Hydrotest Procedure

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PLTU2NTB2X25MW

Unit Issuing : Construction

DOC. NO

COAL FIRED STEAM POWER PLANT

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PT,

T4.

PT CEMARA SEMITAMA

HYDROTEST PROCEDURE Approved By : Site Manager

ATTACHMENT

1. 2.

Organization Chart

3. 4.

Pressure test boundary for primary and secondary system

Schematic diagram of temporary lines

Pressure time diagrdm

ISSUANCE DATE:

Page 13 of

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RTVISION

O

PT CEMARA SEMITAMA

,@

PLTU2NTB2X25MW HYDROTEST PROCEDURE

ffi,ffiffiA Unit Issuing : Construction

1.0

DOC. NO

COAL FIRED STEAM POWER PLANT TSSUANCE DATE:

Page 2 of 12

Approved By : Site Manager

REVISION

O

scoPE This procedure covers the hydrostatic testing of boiler pressure part, Boiler External Piping and Non-boiler External Piping for PLTU 2 NTB 2 X 25 MW CFSPP.

2.O

PURPOSE

This instruction serves as guide in hydrostatic testing of the above scope. This is also

to

satisfy the contract technical requirement, boiler manufacturer's requirement/

reference codes and standard as well as government regulations.

3.0

RESPONSIBILITIES

3.1 The Construction

Manager shall make sure

that this instruction

is

implemented at site.

3.2

The Boiler engineer and Piping Engineer are responsible for implementation of

this instruction. He has to check that requirement in Hydrostatic test are properly adhered to as indicated in this instruction.

3.3

The Boiler Supervisor is responsible for the arrangement of all processes involved in the execution of hydrostatic test. He has to make sure that standard code practice is applied accordingly.

3.4

The Welding Superintendent and Welding Supervisor shall make sure that all welding directly on pressure retaining parts are complete.

3.5

The QA/QC personnel in charge

of

hydrostatic test are responsible in

assuring that the requirement in this procedure are properly implernented and

followed. They have

to make sure that all NDTs and hot works on pressure

retaining parts are completely executed before the test. They have to make all pertaining records ready and available for review by all pafties concerned. They have to perform hydrostatic testing in process inspections. They have to prepare pertinent records after the test.

4.

TEST SCOPE

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PT CEMARA SEMITAMA


PT,ffiffiAffiffi&ffi Unit Issuing : Construction

DOC. NO



ISSUANCE DATE: Page 3

of 12

REVISION

O

the different pressure ratings, the hydrostatic test is divided in two systems namely primary system (superheating system) and secondary system Considering

(reheated system). 4.2

Primary system. This

is consists of feed water operating valve block,

economizer system, steam drum, water-cooled wall system, and superheated

as well as associated inter connecting piping, drains, blow down, heating

,

chemical dosing, feed water & desuperheated water piping & valves.

The test boundary for superheater system should be until hydrostatic test isolated valve located in boiler building. 4.2

Secondary System. This is consists of wall reheater, medium temperature

reheater, high temperature tube banks, channels, interconnecting piping, desuperheated water, drains, discharge piping & valves. The boundary shall be

from cold reheat valve to hot reheat outlet valve. 4.3

The blind valve was designed at the Final RH outlet, Panel RH inlet and Final SH

outlet; therefore it is regarded that the blind valves of the main steam, reheat hot pipe and cold pipes and boiler proper shall be identified as their boundary of hydraulic test. 5.

TESTING PRE.REQUISITES

5.1

The erection of boiler steel structure shall be completed, inspected and accepted by all parties; high strength bolts shall be completely tightened in accordance with

the requirements of the drawings and

procedure. The

following records shall be made available: a. The deflection of boiler roof girders before the boiler pressure parts lifting as

well as the record of before and after water filled. b. Settlement observation result of foundation.

PT CEMAR.A SEMITAMA

PLTU2NTB2X25MW

DOC. NO


ffi,ffiffiffiffi Unit Issuing : Construction

5.2

HYDROTEST PROCEDURE Approved By : Site Manager

ISSUANCE DATE:

Page 4 of 12

REVISION

O

The erection of boiler heating surfaces and pressure parts including buck stay have been completely done, inspected and accepted.

5.3

of all equipments, piping, valves, fittings and hangers and supports within the scope of hydro static test, and the variable & constant Complete erection

hangers have been fixed with dowel pin or temporarily fasten to keep it under

the rigid state.

