Boiler Hydro Checklist

Equipment availability:

• CW duct charged
• ACW pump available,ACW strainer boxed up
• ECW pump available
• ECW tank filled.
• DM/CST pump available.
• Boiler fill pump available.
• Wet Lay up pump, NH3, N2H4 pump available.
• Condenser Hotwell normal level.
• CEP available, DA level C/V, Isol. Valve operation OK
• CPU one stream available.
• Deaerator boxed up, level normal.
• MD BFP’C’ available, lined up.
• Feed line vented upto FRS.
• FRS LOW range C/V, Isol. Valve opn OK OK
• LPH, HPHs bypass valve available & lined up.
• Eco inlet valve E2 open (Operation) OK
• Eco R/C valve E18, E20 Opn OK.
• Boiler drum clearance.
• Low point drains header valve clearance.
• SH header valves clearance.
• SH spray valve clearance & all valve closed.
• All CC pumps cavity filled.
• Boiler stop valve (L&R) opn checked, Integral bypass opn OK
• EBD, CBD, IBD valve cleared, opn checked.
• SH drain valve before Blr. Stop valve opn OK.
• SH air/startup vents opn OK.
• Drum vents Opn OK.
• Soot blowing steam Isol. (Manual) valve closed.
• RH spray main block valve close.
• Main steam strainer drain & MS line drain open.
• CRH line drain open.
• HP bypass spray line manual valve close.

SAFETY PRECAUTIONS:

• Lighting on all boiler elevations are available.
• All scrap materials/Insulation materials removed & areas cleaned.
• All permits on required equipment/valve cleared & clearance given.
• The fire water pump is running.
• The healthiness of all supports & hangers are checked.
• Hydrostatic test plugs/gags were fitted on all the boiler safety valve.

Following systems Readiness/Trial was taken:

• DM Tank/CST tank flushed, water quality ensured.
• DM plant informed for Hyd. Test.
• Hotwell flushing done on______ & filled to normal level.
• ECW tank flushing done on______& filled upto normal level.
• D/A flushing done on_______& filled upto high level.
• D/A level, level switches alarm OK.
• CW ducts are charged by opening ICV on__________
• ACW trial taken on_________ kept I/s.
• DMCW pump trial taken on_________kept I/s.
• CEP Protection/Interlock checked, Trial taken on_________.
• MD BFP’C’ protection & interlocks checked & trial taken on________
• Boiler drum level Tx, hydrastep, PG/ pr.Tr for drum & MS line before ESV charged & made available.
• CC pump filling completed on  

Drum Filling Procedure

• Blr. Filling clearance from O/H group on -----.
• Blr. Stop valve, Int. bypass valve fully closed.
• Startup vents, SH vents, Drum vents are fully open.
• SH header drain individual valves open & master drain closed.
• Boiler water sample line is closed.
• Low paint drain header lined up through Bottom ring header.
• CBD, EBD, IBD valve, SH header drain valve before ESV closed.
• FRS low range is lined up, Eco inlet valve open.
• PO4 dosing line valve, SB manual valve closed.
• All SH/RH spray valve closed.
• MS strainer & MS line drain, CRH line drain valve open.
• Boiler fill pump started & kept on R/C.
• NH3, N2H4 dosing soln. ready & lined up for BFP.
• Start wet lay Pump.
• Start filling the Boiler through SH filling line for back flushing.
• MD BFP’C’ is started & in R/C.
• Maintain water quality by running NH3 & N2H4 pump, Wet lay p/p.
• Start taking water through BFP’C’/TDBFP.
• When drum level becomes normal, isolate filling line & stop BFP.
• When water starts coming out through Drum vents SH vents, closed all vents at 2KSC drum pr.
• Close SH start up vents after closing all air vents.
• Drum level high, high high alarm checked.

BOILER PRESSURISATION:

• Boiler is pressurized slowly upto desired pr. (as per requirement of Blr. Inspector or maintenance).
• Drum Pr. high, high high alarm appeared.
• Pr. maintained for 10 mts. at required pr.
• Boiler pr. reduced to 120 KSC.
• Inspection of boiler pr. parts, Drums, CC pumps carried out.
• Leakages observed.
• Rate of pr. drop observed.
• Boiler depressurized & drum/SH vents opened at 2KSC,
• SH,W/W,Economizer drained.
• Drum level low/low low alarm appeared.
• Remark:

