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Doc.
Revisions No. ES-(XTJB)5,6-09-00-0023

Rev. Description Revised Checked Approved Date

0 First issue - - - -

Y.Ishii

CONFIDENTIAL
THIS DOCUMENT IS THE PROPERTY OF SUMITOMO CORPORATION BOILER DIVISION (SCBD) AND CONFIDENTIAL. IT MUST
NEITHER BE COPIED NOR USED FOR ANY PURPOSE OR MANNER OTHER THAN EXPRESSLY PERMITTED BY SCBD OR WITH
A PRIOR WRITTEN CONSENT OF SCBD NEITHER IS IT TO BE HANDED OVER NOR COMMUNICATED TO A THIRD PARTY IN
ANY WAY. BREACH OR INFRINGEMENT OF ANY KIND WILL LEAD TO LEGAL ACTION.

SUMITOMO CORPORATION BOILER DIVISION

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Doc.
No. ES-(XTJB)5,6-09-00-0023

(1) Scope
This document covers the Shower Leak Test of boiler installation on Site.

(2) Attached documents

PTJEL-QCP-009_R3 SHOWER LEAK TEST PROCEDURE

SUMITOMO CORPORATION BOILER DIVISION

 PT. Jurong Engineering Lestari
PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
COALFIRED POWER PLANT INDONESIA

SHOWER LEAK TEST PROCEDURE

(PTJEL-QCP-009)

SHOWER LEAK TEST PROCEDURE

Procedure No: PTJEL-QCP-009

Page 1 of 7
 PT. Jurong Engineering Lestari
PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
COALFIRED POWER PLANT INDONESIA

SHOWER LEAK TEST PROCEDURE

(PTJEL-QCP-009)

TABLE OF CONTENTS

1.0 PURPOSE
2.0 REFERENCE DOCUMENTS
3.0 SCOPE
4.0 RESPONSIBILITIES
5.0 DEFINITION
6.0 PROCEDURE
7.0 ATTACHMENT

Page 2 of 7
 PT. Jurong Engineering Lestari
PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
COALFIRED POWER PLANT INDONESIA

SHOWER LEAK TEST PROCEDURE

(PTJEL-QCP-009)

1.0 PURPOSE

This procedure is to describe all the activities to be performed in confirming the integrity of all Ducts
welds at the erection for the construction of 2 x 1000 MW Tanjung Jati B 5&6 Coalfired power Plant
project.

2.0 REFERENCE DOCUMENTS

2.1 Erection Drawings

2.2 ASME Section I -2015
2.3 ASME Section V -2015
2.4 AWS D1.1 -2015
2.5 Project ITP- TJB56-C2-OFF-C-00-Q-ITP-0020
2.6 HSE Management plan TJB56-L2-ON-C-00-H-PLA-0001
2.7 Weld Visual Report

3.0. SCOPE

This procedure defined the methods and procedure of testing the integrity of welds for Duct
connections during the assembly and erection at site.

4.0 RESPONSIBILITIES

The Mechanical Group (LOT-2) doing the Duct assembly and erection works shall be responsible for
the implementation of this procedure and ensure that the assembly/erection/installation is effectively and
safely carried out.
The Safety Engineer is responsible for ensuring that all activities are carried out in a safely manner and in
compliance with the established safety procedure.
The Mechanical QA/QC Inspector of LOT-2 shall be responsible to monitor, inspect and evaluate the leak
testing works ensuring these are being done in compliance with this procedure, standard and Inspection test
plan.

5.0 DEFINITION

This is process of checking the weld joints integrity using pressurized air blown on the joints outside Duct.
Water with soap detergents will be sprayed on to the weld joints (Inside Duct).

