PETRONAS TECHNICAL GUIDELINES

Leak Testing Guidelines for Shell and Tube Heat

Exchangers

PTG 12.21.11
January 2018

© 2018 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

The primary purpose of the PETRONAS Technical Guidelines is to provide a guide on recommended
standards for safe and efficient technical practices across the PETRONAS Group. This PTG shall be used
exclusively for the said purpose.

The PETRONAS Technical Guidelines supplements the PETRONAS Technical Standards (PTS) and
industry standards and practices endorsed by PETRONAS.

PETRONAS does not imply any warranty regarding the accuracy or completeness of the information
contained in this PTG. Users shall always validate the applicability of the guidance for their specific
intended application. Users shall also ensure appropriate implementation, and shall remain
responsible for the consequences of the outcome.

PETRONAS Technical Guidelines are based on the accumulated knowledge, experience and expertise
of the PETRONAS Group.

PETRONAS is the sole copyright holder of this PTG. Its contents are proprietary and confidential. No
part of it shall be disclosed by users in any manner to a third party (including consultant, manufacturer,
vendor or other) without the prior written consent of the relevant PETRONAS Group Technical
Authority. Where such consent is provided, the third party shall not reproduce, store in a retrieval
system or transmit the contents in any form, or by any means (electronic, mechanical, recording or
otherwise).
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Table of Contents
1.0 INTRODUCTION ................................................................................................................ 4
1.1 SCOPE ................................................................................................................................. 4
1.2 GLOSSARY OF TERM ........................................................................................................... 4
1.3 SUMMARY OF CHANGES .................................................................................................... 5
2.0 TECHNICAL REQUIREMENTS ............................................................................................. 6
2.1 GENERAL ............................................................................................................................. 6
2.2 SPECIFIC REQUIREMENTS ................................................................................................... 7
3.0 PROCEDURE FOR EXCHANGER TIGHTNESS TEST .............................................................. 11
3.1 FIXED TUBESHEET EXCHANGER WITH TEMA TYPE A AND TYPE B CHANNEL HEAD ......... 11
3.2 U-TUBE EXCHANGER & KETTLE TYPE REBOILER WITH TEMA TYPE A AND TYPE B
CHANNEL HEAD ................................................................................................................ 12
3.3 FLOATING HEAD EXCHANGER WITH TEMA TYPE A AND TYPE B CHANNEL HEAD WITH OR
WITHOUT EXTENDED TUBE SHEETS ................................................................................. 12
4.0 ACCEPTANCE CRITERIA ................................................................................................... 14
4.1 LEAK TIGHTNESS TEST USING WATER .............................................................................. 14
4.2 LEAK TIGHTNESS TEST USING PNEUMATIC ...................................................................... 14
5.0 BIBLIOGRAPHY ............................................................................................................... 15
APPENDIX 1 : TERMINOLOGY OF HEX COMPONENTS AND LEAK TEST CONFIGURATION ............ 16
APPENDIX 2 : RECOMMENDED PRACTICE FOR SOAPY TEST TO CHECK TUBE-TO-TUBESHEET JOINT
.......................................................................................................................... 21
APPENDIX 3 : CHECKSHEET/ TEST RECORD FOR LEAK TESTING .................................................. 22
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1.0 INTRODUCTION

This PTG provides minimum technical requirement for Shell and Tube Heat Exchanger leak/
tightness test during maintenance/ shutdown when the exchanger are worked on for activities
e.g. loosening/ tightening of girth flanges, flange machining, leak rectification etc. This PTG is
developed based on ASME PCC 2, ASME Section V, relevant PTS, PETRONAS lesson learnt and
best maintenance practices.

1.1 SCOPE

1.1.1 The scope covers leak / tightness testing of all types of Shell and Tube Heat Exchangers (STHE)
including Steam Surface Condenser installed at the PETRONAS asset. The scope indicates the
procedure of leak testing, and the associated requirement such as test medium, test pressure,
safety precautions and test arrangement tools to perform leak testing.

