Chambal Fertilisers and Chemicals Limited

G3AU Project
HELIUM LEAK TEST PROCEDURE
TEIPL Work No: 6341
Project Doc. No.: VD-M-U00-STA-PRC-BYDC001-5008 Page 1 of 07
P.O No: P/6341/12153/BYDA001
Vendor Work No: DV364/DV365 Vendor Doc. No.: 2016-DV364-HLT Date:28-JUL-2016

Chambal Fertilisers and Chemicals Limited

G3AU Project
Brown-Field Expansion Fertilizer Project
2200 MTPD Ammonia and 4000 MTPD Prilled Urea Plant
in Gadepan, Kota, Rajasthan (India)

HELIUM LEAK TEST PROCEDURE

FOR APPORVAL
☐ AP APPROVED

☐ AC APPROVED WITH COMMENTS

☐ RE NOT APPROVED (Re-submit)

☐ RV REVIEWED WITHOUT COMMENTS

☐ RC REVIEWED WITH COMMENTS

☐ NR NOT BE RETURNED

RETURN DATE Aug. 22, 2016

PROJECT ORIGINATOR
RECEIVED DATE

System No. Equipment No. FWBS/AWBS

NA U-DC3101/U-DC4101

SUBRATA JIGAR
2 28-Jul-2016 2nd Issue SUBRATA BERA JIGAR PRAJAPATI
BERA PRAJAPATI
SUBRATA JIGAR
1 19-Jul-2016 2nd Issue SUBRATA BERA JIGAR PRAJAPATI
BERA PRAJAPATI
SUBRATA JIGAR
0 1-Jun-2016 1st Issue SUBRATA BERA JIGAR PRAJAPATI
BERA PRAJAPATI
DATE
REV ISSUE PURPOSE PREPARE CHECKED APPROVED AUTHOLIZED
ISSUED

ISGEC HITACHI ZOSEN LTD.

 Procedure No.  : 2015‐DV364‐HLT 
Revision  : 02 
HELIUM LEAK TEST PROCEDURE  Date  :28.07.2016 
Job No.  : DV‐364 & DV‐365 
 
Page  : 1 OF 4 
 
NDE PROCEDURE

(HELIUM LEAK TEST PROCEDURE FOR LINER JOINT)

  CUSTOMER : CHAMBAL FERTILIZERS AND CHEMICAL LIMITED

   
  PROJECT : 2200 MTPD AMMONIA AND 4000 MTPD PRILLED UREA PLANT,
GADEPAN, KOTA, RAJASTHAN
  CODE OF : ASME Sec. VIII Div.2, Ed. 2015
CONSTRUCTION
  P.O. NO. : -

  ITEM NO. : U-DC3101 / U-DC4101

  IHZL JOB NO. : DV-364 & DV-365

  INSPECTION : AI/LRA/TOYO

                                                                                      REVISION DETAILS

REVISED TO INCORPORATE Subrata Bera Jigar Prajapati

R2 28.07.2016
COMMENTS (NDE Level-II) (NDE Level II)
REVISED TO INCORPORATE Subrata Bera Jigar Prajapati
R1 19.07.2016
COMMENTS (NDE Level-II) (NDE Level II)
Subrata Bera Jigar Prajapati
R0 01.06.2016 ORIGINAL
(NDE Level-II) (NDE Level II)
REV
DATE DESCRIPTION OF THE REVISION PREPARED BY CHECKED & APPROVED BY
NO.
 
AI HITZ  TOYO 
COMMENTS / REMARKS: COMMENTS / REMARKS: COMMENTS / REMARKS:
     

SIGN & STAMP: SIGN & STAMP: SIGN & STAMP:

     

 
 Procedure No.  : 2015‐DV364‐HLT 
Revision  : 02 
HELIUM LEAK TEST PROCEDURE  Date  :28.07.2016 
Job No.  : DV‐364 & DV‐365 
 
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1.0 SCOPE
This procedure is applicable for Helium leak testing for Lining patrs of item No. U-DC3101 / U-
DC4101.

