RECOMMENDED PROCEDURE

FOR

AIR TIGHTNESS TEST

OF

FURNACE & DUCTS

PROJECT: INDIA BULLS (5X270MW)

BHEL Ref No. BHEL/TS/AMT-NSK1/CS 002 REV.NO:

DOC.
NO.

PS WR

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR –WESTERN REGION
Shree Mohini Complex, 345 – Kingsway, Nagpur – 440 001
INDIA BULLS
(5X270 MW) BHEL Ref No. BHEL/TS/AMT-NSK1/CS002 /REV
Page 2 of 16

Plant area: BOILER

PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

INDIA BULLS AMRAVATI & NASIK ( Ph -1)

PROJECT

PROCEDURE AIR TIGHTNESS TEST OF FURNACE & DUCTS

PURPOSE OF
FOR EXECUTION / INFORMATION
DOCUMET
DOC.NO.BHEL/TS/AMT-NSK1 /CS/002/REV
DOCUMENT

Copy:

Issued to: CM / BHEL SITE OFF/AMRAVATI & NASIK

00
Rev.No. Prepared by Reviewed by Approved by Date

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR –WESTERN REGION
Shree Mohini Complex, 345 – Kingsway, Nagpur – 440 001

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SLNO
LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVES

3.0 PROPOSALS

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURES

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10.0 APPENDICES

a) LOGSHEET
b) PROTOCOL

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL NO STATUS

1.0 PLANT DETAILS:

1.1 The steam generator is a natural circulation, dry bottom and

radiant Reheat boiler. The furnace consists of water cooled
tubes complete with down comers, water wall headers steam
generating tubes, bottom hoppers, drains, vents, sample line
connections etc.

1.2 The Air path of the boiler consists of Primary air and Secondary
air circuits. Primary air is basically meant for drying and
transporting pulverized coal from Mills to furnace. This primary
air circuit consists of 2 Nos. of Primary Air Fans, 2 Nos. of
APHs with bypass provisions,

1.3 Secondary air is basically meant for assisting combustion. The

secondary air circuit consists of 2 Nos of Forced Draft Fans, 2
Nos APHs, with bypass provisions, and associated ducts up To
wind box.

1.4 Flue gas path circuit consists of Furnace, 1st and 2nd passes,
2 nos ID fans 4 ESP passes and all flue gas connecting ducts
up to stack.

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Plant area: BOILER

PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL NO STATUS

2.0 OBJECTIVES :

2.1 The air tightness test is carried out in Boiler furnace, air ducts
etc., in order to find out the leaks, incomplete weld joints, crack
on the weld joints, left out portions of welds, flange joint leaks,
etc. and to arrange for repair/rectification.

2.2 The air tightness test is only a test to find out the tightness of the
boiler furnace, air ducts with respect to the outside environment
and is not performed to assess the strength to withstand the
operating pressure.

3.0 PROPOSALS

3.1 The Test shall be carried out using Physical Leak Detection
method.

3.2 The Test shall be carried out in stages.

3.2.1 Stage – I will cover the section between FD Fans and Secondary
APHs Air side outlet dampers. This will include their bypass
ducts also.

3.2.2 Stage – II will cover the sections between Secondary APHs air
outlet dampers and wind box dampers. This will include
Secondary APHs, wind-boxes and connecting ducts. Secondary
APHs Flue gas inlet & outlet dampers are to be kept closed /
blanked.

3.2.3 Stage – III will cover the section between Wind-box dampers and
Secondary APHs Flue gas outlet dampers. This will include
Furnace 1st & 2nd Passes and all connecting ducts. APHs may
be included in this stage keeping their outlet flue gas dampers
closed.

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS
3.2.4 Stage – IV Circuit cover in this from PA fan outlet to APH inlet
and up to cold air gates. This will include their bypass ducts and
Cold Primary air ducts up to cold air gates of all Mills and Seal air
pipes.

3.2.5 Stage – V will cover the section between Primary APHs air inlet
dampers and Hot air gates of all Mills.

3.2.6 Stage - VI will cover the section between Hot air gates of all Mills
and Gates on PF pipes near Burners.

3.2.7 Stage – VII Circuit covered in this stage is from Gas duct from
secondary APH outlet to ESP inlet gates

3.2.8 1 No. of each of FD Fan and PA Fan will be used in conducting

the test as explained in section 8.0. Remote operation of FD Fan
and PA Fan will be made available with required interlocks and
protections.

