BOILERHYDROTESTPROCEDURE

Themainpurposeofhydrotestistoensurealltheweldingjoints,pipebents
andallheadersarewaterleakproof.Thehydrotestisgenerallydoneata
pressureof1.5timesofdesignpressure,Forexampleifaboilerisdesigned
withmaximumworkingpressureof135kg/cm2thenthehydraulictestpressure
willbe202.5kg/cm2.Thehydraulictestisdoneandcertifiedwiththepresence
offactory/boilerinspector.Oncehydraulictestiscertifiedthenyoucangofor
furtherrefractoryandskincasingwork.
Pressurepartsinvolvedinhydraulictestis:
Thisoperatingpressurepartsareinvolvedduringhydrotestassteamdrum,
downcomers,supplypipes,furnacewall,cagewall,riser,saturatedpipe,
superheater,economizer,internalandexternalpipinglikeboilerdrainsand
vents.

HYDROTESTPUMP
Prechecklistforboilerhydrotest:
1)Allerectionworkshouldbecompleted.
2)Confirmthatnoforeignmaterialorloosematerialleftintheboiler.
3)Confirmthedrummanholeisclosedwithpropergasket.
4)Confirmallthedrainsystemreadyforoperation.
5)AllsafetyvalveshouldbeGagged.
6)Therangeofthepressuregaugeshouldbetwotimesofthemaximumtest.
pressurebutnotlessthantestpressure.
7)Thepressuregaugeshouldbeprecalibratedbeforetest.
8)Thetestpumppressureshouldhavecapacityofmorethantestpressure.
9)Thetestpumpshouldhavepressuregauge,checkvalve,drainvalve
10)Torchesor24voltlampsshouldonlybeusedforinternalinspectionofthe

boiler.
11)MinimumquantityofDMwatershouldbeavailableequivalenttotheboiler
capacity.
12)EnsureCondensate&FWchemistryparameterstostrictlyadheretothe
requiredstandard:
13)ThePHvalueshouldbeintherangeof8to9.
14)Thewatertemperatureshallbenotlessthan21.1degc.
15)Ensureallventvalveofeconomizer,drum,superheaterandwaterwall
shouldbeopencondition.
16)Isolateallpressureandtemperaturegaugesexceptsomepressuregauges
forhydraulicpressuremeasurement.

Startthehydrotest:
1)Starttheboilerfillingwiththefillingpumpthroughthedrainheaderorfilling
lineattherateof40~50tph.
2)Closetheallventssequentiallyafterwatercomingfromthevents.
3)Startthehydrotestpump(ensureallventsclosed)andrisepressure
graduallywith25ksc/minuteuptothedesignpressureandthenthepressure
toberaised@2kg/cm2uptotestpressure.(Forexampleifthedesign
pressureis135kg/cm2thenthetestpressureshouldbe202.5kg/cm21.5
timesofdesignpressure)
4)Duringpressurerisingcloselymonitorthetheafterdrainofboilermainstop
valveandturbinesidedrain,ifthereisanypassingthenstophydrotestand
depressurisingtheboileruntilpassingofmsvarrest.
5)Duringpressurerising,closelymonitortheturbineinlettemperatures.Ifany
dropisobservedduetopassinginBMSSVs,immediatelystoppressureraising
,bringdownthepressure.AfterhandtighteningtheBMSSVs,continuethe
pressureraising.
6)Holdthepressureraisingat50kg/cm2&100kg/cm2,tocheckanyvalve
passing&inspectleakageinpressureparts.
7)Oncethepressurereachedtotestpressurestoppressurizingandobserve
pressuredropifthepressuredropisverylessthenthetestissuccess.
8)Ifanydefectisfound,sametobenoticedandtakingaccountthetypeof
defectandsolvedlater.
9)Ifthepressureisholdingbetterthendepressurizepressure@10kg/cm2by
openingtopvents.
10)Afterdepressurizeallowcheckteamforphysicalinspectionofinsideboiler.
11)Aftersatisfytest,documentstobepreparedandsignedwiththeconcerned
authorities.