1.1.2 The leak/ tightness testing of other types of heat exchangers is excluded from this PTG and
shall be carried out in accordance with respective asset leak test standard procedure.

1.1.3 The requirements of the Pressure Test e.g. hydrostatic/ pneumatic test of STHE shall be in
accordance with the applicable design code including PTS 12.21.01 and excluded from the
scope of this PTG.

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definition of Terms

No Term Definition
A test using the process medium of the pressure
1. In-service leak test
equipment performed at start-up of the equipment.
A test performed to ensure overall leak tightness of the
system or its connections before introducing the
process medium. The test includes tightness of tube-to-
tubesheet joint, gaskets joints etc.
2. Leak/ tightness Test
A sensitive leak test using tracer gases in accordance
with ASME Sec V, Article 10 may be used for leak test to
ensure tightness of tubes and/ or tube to tube sheet
joints for critical services where intermixing of fluid is
not permitted.
A pressure or tightness test where a gas generally
3. Pneumatic test
nitrogen or air is the test medium.
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No Term Definition
A test performed to ensure the gross integrity of the
pressure component on new pressure equipment, or on
previously manufactured equipment that has been in
service and that has undergone an alteration or major
Pressure test
repair to a pressure boundary(s) to ensure the gross
4. (hydrostatic and
integrity of the pressure component to the original
pneumatic)
code of construction. A pressure test may be performed
with liquid (hydrostatic test), with gas (pneumatic test),
or a combination of both (hydro-pneumatic test) as
acceptable by design code.
Table 1.1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

1 STHE Shell and Tube Heat Exchanger

2 MDMT Minimum design metal temperature

3 BFJA Bolted Flange Joint Assembly

Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This is a new PTG.
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2.0 TECHNICAL REQUIREMENTS

2.1 GENERAL

2.1.1 The purpose of the of STHE is to ensure the tightness of the shell side and/ or the tube side
that include girth flanges, tube sheets, floating head and channel cover or both as the case
may be, to avoid the risk of leakage during start-up/ re-commissioning of the heat exchanger.
Therefore, it is essential to conduct the leak testing of heat exchangers after major joint
connections are worked on to ensure the tightness of the system or its connections before
start- up/ re-commissioning of the equipment to prevent leakage of process medium.

2.1.2 During leak /tightness test, leakage, if any, from the tubes, tube-to-tube-sheet joints, girth
flanges shall be ascertained. Any leak detected shall be rectified as per standard procedure
and re-tested to ensure leak free joints.

2.1.3 If the exchanger has been pressure tested to the code requirement for both shell and tube
sides to determine the integrity of tube, tubesheet joints and girth flanges/ tube sheets
gaskets, a separate leak testing is not required. However, if after the pressure testing the girth-
flange gasket joint is broken-out/ loosen, the gasket shall be replaced, retightened and
leak/tightness test shall be conducted.

2.1.4 Requirements for leak testing for Surface Condenser:

i. The tube side of surface condenser have low-pressure service water/ seawater and the
shell side condense exhaust steam which has little Vacuum and connected with steam
turbine exhaust flange with a bellow connection. The tightness test of Condenser shall
be conducted considering the following and recommendation of Manufacturer/ as per
O&M manual.

ii. Leak/ tightness test at the shell side may be carried-out using potable water. When a
leak is suspected in tubes, it should be checked by hydrostatic fill test up to maximum of
95% of the shell diameter to have sufficient hydrostatic head. Alternatively, water may
be filled 100 mm above the tube level and pressurized using air up to 1 barg maximum
or as indicated in the O&M manual. To perform the test, the shell side nozzles shall be
blanked - off towards both condensate pump side connected to hot well and turbines
side. Unless otherwise recommended by Manufacturer at least 10 mm thick carbon
steel plate shall be selected for blanking off the turbine exhaust side nozzle (below the
bellow). The tube side hand-hole/ water box covers shall be kept open to examine and
identification of leakage from tubes and tube to tube-sheets joints. If water is leaking
out between the tube and tube-sheet joint, it shall be repaired by tube expansion and
/or seal weld. Leaking tubes may be plugged using appropriate tube plug in both ends of
the tube or replaced.

