Boiler Hydro Test[1]

Procedure for Hydro Test

DOC NO:UBEL/WPCPL / HOP / PRT/PWP- 01 Rev. 00 P!e 1 of 7

CONTENT"

1.0 "COPE#############################. $.0 PURPO"E############################. %.0 &RE& O' &PPL(C&T(ON#####################. ).0 RE'ERENCE DOCU*ENT"#################### +.0 PRE-RE,U("(TE"########################.. .0 E,U(P*ENT"  &CCE""OR(E"################## .0 ENER&L RE,U(R*ENT"/TE"T PREP&R&T(ON 'OR TE"T(N##... .0 TE"T *ED(U*2 TE"T PRE""URE  TE"T PRE""URE &UE#### 3.0 TE"T(N PROCEDURE###################### 10.0 CO*PLET(ON O' TE"T(N###################. 11.0 &CCEPT&NCE &CCEPT&NCE CR(TER(&####################. CR(TER( &####################. 1$.0 "&'ET4############################.. 1%.0 RECORD"###########################.. 1).0 &TT TT&CH*ENT"########################.. &CH*ENT"########################..

Procedure for Hydro Test 1.0


"COPE:

This Procedure covers the general requirement for hydro testing of Pressure parts, piping, and equipments etc.at project site. $.0

PURPO"E:

This Procedure provides guidelines on requirements, performance, inspection and documentation for hydrostatic testing. %.0

&RE& O' &PPL(C&T(ON :

This procedure is applicable to perform hydro testing of Pressure parts, piping, equipments etc. for erection & associated or!s of "oiler & #u$iliaries & T% au$iliaries of '1() *+ TPP at arora. ).0

RE'ERENCE DOCU*ENT":

.1

#*- -/0

.2

#*- " (1.1

.(

0ndian "oiler egulation 0"3

.

#pproved 4raing

.)

Project pecification

+.0

PRE-RE,U("(TE":

).1

Pressure parts, piping *aterial should be erected as per approved draing.

).2

#ll pipes should be physically e$amined from outside and for large pipe visual inspection from inside shall also be performed.

).(

#ll inspection reports i.e. final visual, 54T, P+6T, P*0 etc. *echanical & 54T clearance3 should be revieed and signed by lient8ner.

).

#ll pressure gauges should be calibrated & ithin specified ranges.

).)

#ll supports should be installed as per approved draing.

.0

E,U(P*ENT"  &CCE""OR(E":

9.1

:illing pump & Pressuri;ing pump.

9.2

:illing & pressuri;ing hose, gate valve, pressure relief valve, 5< for :illingpressuri;ationventing & draining line


DOC NO:UBEL/WPCPL / HOP / PRT/PWP- 01 Rev. 00 P!e ( of 7

9.(

alibrated pressure gauge ith valid calibration certification min. to =23 nos.

9.

:iltered ater & 6and Tools.

.0

ENER&L RE,U(R*ENT"/TE"T PREP&R&T(ON 'OR TE"T(N:

7.1

"efore pressure testing, all piping shall be cleaned by flushing ith cleaned filtered ater, to ma!e it free from dirt, loose scale, debris and other loose foreign material.

7.2

Testing shall be carried out ith permanent gas!et unless specified.

7.(

#ll system to be hydro tested shall be vented at the high points & drained at the lo points.

7.

+herever in the system, any void e$ists li!e absence of control valves, instruments etc. it shall be filled ith temporary spools

7.)

#ll eld joints, mechanical joints, screed or flange etc. shall be left e$posed for e$amination during the test.

7.9

"efore pressuri;ing the system, each eld joint shall be cleaned by ire brush to free it from rust or any other foreign matter.

7.7

>ines hich are directly open to atmosphere need not be tested, but all joints shall be visually inspected.

7.?

-nsure all flanged and bolted connections are tight.

.0

TE"T *ED(U*2 TE"T PRE""URE  TE"T PRE""URE &UE:

?.1

T-T *-40@*A

?.1.1

6ydro testing shall be carried out using clean & filtered ater.

