HYDRAULIC TESTING OF BOILER

Faculty: Ashok Rasekar

 Boiler Hydraulic test
After installation of all pressure
parts and any tube replacements
theBoiler is subjected to
Hydrostaticpressure. This is done to
ensure healthiness of material and
correctness of workmanship.This is
also a statutory requirement with
respect to IBR.
 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 than1.5times the maximum
working pressure.
 TestPressure

1.5 times the

maximum working
pressure
Note:Components other than tubular
products shall not require hydraulic testing
before assembly into the boiler if the
completed boiler is tested hydraulally
to1.5times the maximum permissible
working pressure at site.
 State of the plant
All vents are open

All the hangers in Boiler and Piping

are set/locked as per
recommendations
All safety valves on Drum ,S/H outlet
Line are locked.

Required manholes and peepholes in

the furnace are open for inspection
SkyClimbers/Scaffolding
arrangements are provided inside
boiler

All debris are removed from

various elevations

All handrails and platforms are

completed
 Hydraulic test of boiler
Before carring out hydraulic test,ensure the
following points
1) Lockking of pipe line hangers
2) Isolation of drum gauge glasses
3) Closing of all drain valves
4) Locking of all safety valves
 5)Callibration of all the pressure gauges on
the line
6) If reheater is not to be tested, open all the
drains in cold reheat and hot reheat lines.
Also open the all drains after ESV
7)Opening of vents of drum,superheater,R/H
and pipe lines.
 8) Tight closing of HP bypass isolating valves
and opening of downstream drains of HP
bypass
9)Close isolating valves on rotor
heating,flange and stud heating lines for HP
and LP. And open drains after valve.
10) Availability of atleast one feed pump
 11)Open drains of HP and IP transfer pipe
lines
12) constantly watch HP & IP casing temp and
delta of HP& IP.
13)PRDS isolating valves should be hand
tightened.
14) Spray line isolating valve should be
closed.
15) Check availibility of DM water.
 AFTER ENSURING ABOVE POINTS PROCEED AS
FOLLOWS
1) Fill the deareator through initial fill pump
and charge the boiler feed pump
2)Charge feed water slowiy,till sufficient flow
is there through feed line vents.
3) Start filling boiler through initial boiler fill
pump.
4) Keep the constant watch on vents.
5) Approximate filling time 3.5 hours.
 Hydro Test of Pressure Parts
The Boiler system is filled with fill pump
from bottom using drain cum fill lines with
the treated DM water.

Completion of filling of various circuits is

ensured by water coming out of vents

Close and open the vent several times

to ensure proper venting
ECO DRUM WATER S/H PIPING
WALL
25.17 t 37.20 t 97.80 t 12.05 t

126.30 t

Total 346 t water for hydraulic test

Total 163 t water for normal operating level

PREPARATION TO DEA
OF WATER OHDM TANK INITIAL FILL

CIRCUIT
TO BOILER
INITIAL FILL

TO COND HOTWELL
MAKEUP

IDM TANK

UNIT DRAIN
PUMP

IDM PUMP
UNIT DRAIN
FROM WT PLANT TANK
 ECO

BFP DISCHARGE

IBD TANK

BOILER INITIAL
FILL
 P/SH,FS/H
FROM CEP DISCHARGE
VC

FST
FST

BFP
TO DEA
IBD
INITIAL FILL
HPH

FROM TO BOILER
UNIT INITIAL FILL
TO WATER WALL
DRAIN
RING HEADER
PUMP
 1)After sufficient flow is established through
vents,close vents.
2) Boiler press. will start increasing through
initial fill pump upto 18 kg/cm2.Crack open
RV of initial fill pump to establish minimum
flow on fill pump
3) Start boiler feed pump.
4) Stop boiler fill pump after increasing boiler
press above 20 kg/cm2
 TestProcedure

.The test pressure shall be raised

gradually .
.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 20C -50C.
FROM CEP DISCHARGE

PLATEN S/H FINAL S/H REHEATER

VC

FST

PRI S/H
BFP
WATER WALL

HPH ECO

FROM UNIT DRAIN PUMP DISCHARGE

 The pressurizing pump is started and
pressure is raised upto 25 Kg/cm2
and thorough inspection is made.
Pressure should be raised in steps and held
for 10minutes at 100 and 200 Kg/cm2.

Average rate of rise of pressure shall be

10Kg/cm2/minute upto 80%of test
pressure.Afterwards,it should
be2Kg/cm2/minute.
At test pressure pressurizing pump shall be
stopped or minimise scoop to zero and drop in
pressure shall be monitored for 30 minutes.
 BOILER DRUM
210 Kg/cm2 PRI S/H
ECO VC
PEND.S/H FINAL S/H
WATER
WALL FST

100 T/HR

HPH

8 T/HR
BOILER FEED MOTOR
PUMP BOOSTER PUMP
UDT
 Completion Criterion

The drop rate should not be more than 1

Kg/cm2/minute and no appreciable deflection of
components

After completion of test Boiler shall be

depressurized at the rate of 1
Kg/cm2/minute using CBD/IBD Valve.
 At a pressure of 50 Kg/cm2,the pressure is
held and Boiler is thoroughly inspected.

If found satisfactory,full depressurization

and draining can be done

At 2 Kg/cm2 the vents are left full

opened.
 Start the draining of boiler upto normal
operating drum level if hydraulic test is
successful.
Unlock the the pipe hangers.
Unlock all safety valves.
Normalise all the valves for light condition.
33