iii. The leak testing of the tube side to check the tightness of the gasket shall be done using
hydrostatic tightness test up to the design pressure (maximum) and the hot well/
bottom most nozzle shall be open to determine any leakage to ensure leak tightness of
tube and /or tube to tube- sheet joints.

iv. Condenser vacuum test using air ejector shall be conducted to determine air leakage
around valves, valve stems, gauge glasses, flow control apparatus, flange gaskets, and
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shaft seals. An air leakage meter located at the vent of the after condenser or on the
separator vapour outlet.

2.2 SPECIFIC REQUIREMENTS

2.2.1 Leak Testing Medium

i. Where appropriate water of suitable specifications to be used as leak test medium.

However, water shall not be used if damage of internals of equipment / lining is
expected or if there is a possibility to contaminate the catalyst or to the process fluid
during operation due to moisture.

ii. If leak test using water is not feasible, pneumatic test using Air or Nitrogen may be
carried-out. Special precaution required to ensure undesired auto ignition (from
presence of pyrophoric materials) during the leak test using pneumatic test.

iii. Air/Nitrogen used for leak/tightness testing has higher level of potential energy. Hence,
the desired safety distances and precaution mentioned in Article 5.1 of ASME PCC 2 and
Appendix 5 of PTS 12.30.05 shall be complied with.

iv. Helium as a tracer gas in the test medium may be used for sensitive leak test. Under
such condition, mandatory Appendix 5 of Article 10 of ASME Sect V to be followed.

2.2.2 Leak Test Pressure and quality of test medium

i. Each sides of heat exchanger (shell side and tube side) shall be leak tested as required
to check for any leakage. The leak/tightness test pressure shall be as recommended in
Table 2.1 below.
No. Test Test Test Pressure Remarks
Medium condition
1 Maximum: Not more than
Design Pressure of shell side. If the tube sheet is
Shell side
Minimum: Not less than designed for
Water Operating Pressure of shell side. differential test
2 Maximum: Not more than pressure (∆P) , the
Design pressure of tube side. maximum test shall
Tube side
Minimum: Not less than not exceed ∆P.
operating pressure of tube side.
3 Maximum: ≤ 35% design
pressure of shell side.
If the tube sheet is
Shell side Minimum: Up to 25% operating
designed for
pressure or 1.5 bar g whichever
differential test
Pneuma is less.
pressure (∆P) , the
4 tic (Note 2) Maximum: ≤ 35% design
maximum test shall
pressure of tube side.
not exceed 35% of
Tube side Minimum: Up to 25% operating
∆P.
pressure or 1.5 bar g whichever
is less)
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Notes:
1) Where bellow is installed in the exchanger, special precautions shall be taken to avert any damage,
i.e. protection of bellow surface, locking of tie rods/bolts, verify test pressure etc.
2) The stored energy and safe distance calculation shall be carried out and verified by Owner in
accordance with Article 5.1 of ASME PCC2 or Appendix 5 of PTS 12.30.05 before start of
leak/tightness test using air/nitrogen.
Table 2.1: Recommended Leak Test Pressure

ii. The exchanger shall be gradually pressurized for leak testing up to 50 % of the test
pressure and hold for a brief period to allow for any relaxation to take place before
gradually increase to 100% of test pressure. The leak/tightness test pressure to be
maintained for a duration sufficient to enable inspection and observation of all the
location of interest of the tested equipment. Test pressure shall be reduced at similar
rate.

iii. The minimum water temperature shall be 17°C above the MDMT of the vessel. At all
times, the water shall be in the liquid form during testing period to prevent any increase
in testing medium volume. The pneumatic tightness testing shall not be carried out if
ambient temperature is below 7 °C. The test fluid and vessel material temperature shall
equalize to approximately the same temperature before start of pressurization.

iv. The quality of Air for Leak test shall be as follows:

