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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test

1. ...................................................... .....................................................2 Compilation Basis 2.

...................................................... ..............................2 Outline of Project and Tasks 3. ...................................................... .....................4 Operation Preparation and Environmental conditions 4. ...................................................... ............................8 Tools & and Fittings Needed in Hydrostatic Test 5. . .................................................... .............................9 ========================================2 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test

Procedure and Method of Hydrostatic Test 6. ......................................................... ..........12 Occupational Safety and Health, and Environmental management

1. Compilation Basis 1.1 Equipment drawings and technical documents supplied by Dongfang Boiler Group Co. Ltd. 1.2 Technical code for erection and acceptance for power construction (section of boiler) 1.3 Technical code for erection and acceptance for power construction (section of chemistry) 1.4 Technical code for erection and acceptance for power construction (section of piping) 1.5

 Quality inspection and evaluation criteria for thermal power construction (section of boiler) 1.6 Safety technical supervision regulations for steam boiler 1.7 Metal technical supervision regulations for thermal ========================================3 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test power plant 1.8 Safety technical supervision regulations for pressure vessels 1.9 Documents of occupational health & safety and evironmental management system 1.10 Documents of quality control system 1.11 Typical outline of quality supervision and inspection prior to hydrostatic test of boiler for wer project 1.12

thermal po

DL5009.1-2002; DL5009.1-2002 of Safety working regulation for power construction (section of thermal power plant) 1.13 1# Professional construction organization design for 1# boiler 1.14 Construction drawing and technical information supplied by the design institute 2. 2. 2. 2.

 Outline of Project and Outline of Project and Outline of Project and Outline of Project and T TT Tasks asks asks asks 2.1 Main design parameters of boiler 315MW This boiler matches steam turbine generator unit of 315MW. The boiler is a kind of natural circulation drum boiler with subcritical parameters and four-corner tang entially Fired mode. It is laid out in semi-outdoor mode in shape of single furnace. It uses lignite as fuel, mode of single reheat, balanced ventilation and dry ash extraction, and structur e of whole steel frame, with metal anti-rain cover. 2.2 Main parameters of boiler are as follows: Rated power of unit MW 315 Rated evaporating capacity t/h 971.062 Maximum continuous evaporating capacity t/h 1025 ========================================4 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test Outlet pressure of superheated steam(BMCR) Outlet temperature of superheated steam Reheated steam flow (BMCR) / t/h MPa 17.5 541

798.103

Inlet/outlet pressure of reheated steam (BMCR) / Inlet/outlet temperature of reheated steam (BMCR) 322/541 Feed temperature (BMCR/BECR) 2.3 System flow 2.2.1

MPa

3.625/3.438

275.5

Primary steam system flow: Main feed water piping of high pressure conduit at entrance of economizer entrance header of economizer serpentine tube set of economizer hanging exit header of economizer connecting pipe steam drum centralized downcomer sewage connecting tube water wall tube entrance header panelized-tube-wallsection water wall tube exit header steam-water connecting tube steam drum saturated vapor connecting tube

ceiling ========================================5

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test entrance header steam connecting tube both side wall enclosure entrance header wall enclosure tube bundle ring header of wall enclosure pass serpentine tube in low temperature pass exit header in low temperature conduit entrance header of full big platen tube bundle of full big platen exit header of full big platen conduit entrance header of rear platen superheater tube bundle of rear platen exit header of rear platen conduit entrance header of high temperature superheater tube bundle of high temperature superheater exit of high temperature superheater exit conduit of high temperature superheater plugged valve for hydrostatic test at exit of high temperature superheater Ceiling entrance header ceiling tube

ceiling exit header header connecting tube wall enclosure entrance header at extended side tube bundle of extended wall enclosure header below extended wall enclosure connecting tube ring header of wall enclosure (same as above) Source station of soot blower 2.2.2 Secondary steam system flow: Cool zone of turbine entrance header of wall reheater tube bundle of wall reheater exit header of wall reheater attemperator of reheater entrance header of mid temperature reheater tube bundle of mid temperature reheater tube bundle of high temperature reheater exit header of high temperature reheater exit conduit of high temperature reheater plugged valve for hydrostatic test at exit of high temperature reheater 2.3 Objective of hydrostatic test After finishing installation of boiler heating surface, in order to test tightne ss and strength of compressive parts like welding joint, parent metal and valve of the system in co ld state, hydrostatic test has been done for boiler proper and its auxiliary piping accord ing to requirements

of technical documentation of the equipment. ========================================6 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 2.4 Scope of hydrostatic test This hydrostatic test of boiler is done by dividing into two parts, primary stea m (superheated steam) system and secondary steam (reheated steam) system. 2.4.1 Scope of hydrostatic test for primary steam system of boiler includes, boiler drum, water wall, economizer, superheater, attemperator and connecting tube in system of boiler proper heating surface. It starts from high pressure feed water front pedestal and ends at plugged valve for hydro static test at exit of high temperature superheater. 2.4.1.1 Superheater piping system in scope of boiler proper: attemperator of superheater, emergency water release, re-circulation, steam release, dosing, dra in, back wash, continuous blowdown, sequencing, sampling, nitrogen charge, piping of water leve l gauge, heating of adjacent boiler and other auxiliary pipings inside of primary air reg ulator. Water level gauge is only included in working pressure test. 2.4.2.2 Thermodynamic instrumentation: pressure sampling, Liquid Indicator of boiler drum and others inside of primary air regul ator. 2.4.2 Scope of hydrostatic test of boiler secondary steam system includes, wall reheat er, mid temperature reheater, high temperature reheater, attemperator of reheater, condu it of reheater, from cold zone to plugged valve for hydrostatic test at exit of reheater. Piping syst em of reheater in scope of boiler proper: attemperator of reheater, steam release, drain, sampling and other pipes inside of primary air regulator. 2.5

