Hydrostatic Test Procedure Site RevD

7/29/2019 Hydrostatic Test Procedure Site RevD

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Owner

Torrent Power Generation Limited

Consultant

TCE CONSULTING ENGINEERS LIMITED

MUMBAI

D 2007/03/22 S,K.AN Revised to reflect to site preparation.

C 2007/02/22 S,K.AN Revised as Siemens Comment.

B 2007/02/15 S,K.AN Revised as Siemens Comment.

A 2007/01/20 S.K. AN First IssueIndex

Rev.

Datum

Data

bearb.

Coord.

gepruft

Checked Anderungshinweis / Details of RevisionSub-Contractor

Sub-Contractor document No.

IKR-PROC-001Urspaung-Nr./Original No.Ursprung/ Original Urspr-PKZ-Nr.

Orig.-PC

Projekt/project

1100 MW SUGEN CCPPPKZ/PC

IND696Datum Data Name MaBstaB

Scale A4 UA/DCCType DH01gezeich.Drawn

bearb,Coord.

GepruftChecked

InfalrskennzeichenContents Code

HA

AbtlgDept. E932

Benennung/Title

HYDROSTATIC TEST PROCEDUREFOR HRSG (SITE)

Zahl-Nr.

Reg.No. 223104

SIEMENS Dienstst./DetE932 UNID 458077234 Index/Rev.D Version

IND696-DH01-HA-223104

Ang-VR./Offer-Var. Var./Opt. Blatt-Nr./Page-No.

23Erstellt mit / designed with:Intergraph

Ersatz furSupersedes

Copyright

(C)Siemens2001

x

Inkor Engineering Pvt. Ltd.This document is the property of INKOR, and is to be used only for thepurpose of the agreement with INKOR pursuant to which it is furnished

Thereproduction,

transmissionoruseofthisdocu

mentoritscontentsis

notpermittedwithoutexpresswrittenauthority.

Offenderswillbeliablefordamages.

Allrights,

includingrightscreatedby

patentgrantorregistrationofautilitymodelordesig

n,arereserved.


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1100MW SUGEN CCPP HRSG

Hydrostatic Test Procedure for HRSG (Site) Doc.No : IKR-PROC-001Rev.0 Page 2 of 23

TABLE OF CONTENT

1. INTRODUCTION

1.1 Purpose

1.2 Applicable Code and Reference Data for Hydrostatic Test

1.3 Responsibility

2. CONDITIONS FOR HYDROSTATIC TEST

2.1 Preliminary

2.2 Hydrostatic Test Pressure and Water Volume.

2.3 Treated Water Requirement

3. PRE-TEST PREPARATION

3.1 Safety Valves

3.2 Test Gauges

3.3 Temporary Facility

3.4 Communication

3.5 Advance Material Readiness

4. HYDROSTATIC TEST GENERAL REQUIREMENTS

4.1 Boiler Metal Temperature

4.2 Sectional Testing of the HRSG System

4.3 Double Valve Arrangement

4.4 Communication

5. PROCEDURE

5.1 Inspection before Hydrostatic Test

5.2 Hydrostatic Test

6. INSPECTION AND TEST

7. Post Hydrostatic Test Procedures

8. APPENDICES AND ATTACHMENT

8.1 The Pressure curve of Hydrostatic Test for HRSG (Typical)

8.2 Pressure Test Circuit.


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1. INTRODUCTION

After installation of all pressure parts, Section I of the ASME Boiler and Pressure Vessel Code

requires that a boiler shall be subjected to a Hydrostatic Pressure Test. This will be conducted at

a test pressure of 1.5 times the maximum allowable working pressure as stamped on the boiler

identification plate.

This procedure is applicable to the hydrostatic test for the pressure parts of HP, IP, LP, CPH

section for 1100MW SUGEN CCGT HRSG.

This description only describes the general procedure for the hydrostatic pressure test of the

HRSG. The detailed description will be contained in an additional detail engineering document.

1.1 Purpose

The primary purpose of this procedure is to provide a good quality of performance of HRSG

before chemical cleaning and commissioning operation. And also to find a fault in site welding

parts and to repair it.