If there is no risk of combustion or damage to equipment/ internal using air as leak test:
 The quality of Air for Leak test shall be clean, dry, and oil free, plant air can be used if
the particle size (d) is 1.0 ≤ 5.0 μm and maximum number of particles per cubic metre
is ≤ 10000; pressure dew point °C ≤ + 3 and concentration of total oil (liquid, aerosol
and vapour) in mg/m3 is ≤ 3.
 If the exchanger is not free from hydrocarbon nitrogen may be used, alternatively
clean, dry, oil free Instrument air can be used if the particle size (d) is 1.0 ≤ 5,0 μm and
maximum number of particles per cubic metre is ≤ 100; pressure dew point ≤ - 40 °C
and concentration of total oil (liquid, aerosol and vapour) in mg/m3 is ≤ 0.1.
Note: Reference – ISO 8573-1, Compressed Air – Part 1: Contaminants and purity classes

v. The leak/ tightness test pressure holding time and acceptance criteria using water and
pneumatic are specified in Section 4 of this PTG.

2.2.3 Test Equipment: When leak testing is conducted using water the equipment shall be properly
vented during filling to avoid air pockets. The following test equipment shall be used during
leak test either using water or pneumatic:
i. Test pump shall be of small capacity so that the pressurization can be gradual. A
pressure gauge shall be installed at the highest point of the equipment and on the
discharge of test pump, the pressure gauge shall be equipped with valve manifold for
checking of gauge reading as Zero before start of pressurization. In case of pneumatic
test, a PRV should be installed at the pump side the PRV shall be set at 110 % of test
pressure. The schematic sketches are shown below:
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Sketch 1: Typical Tightness Test Schematic for Water Testing

Sketch 2: Typical Test Schematic for Pneumatic Testing

Note: The pressure gauge shall be with valve manifold to check the gauge reading as zero.

ii. All pressure gauges shall be as per applicable code having minimum diameter of 100 mm,
it shall have a scale range from 0 to a maximum of 1.5 times the leak/tightness test
pressure i.e. the tightness test pressure shall be at 2/3 of the maximum pressure range.
It shall be tested for its accuracy of at least 1% of the scale range and certified and sealed.
It shall have scale range from 0 to a maximum of 1.5 times the leak test pressure. No
valves shall be installed between the equipment under test and the pressure gauges.

iii. Where applicable pressure and temperature recorder with suitable chart range shall be
used throughout the leak/tightness test.

iv. The pressure gauges used for the leak tested shall be calibrated in accordance with
respective asset leak/tightness test standard procedure.

v. Exchanger manufactured from carbon steel or low-alloy steel may be tested with potable
water having chloride content maximum 250 ppm. For Austenitic stainless steel
exchanger, the water used should be free from chloride, preferably boiler feed water or
demineralized water/ alternatively potable water having maximum 50 ppm chloride may
be used and flushed soon after testing and cleaned by dry air.
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vi. During testing, temporary and/or flexible tube connections shall not be used unless they
are manufactured and certified specifically for the service intended. The end connections
shall be suitably rated and inspected for any mechanical damage.

vii. No bolting work shall be performed during a pneumatic pressure test. In the event of a
flange leak, then the system shall first be depressurised for tightening or flanged seal
faces inspection/repair or gasket replacement.

viii. Ensure that blanking-off devices and screwed plugs or any connections are not liable to
be ejected during testing, i.e. as a result of thread failure or any push fit tube plugs.

ix. The testing area shall be cordoned off and entry is restricted for un-authorized personnel.
Test areas, pumps and instruments should be screened by temporary guards fitted with
visible warning notices. "Keep Away – Leak test / Pressure Test in Progress" and
"Authorized Personnel Only”.

2.2.4 Personnel supervising the leak test shall maintain constant surveillance over the testing
operation. Inspection and testing records shall be maintained in the format attached in this
PTG.

2.2.5 After testing, the equipment shall be immediately drained and dried to prevent corrosion. The
system shall not be left as filled with water after the testing. During draining, vent shall be
opened at the highest point of the equipment to prevent vacuum. Prior to lining up the
equipment into service, the equipment should be purged with nitrogen.