 Pressure of hydrostatic test ========================================7

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 1.25 18.59MPa1.25=23.24MPa 1.5 3.8MPa1.5=5.7MPa It is decided according to technical documents supplied by Dongfang Boiler Group Co. Ltd as follows: Pressure of hydrostatic test for primary steam system is 1.25 times of steam dru m working pressure. i.e. 18.59Mpa 1.25=23.24MPa Pressure of hydrostatic test for secondary steam system is 1.5 times of working pressure of entrance header of wall reheater. i.e. 3.8MPa1.5=5.7Mpa 3. 3. 3. 3. Operation Operation Operation Operation P PP Preparation and reparation and reparation and reparation and Environmental Environmental Environmental Environmental conditions conditions conditions conditions 3.1 Water used for hydrostatic test 3.1.1 Water quantity

Boiler drum 3 Water cooling system 3 Economizer 3

54m

138m

32m

Superheater system 200m 3 Reheater system 112m 3 536m 3 1608m 3 Total volume is 536m 3 , considering for preventing accidental condidtion happens, 1608m 3 demineralized water shall be prepared. 3.1.2 Water temperature ========================================8

2070 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 5 28 According to design requirements of Dongfang Boiler Group Co. Ltd and specifications needs, during hydrostatic test of boiler, feed water temperature shall be controlled between 20 and 70 , and the surrounding temperature shall be higher than 5 , temperature of feed water shall vary from that of boiler drum by less than 28 . As test program is executed in initial summer, both water temperature and surr ounding temperature can meet the requirements. Therefore, temperary heating system can b

e omitted. 3.1.3 Water quality Use demineralized water admixed with Ammonia and diamine. Water quality shall me et the following requirements: 0.25mg/L

200mg/L 300 mg/L PH =10 10.5 , 500 mg/ L

Chloride ion content in water is less than 0.25mg/L. Diamine content is 200mg/L 300 mg/L

PH value = 10 to 10.5 adjusted by use of ammonia water, Ammonia density is 500 mg/ L 40% Dosage of 40% industrial diamine is: 25010 -6 53610 3 = 335(Kg) 40% Amount needed 25010 -6 53610 3 = 335(Kg) 40% 25% 50010 -6 53610 3

=1072(Kg) Dosage of 25% ammonia water is: ========================================9

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test Amount needed 50010 -6 53610 3 =1072(Kg) 25% 3353=1005Kg 10723=3216 Kg Industrial diamine shall be prepared in amount of 3353=1005Kg, and ammonia water prepared in amount of 10723=3216 Kg. 3.2 System layout 3.2.1 Water filling system flow:

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 3.2.2 Dosing system , Condensation tank is used as container for storing water and dosing. Ammonia and diamine are added through manhole of the tank. Start wat er filling pump after dosing, then start re-circulating line for fully mixing even. Once do sing density meets the requirements, close re-circulating valve and open water filling gate to fill water to the system. Water quality shall be tested and evaluated with help of chemical workshop of th e power plant. 3.2.3 Pneumatic System 0.7 MPa 284 For air source, air compressor (its outlet pressure is 0.7Mpa) is used by connec ted to temporary Demineralized water Condensation tank Condensate transfer pump Condensate line Main feed line Entrance header connector of economizer Drain line of entrance header of reheater Steam drum Primary steam system Secondary steam system ========================================11 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test water filling line with steel pipe of 284, for pressure charge to the system. 3.2.4 Pressure boosting system flow:

Pressure boosting pump Pressure boosting line Drain line of entrance header of wall reheater Secondary steam system Heating of adjacent boiler and header drain Primary steam system Water fillingline

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 3.2.5

3.2.5 Water discharge system flow: 3.3 Pre-conditions for hydrostatic test 3.3.1 Construction of all bearing structures, ladder, handrail, platform and other par ts in scope of boiler proper has been completed, and passed acceptance with complete certificates. Hig h strength bolt of steel frame has been tightened finally, and settlement of steel frame is stab le and meets the design requirements. 3.3.2 Installation of various heating surface and compressive parts of boiler proper has been finished and passed acceptance (incl uding inside Drain header waste Liquide Pool for Boiler Washing Various drain lines ========================================13 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test check and clearing of header, ball passing of pipeline, seal of pipe head, align ment and connection of various parts and so on). 3.3.3 Construction of pipeline and supports and hangers for hydrostatic test has been finished. Pipelines for air discharge, drain, sampling, dosing, instrument control, blowdown, attemp erating water,

emergency drain and heating of adjacent boiler have been installed to primary an d secondary air regulator (at least to primary air regulator), with full consideration of compen sation of thermal expansion. Installation of pipeline valve and fittings for main steam, reheating steam and feed of water shall be completed. 3.3.4 All welding in scope of hydrostatic test has been completed and passed quality standard by way of visual examination and inspection of heat treatment a nd nondestructive inspection. 3.3.5 All parts welded on pipeline or compressive part of heating surface, such as fin, pin, sea ls, wearing cover, boiler retarder, locating plate, heat preservation hooknail, sealing box of door opening, sampling source for thermal detection, have been finally welded, and passed appearance in spection without weld slag. Sealing weld between furnace and wall enclosure is done tightly, and wide gap has been filled well according to standards requirements. 3.3.6 All defects found in equipment inspection and installation by manufacturer have been handled well and passed acceptance with corresponding treatment records formed. 3.3.7 Temporary iron part welded on compressive part for temporary strengthening or hoisting has ben cut away smoothly by grinding without damaging the parent ========================================14 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test metal. 3.3.8 All parts belonging to metal supervision in scope of hydrostatic test shall be through spe

ctrum check t and shall 3.3.9

analysis to without error with corresponding spectrum analysis report. Alloy steel par weld joint be checked by spectrum analysis or other methods without any detect found.