1.2 Applicable Code and Reference Data for Hydrostatic Test

a) ASME Boiler and Pressure Vessel Code Sect. I

b) ANSI B31.1 (for external piping)

c) IBR1950

1.3 Responsibility

a) Erector is responsible for confirming and controlling the hydrostatic test job is being carriedout according to the prescribed procedure.

b) The manager in charge of hydrostatic test for HRSG must follow the procedure as

requested, review and manage in accordance with the prescribed procedure.

c) Temporary control office should be placed around the pressurization pump. The

communication system for pressurization and depressurization shall be carried out by

means of walkie-talkie.


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2. CONDITIONS FOR HYDROSTATIC TEST

2.1 Preliminary

Before starting to fill the boiler make sure all drums and headers are cleared of foreign material.

Close all drains. Open all vents normally used when filling the HRSG (such as superheater link

vents, economizer link vents, drum vents).

2.2 Hydrostatic Test Pressure and Water Volume

System

Design

Pressure

(barg)

Hydrostatic

Test Pressure

(barg)

Water

Volume

(M3)

Remarks(Test Circuits Color / P&ID No.)

HP

(F.W)257 385.5 3 Dark Blue (IND696-XG02-HAD10-220011)

HP

(SH,Eva,Eco)145 218 161 Purple (IND696-XG02-HAD10-220011)

IP

(F.W,Eco)110 165 3 Blue (IND696-XG02-HAD50-220051 / 220052)

IP

(SH,Eva)38 57 43 Mauve (IND696-XG02-HAD50-220051)

RH

(RH,HP Bypass Outlet)

38 57 50Mauve (IND696-XG02-HAD50-220052 /

HAD10-220011)LP

(F.W)50 75 2 Light Blue (IND696-XG02-HAD80-220081)

LP & LBG 11 16.5 47Orange (IND696-XG02-HAD80-220081 /

LAA20-412001 / LBG10-421111)

Deae. To Cond. Sys 50 75 3 Brown (IND696-XG02-LAA20-412001)

Deaerator 8 12 25 Deep Purple (IND696-XG02-LAA20 / 412001)

CPH 50 75 34 Light Green (IND696-XG02-LCA30-413032)

HP Bypass Cooling

water

58 87 Nil Gray (IND696-XG02-HAD10-220011)

Total 371

2.3 Treated Water Requirement

1) Superheater and Reheater

- Type : Demineralized water

- Temperature : 21 C to 49 C

- Contents : Ammonia 10ppm solution

Hydrazine 200ppm solution


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- pH : 10

NOTE : Demineralized or Condensate quality water is defined as containing no more than

1 ppm (1 / ) of identifiable solids and essentially a zero concentration (orlowest detective level ) of organic material.

CAUTION : The use of fill water, treated with solid chemicals, should be avoided.

Deposits of solid materials in superheaters can be detrimental from heat transfer

and corrosion standpoints. Superheaters containing stainless steel tubing are

particularly vulnerable to stress corrosion cracking in the presence of such

chemicals as caustic and chlorides.

2) Remainder of HRSG unit:

Fill with treated condensate or treated demineralized water, or, if not available, with a

clean source of filtered water with 10 ppm (10 cm3/m3) of ammonia and 200 ppm (200

cm3/m3) of hydrazine

The water conditions as stated above can be adjusted by pouring chemicals, Ammonia in the

temporary storage tank i.e. condensate storage tank.

The water can be treated with only ammonia. This will however reduce the period of time that

this water can be left in the system.

3. PRETEST PREPARATION

3.1 Safety Valves

All safety valves will be checked for having the Hydro Plug inserted if applicable. TheCompression screw on the Safety Valve must be turned clockwise until the locknut makes up on

the Yoke.

3.2 Test Gauges

- Only recently calibrated test gauges are to be used.

- Dial pressure gauges used in the testing shall preferably have dials graduated over their

entire range of about double the intended maximum test pressure, but in no case shall the


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range be less than 1 times that pressure.