2.0 REFERENCE DOCUMENT:

1) Article 10 of ASME Section V, Edition 2015
2) IHZL Drawing No: 2016-DV-364-S1
3) IHZL Drawing No: 2016-DV-364-S2

3.0 EQUIPMENT & ACCESSORIES:

3.1 Helium Leak Detector Makes – Working on MSLD Principle, Pfeiffer Vacuum, H.
Fillunger/Alcatel or equivalent reputed manufacture capable of demonstrating sensitivity of 1.0 X
2
10-10 Pa-cubic Meter/sec (i.e. 1X10-9 std. atm. cc/sec)
3.2 Detector Probe make-H.Fillunger/Alcatel or equivalent reputed manufacture with tube or hose
having length less than 4.5 meter.
3.3 A constant voltage transformer may be used conjuction with the instrument when line voltage is
subjected to variation.
3.4 Pressure regulator with calibrated pressure gauge shall be used to avoid over pressure and lining
bucking.
3.5 Calibrated pressure gauge to be capable to measure 1.5 to 4 times of test pressure.
3.6 Standard leak make Permeation type Laco type/Alcatel or equivalent reputed manufacture with a
leak rate between “10-6 to 10-9” std.atm.cc/sec.
3.7 He gas (Welding Grade).

4.0 NDT PERSONNEL:

Test shall be performed by person certified as Level-I or Level-II in accordance with ASNT
specification no SNT-TC-1A. The test shall be evaluated by person certified as Level-II in
accordance with ASNT-SNT-TC-1A.

5.0 TEST STAGE & TEST TEMPERATURE

Helium leak testing shall be conducted after Hydro test of Lining joints. Testing shall be
conducted at ambient temperature.

6.0 TEST MEDIUM

Helium Gas having purity at least 99%

7.0 CALIBRATION

7.1 Instrument Calibration

Permeation type standard leak of the order 10-6 to 10-9 std.cc/sec shall be used to calibrate the
instrument before testing and after testing and at intervals of not more than 4 hours during test.

7.2 System Calibration

7.2.1 Standard Leak size: The maximum leakage rate Q for the leak standard shall be calculated as
follow.
Q=Qs X %TG/100
Where Qs is 1X10-6 std.atm.cc/sec & %TG is the concentration of helium to be used for test.

7.2.2 Scanning Rate:

After connecting the detector probe to the instrument the system shall be calibrated by passing the
detector probe tip across the orifice of the leak standard Q. The probe tip shall be kept within 3
 Procedure No.  : 2015‐DV364‐HLT 
Revision  : 02 
HELIUM LEAK TEST PROCEDURE  Date  :28.07.2016 
Job No.  : DV‐364 & DV‐365 
 
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mm of the orifice of the leak standard. The scanning rate shall not exceed that which can detect
leakage rate Q from the leak standard.

7.2.3 Detection Time:

The required time to detect leakage from the leak standard is the detection time. And it should be
observed during system calibration.

8.0 PROCEDURE

8.1 The surface to be tested shall be free of oil, grease, paint and other contaminants which might
mask a leak. If liquids are used to clean the component or if a pressure test is performed before
leak testing, the component shall be dry before leak testing.
8.2 All vent holes for layered construction and holes for liners (Leak detection) or pipes for leak
detection shall be sealed using plugs or covers or sealing wax or cement or other suitable material
which can be readily and completely removed after completion of the test, except for the vent
holes/ leak detection path utilized for filling the gas and attaching the pressure gauge.
8.3 Calibration of Pressure gauge shall be checked before helium leak test.
8.4 The Helium gas shall be filled from the leak detection nozzle hole, which are remained at bottom
of the equipment, and Pressure gauge shall be connected to the leak detection nozzle hole which
are remained at top of the equipment.
8.5 Helium leak test shall be performed by hood technique. If any leakage found, then that seam will
be tested by sniffer method.
8.6 Prepare an envelope around the area/portion to be leak tested. All the openings/edges shall be
properly closed with suitable tape.
8.7 Fill up Helium gas within the space between Inner shell and Liner, and pressurize that to 0.2
kg/cm2(g). For Nozzle sleeve pressurize it to 1.0 kg/cm2 (g). The concentration of helium gas
shall be 100% by volume.
8.8 Allow soaking period for minimum 30 minutes.
8.9 Tune and warm up the Helium leak detector as per HLD manufacturer’s operating instruction.
8.10 Check and calibrate the instrument sensitivity with the standard leak for sensitivity required by
reference specification.
8.11 Insert the detector probe into envelope by puncturing plastic cover. Record the observation after
completing the response time of helium detector.
8.12 Pressurization shall be done in alternative compartments during testing.

