TABLE OF CONTENTS
1) General
2) Limits Of Hydrostatic Test
3) Test Pressure
4) Pressure Gauges
5) Preparation For The Test
6) Water Quality
7) Air Testing The Pressure Parts
8) Filling Pump And Pressurizing Pump With Temporary Connected Pipelines
9) Filling The Systems
10) Pressurizing The Systems
11) Hydrostatic Testing
12) Depressurization Of The Pressure Parts
13) Inspection Of The Boiler Pressure after Testing 'Arts
14) Proceeding To Prevent Accidents And Endangering Of Persons During Pressure
Test
15) Hydrostatic Test Report
16) Preservation Of Boiler After Hydrostatic Test
17) Figures
a. Hyd. Test Limit Boiler Water Circulation System
b. Hyd. Test Limit Superheater System
c. Hyd. Test Limit Reheater System
d. Hyd. Test Limit Boiler Water Circulation System and Super-heater System
e. Silica in Boiler Water Relationship with Drum Pressure.
Tables
a. Typical Hyd. Test Pressure And Test Pressure Gauge Ranges
b. Quality of Water
c. Water Volume (Typical For Various Capacity Of Units)
GENERAL
After installation of all pressure parts, the unit is subjected to the required initial Hydrostatic
Pressure tests. The exact Hydrostatic test-procedure to befolloweddependsonlocaljob
=it"-"""oiii"ns.
The procedure ouilined below is general in nature-
LTMITS OF HYDROSTATIC TEST
[Link](frornfeerlcheckvalveinlettodrum)with
Si saturated [Link] blanked)' Ref' Fig' 1
2.2 SH SY$TEnfi
From drum (with sH saturated conn'tubes blankecl) to MS stop valve' {Ref' Fig' 2)
2.3 RH SYSTEM
RH inlet header to RH outlet header- (suitably blanking the RH inlet& outlet headers
with the isotatin;;;;ices ir provrded or by means of blank langes) Ref' Fig' 3'
TEST PROGEDURE
The Unit shall be hydro-tested for conformation to lgRbode requirement in two areas {i)
primary Circuitary, ptu1n", F."nomiser$, Waterwalls, Superheaters at one anrl half times
the design pressute - and (ii) Reheaters at one and half times the design pressure or at
minimum 70 kg/sq'cm- (g)'
NOTE
It is preferable to do the hydro test at one stroke at the stipulated hydro test pressure
indicated !n the pres!"r* pJtt arrsngement drawing. ll it is not possible to aecomplish this
thehy(lrotestmaybeconductedtvrice,oncefordrainableportionandanotherincluding
non drainable portion atthe stipulated hydro test pressure (official test 1% tirne-s the design
pressure). ln case site would'prefer to conduct a hydro test at a lower pressure prior to
officiat hydrotest the same may be done once at the design pressure' For the s1e hydrostatic
pressure respective BoILER pressure part arrangemenl drawing has to be relerred'
PRESSURE GAUGES
During testing, atleast three [Link] calibrated pressure gauges are to be located one at
drum level, one at operating itoor teuet and one near pressure raising pump'
The indicator of the pressure gauges selected should have atleast 6" dialwilh dials gradualed
over a range of OouUte the in-tended maximum lest procedule' but in no case the range be
less than 1% times ltt"t pr"r*ure. The pressure gauges should be calibrated as per FQAF-
l5 ol FOA sYstems manual'
For typical "Test Pressure Gauge Range" Refer l9!lt 1 - "TYPICAL HYD' TEST
PROCLDURE AND TEST PRESSURE GAUGE RANGES-
3.0
4-0
0642 -VOL -A1 TAB -6-272
\"r" 5.0 PREPARATIONS FOR THE TEST
prtor to Hydrostatic testing, the following items should be inspebted'
i. A1 necessary welds completed, x-rayed ani stress relieved.
ii. A1 necessary valves including drain valves installed and closed.
iii. Ail sefety valves installed and hydrostatic plugs, should be assembled before
commencing the test.
. iv. Alldebris shalt be removed manually frorn all pressure parts including headers and
drurns.
v. The drain valve and test valve in the official calibrated pressure gauge sensing line
must be open.
vi' All manhole closure plates (except drurn manhole) and header handhole caos should
be closed and bolted or welded tightvii.
The isotating valves provided in all the other branching systems like SB System
tapping, SHlpray connections, [Link] elc',have to be closed tightly'
viii. A1 vents necessary to prevent air entraprnent during filling operation such as
superheater link vents, economiser link vents, drum vents etc., shall be kept open'
L'1 ix. When valves are in TANDEM {Double valved) both valves must be closed during the
hydrotest.
x, ln S00 MW Units, if the boiler circulating pumps are of the sub-merged motor or
canned motor type, installation of the rotating elements should be defered until the
hydrostetictesf of the unit has been cornpleted. The pump casings must be blanked
off during the test.
, xi. Joint lnspection protocolpricr to Hydrostatic Testirrg of Boiler prepared by FQA also
to be duly filled up, {FQA-01-00-00-L-17 {a)
6.0 WATER OUALITY
' 6.1 lt is the responsibility of the customer to provide pr$perly treated water, as specified
below at ambient temperature but in no case less than 70"F (21"C)
NOTE
The temperature limitalion for hydiostatic testing is 70"F or ?1'C. The important
point is that the hydrostatic pressure should rrot be applied when the water is less
than this limit. lt does not make any difference if the water is heated externally or
once it has been pumped in to the boiler,
The easiest way lo achieve and maintain proper hydrostatic iemperature in cold
weather is with an external steam supply. The full waier 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. lt is advised to consider electric
0642 -VOL -A1 TAB -6-273
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heaters or