- There should be at least two (2) pressure gauges installed, one of which is at the highest

point of the system, the other gauge is to be installed at the Hydro-Pump.

3.3 Temporary facility

Description Capacity Qty Remarks

D.M Pump 1 Water filling for Temp. Tank

Filling Water Pump 20 kg/cm2g 1 Water filling for System

Pressurizing pump 450 kg/cm2g 1 Pressurizing

Temporary Water Tank 10 m3

1 Pressurizing

Air Compressor 10 kg/cm2g 1

Fire Hose 2 ~ 20m 5 Water filling for System

High Pressure Hose ~ Multitude

Pressurizing

Temporary Piping Water filling & Pressurizing

3.4 Communication

All communication between the boiler control station and the Hydro-Pump station will be with

Radios. Back-up radios are to be readily available at each control station.

- Radio : More than 4 walkie-talkie

- Location : Control center (filling water pump or pressurization pump area) Top (pressure

gauge, thermometer and vent area) Inspector

- Inspector and recorder must be placed in a convenient area to communicate for the

pressure gauge, inspection of thermometer and control center.

3.5 Advance Material Readiness

Scaffolds, lights and repair tools are to be ready at time of Hydro-Test.

4. HYDROSTATIC TEST GENERAL REQUIREMENT


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4.1 Boiler Metal Temperatures

The metal temperature of all components to be Hydro-Tested must be at least 21 C (70 F)

before applying the Hydro Test pressure but shall not exceed 48.8 C(120F)

4.2 Sectional Testing of the HRSG Systems

When Hydrostatic Testing is to be done on a section of the system which is not directly linked to

a lower than test pressure designed system, but segregated by the test boundary isolation, all

vent valves in the lower pressure designed system must be open to avoid over pressurization of

the same.

4.3 Double Valve Arrangements

- All components tested will be as indicated on the flow chart or P&ID for the specific test.

- Always open the root valve fully and throttle with the down stream valve when

depressurizing or draining a system.

4.4 Communication

All communication / Co-ordination concerning the Hydro-Test has to be addressed through

designated personnel.

5. PROCEDURE

5.1 Inspection before Hydrostatic Test

5.1.1 Check for any foreign materials of tools, clothes and other things inside the drum, heater,

manifolds etc. and then close the manholes and all holes of the pressure.

5.1.2 The pressure gauge to be used for Hydro-Test should exactly be calibrated. In addition to

this, the filling piping and pressurization shall be checked.

5.1.3 It is very important to check whether the instruments and the temporary construction piping


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are free from foreign particulate matters.

5.1.4 The safety valves gagged. (when the worker install safety valve, he must check whether

the test plug is inserted or not, and if inserted, a tag with No operating must be attached)

5.1.5 Before filling , to close the block valves and open the vent valve of each system,

Authorization of concerned in charge is required to be done in the valve operation list.

5.1.6 In case of deaerator, Spray valve & tray should be separated to avoid foreign material. But

if spray valve is installed in deaerator, take a note water filling must not be done through

spray valve.

5.2 Hydrostatic test

5.2.1 Water filling

In case of non availability of condensate transfer pump, which are to fill the water, filling of

water shall be done by temporary filling water pump shall be installed in each system as

paragraph 5.2.1.2.

5.2.1.1 In advance, in the close condition of the specified valve, it has to be checked then the

signature on the control list is requested under the open condition of top air vent valve. If

the above condition is pleased it may be filled for water washing.

5.2.1.2 It is a fundamental rule to fill the inside of HRSG through specified valves for each

system(HP, IP, LP, CPH and Deaerator).

5.2.1.3 If water is seen being filling from bottom valve, each air vent valve shall be closed on

sequentially till top air vent valve at that time a full filling should be confirmed at top air

vent valve.