5.4

All vents, sampling, desuperheating and emergency blow-off pipes, steam drum

connecting pipe, and boiler temporary heating pipe shall be erected up to the second valves based on the scope of hydro static test. The intermittent blow down piping and drainage pipes have been connected with the main pipe which is set before the intermittent blow down flash tank, othenruise the main pipe of

the nitrogen system shall be erected up to the boiler ground level.

5.5

All the welding fixing parts on the boiler wall, such as the fin on the tube of heating*- sudace

or

pressure pdrt, sealing pdtr, antiseptic device, fixture,

insulation nail, sliding pieces, hook, inspection hole as well as the tapping point

of I & C elements etc, shall be completely installed. After the hydro test, no welding work is permitted on the boiler pressure part.

5.6

All the temporary stiffening pdfu, lifting lugs or the other steel welded on heating sudace and pressure pads for lifting and transportation have been removed, and smoothly ground.

5.7

The hangers and rods of boiler proper must be completely installed and adjusted to ensure the balance force and tension is carried on.

5.8

is done in boiler area pafticularly on top of boiler, stainruay, platform, ground level, furnace, cold ash hopper, corner water wall, Housekeeping

superheaters, reheaters, economizer, etc.

5.9

All hot works including PWHT on pressure retaining parts have been done & completed.

5.10 All NDTs have been completed & documented. 5.11 Punch listing prior to testing has been done; punch killing completed documented.

&

PT CEMARA SEMTTAMA

PLTU2NTB2X25MW

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HYDROTEST PROCEDURE


5.tz

Approved By: Site Manager

ISSUANCE DATE:

Page 5 of

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|

REVISION 0

All records pertaining to pressure retaining paft erections have been completed & readily available for review.

5.13 All weld joints and weld attachment areas shall be left un-insulated

and

exposed for examination during test.

5'14

Equipment not subjected

to

pressure test shall be disconnected from the

system or isolated by blank or valve or plug. The core of boiler safety valve and

other safety valve are all replaced and blocked, economizer inlet feed water line, attemperator spray water piping, drain and vent are all isolated from not tested areas using valve.

5.15 All valves included

in the test boundary will be tagged open/close as per test

requirement.

5.16

Temporary water filling line and pressurizing line shall be flushed and in seruice leak tested before water delivery into the systerns. The pressurizing line should

,.,:.'.,':",;,, undergo hydro testing to assure that the line has the capacity to carry the pressure of the system while in hold.

5'17 The quality of

chemical demineralized water shall

be acceptable with the qualified repoft, and enough amount of water shall be prepared for hydraulic test.

5.18 The expansion indicator have been mounted properly according to

the

instruction on the drawings and adjusted to 0 positions.

5.19

Check the expansion clearance and

its position of boiler proper whether it

meets the requirements of designed drawings or not.

5.20

All temporary pipelines to be used in water filling are flushed and checked as safe for operation.

5'2L All permanent

equipments

to be used for water filling are inspected and

documented.

5.22

All parties are convinced and agreed that the systems are ready for hydrostatic testing, Clearance Certificate shall be signed off by all parties before the test.

6.

TEST PREPARATION

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PLTU2NTB2X25MW

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HYDROTEST PROCEDURE

ISSUANCE DATE: Page 6 of 12



6.1

PT CEMARA SEMITAMA

REVISION

O

Equipment A)

Filling Pump: Permanent boiler start up feed water pump shall be used in

water filling. B)

Pressurizing Pump

c)

Tempora'ry water line: detail to be informed later

D)

Air Compressor: specification to be informed later

E)

Test Gage

An indicating gage, visible to the person controlling the pressure applied, shall be connected to pressure parts. The location for the primary system shall be in

steam drum and the other one is close

to the

pressure pump. For the

secondary system, the location of the pressure gage shall be at the reheater

outlet and the other one shall be close to the pressure pump. The hydrostatic head on the gage shall be considered'such that the test pressure is achieved at

the top of the boiler. Dial pressure gages to be used in testing shall preferably have dials graduated

over their entire range of about double the intended maximum test pressure, but in no case shall the range be less than 1.5 times that pressure. The spacing between graduations shall be such that the inspector and the person controlling

the test shall be able to determine when the required test pressure has been applied. Test gages shall be accompanied with valid calibration certificates and

should be equipped with snubber to keep hammering from affecting the gage calibration.

a.

Communication

All communication between the boiler control station and the hydropump station will be by walkie-talkie. There will be a second radio at each station for back uP.