BOILER HYDRO TEST CHECKLIST1. WORK IN BOILER STEAM & WATER CIRCUIT COMPLETED.
2. BOILER DRUM BOXED UP.
3. RING HDR MANHOLES BOXED UP.
4. DRUM VENTS,SH VENTS/START UP VENTS AVAILABLE
5. SH DRAIN(18 NO) + MASTER DRAIN BOXED UP.
6. SH FILLING LINE CONNECTION TO SH DRAIN HEADER COMPLETED
7. ALL V/V’S IN LOW POINT DRAIN HDR ALONG WITH MASTER DRAIN
BOXED UP.
8. CBD/EBD/IBD ISOLATING V/V’S AT DRUM LEVEL CLOSE
9. SOOT BLOWER STEAM LINE Ist ISOLATING V/V TOWARDS BOILER
CLOSE
10. PHOSPHATE DOSING ISOLATING V/V CLOSE,
11. CC P/PFILL&PURGE COMPLETED/ANY ONE CC P/P DISCH V/V OPEN
12. BOILER DRUM & SH SAMPLING LINE ISOLATING V/V CLOSED
13. MDBFP AVAILABLE.
14. D/A & FST AVAILABLE FILLED UPTO NORMAL LEVEL.
15. BOILER FILL P/P’S AVAILABLE
16. ALL BFP’S SH & RH SPRAY LINE ISOLATING V/V’S CLOSE.
17. BD V/V’S MANUAL ISOLATING CLOSED
18. MS 1,2,3,4,5&6 CLOSED TIGHTLY & SUPPLY ISOLATED.
19. MS 9 & 10 CLOSED( SUPPLY ISOLATED). THEIR MANUAL ISOLATING
V/V CLOSED.
20. E2 & E2A AVAILABLE –OPEN
21. E20 ( ECO RECIRCULATION )AVAILABLE.
22. ALL TURBINE SIDE (MS/HRH/CRH) LINE ATMOSPHERIC DRAINS FULL
OPEN.
23. MS/HRH STRAINER DRAIN TO IBD TANK OPEN.
24. HP/IP STOP V/V’S GAGGED IN CLOSE POSITION.
25. HYDRASTEP & DRUM PR. TRANSMITTERS AVAILABLE.
26. MS PR. GAUGE( BEFORE STOP STOP V/V’S) AT DRUM LEVEL AVL.
27. HP HEATERS FW CIRCUITS & FRS V/V’S AVAILABLE.
28. MS PRDS MANUAL V/V AT PRDS TIGHTLY CLOSD.
29. ECW/DMCW SYSTEM AVAILABLE WITH ATLEAST ONE DMCW P/P I/S
FOR MDBFP COOLING WATER.
30. ATLEAST ONE CLCW P/P I/S(OPTIONAL)
31. ATLEAST ONE PHE CHARGED FROM DMCW/CLCW SIDE.
32. WETLAY P/P AVAILABLE(LINED UP TO LOW POINT DRAIN HDR.
33. CHEMICAL SOLUTION AT DOSING TANKS( HYDRAZINE/AMMONIA)
AVL.
34. CC P/P CAVITIES FILLED/ FILL PURGE COMPLETED.
35. ERV(MS LINE) MANUAL V/V CLOSED.

500 MW BOILERS

CHECKLIST FOR HYDRO – TEST

UNIT:                                                                                                                                 DATE:
S.N. DESCRIPTION RESP. STATUS REMARKS

01. CC Pumps cavity filled. Opn.
02. MS stop valves & equalisers closed. Opn.
03. MS ERVs isolating valves closed. Opn.
04. Soot blowing station isolated. Opn.
05. CBD root valve closed. Opn.
06. SH attemperation valves from all BFPs Opn.
Closed.
07. RH attemperation valves from all BFPs Opn.
Closed.
08. SH / RH attemperation station cleared. PP
09. HP Bypass spray valves & manual Opn.
Valve closed.
10. PRDS spray, manual valves closed. Opn.
11. Condensate system cleared & charged. TM/Opn.
12. Feed water system cleared & charged. TM/Opn.
13. CEP, MDBFP P&I checks completed, C&I/Opn.
Pumps started & kept in service.
14. HP Bypass valves & main turbine TM/Opn.
Stop valves are closed.
15. MS line drains are kept open. Opn.
S.N. DESCRIPTION RESP. STATUS REMARKS
16. MS and Drum safety valves are gagged PP
(for pressures above 180 KSC).
17. Necessary C&I indicators and recorders C&I
are available.
18. Men & material removed from Boiler PP
first and second pass.
19. Men & material removed from bottom AHM
ash hopper and economiser hoppers.
20. Clearance for boiler filling obtained, PP
from Pressure Parts.CLEARANCESS.N. DEPARTMENT SIGNATURE REMARKS
01. Pressure Parts (PP)
02. Turbine Maintenance (TM)
03. C&I Maintenance (C&I)
04. Ash Handling Maint. (AHM)
05. Opn. / Recommissioning
HYDRO-TEST DETAILSINTERNAL:Date / Time :
Pressure (KSC) :
Leakages, if any :
Result :EXTERNAL:Date / Time :
Pressure (KSC) :
Leakages, if any :
Result :Signatures:Pressure Parts Opn./ Recommissioning