5.2.2 Pressurization

5.2.2.1 HP F.W. Section

a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable working

pressure(design pressure 257barg).

b) Observe test section for any obvious leaks.

c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-test


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pressure (385.5 barg) ofHP F.W. section and held for min. 30 minutes. The pressure

must be under control at all times and shall never exceed by more than 6%(23.1 bar)

of the desired Hydrostatic Test Pressure.

d) The pressure shall be reduced by 2~3 kg/cm^2/min. (depressurization rate) till the

design pressure by opening drain valve.

e) A close visual inspection of all boiler pressure parts and connecting piping shall be

carried out after the pressure was lowered from hydrostatic test pressure to design

pressure.

f) If the result during checking is under the normal condition, the pressure shall be

reduced by 3~5 kg/cm^2/min. by opening a drain valve.

5.2.2.2 HP section


pressure(design pressure 145 barg).



pressure (217.5 barg) ofHP section and held for min. 30 minutes. The pressure must

be under control at all times and shall never exceed by more than 6%(13.0 bar) of

the desired Hydrostatic Test Pressure.





pressure.


reduced by 3~5 kg/cm2^/min. by opening a drain valve.

5.2.2.3 IP F.W Section


pressure(design pressure110 barg).



pressure (165 barg) ofIP F.W. section and held for min. 30 minutes. The pressure



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pressure



5.2.2.4 IP Section

a) The pressure should be increased by 3~5 kg/cm^2/min. up to Max. allowable

working pressure(design pressure 38 barg).



pressure (57 barg) ofIP section and held for min. 30 minutes. The pressure must be

under control at all times and shall never exceed by more than 6%(3.4 bar) of the

desired Hydrostatic Test Pressure.





pressure.


reduced by 3~5 kg/cm2^/min. by opening a drain valve.

5.2.2.5 LP F.W. Section





pressure (75 barg) ofLP F.W section and held for min. 30 minutes. The pressure





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pressure.

f) If the result during checking is found in normal condition, the pressure shall be


5.2.2.6 LP section





pressure (16.5 barg) ofLP section and held for min. 30 minutes. The pressure must

be under control at all times and shall never exceed by more than 6%(1 bar) of the


d) The pressure shall be reduced by 2 ~ 3 kg/cm^2/min (depressurization rate) till the




pressure.



5.2.2.7 CPH section


working pressure (design pressure 50 barg).b) Observe test section for any obvious leaks.


pressure(75 barg) ofCPH section and held for min. 30 minutes. The pressure must

be under control at all times and shall never exceed by more than 6% (4.5 bar) of the






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pressure.



5.2.2.8 Deaerator section


working pressure (design pressure 8 barg).



pressure(12 barg) ofDeaerator section and held for min. 30 minutes. The pressure

must be under control at all times and shall never exceed by more than 6% (0.7 bar)






pressure.



5.2.2.9 HP Bypass Cooling Water Section


working pressure (design pressure 58 barg).


c) Then the pressure should be increased by 2~3 kg/cm^2/min till the hydro-testpressure(87 barg) ofHP Bypass cooling water section and held for min. 30 minutes.

The pressure must be under control at all times and shall never exceed by more

than 6% (5.5 bar) of the desired Hydrostatic Test Pressure.





pressure.


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6. INSPECTION AND TEST

6.1 All welding points, valves and hangers which were welded on pipe must be inspected

during the hydrostatic test. During the inspection if there is an abnormal condition the

inspection should be stopped and a repair work should be done.

6.2 The test data should be recorded at an interval of 5 minutes but not less than 5 measuring

data in each case during hold time and during subsequent inspection, and the basis of the

pressure is the pressure gauge installed at the highest point of the system, and

temperature should be recorded from the temporary temperature gauge installed near the

pressure gauge.

6.3 The inspection must be witnessed as per the inspection points in hydro test inspection

table.

NOTE : Hydrostatic test pressure should not be applied to the boiler of the metal

temperature of the pressure parts is below 70 F ( 21 C ). Since there is generally

some time delay between the hydrostatic test and the initial boiling out and

cleaning for the boiler the unit should remain full of water, air should not be allowed

to enter.

7. Post Hydrostatic Test Procedures

7.1 Hydrostatic test water will be left in the system for preservation. Pressure approximately 3to 5 psig (21 to 34 kPa) to be maintained, checked and recorded on a regular basis.