G

PT CEMARA SEMITAMA

PLTU2NTB2X25MW

DOC. NO


HYDROTEST PROCEDURE

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Approved By : Ste Manager


ISSUANCE DATE:

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REVISION

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Tools and Scaffolding

b.

Scaffolding, lights, and repair tools are to be ready

at the time of

hydrostatic testing. c.

Compressed Air

Air Pressure used for testing prior to the Boiler hydro-test shall not exceed 0. 3 Mpa to be kept for a minimum of 2 hours for air tightness test. d.

Demineralised Water

This type of water is to be used for hydrostatic test to be produced from permanent water treatment Plant. e.

Drainage Boiler drain line shall be routed to main pipes of intermittent blow down

and drain pipe then to be connected with temporary piping going to waste water Pond.

7.

TEST PROCEDURE

7.1

Pneumatic Test

In order to find any serious leakage as early possible the primary and secondary system shall be connected temporarily before hydro test. The same

temporary line intended for hydrostatic testing will be used for air test. The system shall be filled with compressed air at a pressure of 0.3 MPa,

It

shall be

held for a minimum period of 2 hours for air tightness test and check. Leakage shall be checked by listening to the sound and by spraying soap solution.

7.2

HydrostaticTesting

PT CEMARA SEMITAMA

PLTU2NTB2X25MW

DOC. NO


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HYDROTEST PROCEDURE

Unit issuing : Construction

ISSUANCE DATE:


Page B of 12

REVISION

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Water Quality The content of chlorine ion (cL-) in the water shall be less than Zlmgll,

and then put into the 40% ammonia (NH3.H2O) in concentration and hydrazine (N2HaH2o). The acidity and alkalinity value of aqueous solution

shall normally be control under

PH >

10-10.5, the concentration of

hydrazine shall be taken 250-300ppm (mg/l), and this valve shall be confirmed and determined by chemical supervision engineer.

b.

Testing Pressure Based on the boiler manufacturer's requirement, the testing pressure is as

follows; Primary System: 1.25 x boiler drum working pressut'€=......X1.25=.......Mpa

Secondary System: 1.5 x reheat inlet working pressure= ....X1.5=.......Mpa

Water Filling Sequence Demineralized water will be taken from

......-.

on the demin

water tank. Permanent make up water line shall be used to transfer

the water up to condensate make up water tank. Permanent boiler feed water pump shall be used to fill water to the boiler system. Temporary filling line from boiler start up feed water pump up to the boiler filling point shall be provided.

n

Temporary water filling lines (includes the permanent drain header

to boiler blow down tanks which will be used for filling as well draining

of the test

as

system) and pressurizing lines shall be in

service leak tested and flushed before transferring test water in to

the circuit or commencement of pressurizing. Pressure test of the

PT CEMAM SEMITAMA

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PLTU2NTB2X25MW

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HYDROTEST PROCEDURE

Fry,ffiffi Unit Issuing : Construction


temporary line that

ISSUANCE DATE: Page 9

of 12

REVISION

O

will be bounded by test circuit shall be

separately hydro tested. Radiography shall be done on temporary water filling lines as the permanent piping line. tr

Temporary power supply complete with appropriate control panel shall be provided, to supply power and control the permanent boiler

stad up feed water pump. u

Check

the

pumps electrical connections, control panels and

lubrication prior to running. l.-

Trial run of the pumps shall be done before the test.

n

Sampling

of

water shall be taken before filling

of boiler and

recorded before commencement of filling.

n

All vents shall be kept open and hoses to be connected to convey venting spill to the drain funnel which is connected through the permanent drain header on the floor sump. Temporary hose will be connected to the storm water draining to the sea.

n

Open water-feed valves of the temporary systern and all vents, and

shutdown all the primary valves, and then start up feed water pump to fill water into boiler. Normally, the temperature of filling water shall be taken 20-70oC, the temperature difference between filling water and the wall of steam drum shall not exceed zBoC.

n

During the time of water feeding, all pressurized parts shall be

checked

for

leakage.

If

found, the handling shall be made

intermediately, after fixed and the feeding shall be continued. Until

2-3 minutes overflow of all vents happened, it is confirmed that boiler has been filled fully; the vent valves can be closed and stop feed water pumping and shutdown feed water valve.

n

The super heater and the reheater outlei shall be interconnected by pipeline with appropriate valves in order to fill and pressurize both systems systematically. This line will be isolated if each system at the time of pressurizing.

o

PT CEMARA SEMITAMA


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iSSUANCE DATE:

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Approved 8y : Site Manager


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DOC. NO


12

REVISION

O

Pressurizing Monitor all the vents and ensure that all

air entrapment has

been

completely released and the test circuit is completely filled with water.

