Project:- 1 x 15 MW WHR BASED CPP

Client:- ULTRATECH CEMENT LTD., HIRMI

Doc. No.:- BC-08/1-UTCL-HRM Rev No. :- 0
Date:- 25.01.2018 Project No. :- 2M.0038

HYDROTEST PROCEDURE
(FOR AQC & PH 1,2 BOILERS)

Project 1 x 15 MW WHR BASED CPP

Purchaser / End User ULTRATECH CEMENT LTD., HIRMI

0 25.01.2018 Hydrotest Procedure

Rev. Date Description Approved by

Prepared By : MP
Checked By : SN/SC Page 1 of 8 Boiler & Power Plant Division
Approved By : Construction/B&PP
Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

CONTENTS

SECTION DESCRIPTION SHEET NO.

1 INTRODUCTION 03
2 WATER & STEAM CIRCUIT DESCRIPTION 03
3 HYDRO TEST PROCEDURE 04
4 HYDRO TEST PRESSURE PARAMETERS 06

5 HYDRO TEST SEQUENCE 07

6 HYDROTEST COMPLETION CRITERIA 07

ANNEXURES:
1. P&IDs for PH & AQC Boiler Water & Steam System
2. DM water quality

WO No. 2M.0038 Page 2 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

1. INTRODUCTION:
Prior to alkali boil out and Steam blowing, Hydro Test is a mandatory requirement for all the
boilers to ascertain no leakages & pressure withstanding capability of the parts under test.
Treated water is filled inside the boiler tubes and headers and then all the isolation valves
are closed, pressure inside the boiler tubes and headers is raised to 1.5 times of maximum
operating pressure and is held there for 30 minutes. If any leakage is found the boiler is
depressurized and drained to attend the leakage and after the rectification, Hydro test has to
be repeated to ensure no further leakage.

2. WATER & STEAM CIRCUIT DESCRIPTION: (Refer Schematic : Annexure – 1 )

Plant consists of three WHR Boilers installed behind cement kiln (2 nos. PH Boiler and 1 no.
AQC Boiler). PH boiler consists of LP & HP sections and AQC boiler consists of only HP
section. There are dedicated boiler feed pumps for LP & HP sections. Economizer is placed
in AQC boiler which is common for AQC and PH boiler HP sections. Feed water from HP BFP
Outlet First Enters the Economizer of AQC boiler and from Economizer outlet feed water
enters to the Drum of AQC and PH boiler. From Drum of AQC boiler saturated steam enters
at PSH of AQC boiler from there steam goes to SH mixing header. Saturated Steam from
both PH boiler Drum enters to HP SH of PH boiler and then both HP steam from PH boilers
going to the SH mixing header. From SH mixing header steam enters to Final super heater
(FSH) located in AQC boiler. Superheated steam from outlet of Final super heater goes to
turbine.

In LP section, feed water from LP BFP Outlet Enters the steam Drum of PH 1 and 2 LP
steam Drum. Saturated steam from Drum enters into LP SH and then to turbine inlet.

Three tapings have been taken from HP main steam line to TG inlet, one for deaerator
pegging requirement, One for ACC ejector and the other for STG gland sealing requirement.

After hydro test of boilers, alkali boil out & steam blowing are the next activities in
sequence.

WO No. 2M.0038 Page 3 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

3. HYDRO TEST PROCEDURE:

3.0 Prerequisites For Hydro Test:
1. Boiler pressure part erection to be 100% completed along with all supports and
attachment weldings.
2. Sufficient DM water should be available for hydro test as mentioned below
a) PH Boiler-1 : 162 m3
b) PH Boiler-2 : 102 m3
c) AQC Boiler : 53 m3
d) Additional qty. for venting: 5 m3
Individual equipment should be hydrostatically tested to a minimum of 1.5 times the
maximum working pressure, in the factory, and copies of the Manufacturer's Data report,
signed by the Authorized person witnessing and evidencing the test is forwarded to all
authorities. However, the complete system, along with all interconnecting piping, should be
hydrostatically tested before the start-up to comply with statutory requirements and to be
checked for leaks that may have occurred at interconnections and also due to faulty
erection. This test should be completed under supervision and witnessed by Authorized
personnel. The boiler and process lines must be completely vented in order to fill them with
water. The vent valves are then closed and system is pressurized with the DM water.
Check list for filling the Boiler with DM water for Hydro test:-
SL No. Description Checked
Boiler initial filling piping, Pressure part and its supports erection is
1. 100%completed
2. Boiler initial fill pumps are ready for operation

