Wartsila India Ltd.

PREPARED BY : MECH APPROVED BY : PPM ISSUED BY : PPM DATE :

Operations & Maintenance PAGE DOC. NO. EDITION REVISION : : 496024P32 :0 :0

PLANT SMP BOILER HYDRO

TEST

AT STERLITE THERMAL POWER DIVISION

1. 2. 3. 4. 5. 6. 6.1 6.2

PURPOSE: SCOPE: RESPONSIBILITY: INPUT / TOOLS: OUTPUT: Record PROCEDURE: Take PTW. Erect proper scaffolding.

Boiler hydro test Boiler Mechanical Maintenance Engineer 1. Hand gloves 2. Mechanical tool box kit 3. Hydro pump 4.Gagging tool

1. All vents open and drains closed. 2. Hydra step and all transmitters to be isolate (except one drum level and one pressure transmitter). One drum level transmitter to be isolate after drum level full. 3. All sampling line, start up vent, soot blowing line all valves to be closed. 4. CBD, IBD valves to be closed. 5. All safety valves to be gagged. 6. M.S stops valve and equalizing valve to be closed. 7. F.R.S station to be isolate with provision for water filling. 8. Economizer filling line to be charged if required for filling water. 9. Except 2 ring header drains others to be isolated as per requirement for water filling. 10. Water filling to be started through ring header & Economizer drains By starting the filling pump and proper lineup for header valves. 11. Filling line valves for desired boiler to be opened & others to be isolated. 12. Water Pr. Of pump discharge to be checked intermittently. 13. After complete filling and sufficient venting all vent lines to be closed. When drum pr.is constant for 4-5 mins.filling pumps to be stopped & discharge valves to be closed. 14. Hydro pump line to be charged for pressure rising. 15. After opening the discharge valve pump to be started & pr. To be observed. rate of pressure to be controlled. 16. At 60 bar & 95 bar pr.raising to be stopped & boiler to be checked internally for any leakage. Rate of pr.drop to be observed for 20 minutes. All pr.gauges to be checked for value matching with transmitter & control room. 17. After reaching the desired pr. i.e. operating pr.X 1.25 times pump to be stopped & discharge valve to be closed. 18. Rate of pr.drop to be observed for atleast 10 mins. & internals checking to be done for any seepage or leakage. 19. When hydro is satisfied boiler to be drained slowly through CBD sampling line or any water side drain line. 20. Safety valve gag to be removed when pressure is below 80 bar. 21. Boiler to be made ready for light up. 22. Rate of pr.drop to be controlled @ 50 psi/min 23. All vents to be opened @4 bar drum pr. 24. Boiler to be line up for lit up by normalizing the system.

Wartsila India Ltd. PREPARED BY : MECH APPROVED BY : PPM ISSUED BY : PPM DATE :

Operations & Maintenance PAGE DOC. NO. EDITION REVISION : : 496024P32 :0 :0

PLANT SMP BOILER HYDRO

TEST

AT STERLITE THERMAL POWER DIVISION

25.Cancel PTW.

7. QUALITY: 7.1. All the parameters, activities are maintained within prescribed limit. 7.2. Any deviation from the norm is recorded and corrective action is taken accordingly. 8. ENVIRONMENT: 8.1. Not applicable. 9. OHSAS: 9.1. Ensure PPE, Helmet, adequate lighting near the work place. 9.2. Ensure the lifting tools are in adequate condition. 9.3. Ensure proper earthing of the equipment / area of work as the case may be. 9.4. Ensure healthiness & safety of the entire activities with respect electrical system. 10. RECORDS: WIN/SIL/4/F/05