®

H M EL
HPCL-Mittal Energy Limited
Guru Gobind Singh Refin ery, Bathin da.

SOP fo r Hydro Test Proced ure

2x300 TPH CFBC Boiler, UB#5
911 2 - 575 - aPR - 704 - 00046 Rev:01

O&M By:

· )
BOI LERS
HEAVY ENGIN EERING LTD

~.

Mr. As his h Mr. Raj esh Mr. Laxman Tari

01 IFI Mr. Prashant Dharmendra
12/06/18 Kum ar SI Mitra Dy. Mgr
Eng (ISGEC) Kr. Khare
(ISGEC) PM (ISGEC) (HMEL)
OM (ISGEC)

Mr. K. Raju Mr. Amresh Mr. Raj esh Mr. Laxm an Tari
00 20101/20 IFI Mr. Prashant Mitra
Asst.Mgr Kum ar SI Dy. Mgr
17 Eng (ISGEC)
(ISGEC) (ISGEC) PM (ISGEC) (HMEL)

ISSUE
REV STATUS PREPARED REVI EWED CHECKED APPROVED CONCURRED
DATE
This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of HPCL-
MITT AL ENERGY LTD. The copyright of this document is vested in HPCL-MITTAL ENERGY LTD. All rights reserved. Neither the whole nor any part of this
document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or
otherwise) without the prior written consent of the cop right owner. Format No. 9111·000·PCT ·007·00006 Rev·OO
 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2x300 TPH CFBC Boiler Issue Date 12106/2018
Next Review 12106/2019
® UB#5: 9112-S7S-0PR-704-00046 Rev 01
HMEL Page 2 of 16

REV DATE REV DETAILS

00 20/01/2017 ISSUE FOR INFORMATION

01 12/06/2018 ISSUE FOR INFORMATION

"

List of Person ParticiQated in PreQaration/review of SOP

S Name Designation Signature

No.

1 Mr. Laxman Tari Deputy Manager Operations ,~?

2 Mr.Rajesh Mitra Plant Manager-O&M ~.

3 Mr. Dharmendra Kr. khare Operation Manager- O&M &~

/ ~
/' ~
Mr. Ashish kumar Shift Incharge- O&M
4 ' ~

5 Mr. Prashanth Kumar Sharma Control Room Engineer- O&M ( \\cA~

~
Note:

The Owner of this Document is Department OPERATION at BATHINDA. Please Contact AGM / OPERATION
Manager- for any clarifications, Updates or Revisions.
 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
Next Review 12106/2019
® UB#5: 9112-575-0PR-704-00046 Rev 01
HMEL Page 3 of 16

INDEX

S. No. DESCRIPTION Page No

4
, C'_,_~
4
- 'r

3 References 4

4 Responsibility 4

5 Tools & equipment's 4

6 Safety precaution 4-5

Safety, Health & Environment Precautions. 5

8 Documents and References 6

9 Definition and Abbreviations 6-7

10 System Overview & Detail Procedure 7-11

11 Pre-requisite for training and competency 12

12 Flow sheet / Detail Drawing 12

13 Performance indicators 12

14 Records 12

15 Check list 12-16

16 Change Register i 16
 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
Next Review 12106/2019
® UB#5: 9112-575-0PR-704-00046 Rev 01
HMEL Page 6 of 16

8. Related Documents and References:

~ ISGEC manuals
~ J B0940-50990200-P I 0-0006

9. Definition and abbreviation:

DEFINITIONS OF LABEL

LABEL DEFINITIONS
DANGER:
DANGERS alert you to an immediate hazard that causes serious injury or death and
requires special Precautions to be taken
CAUTION:
CAUTION alert you to a potential hazards that causes serious damage to equipment!
Pro ert under certain condition
WARNING:
WARNING alert you to a potential hazard that causes serious injury or death under certain
condition

