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    Helium Leak Testing Dubai

    Uploaded by

    Abhijit
    This document describes the helium leak test procedure used to test the inner bore welds between tubes and tubesheet joints in heat exchangers. A special fixture is used to pressurize the tube from inside with helium while a sniffer probe detects any leaks in the weld from outside. Over 10,000 tube to tubesheet welds were tested using this method to ensure no process fluid could leak and accumulate in the welded joints. The leak test identified any defects before further hydrotesting and commissioning of the heat exchangers.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Helium Leak Testing Dubai

    Uploaded by

    Abhijit
    160 views32 pages
    This document describes the helium leak test procedure used to test the inner bore welds between tubes and tubesheet joints in heat exchangers. A special fixture is used to pressurize the tube from inside with helium while a sniffer probe detects any leaks in the weld from outside. Over 10,000 tube to tubesheet welds were tested using this method to ensure no process fluid could leak and accumulate in the welded joints. The leak test identified any defects before further hydrotesting and commissioning of the heat exchangers.

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    Helium leak testing

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    This document describes the helium leak test procedure used to test the inner bore welds between tubes and tubesheet joints in heat exchangers. A special fixture is used to pressurize the tube from inside with helium while a sniffer probe detects any leaks in the weld from outside. Over 10,000 tube to tubesheet welds were tested using this method to ensure no process fluid could leak and accumulate in the welded joints. The leak test identified any defects before further hydrotesting and commissioning of the heat exchangers.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    160 views32 pages

    Helium Leak Testing Dubai

    Uploaded by

    Abhijit
    This document describes the helium leak test procedure used to test the inner bore welds between tubes and tubesheet joints in heat exchangers. A special fixture is used to pressurize the tube from inside with helium while a sniffer probe detects any leaks in the weld from outside. Over 10,000 tube to tubesheet welds were tested using this method to ensure no process fluid could leak and accumulate in the welded joints. The leak test identified any defects before further hydrotesting and commissioning of the heat exchangers.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 32

    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Title:
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT BY
    PRESSURISING THE TUBE(38.1MM OD) FROM INSIDE WITH SPECIAL FIXTURING
    ARRANGEMENT

    Company Name:
    Authors:
    S P Ghiya
    Larsen & Toubro Limited, J L Songhela
    Heavy Engineering Division, N S Choksi
    Hazira Manufacturing
    Complex,
    Dist:Surat
    Tel:0091 261 2805353
    Fax:0091 261 2805050
    Date: 10th October, 2010
    Location: Dubai
    Product
    Reacto s
    Column Regenerato
    r r

    Steam EO End
    Generator Reactor Shield

    Reacto Product PP
    r Splitter Reactor
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Introduction

    Leaks are special types of defects which can have a major


    importance in systems where they have influence on safety and
    performance.

    Many objects will have a reduced reliability if they contain leaks

    Leak testing is a non destructive examination method which is used


    for detection and localisation of leaks and for measurement of
    leakage in systems
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    In principle two methods are applied for leak testing and localisation
    of leaks, the "Vacuum method" and the "Overpressure method".
    At the "Vacuum method" the object to be examined for leaks is
    evacuated and sprayed from the outside with a search gas, in
    this case Helium. The gas enters through any leaks present in
    the object and is detected by a sensor connected to the leak test
    instrument
    At the "Overpressure method" the object to be examined for leaks is
    filled with a search gas, Helium, under slight overpressure. The
    search gas escapes through any leaks present to the outside
    and is detected by a detector probe. This detector probe is in
    most cases called a "sniffer" acting as a gas sampling probe.
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Leak rates down to 10-10 mbar l / s can be detected


    Both objects with vacuum or overpressure can be examined
    the objects can be examined during operation
    The examination can be performed fast and effective
    Non poisonous, non explosive and inexpensive gasses are
    applied
    Leaks can be detected in due time to prevent safety or
    operational hazards
    Leaks can be detected in due time to prevent unplanned and
    expensive shut downs
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    IBW is mainly done to prevent accumulation of process fluid between the


    gap of outer surface of tube and tube sheet hole.
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Vacuum method - Hood test