Page 3 of 7
 PT. Jurong Engineering Lestari
PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
COALFIRED POWER PLANT INDONESIA

SHOWER LEAK TEST PROCEDURE

(PTJEL-QCP-009)

6.0 PROCEDURE

6.1 Shower Leak test procedure for weld joints.

6.1.1 Equipment and Materials

• Air Compressor
• Air Hoses, sufficient length
• Air Hose Nozzle
• Mixing Bucket
• Leak Detector Solution (Water with soap)
• Leak Detector Solution (Water with soap) Applicator (plastic squeeze bottle and hand operated spray
applicator or brush)
• Flashlight or other adequate light source
• Clean dry rags / cloth or towel

Important Notes:
Prepare a solution of adequate liquid detergent or soap with water in advance to allow the
bubble and foam to disperse

6.1.2 Preparation/Sitting of Inspection

1. Remove standing water, weld slag, mud, dirt and other debris which may prevent bubble formation
from areas to be leak tested.
2. Provide adequate lighting for examination (daylight, flash light or another sufficient source).
3. Operate the Compressor until air pressure reaches between the ranges of 5 to 7 bar to be confirmed
by reading on adequate Gauge.
4. Positioning of Air Nozzle with control valve into position according to figure-1.

6.1.3 Process Application (Inspection Procedure)

1. Blow pressurized air from the outside duct of the weld joints. Air pressure should be between 5 to 7
bar gauges.
2. Apply the leak detector solution (Water with soap) by spray or brush on the inside on the weld
where pressurized air is blown. Solution should be applied in a continuous film and relatively free
from bubble. See Figure 1 for the typical configuration of the process.
3. Observe the detector solution for leakage for at least ten (10) seconds at all locations.
4. Continue the whole length of joint in each welding connection of Duct.

6.1.4 Acceptance Criteria

The area under test is acceptable when no bubbles formation is observed.

Page 4 of 7
 PT. Jurong Engineering Lestari
PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
COALFIRED POWER PLANT INDONESIA

SHOWER LEAK TEST PROCEDURE

(PTJEL-QCP-009)

6.1.5 Repair / Retest

When bubble formation is observed, the location of the leak (s) shall mark and remedial repair
works shall be made. The repair area shall be retest following process step "1” to "4" on the
above process application to confirm the air tightness.

6.1.6 Post Cleaning

After testing, surface cleaning may be required for product serviceability. The post
cleaning of the weld joint shall be done by waste clothes to keep it dry.

6.1.7 Report

The evaluation result shall be recorded in a report as shown in Attachment I.

Figure -1
Typical Application for Shower Leak Test

Seal weld Inside

Control Valve

Page 5 of 7
 PT. Jurong Engineering Lestari
PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
COALFIRED POWER PLANT INDONESIA

SHOWER LEAK TEST PROCEDURE

(PTJEL-QCP-009)

ATTACHMENT 1

SHOWER LEAK TEST RECORD

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 2 X 1000MW TANJUNG JATI B 5 & 6 COAL FIRED POWER PLANT
SCBD
Sumitomo Corporation
Boiler Division

Report No TJ- SC(PTJEL) - QCP(009) -XXX -XXX

SHOWER LEAK TEST RECORD
RFI NO:

SUB CONTRACTOR : PT JURONG ENGINEERING LESTARI DATE:

STRUCTURE NO.:

DESCRIPTION :

DRAWING NO.:
REF DOCUMENTS/ PROCEDURE : TJ-B5&6-M-PTJEL-QCP-009

Stage of Examination As welded Blowing

Surface Preparation Brushing Grinding

Calibration Certificate
Pressure Gauge No. Manufacturer Range Calibration Date Expiration Date
No.

ITEM NO DRAWING NO. JOINT NO. SIZE THICKNESS TEST PRESSURE OBSERVATION RESULT

Result □ Acceptable □ Unacceptable

PTJEL SCBD EPC-IHE BJP-PLN
Name: Name: Name: Name:

Signature/Date: Signature/Date: Signature/Date: Signature/Date:

RESULT LEGENDS: A=ACCEPT, R=REJECT, NA=NOT APPLICABLE PTJEL-QCP-009

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