NOTE:
NOT Note emphasize or remind you of an important place of information

Utility Boiler Hydro Test Philosophy

Boiler Hydro Test shall be performed as per IBR regulations, 1950.
Guideline for Utility Boiler Hydro Test Pressure
. As per the section 379 (g) of the Indian Boiler Act 1973, it is required to hydro test the boiler
installed at site at 1.25 times of the maximum allowable working pressure
MAWP of Utility Boilers: 136 Kg/cm2
ABBREVIATIONS
1 BFP Boiler Feed Pump
2 FE Field Engineer
3 CRE Control Room Engineer
4 SIC Shift In-charge
5 PSV Pressure safety valve
6 MOV Motor operated valve
 HPCL-Mitta\ Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
Next Review 12106/2019
® UB#5: 9112-575-0PR-704-00046 Rev 01
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7 MSSV Main steam stop valve

8 ERV Emergency relief valve
9 IBD Intermittent blow down
10 CBD Continuous Blow Down
11 ECO Economiser
12 SH Super heater
13 MAWP Maximum allowable working pressure
10. System overview & Detail Procedure:
.:. Boiler: 300 TPH
.:. Drum working pressure: 126 kg! cm 2 •
·:·Max Working Temperature: S1S±So C
.:. Water Holding Capacity: 22SM 3

Hydraulic test in a boiler is carried out to check leakages & welding strength of
pressure parts and prove the strength of the boiler at a pressure greater than the
working pressure and is carried out at following stages:-
.:. On completion of repair of boiler pressure parts .
•:. On completion of annual overhaul.
.:. At the request of statutory authority to fulfill the statutory requirement.

Operating Procedure for Hydro test:

Operating Procedure for Hydro test:
Pre checkups:

S ACTION BY
DESCRIPTION
No FE- CRE- SIC
Ensure that all the air vents of drum are fully opened (12-GLV-
1 0424 & 12-GLV-423), (12-MOV-0401, 12-MOV-0402, 12-MOV- ~ ~
403, and 12-MOV-404).
Ensure that Main Steam Line stop valve (12-MOV-OS11) is fully
2 closed & bypass motorized valve (12-MOV-OS13, 12-MOV- ~
OS12) is also fully closed.
Ensure that main steam line stop valve main & bypass (Burner
3 floor) (12-MOV-OS14 & 12-MOV-OS1S) is close & make sure ~
manually tight.

4 Wing wall air vent (12-GLV-OS26, 12-GLV-OS2S) is fully opened. ~

Ensure that the Startup vent valve (12-MOV-OS09) is fully
opened & control valve (12-PV-OS01) is in opened condition.
5 ,L __
~
\,~ Cvutroi vaive should be in 20% open condition
 HPCL-Mittal Energy Limited Revision 01

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Ensure that all the air vents in saturated steam line (12-GLV-
OS06) (12-GTV-OS09) (12-GLV-OS01) (12-GTV-OS02) (12-GLV-
6 OS2S/OS26), & Super heater steam line (12-GLV-OS31/0S32), ./
Wing wall «12-GLV-OS19/0S20), COD (12-GLV-OS13/0S14) is
in full open condition.
Super heater drain isolation valve (12-GLV-OS31, 12-GLV-
7
OS32) is fully closed.
./
The Drum level gauge glass must be flushed properly for clear
8
visibility.
./
Ensure that the pH level of Boiler Feed water (OM) 8.8 pH to
9
9.2 pH.
./
Ensure that Soot blowing main isolation valve (12-GTV-1S01) is
10
fully closed.
./
-c--
Ensure that the entire down comer drain isolation valve (12-
11
GLV-0487) (12-GTV-MOV-0413) is fully closed.
./ ./
Ensure that Rear wall bottom header (12-GLV-0489) (12-GTV-
12
MOV-0414) is fully closed.
./ ./
Ensure that Compact separator return ring wall header drain
13 isolation valve (12-GLV-0496), (12-GLV-0497) (12-GTV-MOV- ./ ./
0416) is fully closed.
Ensure that Compact separator 01 top & rear wall header (12-
14
GLV-0494) (12-GTV-MOV-041S) is fully closed.
./ ./
Ensure that Compact separator 02 return ring wall header (12-
15
GLV-041 04/041 OS) (13-GTV-MOV-0417) is fully closed.
./ ./
Ensure that Compact separator 02 top rear wall (12-GLV-
16
04107) (12-GTV-MOV-0418) is fully closed.
./ ./
Ensure that Down comer drain (12-GLV-04113) (12-GTV-
17
MOV-0419) is fully closed.
./ ./
Ensure that Wing wall bottom header drain (12-GLV-0411S)
18
(12-GTV-MOV-0420) is fully closed.
./ ./
Ensure that all the drains of Main stem line are close (12-GLV-
19 OS69, 12-MOV-OS21, 12-GLV-S68, 12-MOV-OS22, 12-GLV-S70, ./ ./
and 12-MOV-OS20).

