,@ PT CEMARA SEMITAMA

PLTU2NTB2X25MW
COAL FIRED STEAM POWER PLANT
DOC. NO

PT, ffiffiffi HYDROTEST PROCEDURE ISSUANCE DATE:

Page 13 of
Unit Issuing : Construction Approved By : Site Manager RTVISION O
t2

T4. ATTACHMENT

1. Organization Chart
2. Schematic diagram of temporary lines
3. Pressure test boundary for primary and secondary system
4. Pressure time diagrdm
 PT CEMARA SEMITAMA
,@ PLTU2NTB2X25MW
COAL FIRED STEAM POWER PLANT
DOC. NO

HYDROTEST PROCEDURE TSSUANCE DATE:

ffi,ffiffiA
Unit Issuing : Construction Approved By : Site Manager Page 2 of 12 REVISION O

1.0 scoPE

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

2.O PURPOSE

This instruction serves as guide in hydrostatic testing of the above scope. This is also
to satisfy the contract technical requirement, boiler manufacturer's requirement/
reference codes and standard as well as government regulations.

3.0 RESPONSIBILITIES
3.1 The Construction Manager shall make sure that this instruction is

implemented at site.
3.2 The Boiler engineer and Piping Engineer are responsible for implementation of
this instruction. He has to check that requirement in Hydrostatic test are
properly adhered to as indicated in this instruction.

3.3 The Boiler Supervisor is responsible for the arrangement of all processes
involved in the execution of hydrostatic test. He has to make sure that
standard code practice is applied accordingly.
3.4 The Welding Superintendent and Welding Supervisor shall make sure that all
welding directly on pressure retaining parts are complete.
3.5 The QA/QC personnel in charge of hydrostatic test are responsible in
assuring that the requirement in this procedure are properly implernented and
followed. They have to make sure that all NDTs and hot works on pressure
retaining parts are completely executed before the test. They have to make
all pertaining records ready and available for review by all pafties concerned.
They have to perform hydrostatic testing in process inspections. They have to
prepare pertinent records after the test.

4. TEST SCOPE
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PT CEMARA SEMITAMA
PLTU2NTB2X25MW DOC. NO
COAL FIRED STEAM POWER PLANT

PT,ffiffiAffiffi&ffi HYDROTEST PROCEDURE ISSUANCE DATE:

Unit Issuing : Construction Approved By : Site Manager Page 3 of 12 REVISION O

the different pressure ratings, the hydrostatic test is divided in two

Considering
systems namely primary system (superheating system) and secondary system
(reheated system).

4.2 Primary system. This is consists of feed water operating valve block,
economizer system, steam drum, water-cooled wall system, and superheated
as well as associated inter connecting piping, drains, blow down, heating ,
chemical dosing, feed water & desuperheated water piping & valves.

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

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

reheater, high temperature tube banks, channels, interconnecting piping,
desuperheated water, drains, discharge piping & valves. The boundary shall be
from cold reheat valve to hot reheat outlet valve.

4.3 The blind valve was designed at the Final RH outlet, Panel RH inlet and Final SH
outlet; therefore it is regarded that the blind valves of the main steam, reheat
hot pipe and cold pipes and boiler proper shall be identified as their boundary
of hydraulic test.

5. TESTING PRE.REQUISITES

5.1 The erection of boiler steel structure shall be completed, inspected and
accepted by all parties; high strength bolts shall be completely tightened in
accordance with the requirements of the drawings and procedure. The
following records shall be made available:

a. The deflection of boiler roof girders before the boiler pressure parts lifting as

well as the record of before and after water filled.

b. Settlement observation result of foundation.

 PT CEMAR.A SEMITAMA
PLTU2NTB2X25MW DOC. NO
COAL FIRED STEAM POWER PLANT

ffi,ffiffiffiffi HYDROTEST PROCEDURE ISSUANCE DATE:

Unit Issuing : Construction Approved By : Site Manager Page 4 of 12 REVISION O

5.2 The erection of boiler heating surfaces and pressure parts including buck stay
have been completely done, inspected and accepted.
5.3 Complete erection of all equipments, piping, valves, fittings and hangers and
supports within the scope of hydro static test, and the variable & constant
hangers have been fixed with dowel pin or temporarily fasten to keep it under
the rigid state.
5.4 All vents, sampling, desuperheating and emergency blow-off pipes, steam drum
connecting pipe, and boiler temporary heating pipe shall be erected up to the
second valves based on the scope of hydro static test. The intermittent blow
down piping and drainage pipes have been connected with the main pipe which
is set before the intermittent blow down flash tank, othenruise the main pipe of
the nitrogen system shall be erected up to the boiler ground level.
5.5 All the welding fixing parts on the boiler wall, such as the fin on the tube of
heating*- sudace or pressure pdrt, sealing pdtr, antiseptic device, fixture,
insulation nail, sliding pieces, hook, inspection hole as well as the tapping point
of I & C elements etc, shall be completely installed. After the hydro test, no
welding work is permitted on the boiler pressure part.
5.6 All the temporary stiffening pdfu, lifting lugs or the other steel welded on
heating sudace and pressure pads for lifting and transportation have been
removed, and smoothly ground.
5.7 The hangers and rods of boiler proper must be completely installed and
adjusted to ensure the balance force and tension is carried on.
5.8 Housekeeping is done in boiler area pafticularly on top of boiler, stainruay,
platform, ground level, furnace, cold ash hopper, corner water wall,
superheaters, reheaters, economizer, etc.
5.9 All hot works including PWHT on pressure retaining parts have been done &
completed.
5.10 All NDTs have been completed & documented.
5.11 Punch listing prior to testing has been done; punch killing completed &
documented.
 PT CEMARA SEMTTAMA
PLTU2NTB2X25MW DOC. NO
COAL FIRED STEAM POWER PLANT

ffi,ffi
Unit Issuing : Construction
HYDROTEST PROCEDURE
Approved By: Site Manager
ISSUANCE DATE:

Page 5 of 12 | REVISION 0

5.tz All records pertaining to pressure retaining paft erections have been completed
& readily available for review.
5.13 All weld joints and weld attachment areas shall be left un-insulated and
exposed for examination during test.
5'14 Equipment not subjected to pressure test shall be disconnected from the
system or isolated by blank or valve or plug. The core of boiler safety valve and
other safety valve are all replaced and blocked, economizer inlet feed water
line, attemperator spray water piping, drain and vent are all isolated from not
tested areas using valve.
5.15 All valves included in the test boundary will be tagged open/close as per test
requirement.
5.16 Temporary water filling line and pressurizing line shall be flushed and in seruice
leak tested before water delivery into the systerns. The pressurizing line should

,.,:.'.,':",;,, undergo hydro testing to assure that the line has the capacity to carry the
pressure of the system while in hold.
5'17 The quality of chemical demineralized water shall
be acceptable with the
qualified repoft, and enough amount of water shall be prepared for hydraulic
test.
5.18 The expansion indicator have been mounted properly according to the
instruction on the drawings and adjusted to 0 positions.
5.19 Check the expansion clearance and its position of boiler proper whether it
meets the requirements of designed drawings or not.

5.20 All temporary pipelines to be used in water filling are flushed and checked as
safe for operation.
5'2L All permanent equipments to be used for water filling are inspected and
documented.
5.22 All parties are convinced and agreed that the systems are ready for hydrostatic
testing, Clearance Certificate shall be signed off by all parties before the test.

6. TEST PREPARATION
 PT CEMARA SEMITAMA

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PT,Wffiffiffi
PLTU2NTB2X25MW
COAL FIRED STEAM POWER PLANT

HYDROTEST PROCEDURE
DOC, NO

ISSUANCE DATE:

Unit Issuing : Construction Approved By : Site Manager Page 6 of 12 REVISION O

6.1 Equipment

A) Filling Pump: Permanent boiler start up feed water pump shall be used in
water filling.
B) Pressurizing Pump
c) Tempora'ry water line: detail to be informed later

D) Air Compressor: specification to be informed later

E) Test Gage

An indicating gage, visible to the person controlling the pressure applied, shall
be connected to pressure parts. The location for the primary system shall be in
steam drum and the other one is close to the pressure pump. For the
secondary system, the location of the pressure gage shall be at the reheater
outlet and the other one shall be close to the pressure pump. The hydrostatic
head on the gage shall be considered'such that the test pressure is achieved at
the top of the boiler.