Derrick and cradle of all parts of boiler proper have been finally installed, and its stress meets require ments after adjustment. The locating pin of its spring cradle and constant spring hanger has been locked according to regulations of technical documents and meets requirements through i nspection. 3.3.10 Miscellany inside and outside of boiler and at places like furnace top, platform ladder, zero grade level, furnac e, furnace hopper, horizontal flue, low pass, economizer and its ash hopper, shall be cleared, and inspection passway shall be through without miscellany. 3.3.11 Falsework and lighting for inspection at places inside of boiler shall be comple ted and pass acceptance. 3.3.12 Chemical demineralized water used for hydrostatic test shall be qualified with water quality certificate report. Water temperature shall be guar anteed to meet regulation of the manufacturer, and water volume is enough to meet requirments o f hydrostatic test. 3.3.13 Water filling pump and pressure boosting pump have been installed and reconditioned well, and pass test run with condition for being put into operation. 3.3.14 Temporary ========================================15 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia

The Sector of Boiler>>> Operation Instruction of Hydrostatic Test water filling system, pressure boosting system and water discharge system for hy drostatic test have been installed well according to hydrostatic test system drawing. Temporary water filling line has been flushed, and water tank cleared with records of certification. With all these, they can be connected to formal system for operation. 3.3.15 Instruments and meters for hydrostatic test have been prepared complete, and passed inspection with qua lified accuracy. 3.3.16 Expansion indicator on steam drum, header below water wall and header below wall enclosure has been installed at correct position and soundly, where indicating plate is convenient for observation, and indicating needle is calibrated to zero . 3.3.17 Expansion gap of boiler heating surface has been adjusted up to drawing dimensional requir ements, can meet expansion needs with measurement records. 3.3.18 Compressive weld joint on equipment and pipeline in scope of hydrostatic test, a nd other location to be inspected, shall not be heat-preserved and painted. 3.3.19 Pipeline for deminineralized water to fill into temporary water tank shall be installed and f inished for water filling to boiler. 3.3.20 Temporary pipeline for pneumatic test prior to hydrostatic test has been connected well for operation. 3.3.21 Boiler drum is cleared well, and its manhole is sealed after acceptance. 3.3.22 Steam drum safety valve has been installed and adjusted according to requirments of manufacturer, with relia

ble plugging and isolation of water pressure. 3.3.23 Equipment design and manufacturing defect has been removed and the equipment has passed acceptance. 3.3.24 Compressing measure ========================================16 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test has been adopted for safety valve for hydrostatic test according to instruction manual of manufacturer. 3.3.25 Implementation plan for hydrostatic test has been formulated and approved. Organs and personnel taki ng part in the hydrostatic test have been confirmed with each person responsible for specified tasks. Safety, technical and quality control measures for the test have been disclosed with for mality of clarification. 3.3.26 - Drawing of hydrostatic test system, pressure boosting and depressurization curve and operational card have been hanged up at site, and grasped by operating personnel. 3.3.27 Leading group of hydrostatic test has been established with uniform commanding. Participants shall be clear about their responsibility. Intercom sha ll be provided to ensure reliable communication during hydrostatic test. 3.4 Operational program

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test

4. 4. 4. 4. Tools and Tools and Tools and Tools and F FF Fittings ittings ittings ittings N NN Needed in eeded in eeded in eeded in H HH Hydrostatic ydrostatic ydrostatic ydrostatic T TT Test est est est 4.1

 Machine tool needed in hydrostatic test 4.1.1 110m 3 1 Condensate tank of 110m 3 1 set 4.1.2 0.7MPa 1 Air compressor of 0.7 Mpa 1 set 4.1.3 2 Pressure boosting pump 2 sets 4.1.4 (85M 3 /h135Mh 2 0) 1 Startup water filling pump (85M 3 /h 135Mh 2 O) 1 set 4.1.5 F 8 Temporary F shaped wrench 8 4.1.6 Valve some 4.1.7 Pipeline some 4.2 Measurement instrument Preparation and condition before operation Inspection and remedy before hydrostatic test Pneumatic test Water filling for boiler Hydrostatic test Certificate handling ========================================18 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 4.2.1 1.5 0-1.6MPa 2 Pressure gauge for pneumatic test class 1.5 Range of 0-1.6Mpa 2 piec es 4.2.2 1.5 0-40MPa 2 Pressure gauge for primary steam system class 1.5 Range of 0-40Mpa 2 piece s 4.2.3 1.5 0-10MPa 2 Pressure gauge for secondary steam system class 1.5 Range of 0-10Mpa 2 piece

s 4.3 All tools and devices shall be confirmed to be in good condition and qualified for use after reconditioning and inspection. 4.4 All measurement instruments shall pass inspection by natinal quantative inspection department, a nd be within valid period specified. 5. 5. 5. 5. Procedure and Method of Hydrostatic Test Procedure and Method of Hydrostatic Test Procedure and Method of Hydrostatic Test Procedure and Method of Hydrostatic Test 5.1 Air tightness tes t 0.3 0.5MPa Prior to formal hydrostatic test, air tightness test shall be done for the whole system with pressure of 0.3 to 0.5Mpa, in order to find and remove leakage, to lay a good foundation for hydrostatic test. The air tighness test shall be done according to the following steps: 5.1.1 Connect through pipeline for air tightness test as per the system drawing. 5.1.2 Close all primary steam valves inside of boiler heating surface system. 5.1.3 0.3 0.5Mpa Start air compressor to fill the whole system to pressure of 0.3 to 0.5Mpa, then inspect it. 5.1.4 0.3 0.5MPa If any leakage found, mark it first and handle it after pressure is released. Then boost pressure again to 0.3 to 0.5Mpa to make inspection

