited for alt persons not participating in the pressure tost, Works at the pressure parts or in the direct neighbourhood are not permitted. 44.3 All companies working on the site must be notified of the pressure test in writing. No clam based on the restriction or stopping of work will be accepted 415.0 “HYDROSTATIC TEST REPORT ‘After completion of the hydrostatic test a written report as per the IBR format shall bo issued and signed by the inspection Authority 16.0 PRESERVATION OF BOILER AFTER HYDROSTATIC TEST 46.1 There is generally some time delay between hydrostatic test and further initial boiling ‘out and chemical cleaning of the unit. Hence, the unit should be kept under preservation for protecting tha internal surfaces from oxidation, 16.2 163 164 165 166 167 16.8 169 Remove all the hydrostatic gags from the safety valves and hyd. test pump with temporary pipes connections prior 10 filing the unit, ill the unit with hydrazine and Ammonia treated DM water containing 300 ppm hydrazine and 10 ppm Ammonia with a pH value of 10.0 to 10.5 til it overflows at vents, ‘The unit should be kept under nitrogen cover with a pressure of 0.6 kg/sq.cm. in the absence of nitrogen capping facility the unit should be pressurised with the aid of a fill pump to 5 kg/sq.cm. ‘Samples can be collected periodically say once a week or fortnight, depending on the pressure holding worthiness of the system, tested for pH and hydrazine content, Incase the sample water dces not meet the criteria for lay up water, the conditioning system shall be operated as to restore the required composition, No welding shall be carried out on pressure parts when the system is under preservation or the system is filled with water. if there is a chance of freezing, the water in the drainable circuits can be displeced by nitrogen and the unit can be laid up under nitrogen pressure. Temporary heating equipment should be provided to keep the non-crainable superheater (reheater) elements above freezing temperature. ‘The reheater should be laid up under nitrogen pressure with the reheater isolating devices closed or with the biank flanges. TABLE - 4 TYPICAL HYD. TEST PRESSURE AND TEST PRESSURE GAUGE RANGE BOILERS &SH TESTPR. = RH HYD TEST PR. BOILERS ASSOCIATED HYD.TESTPR GAUGE TEST GAUGE WITH THE MACHINES — KG/SQ.CM(G)_— RANGE: PRESSURE = RANGE KG/SQ.CM. KG/SQ.CM(G)_ KG/SQ.CM. 120 MW 237.0 0-400 70.0 0-150 210 MW (LP) 237.3 0-400 70.0 0-150 240 MW (HP) 263.7 0-400 70.0 0-150 500 MW 306.0 9-600 76.5 0-150 2. PR.OFAIR FOR TESTING PR, PARTS — 2 KG/SQ.CM. (G} PR, AFTER REGULATOR RANGE OF PR. GAUGE. 0-4 KG/SQ.CM. TABLE -2 QUALITY OF WATER 4, DEMINERALISED WATER (SPECIFICATION) 4 pH at25°C : 7802 2. Electrica! Conductivity at 25°C 5 Less than 0.2 Michromhdicm 3 Total Hardness (Ca + tg) PPM Caco, 2 Ni 4 Total Silica Less than 0.02 5 SiO, PPM Less than 0.01 IS preferable 6. Chlonde PPM as NaCl Nil 7. Sodium PPM es Na Less than 0.003 8, Total Organic Carbon (TOC), PPM 2 Max.0.2 9 General Appearance Clear: Free from odour, colour and Haziness. No Glittering to tyndal affect 2. QUALITY OF TREATED DM WATER OR TREATED CONDENSATE The DM water or Condensate treated with 10 PPM ammonia and 200 PPM hydrazine to have a pH value of approximately 10. 3. QUALITY OF BOILER WATER Drum operating pressure 126-165 166-180 181-205 kglsq.cm.(a) Total Dissolved Solids - max (pm) 50 25 15 Specific Electrical Conductivity at 25°C (stem) 100 50 30 Phosphate Residuat (opm) 5-10 510 26 pH at 25°C 9108 91-98 91-96 Silica (max,) (opm) To be controlled on the basis of silica boiler water and drum pressure relationship (Fig. ) to maintain tess than 0.02 ppm in the steam leaving the drum 0.4 4%. QUALITY OF FEED WATER (Crum operating pressure 101 kg/em.sa.(q) and above) Hardness Nil pH at 25°C (copper alloy pre boiler system) 8.81092 pH at 25°C (copper free pre boiler system) 9.010 9.4 Oxygen maximum ppm 0.007 Total Iron {max) ppm 0.01 Total Copper (max) ppm 0.005 Total CO, Nil ‘Total Silica (max) ppm 0.02 Specific electrical conductivity at 25°C ‘measured after cation exchanger in the + from and after CO, removal (max) m s/c 03 Hydrazine - residue ppm 0.01 0.0.02 Permanganate Consumption ppm Nil oil Not allowed TABLE -3 WATER VOLUME ( TYPICAL FOR VARIOUS CAPACITY OF UNITS ) 120MW 200/210 MW 210 MW. 500 MW SYSTEM we (LP Unit) M? (HP Unit) Mé Ne Generating Surfaces 70.4 126.5 130.0 160.0 Drum 244 37.0 35.0 60.0 (Ful) (Pull) (Full) (Full) Economiser 30.0 30.0 25.0 135.0 Superheater (Drum to SHO Header) 470 95.0 95.0 145.0 . Reheater 15.0 43.0 50.0 220.0 Total 183.5 336.5 338.0 720.0 ECONOMISER INN, TUBES: (BLANKED?

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