Dial pressure gages to be used in testing shall preferably have dials graduated
over their entire range of about double the intended maximum test pressure,
but in no case shall the range be less than 1.5 times that pressure. The spacing
between graduations shall be such that the inspector and the person controlling
the test shall be able to determine when the required test pressure has been
applied. Test gages shall be accompanied with valid calibration certificates and
should be equipped with snubber to keep hammering from affecting the gage
calibration.

a. Communication

All communication between the boiler control station and the hydro-
pump station will be by walkie-talkie. There will be a second radio at
each station for back uP.
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PT CEMARA SEMITAMA
PLTU2NTB2X25MW DOC. NO
COAL FIRED STEAM POWER PLANT

HYDROTEST PROCEDURE ISSUANCE DATE:

ffi,ffiffiwffiAffi
Unit Issuing : Construction Approved By : Ste Manager PageT ot 12 REVISION O

b. Tools and Scaffolding

Scaffolding, lights, and repair tools are to be ready at the time of

hydrostatic testing.

c. Compressed Air

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

d. Demineralised Water

This type of water is to be used for hydrostatic test to be produced from

permanent water treatment Plant.

e. Drainage

Boiler drain line shall be routed to main pipes of intermittent blow down
and drain pipe then to be connected with temporary piping going to
waste water Pond.

7. TEST PROCEDURE

7.1 Pneumatic Test

In order to find any serious leakage as early possible the primary and
secondary system shall be connected temporarily before hydro test. The same
temporary line intended for hydrostatic testing will be used for air test. The
system shall be filled with compressed air at a pressure of 0.3 MPa, It shall be

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

7.2 HydrostaticTesting
 PT CEMARA SEMITAMA
PLTU2NTB2X25MW DOC. NO
COAL FIRED STEAM POWER PLANT

ffi,ffiffiffiffi HYDROTEST PROCEDURE ISSUANCE DATE:

Unit issuing : Construction Approved By : Site Manager Page B of 12 REVISION O

Water Quality

The content of chlorine ion (cL-) in the water shall be less than Zlmgll,
and then put into the 40% ammonia (NH3.H2O) in concentration and
hydrazine (N2HaH2o). The acidity and alkalinity value of aqueous solution

shall normally be control under PH > 10-10.5, the concentration of

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

b. Testing Pressure

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

follows;

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

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

Water Filling Sequence

Demineralized water will be taken from ......-. on the demin

water tank. Permanent make up water line shall be used to transfer
the water up to condensate make up water tank. Permanent boiler
feed water pump shall be used to fill water to the boiler system.
Temporary filling line from boiler start up feed water pump up to
the boiler filling point shall be provided.
n Temporary water filling lines (includes the permanent drain header
to boiler blow down tanks which will be used for filling as well as

draining of the test system) and pressurizing lines shall be in

service leak tested and flushed before transferring test water in to
the circuit or commencement of pressurizing. Pressure test of the
 PT CEMAM SEMITAMA
,,G PLTU2NTB2X25MW
COAL FIRED STEAM POWER PLANT
DOC. NO

HYDROTEST PROCEDURE
Fry,ffiffi ISSUANCE DATE:

Unit Issuing : Construction Approved By : Site Manager Page 9 of 12 REVISION O

temporary line that will be bounded by test circuit shall be

separately hydro tested. Radiography shall be done on temporary
water filling lines as the permanent piping line.
tr Temporary power supply complete with appropriate control panel
shall be provided, to supply power and control the permanent boiler
stad up feed water pump.
u Check the pumps electrical connections, control panels and
lubrication prior to running.
l.- Trial run of the pumps shall be done before the test.
n Sampling of water shall be taken before filling of boiler and
recorded before commencement of filling.
n All vents shall be kept open and hoses to be connected to convey
venting spill to the drain funnel which is connected through the
permanent drain header on the floor sump. Temporary hose will be
connected to the storm water draining to the sea.
n Open water-feed valves of the temporary systern and all vents, and
shutdown all the primary valves, and then start up feed water
pump to fill water into boiler. Normally, the temperature of filling
water shall be taken 20-70oC, the temperature difference between
filling water and the wall of steam drum shall not exceed zBoC.
n During the time of water feeding, all pressurized parts shall be
checked for leakage. If found, the handling shall be made
intermediately, after fixed and the feeding shall be continued. Until
2-3 minutes overflow of all vents happened, it is confirmed that
boiler has been filled fully; the vent valves can be closed and stop
feed water pumping and shutdown feed water valve.
n The super heater and the reheater outlei shall be interconnected by
pipeline with appropriate valves in order to fill and pressurize both
systems systematically. This line will be isolated if each system at
the time of pressurizing.
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FT,ffiffiffi
PT CEMARA SEMITAMA
PLTU2NTB2X25MW
COAL FIRED STEAM POWER PLANT