and remove defect until no leakage exists, and air tightness test comes to end. 5.1.5 Leakage detecting method of air tightness test ========================================19 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 5.1.5.1 Listen: normally there is sharp hissing of air release where leakage exists. 5.1.5.2 Touch: try thin paper to place it on leakage spot, there will be slight jittering. 5.1.5.3 Observe: apply soap water to spot with possible leakage, if it is leaking, there will be soap bubble formed around it 5.1.6 Air tightness test shall be done during day as possibly to facilitate inspection and safety. 5.2 Hydrostatic test After finishing air tightness test, hydrostatic test can be started. 5.2.1 Water filling of primary steam system 5.2.1.1 After finish of commissioning of temporary system for pressure test, start dosing for mixing. The mixing is done by method of circulating water in water tank by water filling pump. Water fill can be started after water quality passes lab tes t. 5.2.1.2

Open all air valves, and primary and secondary steam valve, pressure gauge and water level gauge valve of emergency water discharge line of boiler drum, close all primary steam valve of auxiliary pipeline and other thermal instrument except those of tempora ry water line for water filling of primary steam, and start temporary water filling pump to fill w ater into system of primary steam. 5.2.1.3 2 During water filling, water shall be filled slowed, and the filling time shall not be less than 2 hours. 5.2.1.4 Water level in boiler drum shall be carefully monitored during filling, and air valve shall be checked if there is air to be discharged, blocking shall be prevented. ========================================20 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 5.2.1.5 3 5 3 5 After air valve has water to overflow continuously for 3 to 5 minutes, it can be closed gradually. After the highest air valve on furnace top has overflowing water for 3 to 5 minutes, all air valves and inlet v alves shall be closed to stop water filling. 5.2.1.6 After filling water full, fully check the primary steam system, if no abnormality found, pressure boosting can be started (attention shall be paid to drain out air in pipe of pressure gauge, to ensure accuracy of readings). 5.2.2 Pressure boosting test of primary steam system 5.2.2.1 0.294MPa/min Close outlet valve of water filling pump, start pressure testing pump to boost pressure. Pressure shall be boosted smoothly and slowly, and pressure boosting s peed shall not exceed 0.294MPa/min. 5.2.2.2

2.4MPa 18.59Mpa, When boosting pressure to 2.4Mpa, stop boosting pressure, and make rough check for the system. If no abnormality found, continue boosting pressure until working pressure of boiler drum reaches 18.59Mpa, stop b oosting pressure for full check to the system. If no abnormality found after the check, overpress ure test may be done after directed for boosting pressure by test leader. (1) Prior to overpressure test, the following task shall be done well: a) Isolate system well before doing over pressure test, all water level gauges and safety valves a re isolated without participation of overpressure test. b) All checking personnel shall stop check on compressive part, and be evacuated to safety area. c) ========================================21 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test Check zero and furnace top pressure gauge reading. Test pressure of primary stea m system shall take reading of local pressure gauge of boiler drum as standard. When checking r eadings of upper and lower pressure gauge, static pressure difference formed by different elevati on of upper and lower water level shall be attended. Pressure shall be checked all time to preve nt it from exceeding test pressure. (2) 0.1MPa/min 23.24 Mpa, 20 When overpressuring, pressure boosting speed shall not exceed 0.1MPa/min. When pressure is boosted to pressure value for overpresssure test, the

primary steam system is 23.24Mpa, close outlet valve on exit pipeline of pressur e boosting pump, and stop pressure boosting pump meanwhile, and record time timely. Finally keep at this pressure for 20 minutes to observe falling of pressure. 5.2.2.3 20 18.59 Mpa, 0.1MPa/min After keeping the test pressure for 20 minutes, slowly open air valve to drop pressure to steam drum wo rking pressure of 18.59Mpa at falling speed not over 0.1MPa/min. Then a full and carefull check sh all be done, during which no apparent drop of pressure shall happen. If there is no cracking, deformation or leakage happening during the check, the hydrostatic test shall be considered qua lified (water level gauge is not included in overpressure test). 5.2.2.4 0.3MPa/min 1MPa After passing the hydrostatic test, air valve can be opened to drop pressure, while pressure d rop speed can not be over 0.3Mpa/min, until pressure drops to 1Mpa. At earlier stage, boiler shall be filled full for protection, and concrete water discharge time can be decided according to actual progress of project. 5.2.3 Water filling of secondary steam system 5.2.3.1 ========================================22 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test Start dosing for mixing. The mixing is done by method of circulating water in wa ter tank by water filling pump. Water fill can be started after water quality passes lab tes t. 5.2.3.2 Open all air valves, and primary and secondary steam valve, pressure gauge and w ater level

gauge valve of entrance header drain of wall reheater, close all primary steam v alve of auxiliary pipeline and other thermal instrument except those of temporary water line for w ater filling of secondary steam, and start temporary water filling pump to fill water into syste m of secondary steam. 5.2.3.3 2 During water filling, water shall be filled slowed, and the filling time shall not be less than 2 hours. 5.2.3.4 During water filling, all air valves shall be checked if there is air to be discharged, blocking shall be prev ented. 5.2.3.5 3 5 3 5 After air valve has water to overflow continuously for 3 to 5 minutes, it can be closed graduall y. After the highest air valve of exit header of reheater on furnace top has overflowing water for 3 to 5 minutes, all air valves and inlet valves shall be closed to stop water filling. 5.2.3.6 After filling water full, check the secondary steam system thoroughly, if no abnormality found, pressure boosting can be started (attention shall be paid to drain out air in pipe of pressure gauge, to ensure accuracy of readings). 5.2.4 Pressure boosting test of secondary steam system 5.2.4.1 0.294MPa/min Open primary and secondary steam valve of entrance header drain of wall reheater, start pressure testing pump to boost pressure. Pressure shall be boosted smoothly and slowly, and pressure boosting speed shall not exceed 0.294MPa/min. 5.2.4.2 0.4MPa 3.8MPa ========================================23 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test