3. Adequate quantity of DM water is available

4. Boiler Drum vents are open (Saturated steam piping vent)

5. Boiler drum CBD and IBD valves are closed

6. Feed water line isolation valves before initial filling line taping are closed
Boiler ECO, EVAP, Superheater, Mixing header drains are closed and
7.
vents are opened
Instruments like LT, LG, PT are isolated and their isolation valves are
8. closed
9. Boiler feed control station drains are closed

10. Boiler start up vent isolation valves are closed

11. Boiler final steam to Turbine stop valve and its bypass is closed

WO No. 2M.0038 Page 4 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

SL No. Description Checked

12. Feed control station isolation and control valves are 100% open
AQC Boiler attemperator main isolation, control station valves are
100% open and nozzle block MOV (WHRS-AQC-FDW-MOV-003) is
13. closed
Hydro test pump and its piping is ready and pump power supply is
14. available with local control station
Boiler blow down water transfer system is ready to remove the
15. drained water after hydro test
No hot works are in progress for Boiler pressure part and integral
16. piping

DM water parameters are within limits as mentioned in annexure 2

17.
Calibrated Pressure gauges are installed at Hydro pump discharge
18. and respective zone pressure measuring areas
Steam Drum Dosing inlet valves are closed
19.

The following is a recommended procedure for hydrostatic testing:

3.1 Open the steam drum vent valve and blind the safety valve opening with dummy flange
to ensure proper pressurization. Once the hydro test is over these dummy flanges can be
replaced with the safety valves in the position flanges.
3.2 Open the vents on the interconnecting piping between the headers. Close the main steam
stop valve.
3.3 Isolate pressure switches, gauge glasses or control components that are not intended to be
subjected to a hydrostatic test.
3.4 Fill the system with DM water in accordance with water quality recommendations (Refer
annexure 2). The test water temperature range must be 20° C minimum to 50°C maximum.
Care should be taken so that all air is vented while the equipment is being filled. Fill the
equipment until water overflows the vents, and then close the vents.
3.5 Apply pressure slowly with the help of hydrotest pump. The recommended rate of pressure
increase is less than 2 kg/cm² per minute. Proper control must be maintained so that
pressure does not exceed the desired setting of the local steam boiler inspecting agency.
Do not subject any pressure part to more than 1.5 times the maximum operating pressure
rating of any component.
3.6 When the proper desired pressure is reached, inspect in accordance with the test objective.
Examine the system for any leaks. If no leaks are visible, hold the system in a pressurized
static condition for a period long enough (Min. 30 mins.) to satisfy the code requirement.

WO No. 2M.0038 Page 5 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

3.7 Upon completion of the test, release pressure slowly (2-3 kg/cm2 per Minute) by crack
opening vent valve. Then fully open vents and drains when the pressure drops to 2 kg/cm².
Particular Care must be given to make sure that parts not normally containing water during
Operations are drained free of water. The system should be drained fully after hydrostatic
testing.
3.8 If temporary hand hole or man way gaskets were used for the test, they should be replaced
with regular service gaskets. Gaskets should never be reused. Replace gauge glass if
necessary and make sure that the gauge cocks are open. Remove all blanks from safety
valves and install safety valves.
3.9 Additional inspection at this time by the Authorized inspector will determine whether the
installation including piping arrangements, valve gauges and controls and other equipment
on the unit meets Code and/or other jurisdictional requirements.

NOTE:
tkII represents that the information contained in this procedure has been developed in
accordance with tkII standard technical procedures and practices from the latest information
available at the time of this procedure was issued. Please read and follow the instructions
contained in this manual carefully for safe operation.

