Figure 12-7. - Tube corrugation resulting from oil on waterside.

Waterside Inspection of Drums and Headers

Whenever a boiler is opened for cleaning and overhaul, the internal surfaces of the drums and headers should be carefully inspected for evidence of cracking. Particular attention must be given to steam drum manhole knuckles, knuckles at corners of drum heads, corners of cross boxes and headers, superheater header vent nozzles, and handhole openings. Any defect found must be recorded in the boiler water treatment log and in the maintenance log. These defects should also be reported to the maintenance office so that appropriate repair action can be taken.

Hydrostatic Tests

Boilers are tested hydrostatically for several different purposes. In each case, it is important to understand why a test is being made and to use - but NOT to exceed - the test pressure specified for that particular purpose. In general, most hydrostatic tests are made at one of three test pressures: boiler design pressure, 125% of design pressure, or 150% of design pressure. Other test pressures may be authorized for certain purposes. For example, a test pressure of 150 psi is required for the hydrostatic test given before a boiler undergoes chemical cleaning.

The hydrostatic test at design pressure is required upon the completion of each general overhaul, cleaning, or repair that affects the boiler or its parts and at any other time when it is considered necessary to test the boiler for leakage. The purpose of the hydrostatic test at design pressure is to prove the tightness of all valves, gaskets, flanged joints, rolled joints, welded joints, and boiler fittings.

The test at 125% of design pressure is required after the renewal of pressure parts, after chemical cleaning of the boiler, after minor welding repairs to manhole and handhole seats, and after repairs to tube sheets, such as the correction of gouges and out-of-roundness. The "renewal of pressure parts" includes all tube renewals, rolled or welded, except downcomers and superheater support tubes.

The test at 150% of design pressure is required after welding repairs to headers and drums, including tube sheet cracks and nozzle repairs, after drain and vent nipple repairs, and after renewal or rewelding of superheater support tubes and downcomers. The hydrostatic test at 150% of design pressure is basically a test for strength. This test may be (but is not necessarily) required at the 5-year inspection and test.

Before making a hydrostatic test, rinse out the boiler with freshwater. Using at least 50-psi pressure, play the hose onto all surfaces of the steam drum, the tubes, the nipples, and the headers. Examine the boiler carefully for loose scale, dirt, and other deposits. Be SURE that no tools or other objects are left in the boiler. Remake all joints, being sure that the gaskets and the seating surfaces are clean. Replace the handhole and manhole plates and close up the boiler.

Gag all safety valves. Boiler safety valves must NEVER, under any circumstances, be lifted by hydrostatic pressure. When gagging the safety valves, do not set up on the gag too tightly or you may bend the valve stems. As a rule, the gags should be set up only handtight.

Close all connections on the boiler except to the air vents, the pressure gauges, and the valves of the line through which water is to be pumped to the boiler. Be sure the steam-stop valves are completely closed and that there will be no leakage of water through them.

After all preparations have been made, use the feed pump to fill the boiler completely. After all air has been expelled from the boiler, close the air vents and build up the hydrostatic pressure