Boiler Hydro Test-Steps

Boiler hydro test procedure-Qc documents
Work Components to be tested

 Boiler drum and other cylindrical components having internal diameters greater
than 600mm
 All components not reasonably accessible for inspection after assembly into the
boiler
 Tested hydraulically prior to welding at a pressure less-than 1.5times the maximum
working pressure.
Test Pressure
 1.5times the maximum working pressure.
Work Test Procedure

 On completion of manufacture at the makers works in the presence of Inspecting
Officer,
Hydraulic test shall be carried as:
 The test pressure shall be raised gradually
 It shall not exceed by more than 6% of the required pressure
 The test pressure shall be maintained for 30 minutes
 The pressure shall be reduced to maximum allowable working pressure and
maintained for close visual inspection of the pressure parts
 The temperature of water used shall be 20°C -50°C.
Completion Criterion:- No indication of weakness and defects.
Note: Components other than tubular products shall not require hydraulic testing before
assembly into the boiler if the completed boiler is tested hydraulically to 1.5 times the
maximum permissible working pressure at site.
Testing at Site
After Erection (For Registration)
Before grant of increased pressure certificate
After a repair (in case of minor repairs followed by NDT with approved process, it may
not be done)
Components to be tested:- Complete Pressure Parts
Test Pressure:-
1.25 times the maximum working pressure, if all components as per Regulation 268 are
tested.
1.5 times the maximum working pressure, if any of the components as per Regulation268
are not tested.
Site Test Procedure:-

On completion of works in the presence of Inspecting Officer, hydraulic test shall be
carried as:
The test pressure shall be raised gradually
It shall not exceed by more than 6% of the required pressure
The test pressure shall be maintained for 30 minutes
The pressure shall be reduced to maximum allowable working pressure and maintained
for close visual inspection of the pressure parts.
The temperature of water used shall be 20°C -50°C.
Site Completion Criterion

Successful completion without appreciable leakage or undue deflection or distortion of its
parts for at least ten consecutive minutes.
At the first hydraulic test of a boiler deflection measurements shall be made before,
during and after test of each furnace length, fire – box and flattened or other plates.
Should any part of the boiler show undue deflection or indication of permanent set during
the progress of the test, the pressure shall be released immediately such indications are
observed. The working pressure for the part shall-be 40 percent of the test pressure
applied when the point of permanent set was reached. This procedure shall apply to any
boiler at any test.
The Hydro test of Boiler is done in two stages:
Stage-1:
Hydro test of complete water and Super heater steam circuit including drainable and
non-drainable sections of Boiler up to Boiler Stop valves. Thus this will include:
a. Economizer,
b. Boiler Drum,
c. Down comer sand Water walls,
d. LTSH,
e. Platen Superheat (Non drainable),
f. Final Super heater (Non drainable) the hydro test pressure is chosen as the 1.5/1.25
times the maximum of maximum working pressure of components participating.
Stage 2:-
This covers there heater circuit. The QC NRV of re-heater does not participate and CRH
section up to this point is blanked. One Intercept or valve blanking device is also
installed. Thus the circuit comprise of CRH lines from QC NRV to Re-heater, Re-heater
and HRH lines up to IV.
The hydro test pressure is chosen as the 1.5/1.25 times the maximum of maximum
working pressure of components participating.
Services:-
Standard Pressure gauge–one at drum and one near pressurizing pump-Calibrated at
NABL accredited laboratory with least count of 1KSC.
DM Water– Of following quality
Chemicals–
AmmoniaandHydrazineHydrateinquantitysuchthatwaterbeingfilledshallhave200ppmofhy
drazineandpHof9.5-10
Services:-
Pressurizing Pump – Of suitable capacity for pressurization
Boiler Fill Pump – For initial filling, Temporary Chemical Dozing Scheme
Flood Lights and 24V hand lamps, Reliable Communication System
Ambulance and Fire Tender State of the plant
Erection of Boiler PPs and piping is complete as per drawing.
All necessary welding jobs are complete, stress relieved and X-rayed
All necessary valves including drain valves are installed and kept closed
All safety valves are installed and hydro static plugs assembled
The isolating valves provided in all other branches viz. soot blowing tapping, SH spray
connection, RH spray connection are closed tight. They are tested separately at specified
pressures.
State of the plant:-