WO No. 2M.0038 Page 6 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

4. HYDRO TEST PRESSURE PARAMETERS

MAX. WORKING HYDRAULICTEST

S.NO DESCRIPTION PRESSURE PRESSURE REMARKS
(Kg/cm2,g) (Kg/cm2,g)
PH BOILER (1&2) -HP Section
Feed water inlet piping from AQC ECO O/L
1 46.5 69.75
to Feed control station downstream NRV
Feed control station outlet to HP Steam Drum
2 22 33
piping
HP Steam Drum, Evaporator , HP Steam drum
to HP SH interconnecting piping, HP super
3 22 33
heater coil & headers, HP SH to Steam stop
valve
PH BOILER (1&2) -LP Section
Feed water piping from AQC end (WHRS-
1 AQC-FDW-GT-002) to Feed control station 46.5 69.75
downstream NRV
LP Drum, LP Evaporator coil & headers, and LP
2 5 7.5
Super heater coil & header
LP Drum Riser, Supplies and Interconnecting
3 piping from drum to LP SH, LP SH to main 5 7.5
steam stop valve
AQC BOILER
Feed water line isolation valve (WHRS-AQC-
FDW-GT-003) to ECO, ECO coils and headers,
1 ECO to feed control station downstream NRV, 46.5 69.75
Attemperator piping up to control station
manual isolation valve
Feed control station outlet to Steam Drum, Steam
2 Drum, Evaporator coil & headers and PSH, FSH 22 33
coils and headers
Riser, Supplies and Interconnecting piping from
3 drum to PSH, PSH to SH mixing header, SH 22 33
mixing header, SH mixing header to FSH,
FSH to main steam stop valve
For remaining parts such as blow down tank, boiler area piping and BOP piping the hydraulic
test shall be carried out at pressure mentioned on the respective drawings.

WO No. 2M.0038 Page 7 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

5. HYDRO TEST SEQUENCE:

5a) Hydro test of PH boiler (1, 2) -HP section has to be conducted in two phases

1) AQC ECO outlet (WHRS-AQC-FDW-GT-006,015) feed water piping up to PH (1, 2) Feed control
station manual isolation valve.

# Same can be done in combination with AQC Boiler Feed water piping.

For this purpose the hydro test pressure will be 69.75 kg/cm² (g)

2) Feed water line from feed control station to HP Steam Drum, EVAP, HP Steam Drum to HP SH,
HP SH to Main Steam stop valve (WHRS-PH1HP-MAS-MOV-001, 001A)

For this purpose the hydro test pressure will be 34 kg/cm² (g)

5b) Hydro test for PH Boiler (1, 2)-LP section has to be conducted in two phases

1) Feed water piping from AQC end (WHRS-AQC-FDW-GT-002) to Feed control station manual
isolation valve.

# Same can be done in combination with AQC, PH HP feed water piping.

For this purpose the hydro test pressure will be 69.75 kg/cm² (g)

2) Feed control station outlet to LP Steam Drum, LP Steam Drum to LP SH, EVAP, LP SH to Main
steam stop MOV.

For this purpose the hydro test pressure will be 7.5 kg/cm² (g)

5c) Hydro test for AQC Boiler has to be conducted in two phases

1) Feed water piping from isolation valve (WHRS-AQC-FDW-GT-003) to ECO, ECO to Feed control
station manual isolation valve.

For this purpose the hydro test pressure will be 69.75 kg/cm² (g)

2) Feed control station outlet to Steam Drum, Steam Drum to PSH, EVAP, PSH to SH Mixing
header, SH Mixing header to FSH, FSH to Main steam stop valve.

For this purpose the hydro test pressure will be 34 kg/cm² (g)

6. HYDROTEST COMPLETION CRITERIA:

Hydro test can be declared complete only after ensuring that there is no leakage of the
water from tubes, pipes, headers & drums.

WO No. 2M.0038 Page 8 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

WO No. 2M.0038 Page 9 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

PH-1

PH2

WO No. 2M.0038 Page 10 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

DM Water Parameters:-

WO No. 2M.0038 Page 11 of 11

Project: 1x15 MW WHR based CPP Doc No. : BC-08/1-UTCL-HRM
Client: Ultratech Cement Ltd, Hirmi
Date : 25.01.2018

WO No. 2M.0038 Page 12 of 11