Copyright (C) Siemens 2001

Owner

Torrent Power Generation Limited

Consultant

TCE CONSULTING ENGINEERS LIMITED

MUMBAI

The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

D C B A

2007/03/22 2007/02/22 2007/02/15 2007/01/20

bearb. Coord.

S,K.AN S,K.AN S,K.AN S.K. AN

gepruft Checked

Revised to reflect to site preparation. Revised as Siemens Comment. Revised as Siemens Comment. First Issue
Anderungshinweis / Details of Revision

Index Datum Rev. Data Sub-Contractor

Inkor Engineering Pvt. Ltd. This document is the property of INKOR, and is to be used only for the purpose of the agreement with INKOR pursuant to which it is furnished

Sub-Contractor document No.

IKR-PROC-001
Ursprung/ Original Urspaung-Nr./Original No. Urspr-PKZ-Nr. Orig.-PC

Projekt/project

PKZ/PC

1100 MW SUGEN CCPP

Datum Data gezeich. Drawn bearb, Coord. Gepruft Checked Name MaBstaB Scale Benennung/Title

IND696
A4
UA/DCC Type Infalrskennzeichen Contents Code

DH01

HYDROSTATIC TEST PROCEDURE FOR HRSG (SITE)

E932
Dienstst./Det UNID

HA
Zahl-Nr.

Abtlg Dept.

Reg.No.

223104
Version

SIEMENS
Erstellt mit / designed with: Intergraph

E932

458077234
Ang-VR./Offer-Var. Var./Opt. Ersatz fur Supersedes

Index/Rev.

D
Blatt-Nr./Page-No.

IND696-DH01-HA-223104

23

1100MW SUGEN CCPP HRSG

TABLE OF CONTENT 1. INTRODUCTION 1.1 Purpose 1.2 Applicable Code and Reference Data for Hydrostatic Test 1.3 Responsibility 2. CONDITIONS FOR HYDROSTATIC TEST 2.1 Preliminary 2.2 Hydrostatic Test Pressure and Water Volume. 2.3 Treated Water Requirement 3. PRE-TEST PREPARATION 3.1 Safety Valves 3.2 Test Gauges 3.3 Temporary Facility 3.4 Communication 3.5 Advance Material Readiness 4. HYDROSTATIC TEST GENERAL REQUIREMENTS 4.1 Boiler Metal Temperature 4.2 Sectional Testing of the HRSG System 4.3 Double Valve Arrangement 4.4 Communication 5. PROCEDURE 5.1 Inspection before Hydrostatic Test 5.2 Hydrostatic Test 6. 7. 8. INSPECTION AND TEST Post Hydrostatic Test Procedures APPENDICES AND ATTACHMENT 8.1 The Pressure curve of Hydrostatic Test for HRSG (Typical) 8.2 Pressure Test Circuit.

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1. INTRODUCTION After installation of all pressure parts, Section I of the ASME Boiler and Pressure Vessel Code requires that a boiler shall be subjected to a Hydrostatic Pressure Test. This will be conducted at a test pressure of 1.5 times the maximum allowable working pressure as stamped on the boiler identification plate. This procedure is applicable to the hydrostatic test for the pressure parts of HP, IP, LP, CPH section for 1100MW SUGEN CCGT HRSG. This description only describes the general procedure for the hydrostatic pressure test of the HRSG. The detailed description will be contained in an additional detail engineering document. 1.1 Purpose

The primary purpose of this procedure is to provide a good quality of performance of HRSG before chemical cleaning and commissioning operation. And also to find a fault in site welding parts and to repair it. 1.2 a) b) c) 1.3 a) b) c) Applicable Code and Reference Data for Hydrostatic Test ASME Boiler and Pressure Vessel Code Sect. I ANSI B31.1 (for external piping) IBR1950 Responsibility Erector is responsible for confirming and controlling the hydrostatic test job is being carried out according to the prescribed procedure. The manager in charge of hydrostatic test for HRSG must follow the procedure as requested, review and manage in accordance with the prescribed procedure. Temporary control office should be placed around the pressurization pump. The communication system for pressurization and depressurization shall be carried out by means of walkie-talkie.