Ensure that Final super heater drain valve is closed 12-GLV-

20
S71, 12-MOV-OS19, 12-GLV-OS72, and 12-MOV-OS18).
./ ./
Ensure that WING wall drains (12-GLV-OS24, 12-MOV-OS16)
21
are fully closed.
./ ./
Ensure that Primary super heater drains (12-GLV-OS21) are
22
fully closed.
./
Ensure that Primary inlet header drain (12-MOV-OS08) is fully
23
closed.
./ ./
Ensure that COD bottom drain (12-MOV-OSOS, 12-MOV-OS04),
24
CCFWB header drain (12-MOV-OS03) is fully close.
./ ./
 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
Next Review 12106/2019
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25 Ensure that COD side wall drain (12-MOV-0502) is fully close. ~ ~

26 Ensure that COD side wall drain (12-MOV-0501) is fully close. ~ ~

Ensure that Primary Super Heater vent is fully opened (12-GLV-
27
0519, 12-GTV-0520).
~

Blow down valves: [(12-GTV-0483) (12-GTV-0411)], [(12-BAV-

0409) (12-GLV-0471 )], [(12-GTV-0479) (12-GTV-0480)],[(12-
GTV-0481) (12-GTV-0482)], [(12-MOV-0407) (12-MOV-041 0)],
28 [(12-GTV-0476) (12-GTV-0477)], [(12-GTV-0478) (12-GTV- ~ ~
MOV-0405)], [(12-GTV-MOV-0406) (12-GTV-MOV-0405)], [(12-
GTV- 0405) (12-GTV-MOV-0412)], [(12-GLV-3129) (12-GTV-
MOV-0412)] is fully closed.

Wherever double isolation valves are provided close the second

29
isolation valve.
~
Safety valve gags to be fitted on the Drum RHS, LHS safety
30 valves (12-SV-0402/401) & Main steam line safety valve (12- ~ ~
SV-501).

Ensure that all the instrument is Isolated except the test

31
pressure gauges (12-PG-0505/0504) (12-PG-0402/0403).
~

Calibrated pressure gauges (12-PG-0505/0504) (12-PG-

0402/0403) are required to be connected on the boiler steam
32
drum and steam header.
~
NOTE: Only Calibrated pressure gauge to be used

Dial pressure gauge used in hydro test must be greater than

33
(1.25 x 136 kg/ cm2) (MAWP).
~ ~

34 All gasket's available in field. ~

Check all buck stays and seismic supports are installed as per
35
drawing.
~

All attachments welding properly to pressure parts like fins to

36
tubes & anchor to pressure parts.
~ ~

Hanger Tie Rods, pipe supports, locking arrangements are to

37 be placed as per drawing. Constant load hanger, spring loaded ~ ~
hanger are locked in position with locking pin.
38 All temporary supports are to be removed. ~ ~
Check initial feeding line discharge valve (12-GTV-04117) is
39 fully opened. to ECO bottom HDR ~
(12-GLV-03129)
 HPCL-Mittal Energy Limited Revision 01
Issue Date 12106/2018
SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler
Next Review 12106/2019
® UB#5: 9112-575-0PR-704-00046 Rev 01
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Start-up Procedure:

S ACTION BY
DESCRIPTION
No FE- CRE- SIC
1 Ensure that all the above checks are healthy.