    Vacuum method - Tracer probe test
    Overpressure method - Hood test
    Overpressure method - Bombing test
    Overpressure method - Sniffer test

    Helium Leak Test, Vacuum Method, Hood Test


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Vacuum method - Hood test


    Vacuum method - Tracer probe test
    Overpressure method - Hood test
    Overpressure method - Bombing test
    Overpressure method - Sniffer test

    Helium Leak Test, Vacuum Method, Tracer probe test


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Vacuum method - Hood test


    Vacuum method - Tracer probe test
    Overpressure method - Hood test
    Overpressure method - Bombing test
    Overpressure method - Sniffer test
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Vacuum method - Hood test


    Vacuum method - Tracer probe test
    Overpressure method - Hood test
    Overpressure method - Bombing test
    Overpressure method - Sniffer test

    Helium Leak Test, Overpressure Method, Bombing test.


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Vacuum method - Hood test


    Vacuum method - Tracer probe test
    Overpressure method - Hood test
    Overpressure method - Bombing test
    Overpressure method - Sniffer test

    Helium Leak Test, Overpressure Method, Sniffer test.


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Heat Exchanger Vertical View


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Inner bore weld leak tested using Helium lwith following parameters.

    Tube Sheet details: 33.88 hole dia * 180mm thick * 5576mm dia

    Tube Sheet material:: SA 182M-304H

    Tube Details: 38.1mm OD * 2.11 thick * 5820mm long*

    No of tubes: 10696 tubes

    Material: SA213 M-304H individually.


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    180mm

    Tube sheet
    Tube
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Tube # Tube sheet welding using inner bore welding scheme


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Cross section of tubes, welded with tube sheet


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Heat Exchanger fabrication under progress-Vertical assembly


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Verification of Probe size and its functioning on mock up


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Helium Leak Testing Equipment


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Tube fit up/ welding /visual/ ferrite testing in progress in vertical condition
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Tube fit up checking in progress in horizontal condition


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Tube sheet View from Bottom Side


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Top view from tube open end..mock up work for tube # tube sheet welding
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Tube # Tube Sheet joint Inspection Testing Requirements

    Fit up-Inspection

    Weld Visual Inspection (Inside & Outside)

    PT of completed weld (Inside & Outside)

    Ferrite Check ( From outside only )

    Helium Leak test (After each tube welding)

    Pneumatic Test

    Hydrotest
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Helium Leak Testing Sequence


    Isolate joint from inside by providing leak proof fixture as shown in fig.
    Pressurize helium with 5 Psi ( 0.35 Kg / Sq. Cm) to 10 Psi ( 0.703 Kg/
    Sq.Cm)
    Hold the pressure for minimum 30 Seconds
    Check the leakage from the other side with snifter probe of Helium test
    equipment
    Repeat the exercise for the complete row
    In case leak is noticed, repair the weld , before proceeding to the next
    raw

    Preparedness:
    Total twenty such fixtures were made and connected them
    through a
    manifold
    This arrangement enabled us to perform this test at a time in
    multiple
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Helium Leak Test Probe

    Outlet connecting to MSLD Tube

    Tube Sheet Face


    Helium leak test probe
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    3-D Model of Helium Leak Test


    Probe

    Hole

    Probe

    Handle for tightening


    O-Rings

    Handle for holding


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Probe
    Probe with Helium standard leak
    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Weld Visual Testing in Progress


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Weld Bead Finish Through Video Scope , Displayed on Computer Terminal


    HELIUM LEAK TEST OF INNER BORE WELDS OF TUBE#TUBESHEET JOINT

    Conclusion :

    This technique of inspecting flaws in Inner Bore Weld of small

    diameter and inaccessible from outside has provided immense

    confidence to all NDT personnel involved including customer,

    ensuring defect free weld quality.


    Thank
    You

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