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2. CONDITIONS FOR HYDROSTATIC TEST 2.1 Preliminary

Before starting to fill the boiler make sure all drums and headers are cleared of foreign material. Close all drains. Open all vents normally used when filling the HRSG (such as superheater link vents, economizer link vents, drum vents). 2.2 Hydrostatic Test Pressure and Water Volume

System HP (F.W) HP (SH,Eva,Eco) IP (F.W,Eco) IP (SH,Eva) RH (RH,HP Bypass Outlet) LP (F.W) LP & LBG Deae. To Cond. Sys Deaerator CPH HP Bypass Cooling water Total

Design Pressure (barg) 257 145 110 38 38 50 11 50 8 50 58

Hydrostatic Test Pressure (barg) 385.5 218 165 57 57 75 16.5 75 12 75 87

Water Volume (M3) 3 161 3 43 50 2 47 3 25 34 Nil 371

Remarks (Test Circuits Color / P&ID No.) Dark Blue (IND696-XG02-HAD10-220011) Purple (IND696-XG02-HAD10-220011) Blue (IND696-XG02-HAD50-220051 / 220052) Mauve (IND696-XG02-HAD50-220051) Mauve (IND696-XG02-HAD50-220052 / HAD10-220011) Light Blue (IND696-XG02-HAD80-220081) Orange (IND696-XG02-HAD80-220081 / LAA20-412001 / LBG10-421111) Brown (IND696-XG02-LAA20-412001) Deep Purple (IND696-XG02-LAA20 / 412001) Light Green (IND696-XG02-LCA30-413032) Gray (IND696-XG02-HAD10-220011)

2.3

Treated Water Requirement 1) Superheater and Reheater Type Temperature Contents : : : Demineralized water 21 C to 49 C Ammonia 10ppm solution Hydrazine 200ppm solution

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pH : 10

NOTE : Demineralized or Condensate quality water is defined as containing no more than 1 ppm (1 /) of identifiable solids and essentially a zero concentration (or lowest detective level ) of organic material. CAUTION : The use of fill water, treated with solid chemicals, should be avoided. Deposits of solid materials in superheaters can be detrimental from heat transfer and corrosion standpoints. Superheaters containing stainless steel tubing are particularly vulnerable to stress corrosion cracking in the presence of such chemicals as caustic and chlorides. 2) Remainder of HRSG unit: Fill with treated condensate or treated demineralized water, or, if not available, with a clean source of filtered water with 10 ppm (10 cm3/m3) of ammonia and 200 ppm (200 cm3/m3) of hydrazine The water conditions as stated above can be adjusted by pouring chemicals, Ammonia in the temporary storage tank i.e. condensate storage tank. The water can be treated with only ammonia. This will however reduce the period of time that this water can be left in the system.

3.

PRETEST PREPARATION 3.1 Safety Valves

All safety valves will be checked for having the Hydro Plug inserted if applicable. The Compression screw on the Safety Valve must be turned clockwise until the locknut makes up on the Yoke. 3.2 Test Gauges Only recently calibrated test gauges are to be used. Dial pressure gauges used in the testing shall preferably have dials graduated over their entire range of about double the intended maximum test pressure, but in no case shall the

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range be less than 1 times that pressure. There should be at least two (2) pressure gauges installed, one of which is at the highest point of the system, the other gauge is to be installed at the Hydro-Pump. 3.3 Temporary facility

Description D.M Pump Filling Water Pump Pressurizing pump Temporary Water Tank Air Compressor Fire Hose High Pressure Hose Temporary Piping

Capacity

Qty 1

Remarks Water filling for Temp. Tank Water filling for System Pressurizing Pressurizing

