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PUB.NO. 2025
CONTENTS
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 GENERAL LIMITS OF HYDROSTATIC TEST TEST PROCEDURE PRESSURE GAUGES PREPARATIONS FOR THE TEST W ATER QUALITY AIR TESTING THE PRESSURE P ARTS FILLING PUMP & PRESSURISING PUMP WITH TEMPORARY CONNECTED PIPELINES FILLING THE SYSTEMS PRESSURISING THE SYSTEMS HYDROST ATIC TESTING DEPRESSURISATION OF THE PRESSURE PARTS
INSPECTION OF THE BOILER PRESSURE P ARTS AFTER TESTING PROCEEDINGS TO PREVENT ACCIDENTS AND ENDANGERING OF PERSONS DURING PRESSURE TEST HYDROSTATIC TEST REPORT PRESERVATION OF BOILER AFTER HYDROSTATIC TEST
15.0 16.0
TABLE - 1 TYPICAL HYD. TEST PRESSURE AND TEST PRESSURE GAUGE RANGE TABLE - 2 QUALITY OF W ATER TABLE - 3 W ATER VOLUME (TYPICAL FOR V ARIOUS CAPACITY OF UNITS) FIGURE-1 HYD. TEST LIMIT BOILER FIGURE-2 HYD. TEST LIMIT SUPERHEATER SYSTEM FIGURE-3 HYD. TEST LIMIT FIGURE-4 HYD. TEST LIMITBOILER W ATER CIRCULATION SYSTEM FIGURE-5 SILICA IN BOILER W ATER RELATIONSHIP WITH DRUM PRESSURE
1.0 GENERAL
After installation of all pressure parts, the unit is subjected to the required initial Hydrostatic Pressure tests. The exact Hydrostatic test procedure to be followed depends on local job site conditions. The procedure outlined below is general in nature.
2.2
iv. v.
vi.
vii.
viii.
ix.
x.
xi.
The easiest way to achieve and maintain proper hydrostatic temperature in cold weather is with an externa l steam supply. The full water is heated with a direct contact heater and the temperature is maintained by using the steam coil air heater. For a new project where no steam is available. It is advised to consider electric heaters or fuel fired space heaters. 5
The best method of maintaining non-drainable 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 490o C. 6.2 It is recommended to use demineralised or cop ensate 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 leaks requiring draining, repairing and refilling. So it will be in order to use, initially filtered water free from chlorine for drainable portions only. It is necessary that the filtered water is clear, 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. 6.5 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 shall include 10 ppm arnmonia and 200 ppm hydrazine. This treated water will have a pH value of approximately 10. The use of fill water treated with solid chemicals should be avoided. Deposits of solid materials 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 MW. Unit sets, the boiler water circulation pumps are to be filled with condensate or demineralised water before putting water into the boiler for testing boiler with boiler circulating water pumps. NOTE: Demineralised or condensate quality water is defined as containing no more than ppm identifiable solids and essentially a zero concentration (or lowest detectable level) of organic materials. 6.8 After chemical cleaning, steam blowing and lay up of the units, if situation warrants to do hydraulic testing of the pressure parts usage of treated DMwater or treated condensate is only recommended. For quality of treated DM water REFER TABLE-2.
6.3 6.4
6.6
6.7
7.0
7.5
8.0
iv.
v.
8.2
Connected pipe lines (temporary) i. ii. Should all be welded. Delivery line of pressurising pump should be of high pressure seamless pipe to withstand the required test pressure. Mixing tank should be of required capacity. Flow regulating valves, drain valves, overflow lines should be provided with the mixing tank. 7
iii. iv.
9.0
ii.
iii. iv.
v. 9.2
In no 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 R1 + drain header respectively until all the elements are filled and the water overflows through the vent valves. 1. If it is decided to do the hydraulic pretest of boiler water circulating system and superheaters at the same time, treated DM water / condensate 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. The water temperature during hydrostatic test should be ambient temperature but in no case less than 21o C.