 When boosting pressure to 0.4Mpa, stop boosting pressure, and make rough check for the system. If no abnormality found, continue boosting pressure until working pressure of entrance header of wall reheater rea ches 3.8Mpa, stop boosting pressure for full check to the system. If no abnormality found after th e check, overpressure test may be done after directed for boosting pressure by test leade r. (1) Prior to overpressure test, the following task shall be done well: a) Isolate system well before doing over pressure test, all safety valves are isolated without particip ation of overpressure test. b) All checking personnel shall stop check on compressive part, and be evacuated to safety area. c) Check readings of pressure gauge at zero and entrance header of wall reheater. Test pressure of secondary steam system shall take reading of local pr essure gauge of entrance header of wall reheater as standard. When checking readings of upper an d lower pressure gauge, static pressure difference formed by different elevation of upper and low er water level shall be attended. Pressure shall be checked all time to prevent it from exceeding tes t pressure. (2) 0.1MPa/min 5.7 Mpa, 20 When overpressuring, pressure boosting speed shall not exceed 0.1MPa/min. When pressure is boosted to pressure value for overpresssure test, the secondary steam system is 5.7Mpa, close outlet valve on exit pipeline of pressur e boosting pump, and stop pressure boosting pump meanwhile, and record time timely. Finally keep at this pressure for 20 minutes to observe falling of pressure. 5.2.4.3 0.1MPa/min 3.8MPa

Slowly open air valve to drop pressure to working pressure of ========================================24 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 3.8Mpa of entrance header of wall reheater at falling speed not over 0.1MPa/min. Then a full and carefull check shall be done, during which no apparent drop of pressure shall ha ppen. If there is no cracking, deformation or leakage happening during the check, the hydrostatic tes t shall be considered qualified. 5.2.4.4 0.3MPa/min 1MPa After passing the hydrostatic test, air valve can be opened to drop pressure, while pressure d rop speed can not be over 0.3Mpa/min, until pressure drops to 1Mpa. At earlier stage, boiler shall be filled full for protection, and concrete water discharge time can be decided according to actual progress of project. 5.4 For various defects found in hydrostatic test, records and mark shall be done we ll and carefully, to facilitate timely correction after finish of the test. After passing the test, c ertificate shall be handled by each party of installation, turnkey contractor, supervisor and the em ployer, and hydrostatic test is over. 6 Occupational Safety and Healty, and Evironmental Management 6.1 ========================================25

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 6.1 Main hazards identification and environmental factor identification for hydr ostatic test Operational activity Hazards factor(environmental factor) Accidents resulted possibly Corresponding measures

36v

36v ========================================26 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test Operational activity Hazards factor(environmental factor) Accidents resulted possibly Corresponding measures Installatio n of temporary system Electric leakage of power line Electric shock Carefully check before using electric tools to prevent using damaged

power line Dosing Evaporation of ammonia Air pollution Shorten time of dosing Ammonia water splash Body injury Opertators wear protecting suit, medical staff is provided on site Pressure boosting Weld bond leakage and pipeline bursting Body injury Non-testing person is not allowed to enter site, and operator must not stand in front of weld plug or at side of flange Inspection Lighting voltage in furnace is not safety voltage Electric shock Lighting voltage in furnace shall be lower than 36v Inspect during pressure boosting and overpressure Body injury Observe instruction to avoid this happening Falsework at high position is not fixed soundly Body injury Erect falsework as per specifications Water discharge Waste water is discharged without treatment Pollution to water and stream Waste water shall not be discharged until treated up to environmental protection standard. 6.2 Safety measures and requirments of civilized construction 6.2.1 All personnel participating in hydrostatic test must take part in technical and safety disclosure of the test, and formality of disclosure shall be handled. 6.2.2

 Range of pressure gauge used for the test must be qualified, or pass inspection and be within valid period. During hydrostatic test, more than 2 gauges shall be put into use at the same time. 6.2.3 During the test, inspector is not allowed to stand in front of weld plug or at side of flange. ========================================27 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 6.2.4 Before installing temporary pipeline for the test, it shall be cleared to ensure there is no miscellany in pipeline. It shall be welded accordi ng to welding requirments of pipeline of the same class, and weld joint shall be inspected as per requirments. 6.2.5 Special person shall be assigned to be responsible for commanding pressure boosting and drop during hydrostatic test, a nd for operation of water filling pump, pressure boosting pump and valves, no other person is all owed to operate. Responsible person is not allowed to leave work post without permission. 6.2.6 Before starting overpressure test, construction leader must count number of workers. Pressure can not be boosted until all inspectors leave and site is chec ked. 6.2.7 During hydrostatic test, all work in scope of boiler shall be stopped. Non-operating personnel is not allowed to enter test ar ea. Warning rope and plate shall be set up timely and special person is assigned to guard at all passages. 6.2.8 Arc striking for weld on