20 kg/cm2g 450 kg/cm2g 10 m3 10 kg/cm2g 2 ~ 20m ~

1 1 1 1 5 Multitude

Water filling for System Pressurizing Water filling & Pressurizing

3.4

Communication

All communication between the boiler control station and the Hydro-Pump station will be with Radios. Back-up radios are to be readily available at each control station. Radio : More than 4 walkie-talkie Location : Control center (filling water pump or pressurization pump area) Top (pressure gauge, thermometer and vent area) Inspector Inspector and recorder must be placed in a convenient area to communicate for the pressure gauge, inspection of thermometer and control center. 3.5 Advance Material Readiness

Scaffolds, lights and repair tools are to be ready at time of Hydro-Test.

4.

HYDROSTATIC TEST GENERAL REQUIREMENT

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4.1

Boiler Metal Temperatures

The metal temperature of all components to be Hydro-Tested must be at least 21 C (70 F) before applying the Hydro Test pressure but shall not exceed 48.8 C(120F) 4.2 Sectional Testing of the HRSG Systems

When Hydrostatic Testing is to be done on a section of the system which is not directly linked to a lower than test pressure designed system, but segregated by the test boundary isolation, all vent valves in the lower pressure designed system must be open to avoid over pressurization of the same. 4.3 Double Valve Arrangements All components tested will be as indicated on the flow chart or P&ID for the specific test. Always open the root valve fully and throttle with the down stream valve when depressurizing or draining a system. 4.4 Communication

All communication / Co-ordination concerning the Hydro-Test has to be addressed through designated personnel.

5.

PROCEDURE 5.1 Inspection before Hydrostatic Test the drum, heater,

5.1.1 Check for any foreign materials of tools, clothes and other things inside manifolds etc. and then close the manholes and all holes of the pressure.

5.1.2 The pressure gauge to be used for Hydro-Test should exactly be calibrated. In addition to this, the filling piping and pressurization shall be checked. 5.1.3 It is very important to check whether the instruments and the temporary construction piping

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are free from foreign particulate matters. 5.1.4 The safety valves gagged. (when the worker install safety valve, he must check whether the test plug is inserted or not, and if inserted, a tag with No operating must be attached) 5.1.5 Before filling , to close the block valves and open the vent valve of each system, Authorization of concerned in charge is required to be done in the valve operation list. 5.1.6 In case of deaerator, Spray valve & tray should be separated to avoid foreign material. But if spray valve is installed in deaerator, take a note water filling must not be done through spray valve. 5.2 Hydrostatic test

5.2.1 Water filling In case of non availability of condensate transfer pump, which are to fill the water, filling of water shall be done by temporary filling water pump shall be installed in each system as paragraph 5.2.1.2. 5.2.1.1 In advance, in the close condition of the specified valve, it has to be checked then the signature on the control list is requested under the open condition of top air vent valve. If the above condition is pleased it may be filled for water washing. 5.2.1.2 It is a fundamental rule to fill the inside of HRSG through specified valves for each system(HP, IP, LP, CPH and Deaerator). 5.2.1.3 If water is seen being filling from bottom valve, each air vent valve shall be closed on sequentially till top air vent valve at that time a full filling should be confirmed at top air vent valve. 5.2.2 Pressurization 5.2.2.1 HP F.W. Section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure(design pressure 257barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test

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pressure (385.5 barg) of HP F.W. section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6%(23.1 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure. f) If the result during checking is under the normal condition, the pressure shall be reduced by 3~5 kg/cm^2/min. by opening a drain valve. 5.2.2.2 HP section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure(design pressure 145 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure (217.5 barg) of HP section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6%(13.0 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure. f) If the result during checking is under the normal condition, the pressure shall be reduced by 3~5 kg/cm2^/min. by opening a drain valve. 5.2.2.3 IP F.W Section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure(design pressure 110 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure (165 barg) of IP F.W. section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6%(9.9 bar)