?.1.2

ystem subjected to 4* ater shall be tested ith 4* ater only.

?.1.(

+ater temperature during hydro test shall be recorded but in no case less than 2==.

?.2

T-T P-@-A

?.2.1

6ydro test pressure shall be as per approved draing, project specification


DOC NO:UBEL/WPCPL / HOP / PRT/PWP- 01 Rev. 00 P!e  of 7

and applicable codesstandards. ?.(

T-T P-@- %#@%-A

?.(.1

#ll gauges used for hydro testing shall be ithin specified range as per approved draing, project specification and applicable codesstandards. 4igital type pressure gauge may be used ithout ra nge restriction provided the combined error due to calibration and reliability dose not e$ceed 1B of test pressure.

?.(.2 ?.(.(

%auge shall be of a good quality and in first class or!ing condition. Prior to hydro test, all *in. To =23 nos3 test pressure gauge shall be calibrated & valid calibration certificate shall be maintained.

3.0

C.1

TE"T(N PROCEDURE:

#ll vents and other connections used as vents shall be left open hile filling the system ith test fluid for complete removal of air.

C.2

:or pressurising & depressurising the system, temporary isolation valves shall be provided if vents, drains do not e$ist in the system.

C.(

Pressure shall be applied only after the systemline is ready and clearance from clientoner.

C.

Pressure shall be applied by means of suitable test pump or other pressure source hich shall be isolated from the system as soon as pressure is reached and stabili;ed the system.

C.)

# pressure gauge shall be provided at the pump discharge for guidance in bringing the system to the required pressure.

C.9

The pump and the system to be tested shall be provided ith separated calibrated test pressure gauge.

Procedure for Hydro Test C.7

DOC NO:UBEL/WPCPL / HOP / PRT/PWP- 01 Rev. 00 P!e ) of 7

The pump shall be attended constantly during the test by an authori;ed person & shall be isolated from the system henever the pump is to be left unattended.

C.?

Test pressure shall be maintained for a sufficient length of time to permit thorough inspection of all joints for lea!age. Test period shall be maintained as per approved draing, project specification and applicable codesstandards.

C.1=

are shall be ta!en to avoid increase in the pressure due to temperature variation during hydro test.

10.0

1=.1

CO*PLET(ON O' TE"T(N:

#fter hydro test has been completed, pressure shall be released in a manner and at a rate so as not danger to personnel or damage equipment.

1=.2 #ll vents and drains shall be opened before the system is to be drained and shall remain open till all draining is complete so as to prevent formation of vacuum in the system. 1=.(

#fter testing is competed the test blind shall be removed and systempiping isolated during hydro testing shall be connected using specified gas!et, bolts, nuts etc.

1=.

#ny joint found lea!ing during hydro test shall be retested to the specified pressure after repair.

11.0

&CCEPT&NCE CR(TER(&:

11.1

5o lea! on elded joints, mechanical joints and distortion shall be acceptable.

11.2

5o lea! on valve gland and bonnet or any other joint shall be acceptable.

11.(

The drop in pressure shall not be more than 1B per hour of the test pressure.

11.

#ll unacceptable lea!ages shall be repaired & areas of repair shall be retested.



1$.0

"&'T4:

12.1

To ensure that all personnel involved are adequately protected during the course of the hydro test.

12.2

5o or!ing on pressuri;ed system shall be permitted.

12.(

pressuri;ed systems shall not be left unattended.

12.

The instruments, system etc. hich are not designed for the test pressure shall be disconnected or isolated.

12.)

8rifices, discs, strainers shall be removed before hydro test.

1%.0

RECORD":

1(.1

ecords shall be maintained as per attached sample formats.

1).0

&TT&CH*ENT":

1.1

ecord of pressure test.

Procedure for Hydro Test RECORD O' PRE""URE TE"T


Boiler Hydro Test[1]

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