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS

4.0 SERVICES REQUIRED:

4.1 Availability of Cotton waste or marking cloth

4.2 Availability of chalk pieces / paint & brush for marking the leaking
points

4.3 Availability of 0-600 mmwc range manometer

4.4 Availability of Communication / lighting / Man Power for

conducting test.

4.5 Availability of Ambulance at test area.

5.0 SAFETY PRECAUTIONS:

5.1 Following safety equipment should be readily available:

5.2 First – aid kit

Hand gloves

Safety belts

Helmets etc.

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS
6.0 EMERGENCY PROCEDURES:

6.1 During the test, all precautions to be taken at local and remote to
observe the running fans and any trend in increase in bearing
temperature or vibrations should be communicated to control
room for appropriate follow up action.

6.2 Test team should be aware of emergency steps to be taken on

the event of any pressurization of duct while conducting the test.

7.0 STATE OF THE PLANT:

7.1 Erection work of the ducts bellows of the section under test
should be over.

7.2 Insulation should NOT be put on the section/welds for which Air
Tightness Test is yet to be declared complete.

7.3 Alarms and Protections of the Fans, to be used for carrying out
the Air Tightness Test, must be commissioned in view of Safety
of the Fans during the conductance of the Test.

7.4 Adequate approach should be available to the duct under Test.

Furnace bottom should be sealed with sealing water (for Stage –
III).

7.5 PF lines should be blanked or gates near burners should be kept

closed.
7.6 All peepholes and manholes should be properly closed.
Duct, furnace instruments should be either installed or tapping
7.7 points should be plugged.
Depending upon the section being put under test, PA or FD Fan
7.8 is made available for test.

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS

7.9 APH (of the circuit to be tested) should be made ready but kept
under standstill condition during the testing.

7.10 Required communication / lighting / Man Power made available

for testing.

7.11 Installation of all dampers and gates in air and gas path circuits,
where the test is proposed, should be complete.

8.0 METHOD :

8.1 Stage I
Close all access doors and manhole doors of the section under
test.
8.1.1 Assuming that FD Fan A will be operated, the dampers in the
system are lined up as follows:-

8.1.2 APH A & B inlet dampers - Open

FD B disc damper & APH A & B O/L Dampers - Close

8.1.3 Start FD Fan and pressurise the duct up to 200 mmwc. For the
sake of minimum loading of the fan, the Secondary APH outlet
damper closing may be regulated if it is warranted.

8.1.4 Check for leakages and mark

8.1.5 Prepare a list containing the defects, leaks etc. noticed and
arrange for attending the same.

8.1.6 Repeat the test till all leakages are attended.

8.2 Stage II
8.2.1 Close all the manhole doors of the section under test.
Assuming FD Fan – A will be operated, the dampers in the
following circuits are to be lined up

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS
8.2.2 Secondary Air System

8.2.3 APH A & B outlet – Open.

All Secondary air wind box dampers and FD fan B disch –
Closed.

8.2.4 Flue Gas System

8.2.5 APH A & B gas inlet - Closed.

8.2.6 Start FD fan and pressurise the duct upto 200 mmwc. For the
sake of minimum loading of the fan, the Secondary APH gas inlet
damper closing may be regulated if it is warranted.
8.2.7 Check for leakages and mark.

8.2.8 Prepare a list containing the defects, leaks, etc. noticed and
arrange for attending the same.
8.2.9
Repeat the test till all leakages are attended.
8.3
Stage III
8.3.1
Close all the access doors and manhole doors and peephole
doors in this circuit.
8.3.2
Fill water wall seal trough full with water.

8.3.3 Close bottom ash opening gate and fill water in the furnace
bottom ash hopper trough.

8.3.4 Assuming that FD Fan A will be operated the dampers in the

system are lined up as follows:

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS
8.3.5 Secondary Air System
FD Fan A, APH dampers and wind box dampers – Open.
FD B disc - Closed.

8.3.6 Flue Gas System

APHs gas inlet – Closed.

8.3.7 Start FD fan and pressurise the system to 75 mmwc or whatever

maximum pressure is possible in the cold furnace with the
existing water seal.