compressive pipeline and part, or hammering compressive part, is strictly prohib ited. 6.2.9 During pressure boosting, special person shall be provided for monitoring readings of upper and lower pressure gauge, and checking the readings to prevent pressure gauge damaging and that actual pressure exceeds test pressure a s a result. 6.2.10 When hydrostatic test is done for primary steam system, air valve of reheater system shall be opened to prevent overpressu ring of secondary steam system. After finish of pneumatic test, pneumatic system shall be cut off from water pressure system. 6.2.11 ========================================28 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test All valves shall be numbered and marked with sign plate, and operated by special person. During check of hydrostatic test, it shall be grouped and in cha rge by special person. Single inspector is not allowed to enter furnace for inspection, at leas t 2 persons together can do so, besides, special person is provided at outside of furnace for guardin g. After inspection, number of persons out shall be counted again before manhole is closed temporaril y. 6.2.12 When dosing anti-corrosion protective agent, operator should be equipped with co rrect protection products. No open fire and smoking are allowed nearby the agent and o perator. 6.2.13 During inspection, if any seepage or leakage is found, it shall be marked, and reported to commanding group timely. No personal handling can be don e, and inspector shall stay away from leakage spot.

6.2.14 Falsework needed for inspection shall be erected soundly up to specified requirments, and pass acceptance. 6.2.15 Water pressure boosting line shall be fixed soundly, to prevent danger from pipe shaking during pressure boosting. 6.2.16 Lighting arranged in furnce shall be proper, with good and complete power line, and protection device for electric leakage. 6.2.17 Enough communication tool (intercom) shall be provided during hydrostatice test, checked in good condition, fully charged with spare battery, to ensure good communication. 6.2.18 After water filling for hydrostatic test, expansion shall be checked from expans ion indicator, to ensure expansion is not stopped, with proper records done. 6.2.19 Major slab and girder deflection of boiler shall be measured before and after water filling, and after water discharge, and records shall be done for its variation. ========================================29 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 6.2.20 Solid waste management: solid waste non-harmful, non-toxic, unrecoverable and recoverable sh all be put collectively to designated piling area, with apparent mark. Toxic and harmful so lid waste shall be stored by classification. 6.2.21

 Overpressure test shall be done as least as possible. If leakage spot is checked accurately and easy to handle, overpressure test may be ommited. Appendix: Sketch drawing of water filling, drain and pressure boosting of hydrostatic test Curve of pressure boosting of primary steam system during test Curve of pressure boosting of secondary steam system during test ========================================30 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 1 DN10P 55.5 PN19Mpa 2 2 DN100 PN32Mpa 4 3 DN100 PN32Mpa 2 4 DN100 PN32Mpa 2 5 6 7 DN80 PN32Mpa 1 DN80 PN32Mpa 1 DN80 PN32Mpa 4

8 9 10 11 12 13 14 15 16 17

DN50 PN32Mpa 4 DN50 PN32Mpa 2 DN50 PN32Mpa 1 DN50 PN32Mpa 8 DN50 PN32Mpa 4 DN50 PN32Mpa 8 DN32 PN32Mpa 2 DN32 PN32Mpa 2 DN32 PN32Mpa 2 DN32 PN32Mpa 48

18 DN32 PN32Mpa 2 19 DN80 PN32Mpa 5 20 DN50 PN32Mpa 2 21 DN50 PN32Mpa 4 22 DN32 PN32Mpa 4 23 DN20 PN32Mpa 4 ========================================31 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 24 DN20 PN32Mpa 24

25 DN20 PN32Mpa 4 26 DN20 PN32Mpa 2 27 DN20 PN32Mpa 2 28 DN20 PN32Mpa 4 29 DN20 PN32Mpa 6 30 DN20 PN32Mpa 8 31 DN20 PN32Mpa 6 32 DN10 PN32Mpa 2 33 DN4;P 30 PN32Mpa 9 34 DN20;P 55.5 PN32Mpa 4 35 DN20;P 55.5 PN32Mpa 10 36 55.5 PN32Mpa 6 37 DN10;P 55.5 PN32Mpa 3 DN20;P

38 DN50 P56 PN19Mpa 2 39 DN125 PN32Mpa 1 40 DN125 PN32Mpa 2 41 DN150 P 55.5 PN5Mpa 2 42 DN100 P 55.5 PN17Mpa 2 43 DN10 PN32Mpa 7 44 DN10 PN32Mpa 2 45 12 1 46 1 1 47 4 1 48 2 1 49 1 4 50 1 2 ========================================32 ======================================== PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 51 52 1 1

1765WD 2 53 1785WB 4 54 1730WD 2 55 1749WD 3 56 3538W 1 57 2.5 1 58 DN10 4 59 DN10 3 60 DN10 1 61 DN10 1 62 DN10 2 63 DN100 2 64 DN56 16 65 DN56 16 DN10 14

66 67

DN10 6 DN10 7 DN10 3

DN10 7 68 69 70 71 14 1

 1 1 2 PN32,DN125 2 3 14 1 4 12 1 5 14 1 ========================================33

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 6 PN1.6 DN65 1 7 PN2.5,DN150 1 8 PN0.6,DN150 1 9 PN0.6,DN80 1 1 PN32DN50 3 1 PN32DN50 2 1 PN32DN20 7 1 PN32,DN50 3 ========================================