9.0 SYSTEM MEASURED LEAKAGE RATE:

9.1 After completion of the test leakage shall be determined as follows:
Actual leakage rate (QA) = (Observation - Background) 100/%TG
9.2 Actual leakage rate calculation will take care of helium concentration used during testing.

10.0 ACCEPTANCE CRITERIA

10.1 Any leakage (actual leakage rate calculated with indicated leakage rate and helium concentration)
above 1 X 10-6 std.cc/sec. from the area of the interest shall not be acceptable.
10.2 Leakage from temporary joints shall not be considered for rejection.

11.0 DOCUMENTATION
11.1 Record the result in the format attached to this procedure.
 Procedure No.  : 2015‐DV364‐HLT 
Revision  : 02 
HELIUM LEAK TEST PROCEDURE  Date  :28.07.2016 
Job No.  : DV‐364 & DV‐365 
 
Page  : 4 OF 4 
 
Sketch for Helium Leak test

Gauge
Leak detection Pipe 
Shell 

Liner weld to be tested
Plastic Envelop

Leak detection Pipe

  Helium Inlet

Helium Leak test in alternative compartment

 
 
Lining Segment
 
Shell 14  Shell 13  Shell 12 Shell 11 Shell 10

 3   3 

Shell  1 

  1    1    1 

4  4 

  2    2    2 

 HELIUM LEAK TEST REPORT

PROCEDURE NO. REPORT NO. DATE OF TEST DATE OF REPORT

General Description
Manufactured By
Owner
Testing Agency
TPIA
P.O. No. & Date
Project
Test Object
Tag No.
Drawing No.
Material
Test Location
Test Operator
Reference Specification
Test Equipment and Accessories Detail
Make Model Sr. No.
Helium Leak Detector

Make Model Sr. No.

Standard Leak (cm3/S)

Make Model Sr. No.

Pressure Gauge

Calibration Detail
Helium Leak Detector Calibration
Stage Time Target Leak Value Calibration Achieved M/c Background
Start of Test
End of Test

Pressure Gauge Calibration

S. No. Calibration Done On Calibration Due On Range

TEST CONDUCTED BY & TEST REPORT BY VESSEL MANUFACTURER INSPECTION AUTHORITIES

Agency IHZL TPIA CLIENT

Signature

Name
Date
 HELIUM LEAK TEST REPORT
Testing Parameters Detail
Test Medium
Test Temperature
Scope of Testing / Area of test
Extent of Testing
Stage of Testing
Surface Condition
Test Technique
Soaking Time
Pressurization Details
Nitrogen Pressure [kg/cm2 (g)]
Helium Pressure [kg/cm2 (g)]
Total Pressure [kg/cm2 (g)]
Helium Concentration

Test Observation
Observed Leak (Total) Back Ground Actual Leak Rate(QA)
Test Object
R1 R2 = (R1-R2)100/%TG

Acceptable Leak Rate:

Test Result:

TEST CONDUCTED BY & TEST REPORT BY VESSEL MANUFACTURER INSPECTION AUTHORITIES

Agency IHZL TPIA CLIENT

Signature

Name
Date