7.2 Remove all hydrostatic test plugs and gags from the safety valves prior to starting up the

unit.

NOTE: Since there is generally some time delay between the hydrostatic test and the initial

boiling out and acid cleaning of the HRSG, it should remain full of water; air should

not be allowed to enter.


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8. ATTACHMENT

8.1 The pressure curve of hydrostatic test for HRSG

A. HP F.W Section pressure curve (Typical)

B. HP Section pressure curve (Typical)

C. LP Section Pressure Curve(Typical)

D. LP F.W Section Pressure Curve (Typical

E. CPH Section pressure curve (Typical)

F. IP & RH Section Pressure Curve (Typical)

G. IP F.W Section Pressure Curve (Typical)

H. Deaerator Section Pressure Curve (Typical)

I. HP Bypass Cooling Water Section Pressure Curve (Typical)

8.2 Pressure Test Circuit ------- 1 Set

Red Color Marking(golden joint) means pipe will be blanked before hydrostatic test and

RT will be done for weld joint after Hydrostatic test.


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Attachment 8.1. The pressure curve of hydrostatic test for HRSG

A HP F.W. Section Pressure Curve (Typical)

0 50 100 150 200 250 300

0

50

100

150

200

250

300

350

400

Pres

sure

[barg]

Time Hours

Min.30 Minutes

At 385.5 barg(393.4 / )

(hydrostatic Test Pressure)

Inspection Time

At 257 barg

(261.1 / )

(Design Pressure)

Pressure Up Pressure Down

Time [min]


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B. HP Section Pressure Curve (Typical)

Pressure U Pressure Down

Min. 30 Minutes

At 218 barg (222.5 / )

(Hydrostatic Test Pressure)

Inspection Time

At 145 barg

(148.0 / )

(Design Pressure)

P

ressure

[barg]

0

50

100

150

200

250

300

Time [min]

0 50 100 150 200 250


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C. LP Section Pressure Curve (Typical)


0 20 40 60 80 100

0

4

8

12

16

20

24

Pressure

[barg]

Time [Min]

Min. 30 Minutes

At 16.5 barg(16.8 / )


Inspection TimeAt 11 barg

(12 / )

(DesignPressure)

120


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D. LP F.W Section Pressure Curve (Typical)

Min. 30 Minutes

At 75 barg(76.5 / )



(51.0 / )

(DesignPressure)

Pressure Pressure Down

0 20 40 60 80 100

0

15

30

45

60

75

90

Time [Min]

Pressure

[barg]


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E. CPH Section Pressure Curve (Typical)

Min. 30 Minutes

At 75 barg(76.5 / )



(51.0 / )

(DesignPressure)


0 20 40 60 80 100

0

15

30

45

60

75

90

Time [Min]

P

ressure

[barg]

120


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F. IP & RH Section Pressure Curve (Typical)

Min. 30 Minutes

At 57 barg(58.1 / )



(38.8 / )

(DesignPressure)


0 20 40 60 80 100

0

10

20

30

40

50

60

Pressure

[barg]

Time [Min]


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Time [min]

G. IP F.W Section Pressure Curve (Typical)

0 30 60 90 120 150 180

0

25

50

75

100

125

150

175

Pressure

[barg

]

Min.30 Minutes

At 165 barg(168.4 / )


Inspection Time

At 110 barg

(112.2 / )

(Design Pressure)

Pressure Up Pressure Down

200


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H. Deaerator Section Pressure Curve (Typical)


0 15 30 45 60 750

2

4

6

10

12

8

Pressure

[barg]

Time [Min]

Min. 30 Minutes

At 12 barg(12.3 / )


Inspection Time

At 8 barg

(8.2 / )

(DesignPressure)


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Hydrostatic Test Procedure for HRSG (Site) Doc No : IKR PROC 001

I. HP Bypass Cooling Water Section Pressure Curve (Typical)

Min. 30 Minutes

At 87 barg(88.8 / )


Inspection Time

At 58 barg

(59.2 / )

(DesignPressure)


0 20 40 60 80 100

0

15

30

45

60

75

90

Time [Min]

Pressure

[barg]

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