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test List of Opening and Closing of Valves during Hydrostatic Test No. of valve Description of valve Model of valve Quantit y Status of valve Suppl y by factor y Tempora

ry system Wate r fillin g Pressur e boostin g Depres surizati on 1 Throttle valve of superheated steam sampling DN10P 55. 5 PN19Mp a 2 close close close 2 Stop valve of adjacent boiler heating header pipe DN100 PN32Mp a 4 close close close 3 Stop valve of re-circulating pipe of economizer DN100 PN32Mp a 2 close close close 4 Stop valve of first-stage attemperater branch pipe of superheater DN100 PN32Mp a 2 close close close 5 Stop valve of emergency attemperater pipe DN80 PN32Mp a 1 close

close close 6 Stop valve of reheater attemperation header pipe DN80 PN32Mp a 1 close close close 7 Stop valve of second and third-stage attemperater branch pipe of superheater DN80 PN32Mp a 4 close close close 8 Stop valve of fine-adjustment attemperater branch pipe of reheater DN50 PN32Mp a 4 close close close 9 Stop valve of non-utility steam DN50 PN32Mp a 2 close close close 10 Stop valve of continuous sewage discharge of steam drum DN50 PN32Mp a 1 close close close 11 Stop valve of ring header drain of back vertical shaft DN50 PN32Mp a 8 close close close

12 Stop valve of entrance header drain DN50 PN32Mp 4 open open close ========================================35 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test a 13 Stop valve of intermittent blowdown header pipe of water wall DN50 PN32Mp a 8 open close close 14 Stop valve of ceiling entrance header drain DN32 PN32Mp a 2 close close close 15 Stop valve of feed front pedestal drain DN32 PN32Mp a 2 close close close 16 Stop valve of inlet pipeline drain of economizer DN32 PN32Mp a 2 close close close 17 Stop valve of intermittent blowdown pipeline of water wall DN32

PN32Mp a 48 open close close 18 Check valve of steam drum dosing pipe DN32 PN32Mp a 2 close close close 19 Stop valve of attemperater branch pipe DN80 PN32Mp a 5 close close close 20 Stop valve of Nitrogen charge of entrance header DN50 PN32Mp a 2 close close close 21 Stop valve of nitrogen charge of steam drum DN50 PN32Mp a 4 close close close 22 Stop valve of filter drain of attemperater pipeline DN32 PN32Mp a 4 close close close 23 Stop valve of acid cleaning of intermittent blowdown header pipe of water wall DN20 PN32Mp a 4 close

close close 24 Stop valve of adjacent boiler heating device DN20 PN32Mp a 24 close open close 25 Stop valve of heating header drain ofadjacent boiler DN20 PN32Mp a 4 close open close 26 Acid cleaning stop valve of inlet pipeline of economizer DN20 PN32Mp 2 close close close ========================================36 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test a 27 Stop valve of evacuation of link pipeline from economizer to steam drum DN20 PN32Mp a 2 close close open 28 Backwash stop valve of attemperater pipe filter DN20 PN32Mp a 4 close close close 29 Air discharge stop valve of outlet pipe of saturated vapor and superheater branch pipe

DN20 PN32Mp a 6 open close open 30 Stop valve of balance tank DN20 PN32Mp a 8 close close close 31 Stop valve of double color water gauge and electro connecting water gauge drain DN20 PN32Mp a 6 close close close 32 Stop valve for emergency water spray and leak hunting of reheater DN10 PN32Mp a 2 close close close 33 Three way valve for connector of pressure gauge DN4;P 30 PN32Mp a 9 close close close 34 Stop valve of air discharge of reheater attemperter DN20;P 5 5.5 PN32Mp a 4 close close open 35 Stop valve of air discharge of first,second and third stage attemperater

DN20;P 5 5.5 PN32Mp a 10 open close open 36 Stop valve of air discharge of superherter and reheater conduit DN20;P 5 5.5 PN32Mp a 6 open close open 37 Stop valve of dynamic discharge valve system DN10;P 5 5.5 PN32Mp a 3 open close open 38 Backwash stop valve of superheater outlet conduit DN50 P56 PN19Mp a 2 close close close ========================================37 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 39 Gate valve of superheater attemperater header pipe DN125 PN32Mp a 1 close

close close 40 Gage valve of feed front pedestal branch pipeline DN125 PN32Mp a 2 close close close 41 Stop valve of atmospheric relief of reheated steam DN150 P 55.5 PN5Mpa 2 open close open 42 Stop valve of atmospheric relief of superheated steam DN100 P 55.5 PN17Mp a 2 open close open 43 Throttle valve of saturated vapor and reheated steam sampling DN10 PN32Mp a 7 close close close 44 Throttle valve of feed and boiler water sampling DN10 PN32Mp a 2 close close close 45 Gate valve of main pipeline of feed front pedestal 12

1 open close close 46 Adjusting valve of continuous sewage discharge of steam drum 1 1 close close close 47 Adjustment valve of branch pipeline of feed front pedestal 4 1 close close close 48 Adjustment valve of first-stage attemperater branch pipe of superheater 2 1 close close close 49 Adjustment valve of second and third-stage attemperater branch pipe of superheater 1 4 close close close 50 Adjustment valve of fine-adjustment attemperater pipe of reheater 1 2 close close close 51 Adjustment valve of emergency attemperater pipe 1

1 close close close 52 Safety valve of outlet conduit of reheater 1765WD 2 close close close 53 Safety valve of inlet conduit of reheater 1785WB 4 close close close ========================================38 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test 54 Safety valve of outlet conduit of superheater 1730WD 2 close close close 55 Safety valve of steam drum 1749WD 3 close close close 56 Dynamic discharge valve of outlet conduit of superheater 3538W 1 open close close 57 Isolating valve equipped with dynamic discharge valve system 2.5 1 open close close 58 Stop valve of reheated steam inlet sampling DN10 4 close close close 59 Stop valve of saturated vapor sampling

