Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 1 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ SLNO LIST OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS E ER!ENCY PROCEDURE STATE OF T"E PLANT ET"OD CO PLETION CRITERIA APPENDICES #$ APPENDICES

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet . of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ ST'T(S SL.NO 1.0 PLANT DETAILS% Refer to procedure - I 2.0 OBJECTIVE% Refer to procedure - I 3.0 3.1 PROPOSALS% Auxiliary Boiler will be hydraulically tested at 1-5 times the desi ! pressure of the boiler Recomme!ded "ydrostatic #est pressure $ 3%.5 & '(m2 (hemically treated water as specified shall be filled i! the boiler a!d hydro test shall be co!ducted. )Refer 4-2* SERVICES REQUIRED% #wo !umber of calibrated pressure au e + o!e at ,rum le-el a!d other !ear pressuri.i! pump to be i!stalled for testi! . )/east cou!t$ 0referably 1 &1(* (hemically treated water with 222 003 of "ydra.e!e a!d 0" -alue of 4.5 to 12.2 shall be used for "ydraulic test. Approximate 5ua!tity of ,3 water re5uired for "ydraulic test is arou!d 52 to!s. A-ailability of /.# 0ower 1upply6 li hti! etc.

3.2 4.0 4.1

4.2 4.3 4.4

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ ST'T(S SL.NO 5.0 5.1 5.2 5.3 6.0 7.1 7.2 7.3 SAFETY PRECAUTIONS% Readi!ess of stair case6 platforms6 "a!d rails a!d approaches as decided 8oi!tly by B"9/ : ;#0( at site shall be e!sured. ;o perso! is allowed to e!ter the boiler house whe! the pressure i! the boiler is abo-e the maximum operati! pressure. <irst aid &its are a-ailable i! the test area. E ER!ENCY PROCEDURES% #he testi! team should be aware of the procedure to be followed i! case of accide!t i!-ol-i! perso!!el i!8ury. #he testi! team should be aware of the operati! procedure of fire exti! uishers to be used for 5ue!chi! fires. A perso! is to be posted at emer e!cy push butto! a!d i!structed that he should trip the pressuri! pumps i! the e-e!t of emer e!cy bei! !otified to him by obser-ers.

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 2 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ SLN% ST'T(S 7.0 7.1 ST'TE %, THE PL'NT : Erection of the Boiler pressure parts is complete as per drg. ll necessar! "elds completed# $%ra!ed and stress relie&ed. ll '( chec)s as per appro&ed Erection '(* completed. ll necessar! &al&es including drain &al&es installed and closed. ll safet! &al&es installed and h!drostatic plugs should +e assem+led +efore commencing the test. ,he drain &al&es and test &al&e in the cali+rated standard test pressure gauge sensing line must +e open. ,he isolating &al&es pro&ided in all the other +ranching s!stems li)e -B s!stem tapping# -. spra! connections# *r. /auges etc. ha&e to +e tightl! closed. .!draulic test of -B s!stem# -. spra! s!stem etc. is carried out separatel! at specified pressures. ll &ents necessar! to pre&ent air entrapment during filling operation such as superheater &ents# drum &ents etc. shall +e open. 0hen &al&es are in tandem 1dou+le &al&es2 +oth &al&es must +e closed during the h!drotest. ll the hangers in Boiler 3 piping s!stem are set 4 loc)ed as per recommendation. 5eep the re6uired peepholes 4 manholes door in furnace# open for inspection during ..,.

7.2 7.3 7.4 7.5

7.6 7.7 7.8 7.9

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 5 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ SLN% ST'T(S 7.10 Ensure the a&aila+ilit! of re6uired 6ualit! of chemicall! treated 78 0ater near the test area. 178 transfer *ump to +e made use off for this or an alternate method adopted for transporting 78 "ater to u$iliar! Boiler2 Ensure readiness of Boiler 'ill pump or an alternati&e temporar! pump and tan) s!stem and their respecti&e pipe connections to Boiler. Ensure readiness of Boiler *ressurising *ump and its pipe connection from temporar! tan) of sufficient capacit! to a suita+le input point at Boiler +ottom drain header. Ensure lighting in all the areas "here inspection is to +e carried out including inside of Boiler for effecti&e chec)up. Ensure communication +et"een drum le&el and pressuri9ing pump area and other operating areas. Boiler drain is suita+l! connected to storm "ater drain. 7.15 ll connected pipelines 1temporar!2 are "elded. 7.16 7.17 7.18 7eli&er! line of pressuri9ing pump should +e high%pressure seamless pipe to "ithstand the re6uired test pressure. ,emporar! tan)s should +e of re6uired capacit!.

7.11

7.12

7.13 7.14

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 6 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ SLN% ST'T(S 8.0 TEST "ETH%D 8.1 8.1.1 '!R TEST!N- THE PRESS(RE P'RTS Before filling the +oiler "ith "ater# an air tightness test is to +e performed to detect lea)ages due to &al&e left in open position# :%ra! plug forgotten# an! cuts or guages etc. not o+ser&ed +! &isual inspection. ,his "ill reduce the 78 "ater consumption# as "ell as time. ,he +oiler is to +e pressurised not more than 2 )g4s6.cm 1/2. Before admitting air# close drum manhole# isolating &al&es in drain lines# +ranching lines and &ent lines including the &ent &al&es in -. and drum# 7rain and ,est ;al&es in official pressure gauge etc. <nspect for an! lea)age and attend the same. fter completing the air tightness testing )eep &ent &al&es in -. drum and drain and test &al&es in official pressure gauge in open position. TE"P%R'R* B%!LER ,!LL PRESS(R!S!N- P("P3 4!TH C%NNECT!N- P!PEL!NES. P("P3 THE!R TE"P%R'R* TE"P%R'R*

8.1.2 8.1.3

8.1.4 8.1.5 8..