All vents are open
All the hangers in Boiler and Piping are set / locked as per recommendations
Required manholes and peep holes in the furnace are open for inspection.
Sky Climbers / Scaffolding arrangements are provided inside boiler.
Oiler drain is suitably connected to storm water drains.
All de-bris are removed from various elevations
All hand rails and platforms are completed.
Note: No boiler welding including attachment welding is allowed to be done after
successful hydro test.
Test Procedure Air Testing of Pressure Parts:-

Before filling water in Boiler Air tightness test is done to detect any leakages due valve
left open, X-ray plug forgotten, any cuts not observable by visual inspection etc.
This reduces DM water consumption and time.
The air used for testing shall be filtered and free of oil.
Before admitting air all the drain and vents are closed tight.
Boiler is pressurized up to 2KSC with air.
Boiler is inspected and leakage if any shall be corrected.
After test completion all the vents shall be left open.
Completion Criterion – No appreciable pressure drop in a day.
The Boiler system is filled with fill pump from bottom using drain cum fillings with the
treated DM water.
Completion of filling of various circuits is ensured by water coming out of vents.
Close and open the vents ever al times to ensure proper venting.
The pressurizing pump is started and pressure is raised up to 25KSCand thorough
inspection is made.
Pressure should be raised in steps and held for 10minutes at 100 and 200KSC.
Average rate of rise of pressure shall be 10KSC/minuteupto80% of test pressure.
Afterwards, it should be 2KSC/minute.
At test pressure pressurizing pump shall be stopped and drop in pressure shall be
monitored for 30minutes.
Completion Criterion – The drop rate should not be more than 1KSC / minute and no
appreciable deflection of components
After completion of test Boiler shall be de-pressurized at the rate of 1KSC/minute using
vents.
At a pressure of 50KSC, the pressure is held and Boiler is thoroughly inspected.
If found satisfactory, full de pressurization and draining can be done
At 2KSC the vents are left full opened.
Note: During raising pressure for the first time no person should be allowed to enter
Boiler after 50KSC.
Dry/Wet Preservation of Boiler

As the non-drainable parts of boiler cannot be drained completely, the only way to expel
such water is to light-up the boiler.
If boiler light-up is not planned after some duration Boiler shall be dry/wet preserved.
The steam piping shall be dry preserved.
Dry Preservation–Under inert gas capping at minimum pressure of 0.35KSC
Wet Preservation–Regular sampling and feed of chemical to maintain parameters.

Wet Preservation H Circuit
<1 week
Water filled surface: - Hydrazine –200 ppm and Ammonia–10 ppm, PH 9.5-10 pressure
5-10 KSC.
SH Surface: - Hydrazine –200 ppm and Ammonia–10 ppm, PH 9.5-10 pressure 5-10
KSC.
RH Circuit: - Hydrazine –200 ppm and Ammonia–10 ppm, PH 10-10.5 Under N2
capping of 0.35 KSC.
1 week –1 month
5-10 KSC
KSC
capping of 0.35 KSC
1month –6 months
5-10 KSC
KSC
capping of 0.35 KSC
> 6 months
5-10 KSC
KSC
capping of 0.35 KSC

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Boiler Hydro Test-Steps

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Boiler hydro test procedure-Qc documents

Work Components to be tested

Work Test Procedure

Site Test Procedure:-

Site Completion Criterion

DM Water– Of following quality

State of the plant:-

Test Procedure Air Testing of Pressure Parts:-

Dry/Wet Preservation of Boiler

Dry Preservation–Under inert gas capping at minimum pressure of 0.35KSC

Wet Preservation–Regular sampling and feed of chemical to maintain parameters.

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