DN10 3 close close close 60 Stop valve of boiler water sampling DN10 1 close close close 61 Stop valve of feed sampling DN10 1 close close close 62 Stop valve of main steam sampling DN10 2 close close close 63 Stop valve of emergency water discharge of steam drum DN100 2 open close close 64 Stop valve of primary valve of double color water gauge and electro connecting water gauge drain DN56 16 close close close 65 Stop valve of single chamber balance tank DN56 16 close close close 66 Stop valve of steam drum pressure gauge and pressure signal DN10 14 close close close 67 Stop valve of pressure gauge and pressure signal of feed and attemperater pipeline DN10 7 close close close 68 Stop valve of pressure gauge and pressure signal at inlet of reheater DN10 6 close close close

69 Stop valve of pressure gauge and pressure signal at outlet of superheater DN10 7 close close close 70 Stop valve of pressure gauge and pressure signal at outlet of reheater DN10 3 close close close 71 Check valve of feed front 14 1 open close close ========================================39 ========================================

PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test pedestal Primary water filling system 1 Electric gate valve of main feed front pedestal 1 close close close 2 Electric gate valve of main feed front pedestal branch pipeline PN32,DN 125 2 close close close 3 Electric gate valve of main feed front pedestal branch pipeline 14 1 close close close 4

Electric gate valve of main feed 12 1 open close close 5 Electric check valve of main feed 14 1 open close close 6 Stainless steel stop valve PN1.6 DN65 1 open close close 7 Gate valve PN2.5,DN 150 1 open close close 8 Diaphragm Valves PN0.6,DN 150 1 open close close 9 Stop valve PN0.6,DN 80 1 open close close Secondary water filling system 1 stop valve PN32, DN50 3 open close close Primary and secondary water discharge system 1 stop valve PN32, DN50 2 close

close open Primary pressure boosting system 1 stop valve PN32, DN20 7 close open close Secondary pressure boosting system close 1 stop valve PN32, DN50 3 close open close ========================================

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test Material List for Temporary Measures during Hydrostatic Test 1

Seamless steel pipe 1594.5 #20 steel 2 80m

Seamless steel pipe 608 #20 steel 3 200m

Seamless steel pipe 284 #20 steel 4 Forging three-way pipe 60 #20 Steel 5 Swage 60 20 #20 Steel 6 PN10 2 pieces PN32 DN50 100m

3 pieces

Electric gate valve of feed main front pedestal 1 piece 7 PN32,DN125 2

Electric gate valve of feed main front pedestal branch pipeline 2 piece 8

1 14

Electric gate valve of feed main front pedestal branch pipeline 1 piece 9 12

Electric gate valve of main feed 1 piece 10

 14 1

Electric check valve of main feed 1 piece 11

1 PN1.6 DN65 1 piece

Stainless steel check valve 12

1 Gate valve 13 Diaphragm Valve 14 Stop valve 15 Stop valve 16 Stop valve 17 Ammoniawater 18 1005Kg ======================================== 3216Kg PN32 DN20 PN32 DN50 PN0.6 DN80 PN1.6 DN150 PN2.5 DN150 1 piece

1 1 piece

1 1 piece

8 8 pieces

7 7 pieces

Industrial diamine ========================================41

PACITAN 2315MW Thermal Power Project, Indonesia

The Sector of Boiler>>> Operation Instruction of Hydrostatic Test

The A The A The A The Additional Instruction Of Hydraulic Test dditional Instruction Of Hydraulic Test dditional Instruction Of Hydraulic Test dditional Instruction Of Hydraulic Test Procedure Of Feeding Water(Revised)

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test

The reason of changing feed water pipe of primary steam system: because when des igning feed pipe, the main feed water pipe is used to fill water .We found that flow me asuring orifice is on the main feed water pipe after checking drawing, but flow measuring orifice s hould not be in the Hydraulic Test according to the drawing. Then, we connect feed water pipe to steam drum emergency blow off pipe, which is treated as primary steam filling water. 2

Booster Pump (revised) In the former solution there are two set of booster pumps, but a booster pump is enough to satisfy the requirements of hydraulic test on site. 5.2.2.4 0.3MPa/min 0MPa

Article 5.2.2.4 in program (revised) Demineralized water Condensation tank Condensate transfer pump Condensate line Drain line of entrance header of reheater emergency blow off Primary steam system Secondary steam system ========================================43

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test When hydraulic test is accepted, you can start venting valve to decrease pre ssure until the pressure is 0 Mpa, and the speed of decreasing pressure is not more than 0.3MPa/ min. Then you should start all drainage valves to drain water out, and start secondary steam c ompressed air to dry the pipe.

 Organization of Hydrostatic Test

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PACITAN 2315MW Thermal Power Project, Indonesia The Sector of Boiler>>> Operation Instruction of Hydrostatic Test

Leading group: CHEN Lingchang, ZHAI Liheng, LI Zhengping Chief commander: CHEN Lingchang Site commander: ZHANG Zhi Technical section: LI Zhengping, LI Zhifeng, WANG Zhonghua, ZHANG Huanxiang Safety supervisor: LUO Shizhao Quality supervisor: WANG Changchuan Rear service section System operation Dosing staff: WANG Zhonghua Monitoring of pressure gauge: LI Zhifeng Operation of pressure testing pump: WANG Bo Operation of water filling pump: YAN Qiang Operation of temporary system valve System check Boiler drum and water wall Ceiling and steam wall Primary superheater: Platen superheater Final superheater Reheater Economizer Link pipeline on furnace top Hydrometeor branch pipe Pipeline system