2.2.6 Test ring and test flanges: Shell and tube heat exchangers shall be provided with test flanges
or test rings as follows:

i. Each exchanger with a bonnet-type head having a removable bundle and a tubesheet of
diameter smaller than the outside diameter of the connecting shell flange shall be
provided with a test flange.

ii. Each exchanger with split ring floating head (S type) shall be provided with a test ring
with packing gland.

iii. Test flange may not be required for the Exchanger with flanged tube sheet (Extended
portion of tube sheet), see notes below.
Notes:
1. The extended portion of the tubesheet shall be designed for hydrotesting of the shell side or tubeside
independently, with the respective bonnet or shell removed. Suitable collar type studs shall be supplied for
25 % of the bolt holes in the stationary tubesheet to maintain the gasket in its position during the removal of
the channel/bonnet.
2. The stamped marking of the collar bolts shall also be made on each end of stud, one end of collar bolts shall
be machined with standard size for hexagonal head / square head.
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3.0 PROCEDURE FOR EXCHANGER TIGHTNESS TEST

The procedure for various types of shell and tube heat exchangers for leak testing of tubes
and tube-to-tubesheet joint are indicated below. Appendix 1 shows Terminology of HEX
Components and Leak Test Configuration. During Pneumatic test, if leakage is discovered and
inspection of joint is required, reduce system pressure to lesser than 50% of test pressure or
150 kPa before proceeding with tightening.

All bolting including for girth flange, tubesheet, floating covers joints for tightness test shall
be in accordance with Owner’s approved BFJA (Bolted flange Joint assembly) Procedure. If any
joint is dismantled for repair or retest, it must be retightened with new gasket and with
approved BFJA Procedure.

Retightening of the flanged connection are required in case of any leakage. If leakage cannot
be stopped, recheck the gasket surface for any damage / repair and re- test it again.

3.1 FIXED TUBESHEET EXCHANGER WITH TEMA TYPE A AND TYPE B CHANNEL HEAD

The following preparation shall be carried out for fixed tubesheet exchanger with TEMA Type
A and Type B Channel Head:
i. Shell Side Test – For tube-to-tubesheet joint leak & to check tubes leak.
a. Obtain the permit to ensure the exchanger is isolated and hydrocarbon free.
b. Remove both channel head bonnet or channel box cover.
c. Install blind flanges at the nozzles at shell side.
d. Connect to source of test medium for filling and pressurized the shell side to the
desired leak test pressure.
e. Verify there is no leakage from shell side nozzles.
f. Perform Soapy Bubble Test or any equivalent test method to check any leak on tubes
and tube-to-tubesheet joint on both tubesheets.
g. Identify leak location of tubes and tube-to-tubesheet joint (if any) and record it for
repair.
h. Once repair is rectified, repeat the test sequence as above until there is no leak.

ii. Tube Side Test – Check bonnet to tubesheet joint.

a. Obtain the permit to ensure the exchanger is isolated and hydrocarbon free.
b. Refit channel covers on both sides with Control Bolting perform by Owner’s approved
BFJA procedure.
c. Install blind flanges at the nozzles at tube side and shell side.
d. Connect to source of test medium for filling and pressurized to desired leak test
pressure.
e. Verify there is no leakage from the nozzles on the tube side and shell side.
f. Perform Soapy Bubble Test or any equivalent test method to check any leakage on
girth flange joints.
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3.2 U-TUBE EXCHANGER & KETTLE TYPE REBOILER WITH TEMA TYPE A AND TYPE B CHANNEL
HEAD

The following preparation shall be carried out for U-Tube exchanger & Kettle Type Reboiler
with TEMA Type A and Type B Channel Head.
i. Shell Side Test - For tube-to-tubesheet joint & check tubes leak.
a. Insert tube bundle and install Test Ring on the tubesheet to tighten with shell flange.
Test ring may not be required for extended flanged tube sheet.
b. Install blind on shell side nozzles.
c. Connect to test medium for filling and pressurized to desired test pressure.
d. Verify there is no leakage from shell side nozzles.
e. Perform Soapy Bubble Test or any equivalent test method to check any leak on tubes
and tube-to-tubesheet joints.
f. Identify leak location of tubes and tube-to-tubesheet joint (if any) and record it for
repair.
g. Once repair is rectified, repeat the test as above untill no leak has been identified.