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of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure f) If the result during checking is under the normal condition, the pressure shall be reduced by 3~5 kg/cm^2/min. by opening a drain valve. 5.2.2.4 IP Section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure(design pressure 38 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure (57 barg) of IP section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6%(3.4 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure. f) If the result during checking is under the normal condition, the pressure shall be reduced by 3~5 kg/cm2^/min. by opening a drain valve. 5.2.2.5 LP F.W. Section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure(design pressure 50 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure (75 barg) of LP F.W section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6%(4.5 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till the

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design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure. f) If the result during checking is found in normal condition, the pressure shall be reduced by 3~5 kg/cm^2/min. by opening a drain valve. 5.2.2.6 LP section a) The pressure should be increased by 2~3 kg/cm^2/min. up to Max. allowable working pressure(design pressure 11 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure (16.5 barg) of LP section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6%(1 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure. f) If the result during checking is found in normal condition, the pressure shall be reduced by 3~5 kg/cm^2/min. by opening a drain valve. 5.2.2.7 CPH section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure (design pressure 50 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure(75 barg) of CPH section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6% (4.5 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be

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carried out after the pressure was lowered from hydrostatic test pressure to design pressure. f) If the result during checking is found in normal condition, the pressure shall be reduced by 3~5 kg/cm^2/min. by opening a drain valve. 5.2.2.8 Deaerator section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure (design pressure 8 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure(12 barg) of Deaerator section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6% (0.7 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure. f) If the result during checking is found in normal condition, the pressure shall be reduced by 3~5 kg/cm^2/min. by opening a drain valve. 5.2.2.9 HP Bypass Cooling Water Section a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working pressure (design pressure 58 barg). b) Observe test section for any obvious leaks. c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test pressure(87 barg) of HP Bypass cooling water section and held for min. 30 minutes. The pressure must be under control at all times and shall never exceed by more than 6% (5.5 bar) of the desired Hydrostatic Test Pressure. d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate) till the design pressure by opening drain valve. e) A close visual inspection of all boiler pressure parts and connecting piping shall be carried out after the pressure was lowered from hydrostatic test pressure to design pressure.

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f) If the result during checking is found in normal condition, the pressure shall be reduced by 3~5 kg/cm^2/min. by opening a drain valve.

6.

INSPECTION AND TEST 6.1 All welding points, valves and hangers which were welded on pipe must be inspected during the hydrostatic test. During the inspection if there is an abnormal condition the inspection should be stopped and a repair work should be done. 6.2 The test data should be recorded at an interval of 5 minutes but not less than 5 measuring data in each case during hold time and during subsequent inspection, and the basis of the pressure is the pressure gauge installed at the highest point of the system, and temperature should be recorded from the temporary temperature gauge installed near the pressure gauge. 6.3 The inspection must be witnessed as per the inspection points in hydro test inspection table. NOTE : Hydrostatic test pressure should not be applied to the boiler of the metal temperature of the pressure parts is below 70 F ( 21 C ). Since there is generally some time delay between the hydrostatic test and the initial boiling out and cleaning for the boiler the unit should remain full of water, air should not be allowed to enter.

7.

Post Hydrostatic Test Procedures 7.1 Hydrostatic test water will be left in the system for preservation. Pressure approximately 3 to 5 psig (21 to 34 kPa) to be maintained, checked and recorded on a regular basis. 7.2 Remove all hydrostatic test plugs and gags from the safety valves prior to starting up the unit. NOTE: Since there is generally some time delay between the hydrostatic test and the initial boiling out and acid cleaning of the HRSG, it should remain full of water; air should not be allowed to enter.

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8.

