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
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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