Take a clearance from HMEL Shift In charge for fill the boiler
2
with feed water from their existing side.

3 Feed OM water with PH level 8.5 to 10.

When boilers fully fill with feed water then raise up boiler
pressure
4

Closed air vent:

1. First closed the drum vent
2. After that when water comes out from steam line
then closes the vent.
S 3. Hanger tube vent close when water come out from
vent.
4. When water free flow come out from vent's (drum,
steam line pressure parts) that indicate air is fully
release from boiler.
6 Close the Start-up vent.
After that pressurize the boiler gradually
7

Raise the pressure up to hydrostatic test pressure. The pressure

should be under proper control at all times.
9

Stop the Hydro pump / BFP and observe the pressure

10
dro in rate.
Pressure dropping rate should not exceed to 3 kg/cm 2 per
11
min.
If any leakage found or pressure dropping rate going higher
12
then stop the hydro test and check the boiler and attend it.

13 Check gaskets, glands, drains, vents, valves etc.

 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
Next Review 12106/2019
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If pressure dropping rate is found normal then start the

h~9ro pump then raise the pressure slowly
14
f
../
\;~ Raise the pressure with 3,5kg/cm: Imin max
Test pressure should never exceed of required test
pressure.
15 ../ ../
Should never exceed 6% of required test
pressure
For newly erected boiler hydro test pressure must be
maintained for maximum 30mins with 1.5 times of
16 maximum allowable working pressure of drum/design ../ ../
pressure of drum (1.5 )( 136 = 204kg/cm2) maximum for 1st
time.
Hold the pressure with max test pressure
17 ../
\~ Should not hold for more than 30min
After this procedure reduce the pressure from CBO or COO
drain valve to maximum working pressure of boiler and hold
18
it for sufficient time and check the boiler with visual
../
inspection.
19 Reduce the pressure to 75% of test pressure. ../
Again rise the pressure to test pressure and check the
20
boiler.
../ ../
Repeat this process for 3 times if any leakage found then
21
stop the test. If not then check the boiler then
../
22 Stop the hydro pump ../
23 Check the pressure dropping rate ../
24 Pressure dropping rate not exceed to 3.5kg/cm2 max. ../ ../
25 Reduce the pressure gradually ../
When drum pressure comes below 5kg/cm 2 then open the
26 air vents of super heater following by drum vents at ../ ../
2kg/cm 2 , then open start up vent
Follow the above hydro test procedure and check the boiler
27 and repeated this process as often as is necessary until all ../ ../
leak are stopped
28 Stop the Hydro pump/BFP ../
After that decreases the pressure slowly by opening the IBO
29
& CBO line valves slowly
../ ../
Check gaskets, glands, drains, vents, valves etc. for any
30
leakage or passing
../
 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12/06/2018
Next Review 1210612019
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11. Pre-requisite for training and competency:

S Job Role Qualification Experience Training CertificationN Special

No alidation Skill

1 Field ITllDiplomalDegree 3-5 years On job training

Yearly
Engineer
2 Control Room DegreelDiploma 3-7 years On job training Yearly
Engineer
Degree/Diploma
3 Assistant 5-10 years On job training
Shift In Yearly
charge
DegreelDiploma
4 Shift In 7-12 years On job training Yearly
charge

12. Flow Sheet I Detail Drawing:

13. Performance indicators:

~ No leakage, passing and seepage.

