HYDRAULIC TEST OF BOILEROF 210 MW SET

SPECIFICATION
Boiler Type Tangentially Fired, Balanced Draft,
Natural Circulation, Radiant Reheat
Type, Dry bottom with Direct Fired
Pulvirised Coal with Bowl Mills.
MS flow at SH O/L 700 T/hr
MS Temp at SH O/L 540 0C
MS pressure at SH O/L 137 kg/cm2
RH steam flow 578.3 T/hr
RH Temp. at RH O/L 540 0C
RH steam pressure at RH O/L 25.1 kg/cm2
RH steam pressure at RH I/L 27 kg/cm2
FW Temp. at economizer I/L 247 0C
VOLUME OF WATER REQUIRED DURING HYDRAULICTEST
Boiler Drum 37.2 m3
Water Wall 126.30
SH 97.18 m3
RH 48.10 m3
Economiser 25.17 m3
Piping 12.05 m3
TOTAL 346.00 m3 (i.e. @ 4.5 UDT)

1
A PRECHECK
1. Ensure UDT is filled & chemicals are charged.
2. Ensure FST is filled up adequately by ELP & then C/O ELP to boiler
filling through feed station (i.e. through DM-1,2) or bottom blow down
ring header as may be the case. In case water is to be filled up from
bottom ring header, open DM valves E-7,9 near the header, open water
wall drains B-30,31,32,33,34,35. Keep master drain valve closed.
3. BFP main suction pressure low & discharge pressure low tripping
protections are to be bypassed.
4. Ensure feed line is charged & drains / vents are closed.
5. Ensure feed station low load line CV-FW-26 & its both isolating valves
FW-29,30 are opened, also economizer I/L valve E-2 is open.
6. Ensure EBD & CBD & their isolating valves are closed.
7. Ensure locking of pipe line hangers & safety valves gagging from BM.
8. Ensure water wall bottom ring header drains ( LSH<RSH<front & rear
header drains) are closed. Also master drain valve closed & economizer
drain valves closed.
9. Ensure SH drains at FF are closed.
10. Ensure drum ,SH,economizer vents are open.
11. Ensure drum’s both GG are isolated from steam & water side.
12. Close soot blowing isolating valves & open soot blowing line drains.
13. Ensure MS-11,12 hand tightened.& after drains are open.
14. Ensure PRDS valves ( manual & Sulzer) are closed & drains are open.
15. PRDS spray isolating valves ( FW-76) & its bypass valve are closed.
16. Ensure sample coolers at PRDS are closed
17. Ensure chemical dozing valves at the pumps at PRDS level are closed.
(valves at drum levels may be kept open.)
18. Ensure RH spray valve R-17 & LHS/RHS spray (R-18,19) are closed.
19. (A) Ensure following Turbine side valves are CLOSED/OPENED
 MS line drains along with inspection drains opened.
 HP bypass spray, BD isolating valve is closed inspection drains
open.
 MS-1,2,3,4,5,6 are closed & drains between MSV & ESV are open.
 MS-7,8 (HP/LP bypass isolating valves) are closed & after drains
open
 HP/LP bypass drains to UFT are open.
 CRH/HRH drains to UFT along with inspection drains are open.
 HPT/IPT transfer pipe drains along with inspection drains are
open.
 CR-3,4 are closed.
2
  CR-5,6 along with inspection drains are open.
 HPT/IPT casing drains are open.
 HPT/IPT rotor heating valves AS-42,43,44 are closed, inspection
drains are open.
 HPT/IPT flange & stud heating valves As-16,17,18,19,20,21 are
closed.
 Condenser level & UDT levels are to be observed during the
process of hydraulic test to ensure no passing of valves.
B STARTING
1. Start ELP.
2. Close economizer & drum vents after sufficient water flowing.
3. Close SH vents, start up vents after sufficient water venting out.( The
duration to close SH vents is @ 3.5 Hrs.
4. Ensure drum pressure increased to 20 kg/cm 2 once the vents are
closed.
5. After checking by BM, stop ELP. Close DM-1,2 valves water is taken
from feed station or ring header drain valve.
6. Start BFP & raise the pressure to 50 kg/cm2.
7. After getting clearance from BM raise the pressure gradually up to
desired pressure as per statutory requirement. Hold it for some time&
then stop the BFP.
8. Observe pressure drop rate, observe drains at the IBD tank to confirm
that there is no water is coming out due to passing of valves.
9. Reduce the pressure to 50 kg/cm2
10. At @ 4 kg/cm2 pressure, open all Boiler vents & SH drain valves.
11. Reduce drum level to normal operating level
12. Ensure the pipe line hangers are removed & safety valves are
normalized by BM.
13. Normalise the system at Boiler & Turbine side.