9.3
CAUTION :
2.
10.0
11.0
HYDROSTATIC TESTING
11.1 The hydraulic test pressure reading will be taken from the official pressure gauge located at the highest point in the presence of the Inspector. 11.2 After the hydraulic 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. 11.3 If leaks are found, it will be necessary to release the pressure and drain these portions. Make the repairs and refill the unit as mentioned above and repeat hydrostatic test. 11.4 Details of the leaks noticed during Hydraulic Tests are to be furnished as given below for better understanding: a. b. Exact location of leak(s) component circuit, Elevation, materials etc., Description of leak(s) such as straight tube elbow, shop or field weld, torchcut, where alugwas removed and attachment weld etc., Magnitude of leaks-weeping/sweating, leaks, burn through, longitudinal crack.
c.
12.0
13.0
14.0
14.2 During the period of raising, holding and releasing the test pressure, the entry to the boiler house is prohibited for all persons not participating in the pressure test, Works at the pressure parts or in the direct neighbourhood are not permitted. 14.3 All companies working on the site must be notified of the pressure test in writing. No claim based on the restriction or stopping of work will be accepted.
15.0
16.0
10
TABLE - 1 TYPICAL HYD. TEST PRESSURE AND TEST PRESSURE GAUGE RANGE
BOILERS ASSOCIATED WITH THE MACHINES 120 MW 210 MW (LP) 210 MW (HP) 500 MW BOILERS & SH HYD. TEST PR KG/SQ.CM (G) 237.0 237.3 263.7 306.0 TEST PR. GAUGE RANGE KG/SQ.CM 0-400 0-400 0-400 0-600 RH HYD TEST PRESSURE KG/SQ.CM. (G) 70.0 70.0 70.0 76.5 2 KG/SQ.CM. (G) PR.AFTER REGULATOR 0-4 KG/SQ.CM. TEST PR. GAUGE RANGE KG/SQ.CM. 0-150 0-150 0-150 0-150
: : : : : :
Nil Less than 0.02 Less than 0.01 IS preferable Nil Less than 0.003 Should be free in any cast it should not exceed 0.2 PPM on an average. Clear: Free from odour, colour and Haziness. No Glittering to tyndal effect.
4. 5. 6. 7. 8.
9.
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. 11
3. QUALITY OF BOILER W ATER Drum operating pressure kg/sq.cm.(g) Total Dissolved Solids - max (ppm) Specific Electrical Conductivity at 25o C (s/cm) Phosphate Residual (ppm) pH at 25o C 126-165 166-180 181-205
50
25
15
50 5-10 9.1-9.8
30 2-6 9.1-9.6
To be controlled on the basis of silica inboiler water and drum pressure relationship (Fig.1) to maintain less than 0.02 ppm in the steam leaving the drum 0.1
4. QUALITY OF FEED W ATER ( Drum operating pressure 101 kg/cm.sq.(g) and above ) Hardness pH at 25o C (copper alloy pre boiler system) pH at 25o C (copper free pre boiler system) Oxygen maximum Total Iron (Tax) Total Copper (max) Total CO2 Total Silica (max) Specific electrical conductivity at 25o C measured after cation exchanger in the + from and after CO2 removal (max) m s/cm Hydrazine - residual Permanganate Consumption Oil 12 ppm ppm ppm ppm ppm Nil 8.8 to 9.2 9. 0 to 9.4 0.007 0.01 0.005 Nil 0.02
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RECOMMENDED LUBRICATION CHART DUCTS, GATES AND DAMPERS Sl. Equipment Frquency Recommended Lubricants 10C HP BP BP Of Change No. Description 1 Bearings-Guillotin Servogem. Lithan3 Bharat 3 Years Gates HTxx MP Grease 3 2 Filter cum LubricatoServospin 12 Shell 1 Year Tellus 15 HP 3 Actuators Castrol 2 Years Alpha SP 68 of lndrol -Servomesh SP 68
5 Litrs
1.25 Litrs
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