~ Pressure, Pressure Graph, holding time graph

14. Records:
Observe Water level check, pressure rising rate, pressure dropping rate. Log
Book & Checklist of Field & DCS.

15. Check list for SOP:

DCS Checklist

S.no Description Responsibility Status Feedback

Main Steam Line stop valve 12-MOV-
1 CRE OPEN
0511.
Main steam line stop valve main &
2 bypass (Burner floor) 12-MOV-0514 & CRE CLOSED
12-MOV-0515
Bypass motorized valve 12-MOV-0513,
3 CRE CLOSE
12-MOV-0512
 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
Next Review 12106/2019
® UB#5: 9112-S7S-0PR-704-0004S Rev 01
HMEL Page 13 of 16

Startup vent valve 12-MOV-Os09 &

4 CRE OPEN
control valve 12-PV-OsOl is 20%
Drum level transmitter 12L10402A,
5 CRE HEALTHY
12L10402B, 12L10402C
Down comer drain valve (12-GLV-
6 CRE CLOSED
0487) (12-GTV-MOV-0413)
Rear water wall bottom header (12-
7 CRE CLOSED
GTV-MOV-0414).
Compact separator return ring wall
8 header drain VALVE(12-GTV-MOV- CRE CLOSED
0416)
Compact separator 01 top & rear wall
CRE CLOSED
header (12-GTV-MOV-041s)
Compact separator 02 return ring wall
10 CRE CLOSED
header (12-GTV-MOV-0417).
Compact separator 02 top rear wall
11 CRE CLOSED
(12-GTV-MOV-0418)
Final super heater drain valve 12-
12 CRE CLOSED
MOV-Os19,13-MOV-Os18
13 WING wall drains 12-MOV-Os16. CRE CLOSED
Primary inlet super heater drains 12-
14 CRE CLOSED
MOV-Os08.
COD bottom drain 12-MOV-OsOs, 12-
15 MOV-Os04, CCFWB header drain 12- CRE CLOSED
MOV-Os03
1':; COD side wall drain 12-MOV-Os02 CRE CLOSED
;-

il COD side wall drain 12-MOV-OsOl CRE CLOSED

Blow down: (12-MOV-0407) (12-MOV-
0410)]' (12-GTV-MOV-040s)], (12-
18 CRE CLOSED
GTV-MOV-040s)], (12-GTV-MOV-
0412)] ,12 -GTV -M OV -0412)]
If we take water from BFP then de-
HEALTHY
19 aerator level 14L10201A, 14L10201B, CRE
14L10201C.
Hydro test from BFP: follow the BFP
20 CRE
DCS checklist.
 HPCL-Mitta\ Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
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® UB#5: 9112-575-0PR-704-00046 Rev 01
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Field Check list

Responsibilit
S.no Description Status Feedback
y
Air vents of drum 12-GLV-0424 & 12-GLV-
1 423, 12-MOV-0401, 12-MOV-0402, 12- FE OPEN
MOV-403, 12-MOV-404.

2 FE OPEN
Main Steam Line stop valve 12-MOV-0511.
Bypass motorized valve 12-MOV-0513, 12-
3 FE CLOSE
MOV-0512
Wing wall air vent 12-GLV-0526, 12-GLV-
4 FE OPEN
0525
Startup vent valve 12-MOV-0509 &
control valve 12-PV-0501
5 FE OPEN

r,";C~ Should be 20% open

Air vents of saturated steam line (12-GLV-
6 0506) (12-GTV-0509) (12-GLV-0501) (12- FE OPEN
GTV-0502) (12-GLV-0525/0526
Super heater steam air vent (12-GLV-
7 FE OPEN
0531/0532)
8 Wing wall air vent (12-GLV-0519/0520) FE OPEN
9 Cod air vent (12-GLV-0513/0514) FE OPEN
Super heater drain valve 12-GLV-0531, 12-
10 FE OPEN
GLV-0532
Water level gauge glass
PROPER FLUSHING
11 FE
Ensure proper flushing and free
from any debris, foreign particles, dusts
Soot blowing isolation valve (12-GTV-
12 FE CLOSED
1501)
Down comer drain valve (12-GLV-0487)
13 (12-GTV-MOV-0413) FE CLOSED