8.2.1 8.2.2 8.2.3

=hec) for correct direction of rotation of pumps. >pen air &ent of the *ressurising *ump during start%up =hec) "eather a correct fuse is introduced in the circuit to a&oid damages to the motors of these pumps.

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 5 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ SLN% ST'T(S 8.2.4 Before starting the filling pump# the deli&er! &al&e to +e closed and the suction &al&e )ept open. ,hen open deli&er! &al&e graduall! for filling. Before stopping the pump# deli&er! &al&e should +e closed. Before starting the pressurising pump it should +e ensured that the deli&er! &al&e is )ept open. ,!LL!N- THE S*STE"S ,he +oiler 7rum# +an) tu+es and -uperheaters are filled through filling lines connected to the +oiler drain header. =onfirmation of completion of filling of the entire s!stem shall +e done through the &ents. =lose and open the &ent &al&es se&eral times in order to allo" &enting of entrapped air. -top the fill pump. PRESS(R!S!N- THE S*STE"S ,he pressure shall +e raised up +! means of pressurising pumps. ,he pressure shall +e increased at a rate of not more than 10)g4s6.cm 1g2 per minute upto appro$imatel! 80? of the test pressure and +! 1 to 2 )g4s6.cm 1g2 per minute +e!ond that &alue.

8.2.5 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.4 8.4.1 8.4.2

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 8 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ SLN% ST'T(S 8.4.3 @aise the pressure to the h!drostatic test pressure. ,he pressure shall +e under proper control at all times. ,he pump operator and the responsi+le person "atching the official test gauge must ha&e constant contact. 0hen the test pressure is reached# the responsi+le person "atching the test gauge shall gi&e orders to stop the test pumps immediatel! and to cut off the electric connections. ,he test pressure is held for a+out 10 minutes. 7uring the holding time the official test gauge pressure reading shall not drop noticea+l!. H*DR'(L!C TEST ,he h!draulic test pressure reading "ill +e ta)en from the cali+erated standard test pressure guage located at the 7rum le&el. fter the h!draulic test pressure has +een noted# the test pressure is then reduced to not less than the ma$imum allo"a+le "or)ing pr. and the "hole pressure parts chec)s "ill +e carried out. <f lea)s are found# it "ill +e necessar! to release the pressure and drain these portions. 8a)e the repairs and refill the unit as mentioned a+o&e and repeat h!draulic test. 7etails of the lea)s noticed during .!draulic ,ests are to +e furnished as gi&en +elo" for +etter understandingA a2 E$act location of lea)1s2 component circuit# Ele&ation# materials etc.

8.4.4 8.5 8.5.1 8.5.2

8.5.3

8.5.4

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 6 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ SLN% ST'T(S +2 7escription of lea)1s2 such as straight tu+e el+o"# shop or field "eld# torchcut# "here a lug "as remo&ed and attahcment "eld etc. c2 8agnitude of lea)s%seeping4s"eating# longtitudional crac). 8.6 8.6.1 8.6.2 lea)s# +urn through#

DEPRESS(R!S'T!%N %, THE PRESS(RE P'RTS ,he pressure parts shall +e depressurised at the rate of 1 )g4 -6. cm 4 minute. 0hile releasing the pressure# the &ents should +e opened "hen the s!stem pressure reaches 1)g4s6.cm to pre&ent creation of &acumm in the s!stem. !NSPECT!%N %, THE B%!LER PRESS(RE P'RTS ',TER TEST!Nfter completion of the h!draulic test# an inspection of +oiler inside and outside is made to ensure that the +oiler has satisfactoril! "ithstood the test. fter satisfactor! completion of .!dro test# entire Boiler s!stem is drained. H*DR%ST'T!C TEST PR%T%C%L Boint protocol +! B.EC 3 D,*= to +e made after the successful completion of .!draulic ,est.

8.7 8.7.1

8.7.2 8.8 8.8.1

Si/nat0re1 NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-00 1 Sheet 10 of 10 NTPC Ref no S!"#0#TS# # 1 P$ant area: B%!LER &'()!L!'R*+ PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+ ST'T(S SL.NO 9.0 CO PLETION CRITERIA& #he test pressure i! the official pressure au e is held for 12 mi!utes ) or for a duratio! decided by I!spectio! authority* i! prese!ce of I!spectio! authority. #he Boiler shall satisfactorily withsta!d such pressure without appreciable lea=a e or u!due deflatio! or distortio! of its pressure parts. 10.0 APPENDICES% Refer to 0rocedure - I $ 0rocedure for commissio!i! Auxiliary Boiler. of

Si/nat0re1 NTPC BHEL

PR%CED(RE ,%R C%""!SS!%N!N- %, '()!L!'R* B%!LER &H*DR'(L!C TEST+