8.3.8 Check for leaks, defects, etc. from Secondary APH to wind box,
furnace pent house and gas duct up to Air Pre heaters.

8.3.9 Prepare a list containing the defects and arrange for attending the
same.

8.3.10 Repeat the test till all leakages are attended.

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO Stage IV STATUS

8.4 Close all access doors and manhole doors of this section.

8.4.1 Assuming that PA Fan A & seal air fan A will be operated,
dampers and the gates in the system are lined up as follows:-

8.4.2 APH air inlet dampers - closed.

Cold Air gates of all Mills – Closed

PA B disc and APH gas dampers - Closed.

8.4.3 Seal air dampers to be lined up appropriately.

8.4.4 Run the PA Fan and pressurize the system to 300 mmwc. For
the sake of minimum loading of the Fan, APH Primary air inlet
damper closing may be regulated if it is warranted.

8.4.5 Check for leaks and mark

8.4.6 Prepare a list containing the defects noticed and arrange for
attending the same.

8.4.7 Repeat the test till all leakages are attended.

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS
8.5 Stage V

8.5.1 Close all access doors and manhole doors of the section under
test.
8.5.2 Assuming that PA Fan A is operated, the damper and gates in
the system are lined up as follows:-

PA Fan A disc damper – Open

APH (primary air) inlet & out let damper - Open
All Hot air Gates and PA FAN B disc damper – Closed

8.5.3 Pressurize the system to 300 mmwc by running PA Fan A.

8.5.4 Check for leaks and mark.

8.5.5 Prepare a list containing the defects noticed and arrange for
attending the same.

8.5.6 Repeat the test till all the leakages are attended.

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Plant area: BOILER

PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

SL.NO STATUS
8.6 Stage VI

8.6.1 Close all access doors and manholes of the section under test.

8.6.2 Assuming that PA Fan A is operated, the dampers and gates in

the system are lined up as follows:-

Hot air gates and dampers and Clod air gates and dampers of all
mills – Open

PA Fan B disch damper - Closed

Gates on all PF pipes near Burners – Closed

8.6.3 Pressurise the system to 300 mmwc by running PA Fan.

8.6.4 Check for leaks and mark.

8.6.5 Prepare a list containing the defects noticed and arrange for
attending the same.

8.6.6 Repeat the test till all the leakages are attended.

8.7 Stage – VII

8.7.1 Close all access doors and manholes of the section under test.

8.7.2 Assuming that ID A will operate, the dampers and gates in the
circuit are as follows.
APH A&B outlet damper- closed
ESP A & B inlet gate – open
ESP A & B outlet gate – open
ID Fan A inlet damper & outlet gate – open
ID Fan B inlet damper & outlet gate – Closed

8.7.3 All ESP are boxed up and minor leakages can be allowed in the
ESP system. ESP will be subjected to leak test separately.
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8.7.4
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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

8.7.4 Run ID fan and create a negative pressure of 200mmWC by

suitably loading the fan. If necessary some access door may be
kept open for facilitating minimum load of the fan
8.7.5
Check for leaks in the ducting system using hand flame
torch/lighted candle.

8.7.6 Prepare a list containing the defects noticed and attend.

9.0 COMPLETION CRITERIA:

9.1 Air Tightness Test for any stage is declared complete when all
the identified leakages are satisfactorily attended.

9.2 Insulation work for the sections covered in a particular stage

should be taken up only when the Air Tightness Test for that
particular stage is declared complete.

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PROCEDURE FOR AIR TIGHTNESS TEST OF FURNACE & DUCTS

10.0 APPENDIX

LOG SHEET NO.-I

PROJECT:
DATE:
UNIT

STAGE:

Sl.No. LOCATION DETECTED ATTENDED RE-CHECKED.

OF LEAKAGE ON BY/ DATE
1.
2.
3.
4.
5.
6.
7.

DETECTION OF ADDITIONAL LEAKAGES (IF ANY) WHILE RE-CHECKING THE

LEAKAGES DETECTED EARLIER

Sl.No. LOCATION DETECTED ATTENDED RE-CHECKED

OF LEAKAGE ON BY/ DATE
1.
2.
3.
4.
5.
6.
7.

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