Rear water wall bottom header (12-GLV-

14 FE CLOSED
0489) (12-GTV-MOV-0414).
Compact separator return ring wall
15 FE CLOSED
header drain (12-GLV-0496) , (12-GLV-
 HPCL-Mittal Energy Limited Revision 01
SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 12106/2018
UB#5: 9112-575-0PR-704-00046 Rev 01 Next Review, 12106/2019
H MEL Page 150f16

0497) (12-GTV-MOV-0416)
Compact separator 01 top & rear wall
16 header (12-GLV-0494) (12-GTV-MOV- FE CLOSED
0415)
Compact separator 02 return ring wall
17 header (12-GLV-04104/04105) (12-GTV- FE CLOSED
MOV-0417).
Compact separator 02 top rear wall (12-
18 FE CLOSED
GLV-04107) (12-GTV-MOV-0418)
Final super heater drain valve 12-GLV-571,
19 12-MOV-0519, 12-GLV-0572, and 12- FE CLOSED
MOV-0518
r---
WING wall drains 12-GLV-0524, 12-MOV-
20 FE CLOSED
0516.
21 Primary super heater drain 12-GLV-0521 FE CLOSED
Primary inlet super heater drains 12-MOV-
22 FE CLOSED
0508.
COD bottom drain 12-MOV-0505, 12-
23 MOV-0504, CCFWB header drain 12-MOV- FE CLOSED
0503
24 COD side wall drain 12-MOV-0502 FE CLOSED
25 COD side wall drain 12-MOV-0501 FE CLOSED
Primary Super Heater vent 12-GLV-0519,
26 FE OPEN
12-GTV-0520
Blow down: [(12-GTV-0483) (12-GTV-
0411}L [(12-BAV-0409) (12-GLV-0471}L
[(12-GTV-0479) (12-GTV-0480}L[(12-GTV-
0481) (12-GTV-0482}L [(12-MOV-0407)
(12-MOV-0410)L [(12-GTV-0476) (12-GTV-
27 FE CLOSED
0477}L [(12-GTV-0478) (12-GTV-MOV-
0405}L [(12-GTV-MOV-0406) (12-GTV-
MOV-0405)L [(12-GTV- 0405) (12-GTV-
MOV-0412}L [(12-GLV-3129) (12-GTV-
MOV-0412)]
Drum RHS, LHS safety valves (12-SV-
GAGS TO BE
28 0402/401L & Main steam line safety valve FE
PROVIDED
(12-SV-501).
All the instrument is Isolated except the
29 test pressure gauges (12-PG-0505/0504) FE ENSURE
(13-PG-0402/0403).
 HPCL-Mittal Energy Limited Revision 01

SOP for Boiler Hydro Test in 2)(300 TPH CFBC Boiler Issue Date 1210612018
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Calibrated pressure gauges (12-PG-

30 FE ENSURE
OSOS/OS04) (12-PG-0402/0403)
31 Dial pressure gauge FE ENSURE
Gasket's of all isolation valves, control
32 FE Available in field
valves, MOV's
Initial feeding line discharge valve 12-GTV-
34 FE OPEN
04117 to ECO bottom HDR (12-GLV-3129)

17. Change Register:

Sr. No
1
Page No
10
Clause No.
Point no 7 & 9
Previous Clause
When pressure is reached up to
Revised Clause
When pressure is reached up to hydro
I
hydro test pressure (1.25 X Drum test pressure (1.25 X MAWP)
working pressure) immediately immediately stop the pump and Close
stop the pump and Close the the discharge valve.
discharge valve.