CHAPTER 8

LEAK TESTING
DKK2462
Plant Commissioning, Start Up & Shut Down
Semester II 2019/2020
 TOPIC OUTCOMES
 Describe the importance of performing
leak test.
 Explain the best selection criteria for
different types of leak testing methods.
Definition – Leak
 A leak is a hole or other opening, usually unintended and
therefore undesired, in a container or fluid-containing
system, such as a tank or vessel.
 Through which the contents of the container can escape or
outside matter can enter the container.
 The entry, exit, or exchange of matter through the leak is
called leakage.
 The matter leaking in or out can be gas, liquid, a highly
viscous paste, or even a solid such as a powdered or
granular solid or other solid particles.
 A leak can be between two (or more) fluid-containing
systems, allowing transfer of matter from either system to
the other, or even an exchange of matter between them.
 Leakage of matter into a container or other system could
be called inleakage.
 Leakage of matter out of a container or other system could
be called outleakage.
Why Conduct Leak Test
 To check that a pressure vessel does not
have significant leaks at the design
operation conditions.
 Leaks represent:
- Product loss – lower process efficiency
- Hazard – fire, toxic gas
- Environmental pollution – fugitive emissions
 Easier to fix leaks prior to start-up
Sources of Leaks
 Major sources of leaks:
- Flanges
- Valves
- Relief valve
- Valves to flare

>> O-rings
>>Gaskets
General Leak Testing and Detection
 Containers, vessels, or other fluid system are sometimes
tested for leaks - to see if there is any leakage and to find
where the leaks are so corrective action can be taken.
 There are several methods for leak testing, depending on
the situation.
 Sometimes leakage of gas may make a sound which can be
detected.
 For smaller vessels may be tested by pressurizing them
with air and submerging them in water to see where air
bubbles come out to indicate a leak.
 If submerging in water is not possible, then pressurization
with air followed by covering the area to be tested with a
soap solution is done to see if soap bubbles form, which
indicate a leak.
 Other types of testing for gas leaks may involve testing for
the outleaking gases with sensors which can detect that
gas, for example - special sensing instruments for detecting
natural gas.
 A vessel or system is sometimes pressure tested
by filling with air and the pressure monitored to
see if it drops, indicating a leak.
 A very commonly used test after new
construction or repair is a hydrostatic test,
sometimes called a pressure test.
 In a hydrostatic test, a system is pressurized with
water to look for a drop in pressure or to see
where it leaks out.
 Helium testing may be done to detect for any
very small leakage such as when testing certain
diaphragm or bellows valves, which are made to
be practically leak-proof.
 Helium has very small molecules which can go
through very small leaks.
Leak Testing and Detection
 Most of leak testing methods involve pressurizing
the equipment.
 Using a pressure below the design pressure (not
exceed 10% of the design pressure) .
 The vessel to be leak tested should first be
inspected.
 Other method of non-destructive test (NDT) i.e. X
or ∂-rays and by condition monitoring method.
 If pressure leak test is used and the source of
pressure is higher than the test pressure, the
vessel should be provided with protection against
overpressure by use of suitable reducing valves,
pressure gauges and pressure relief valves.
Hydrostatic Test
 A hydrostatic test is the normal way in which a gas
pressure vessel such as a gas cylinder is checked for leaks
or flaws.
 Testing is very important because such containers can
explode if they fail when containing compressed gas.
 Hydrostatic testing is also a way in which leaks can be
found in lower pressure vessels such as pipelines.
 The vessel is filled with a nearly incompressible liquid -
usually water or oil - and examined for leaks or permanent
changes in shape.
 The test pressure is always considerably more than the
operating pressure to give a margin for safety, typically
150% of the operating pressure.
 Water is commonly used because it is almost
incompressible, so will only expand by a very small amount
should the vessel split.
 Small pressure vessels are normally tested using a water jacket
test.
 The vessel is visually examined for defects and then placed in a
container filled with water, and in which the change in volume of
the vessel can be measured by monitoring the water level.
 The vessel is then pressurised for a specified period and
depressurised again.
 The water level in the jacket is then examined.
 The level will be greater if the vessel being tested has been
distorted by the pressure change and did not return to its original
volume or some of the pressurised water inside has leaked out.
 In both cases, this will normally signify that the vessel has failed
the test.
 A simpler test is to pressurise the vessel with water and physically
examine the outside for leaks.
 Red or fluorescent dyes are usually added to the water to make
leaks easier to see.
Hydrostatic Pressure Testing
 Test at designated test pressure
 Remove all fragile
equipment/instrumentation
 Test SS line with demineralised water
(Chloride content less than 1 ppm)
 After test:
i)Open all vents and drains
ii)Remove water from line
iii)Blow air lines dry with N2 or air
 https://www.assda.asn.au/blog/33-
hydrostatic-testing-of-stainless-steels
Plant Purging
 Oxygen must be purged to prevent
formation of explosive or combustible
mixtures
 All process lines/equipment purged with N2
 Oxygen levels should be reduced to 1%
volume
 Fire triangle:

Ignition Source
Corrective Action For Leaks
 In complex plants with multiple fluid systems,
many interconnecting units holding fluids have
isolation valves between them.
 If there is a leak in a unit, its isolation valves can
be shut to "isolate" the unit from the rest of the
plant.
 Leaks are often repaired by plugging the leaking
holes or using a patch to cover them.
 Leaking gaskets, seals, washers, or packing can
be replaced.
 Use of welding, soldering, sealing, or gluing may
be other ways to fix leaks.