3
A BOILER REHEATER HYDAULIC TEST

4
PRECHECK
1. Ensure UDT & FST is filled DM water & chemicals.
2. Ensure ELP is available & its discharge line is connected to CRH drain
valve near UFT & other modification work is carried out, so as to fill
DM water in RH circuit from CRH line.
3. Ensure one BFP is available & charged
 Ensure feed line is charged.
 Feed stations all valves are closed to arrest the entry of water
towards economizer side.
 DM-1,2 valves are closed.
4. Ensure SH spray valve E-13,RH spray valve R-17,18,19 are available for
service & kept closed. Ensure RH attemperator station drain valve is
closed.
5. Ensure SH spray valves (LHS / RHS) S-27,28 are closed.
6. Ensure HP/LP bypass spray blow down isolating valve is closed.
7. Ensure PRDS spray isolating valve FW-76 & its bypass valve is closed.
8. Bypass BFP main pump ‘suction pressure low’ & ‘discharge pressure low’
& ‘FST level high to ELP trip’ tripping protections.
9. Check :-
 Both IVs to be dummied.
 Ensure CRH,HRH & MS lines hangers are locked by TM.
 Ensure RH vents are open.
 Ensure HPH-6 steam extraction valve ES-4 is closed, drain valve
after ES-4 is open to atmosphere. (i.e. ES-18 & inspection drains
are open.)
 ES-4 line drain before ES-4 which is connected to drain before
ES-1 (HPH-7 FCNRV) is blocked. This dummy shall be removed
after concluding RH hydraulic test.
 Ensure CRH drains after HP by pass station HPH drains are
closed.
 Ensure CR-5,6 are open along with inspection drains.
 Ensure CR-3.4 are closed.
 Ensure LP by pass station valve is closed & drain before LP
bypass is also closed
 Ensure MS-7,8 along with HP bypass are closed. Drains before
MS-7,8 & before bypass are open.
 Ensure MS-1,2,3,4,5,6 are closed, drains between MSV & ESV
are open.
 Ensure MS line drains along with inspection drains are open.
 Ensure ES-6,7 are closed. Its line drain valve is open.
 Ensure HPT/IPT transfer pipe drains along with inspection drains
are open.
 Ensure HPT/IPT casing5 drains are open
B STARTING
1. Start ELP for RH filling.
2. Check for any water leakage at Turbine side ,especially at IVs dummies.
3. Close RH vents after sufficient water vented out.
4. Ensure RH pressure is raised to 20 kg/cm2.
5. If no leakage, stop ELP, Close discharge valve.
6. Start BFP & put it on recirculation. Raise the discharge pressure to 50
kg/cm2.
7. Open E-13,R-17 & then R-18,19.
8. Watch the RH pressure is raised @ 35 kg/cm2.
9. Check for leakages.
10. Stop BFP. Depressurise the line.
11. Open RH vents & drains of CRH & HRH lines.
12. Ensure complete draining of RH circuit.
13. Ensure CRH/HRH/MS lines hangers support released by BM

Unusual Occurrence
On 16/7/83 during RH hydraulic test of U # 4 Water started coming out
from ESV(L) which was open for maintenance. Due to this sudden rushing of
water , metallic gasket of ESV was forced into the pipe line. Fortunately it
could be removed by hand otherwise steam blowing would have been
necessary entailing down time of another 15 days.
Analysis
1. drum was full of water & hence level rise due to passing of feed line
valves could not be ascertained.
2. Feed station electrically operated valves were closed electrically but
further closing by manual tightening was not done.
3. E-2 valve was fully open
4. CV of stand by feed line was 40 % open.
5. MS-1 valve found one turn open.
6. Watch was not kept on FST level while it was dropping.
6
7. Feed pump discharge valve was opened when RH pressure was not
increasing by opening its bypass valve.
Conclusion
After starting of feed pump, its discharge valve bypass was opened. As
the RH was already under pressure of 10 kg/cm 2, obviously when the
feed range valves were open water would first go to the boiler drum as it
is the path of lowest resistance. The feed pump common header pressure
will not rise above the static head of the boiler & hence water will not at
all go to the RH .Further the main discharge valve was opened. As soon as
the discharge valve was opened the feed pump discharge pressure
dropped down to 30 kg/cm2 an effort was made to increase by operating
the scoop. This further caused rushing of water to the drum & feed
pump current increased to 350 amp. Finally pump was stopped when water
started rushing out from the open ESV.