ATTACHMENT 8.1 The pressure curve of hydrostatic test for HRSG A. HP F.W Section pressure curve (Typical) B. HP Section pressure curve (Typical) C. LP Section Pressure Curve(Typical) D. LP F.W Section Pressure Curve (Typical E. CPH Section pressure curve (Typical) F. IP & RH Section Pressure Curve (Typical) G. IP F.W Section Pressure Curve (Typical) H. Deaerator Section Pressure Curve (Typical) I. 8.2 HP Bypass Cooling Water Section Pressure Curve (Typical)

Pressure Test Circuit ------- 1 Set Red Color Marking(golden joint) means pipe will be blanked before hydrostatic test and RT will be done for weld joint after Hydrostatic test.

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Attachment A 8.1. The pressure curve of hydrostatic test for HRSG

HP F.W. Section Pressure Curve (Typical)

400

Min.30 Minutes At 385.5 barg(393.4 /) (hydrostatic Test Pressure)

350

300

Inspection Time At 257 barg (261.1 /) (Design Pressure)

Pressure [barg]

250

200

150

100

50

0 0 50 100 150 200 250 300

Time [Hours] Time [min]

Pressure Up Pressure Down

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B. HP Section Pressure Curve (Typical)

300

250

Min. 30 Minutes At 218 barg (222.5 /) (Hydrostatic Test Pressure)

200

Pressure [barg]

150

Inspection Time At 145 barg (148.0 /) (Design Pressure)

100

50

0 0 50 100 150 200 250

Time [min]
Pressure Up Pressure Down

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C. LP Section Pressure Curve (Typical)

24

20
Min. 30 Minutes At 16.5 barg(16.8 /) (Hydrostatic Test Pressure)

Pressure [barg]

16
Inspection Time

12

At 11 barg (12 /) (Design Pressure)

0 0 20 40 60 80 100 120

Time [Min]
Pressure Up Pressure Down

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D. LP F.W Section Pressure Curve (Typical)

90 Min. 30 Minutes 75 At 75 barg(76.5 /) (Hydrostatic Test Pressure)

Pressure [barg]

60

Inspection Time At 50 barg (51.0 /) (Design Pressure)

45

30

15

0 0 20 40 60 80 100

Time [Min]
Pressure Pressure Down

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E. CPH Section Pressure Curve (Typical)

90 Min. 30 Minutes 75 At 75 barg(76.5 /) (Hydrostatic Test Pressure)

Pressure [barg]

60

Inspection Time At 50 barg (51.0 /) (Design Pressure)

45

30

15

0 0 20 40 60 80 100 120

Time [Min]
Pressure Pressure Down

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F. IP & RH Section Pressure Curve (Typical)

60

Min. 30 Minutes At 57 barg(58.1 /) (Hydrostatic Test Pressure)

50

Inspection Time 40

Pressure [barg]

At 38 barg (38.8 /) (Design Pressure)

30

20

10

0 0 20 40 60 80 100

Time [Min]
Pressure Up Pressure Down

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G. IP F.W Section Pressure Curve (Typical)

175

Min.30 Minutes At 165 barg(168.4 /) (Hydrostatic Test Pressure)

150

Pressure [barg]

Inspection Time

125

At 110 barg (112.2 /) (Design Pressure)

100

75

50

25

0 0 30 60 90 120 150 180 200

Time [min]
Pressure Up Pressure Down

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H. Deaerator Section Pressure Curve (Typical)

Min. 30 Minutes

12

At 12 barg(12.3 /) (Hydrostatic Test Pressure)

10
Inspection Time At 8 barg (8.2 /) (Design Pressure)

Pressure [barg]

0 0
15

30

45

60

75

Time [Min]
Pressure Up Pressure Down

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I.

HP Bypass Cooling Water Section Pressure Curve (Typical)

90

Min. 30 Minutes At 87 barg(88.8 /) (Hydrostatic Test Pressure)

75 Inspection Time

Pressure [barg]

60

At 58 barg (59.2 /) (Design Pressure)

45

30

15

0 0 20 40 60 80 100

Time [Min]
Pressure Pressure Down

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