HRSG Hydrotest
HRSG Hydrotest
RFCL (1X32.5 MW GTG + 1X125 TPH HRSG) is a CPP plant with GT @32.5 MW & HRSG
with single drums. The steam generated is used for various processes in fertilizer
plant.
Rating of HRSG:
Drum
BMCR Capacity 125 TPH
Rated Pressure 121 kg/cm²
Rated Temperature 517 C̊
WATER VOLUME
Sr.No. DESCRIPTION
1. Evaporator 16.5 m³
2. Economizer 48.5 m³
2.0 OBJECTIVE
After installation of all pressure parts, the unit is subjected to the initial Hydrostatic pressure
tests. The testing objectives are to ensure healthiness of pressure parts.
3.0 PROPOSAL
Stage-I
Hydraulic test of the Drum, economizer, Evaporator and Superheater circuit panel may be
conducted at a pressure 1.5 times the design pressure. After completing the hydrostatic test,
the system will be drained and vented for drying and released for subsequent work.
RFCL BHEL Ref. No. PSWR:TSX/RFCL/ HRSG Sheet 4 of 5
RAMAGUNDAM
Plant Area: HRSG
PROCEDURE FOR HYDRAULIC TEST
Air tightness test shall be performed before filling water in the Boiler (for carrying out the
hydrostatic test). This is done to detect leakages due to valves left in open position, forgotten
gamma plugs, any cuts not observed by visual inspection etc.
Chemically treated water (as specified) shall be used for conducting hydrostatic test.
During testing at least, 2 Nos. calibrated standard test pressure gauges of suitable range to be
used.
Total Quantity of DM water Required for completion of Hydro test of all the circuits is 150 m3
(Considering 2 fills).
DM water dosed with 200 ppm of hydrazine and pH between 9.5 and 10.0 by addition of
adequate quantity of ammonia.
During testing the temperature of water should not be below 20 Deg.C and should not exceed
50 ̊C.
Readiness of stair cases, platforms, handrails, approaches etc. as jointly decided by BHEL and
RFCL.
Delivery line of pressurising pump should be high-pressure seamless pipe/High pressure flexible
hose to withstand the required hydro test pressure.
Testing team should be aware of the procedure to be followed in case of accident causing injury
to personnel.
A person is to be posted near emergency push button and should have the instruction to trip
the pressurising pump in case of emergency being notified to him by others.
RFCL BHEL Ref. No. PSWR:TSX/RFCL/ HRSG Sheet 5 of 5
RAMAGUNDAM
Plant Area: HRSG
PROCEDURE FOR HYDRAULIC TEST
Erection of the Boiler pressure parts is complete as per drawing. All necessary welding jobs are
complete and Gamma plugs are seal welded.
All Quality checks as per approved Erection FQP are also complete. No welding on tube will be
allowed subsequently.
Copies of FQPs and Erection Protocols with exceptions highlighted are Filled & signed.
Effective communication facility is available between drum floor, pressurizing pump area and
other operating areas.
Boiler drain is suitably connected to drain header or diverted with temporary piping
arrangement to appropriate location.
All debris shall be removed manually from all pressure parts etc.
Delivery line of pressurising pump should be high-pressure seamless pipe to withstand the
required hydro test pressure.
Before filling the boiler with water, an air tightness test @2 Kg/cm2 is to be performed to detect
any leakages from weld joint, opening of valve, and gamma plug. This will reduce the DM water
consumption and time as well.
Before admitting air, close isolating valves of drain and vents. (Drum, ECO and SH).
HRSG is pressurised and hold for 15 minutes for checking any pressure drop.
After completing the air tightness test, vent valves are left in open position.
The HRSG Drum, water walls, economizer, super heater up to MS stop valve are covered under
this stage.
RFCL BHEL Ref. No. PSWR:TSX/RFCL/ HRSG Sheet 6 of 5
RAMAGUNDAM
Plant Area: HRSG
PROCEDURE FOR HYDRAULIC TEST
Chemically treated DM of pH 9.5-10.0 & Hydrazine with 200 ppm is used for the hydro test.
Filling is done thru water wall drain header, economizer inlet header drain and super heater
drain, so that DM water sweeps air up and pushes it out through vents minimizing chances of
air trap.
Confirmation of completion of filling of the entire system shall be done through the vents.
Close and open the vent valves several times in order to allow venting of entrapped air and
steady stream of water overflows from the vents.
Wherever valves are in tandem, both the valves should be checked for passing one by one. All
the drain valves, vent valves and NRVs should be checked for any passing.
The pressure is raised up to 50 Kg/cm2 and hold for thorough inspection of HRSG.
The rate of rise of pressure should not be more than 10 Kg/cm2 per minute up to approximately
80% of the test pressure and should be 1 to 2 Kg/cm2 per minute beyond that value.
The required test pressure shall never be exceeded by more than 6%. of the Hydro test pressure
value.
Hand tight the safety valve gags at 80% of pressure of lowest set safety valve set pressure.
HYDRAULIC TEST
The hydraulic test pressure reading is taken from the calibrated standard test pressure gauge
mounted near the pressurizing pump with necessary correction for the height of the topmost
pressure part of boiler and simultaneously from the gauge mounted at a safe location at
topmost floor as per requirement of the statutory Inspection Authority.
If leaks are found, it will be necessary to release the pressure and drain the concerned portions.
After the repairs, the Boiler is refilled and the hydraulic test is repeated to the satisfaction of
statutory Inspection authority.
The pressure parts shall be de-pressurized at the rate of 1 Kg/cm2 per minute.
While releasing the pressure the vents should be opened when the system pressure falls to
around 2 Kg/cm2.
The test pressure in the official pressure gauge (Calibrated standard test pressure gauge) is held
in presence of Inspection Authority. The Boiler shall satisfactorily withstand such pressure
without appreciable leakage. Minor leakages observed shall be attended.