ii. Tube Side Test – For channel to tubesheet and channel cover joint.
a. Remove Test Ring (after the shell side test) and refit the channel to the shell and to
the channel covers (for Type A channel head) with Control Bolting performed by BFJA
procedure.
b. Install blind on tube side and shell side nozzles.
c. Connect to source of test media for filling and pressurized the tube side to the desired
test pressure.
d. Perform Soapy Bubble Test or any equivalent test method to check any leak on
channel to tubesheet joint and channel cover joint (for Type A channel head).
e. Retighten the flange in case of any leakage. If leakage cannot be stopped, recheck the
flange gasket/surface and tighten/test it again.
f. Connect to source of test media for filling and pressurized the shell side to the desired
test pressure.
g. Perform soap-solution test or any equivalent test method to check any leak on shell
to tubesheet joint.

3.3 FLOATING HEAD EXCHANGER WITH TEMA TYPE A AND TYPE B CHANNEL HEAD WITH OR
WITHOUT EXTENDED TUBE SHEETS

The following preparation shall be carried out for floating head exchanger with TEMA Type A
and Type B channel head with or without extended tube sheets. The floating tubesheet test
ring shall be selected as per its type and configuration.
i. Shell Side Test – For tube-to-tubesheet joint and tube leak.
a. Obtain the permit to ensure the exchanger is isolated and hydrocarbon free.
b. Remove channel head or channel cover.
c. Install Test Ring on the tubesheet to tighten with shell flange. Test ring may not be
required for extended flanged tube sheet.
d. Install blind on shell side nozzles.
e. Connect to test medium for filling and pressurized to the desired test pressure.
f. Verify there is no leakage from shell side nozzles and shell cover flange.
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g. Perform Soapy Bubble Test or any equivalent test method to check any leak on tubes
and tube-to-tubesheet joints.
h. Identify leak location of tubes and tubes-to-tubesheet joint (if any) and record it for
repair.
i. Once repair is rectified, repeat the test as above until no leak has been identified.

ii. Tube side test – For floating head joint and channel to tubesheet joint or channel cover
joint.
a. Remove Test Ring (after the shell side test) and refit the channel head and channel
cover (for Type A channel head) with Control Bolting performed by BFJA procedure.
b. Install blind on tube side nozzle.
c. Remove the floating head side shell cover.
d. Connect to source of test media for filling and pressurized the tube side to the desired
test pressure.
e. Perform Soapy Bubble Test or any equivalent test method to check any leakage on
floating head joint, channel to tubesheet joint and channel cover joint (for Type A
channel head).

iii. Shell Cover Test – For shell cover and shell to tubesheet joint.
a. Refit the shell cover with Control Bolting performed by BFJA procedure.
b. Install blind on shell side nozzles.
c. Connect to test medium for filling and pressurized the shell side to the desired test
pressure.
d. Verify there is no leakage from shell side nozzles.
e. Perform Soapy Bubble Test or any equivalent test method to check any leakage on
shell cover and shell to tubesheet joint.
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4.0 ACCEPTANCE CRITERIA

4.1 LEAK TIGHTNESS TEST USING WATER

4.1.1 The leak test pressure to be maintained for a duration sufficient to enable inspection and
observation of all the location of interest of the tested equipment. Otherwise the holding time
shall be a minimum of 15 minutes.

4.1.2 The test is deemed as acceptable when there is no evidence of leak and there is no evidence
of pressure drop during the holding time of 15 minutes.

4.2 LEAK TIGHTNESS TEST USING PNEUMATIC

4.2.1 The system pressure should be gradually increased until the system pressure is 170 kPa or
50% of the test pressure, whichever is lesser.