HYDROTEST PROCEDURE
DOC. NO

iSSUANCE DATE:

Page 10 of
Unit Issuing : Construction Approved 8y : Site Manager REVISION O
12

d. Pressurizing

Monitor all the vents and ensure that all air entrapment has been

completely released and the test circuit is completely filled with water.
Closg vents one by one as filling continues, the hydro filling pump
continues till the pressure gage register a pressure of about 3 Kg/cm2 and
then the filling stops.

n Check the electrical connections of pressure pump. Proper

lubrication shall be done when required.
x Trial run shall be done on the plunger pump before pressurizing
begins.

tr Pressurizing plunger pump will be started and pressurizing will be

through drain valve of feed water lines.
u Keep the pressure rate at 0.3MPa/min.
D Continue pressurizing up to 10o/o of reheater design pressure, stop
pressurizing anci fully check the system for any abnormality.

u Close the valves interconnecting the secondary and primary system

located at super heater (main steam) line and reheater outlet (hot
reheat) line.
n When no sign of abnormality is observed, continue pressurizing the
secondary system up to operating pressure.
I Stop pressurizing and check again.
I When no sign of abnormality is obserued, continue pressurizing up
to the test pressure of .......MPa.
n Keep the system under test pressure for 20 minutes and then
decrease the pressure to operating pressure. Check the system
thoroughly.
! When the system is checked by all pafties as qualified, open the
vent valve of reheater, check and confirm the valves in between
 PT CEMARA SEMITAMA
PLTU2NTB2X25MW DOC. NO
COAL FIRED STEAM POWER PLANT

HYDROTEST PROCEDURE
FT,ffiffiffiffi$ ISSUANCE DATE:

Page 11 of
Unit Issuing : Construction Approved 8y: Site Manager REVISION O
rz

super heater and reheater as closed until the pressure on primary

system reaches 10% of the operating pressure of the steam drum.
a Check the system for any sign of abnormality.
tr Reroute the temporary pressurizing on primary system and staft
, pressurizing until the pressure reaches operating pressure of the
steam drum.
tr Stop pressurizing and check again.
D When no sign of abnormality is observed, continue pressurizing up
to the test pressure of .......MPa. Stop pressurizing pump, and close
the valve of pressurizing outlet.
! Keep the system under test pressure for 20 minutes and then
decrease the pressure to operating pressure. Check the system
thoroughly.
If Slowly open the drain valves until the pressure reaches 0.3 to 0.5
MPa. Control the pressure decreasing rate at 0.3MPa/min.

8. BASIS OF ACCEPTANCE

Keeping the test pressure in 20 minutes, the pressure of hydro test shall be reduced
down to the design rated for overall inspection. During the period of
pressure
inspection, the pressure shall be held and there should not be any sign of any
leakage, deformation and crack on all the welding joints; manholes, flanges and
valves. If the test is acceptable, the hydrostatic test certificate shall be signed by all
parties involve in the test.

9. PRESERVATION AFTER THE TEST

As recommended by the Client, test water shall remains in the system; the water shall

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

10. REPAIR.
 PT CEMARA SEMITAMA
PLTU2NTB2X25MW DOC. NO
COAL FIRED STEAM POWER PLANT

HYDROTEST PROCEDURE ISSUANCE DATE:

ffi,ffiffiffiffiffiffi Page 12 of
Approved By : Site Managet REVISION O
Unit Issuing : Construction t2

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

Ifany leak is opserved during pressurizing, the pressurizing shall stop. The pressure
shall be released at a permitted rate and the water shall be drained to a level where
repair is Permissible.

11. INSPECTION.

11.1 DEPNAKER as government representative shall be invited to witness and ceftifo

the hydrostatic testing. invitation shall be given on time.
Ll.Z For inspection convenience of all parties the entire test area has been divided
into different zones. Each zone will be manned by a team consisting of 7lo 4

inspectors. Each one of them will be equipped with walkie talkie to immediately
repoft any abnormality found or observed.
11.3 Once satisfactory inspections have been completed pressure will be released
preseruation shall Proceed.

L2. SAFETY.

Safety Requirement is follows;

1. The area of test shall be barricaded once the pressurizing starts.

2. Only authorized personnel will be permitted to enter the test zone.

3. Only trained personnel will be allowed to handle the chemical.
4. Any treated water drains will be securely collected in the retention basin and

treated before disposing to others defined areas.

13.0 RECORD

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