Closg vents one by one as filling continues,

the hydro filling pump

continues till the pressure gage register a pressure of about 3 Kg/cm2 and

then the filling stops.

n

Check

the electrical connections of pressure pump. Proper

lubrication shall be done when required.

x

Trial run shall be done on the plunger pump before pressurizing begins.

tr

Pressurizing plunger pump will be started and pressurizing will be

through drain valve of feed water lines.

u D

Keep

the pressure rate at 0.3MPa/min.

Continue pressurizing up to 10o/o of reheater design pressure, stop pressurizing anci fully check the system for any abnormality.

u

Close the valves interconnecting the secondary and primary system

located at super heater (main steam) line and reheater outlet (hot

reheat) line.

n

When no sign of abnormality is observed, continue pressurizing the secondary system up to operating pressure.

I I

Stop pressurizing and check again.

When no sign of abnormality is obserued, continue pressurizing up to the test pressure of .......MPa.

n

Keep the system under test pressure decrease the pressure

for 20 minutes and

to operating pressure.

then

Check the system

thoroughly.

!

When the system is checked by all pafties as qualified, open the

vent valve of reheater, check and confirm the valves in between

PT CEMARA SEMITAMA

PLTU2NTB2X25MW

DOC. NO


HYDROTEST PROCEDURE

FT,ffiffiffiffi$

Approved


ISSUANCE DATE:

Page 11 of

8y: Site Manager

rz

REVISION

O

super heater and reheater as closed until the pressure on primary system reaches 10% of the operating pressure of the steam drum.

a tr

Check the system for any sign of abnormality.

,

Reroute the temporary pressurizing on primary system and staft pressurizing until the pressure reaches operating pressure

of the

steam drum.

tr D

Stop pressurizing and check again. When no sign of abnormality is observed, continue pressurizing up

to the test pressure of .......MPa. Stop pressurizing pump, and close the valve of pressurizing outlet.

!

Keep the system under test pressure decrease the pressure

to

for 20 minutes and

then

operating pressure. Check the system

thoroughly.

If

Slowly open the drain valves until the pressure reaches 0.3 to 0.5 MPa. Control the pressure decreasing rate at 0.3MPa/min.

8.

BASIS OF ACCEPTANCE Keeping the test pressure in 20 minutes, the pressure of hydro test shall be reduced

for overall inspection. During the period of inspection, the pressure shall be held and there should not be any sign of any

down

to the design rated

pressure

leakage, deformation and crack on all the welding joints; manholes, flanges and valves.

If the test is acceptable, the hydrostatic test certificate shall be signed by all

parties involve in the test.

9.

PRESERVATION AFTER THE TEST As recommended by the Client, test water shall remains in the system; the water shall

be kept on the boiler with the pressure of ...... to ........ MPa. Monitoring Log shall be maintained.

10.

REPAIR.

PT CEMARA SEMITAMA

PLTU2NTB2X25MW

DOC. NO


HYDROTEST PROCEDURE

ffi,ffiffiffiffiffiffi Unit Issuing : Construction

ISSUANCE DATE:

Page 12 of

Approved By : Site Managet

t2

REVISION

O

If any leakage is observed during water filling; the filling shall be stopped and the repair shall proceed as per repair procedure established and approved at site between

the by all Parties concerned. any leak is opserved during pressurizing, the pressurizing shall stop. The pressure shall be released at a permitted rate and the water shall be drained to a level where

If

repair is Permissible.

11.

INSPECTION.

11.1

DEPNAKER as government representative shall be invited

to witness and ceftifo

the hydrostatic testing. invitation shall be given on time.

Ll.Z

For inspection convenience of all parties the entire test area has been divided

into different zones. Each zone will be manned by a team consisting of

7lo

4

inspectors. Each one of them will be equipped with walkie talkie to immediately

repoft any abnormality found or observed.

11.3

Once satisfactory inspections have been completed pressure will be released preseruation shall Proceed.

L2.

SAFETY.

Safety Requirement is follows;

1. The area of test shall be barricaded

once the pressurizing starts.

2. Only authorized personnel will be permitted to enter the test zone. 3. Only trained personnel will be allowed to handle the chemical. 4. Any treated water drains will be securely collected in the retention

basin and

treated before disposing to others defined areas.

13.0

RECORD pressure test certificate shall be prepared and sign off immediately after the test.

Hydrotest Procedure

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