4.2.2 The leak test pressure to be maintained for a duration sufficient to enable inspection and
observation of all the location of interest of the tested equipment. Otherwise the holding time
shall be a minimum of 15 minutes.

.
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5.0 BIBLIOGRAPHY

In this PTG, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each Standards/Publications shall be used, together
with any supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
Bolted Flange Join Assembly(Amendments/ PTS 12.00.06
Supplements to ASME PCC-1)
Field Inspection Prior to Commissioning PTS 12.02.01
Pressure Vessels PTS 12.20.01
Heat exchangers-Shell and Tube Type PTS 12.21.01

INTERNATIONAL STANDARDS
ASME Boiler and Pressure Vessel Code: Non- ASME V
destructive Examination
ASME Boiler and Pressure Vessel Code: Rules for ASME VIII
construction of pressure vessels
Repair of Pressure Equipment and Piping ASME PCC-2

Standards of the Tubular Exchanger Manufacturers TEMA Standards, 9th

Association edition, 2007
Compressed Air – Part 1: Contaminants and purity ISO 8573-1
classes
Petroleum and natural gas industries - Shell-and- ISO 16812
tube heat exchangers
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APPENDIX 1 : TERMINOLOGY OF HEX COMPONENTS AND LEAK TEST CONFIGURATION

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 Leak Test Configuration

Test Floating Head Exchanger with A-Type Channel Head Check Item
1A Shell side pressurized
for tightness test of
a) Tubes to Tubesheet
joint
b) Tubes leak

1B Tube side pressurized

for tightness test of
a) Floating Head and
Joint
b) Channel to
tubesheet joint
c) Channel Cover Joint

1C Shell side pressurized

for tightness test of
Assembly
a) Shell-channel cover
and tube sheets
Joints
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Test Floating Head Exchanger with B-Type Channel Head Check Item
2A Shell side pressurized
for tightness test of
a) Tubes to tubesheet
joint
b) Tubes leak

2B Tube side pressurized

for tightness test of
a) Floating Head Joint
b) Channel to
tubesheet Joint

2C Shell side pressurized

for tightness test of
Assembly
a) Shell-channel cover
and tube sheets
Joints

Test U-Tube Exchanger with Type A Channel Head Check Item

3A Shell side pressurized
for tightness test of
a) Tubes to tubesheet
joint
b) Tubes leak

3B Tube side pressurized

for tightness test of
a) Channel to
tubesheet and
channel cover Joints
 PTG 12.21.11
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Test U-Tube Exchanger with Type B Channel Head Check Item

4A a) Tubes to tubesheet
joint
b) Check tubes leak

4B a) Check Bonnet to
tubesheet joint

Test Fixed Tubesheet with Type B Channel Head Check Item

5A a) Tubes to
Tubesheet
b) Check for tubes
leak

5B a) Channel-tubesheet
Joint
 PTG 12.21.11
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Test Kettle Type Reboiler with Type B Channel Head Check Item
6A a) Tubes to tubesheet
b) Check for Tubes
leak

6B a) Channel-tubesheet
joint

Test Kettle Type Reboiler with Type A Channel Head Check Item
7A a) Tubes to
tubesheet
b) Check for tubes
leak
c) Shell-Tubesheet
Joint

8B a) Channel-
tubesheet joint
b) Channel Cover
Joint
 PTG 12.21.11
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APPENDIX 2 : RECOMMENDED PRACTICE FOR SOAPY TEST TO CHECK TUBE-TO-TUBESHEET

JOINT

Assumption : To check leak on tubes and tube-to-tubesheet joint

1. Apply masking tape on all tubes for both side of tubesheet.

2. Tap small hole on masking tape on every tubes on one side only i.e. either right or left
side of the tubesheet.

3. Fill the shell side with air by compressor or plant air at required tightness test pressure.
4. Spray soap on the every tubes (small holes of masking tape).
5. Inspection to mark and record failed tubes.
6. Gradually release the pressure untill 0 barg / atmospheric pressure.
7. Remove masking tape from both side and plug the identified failed tubes (ensure same
tube is plugged from both side).

8. After plugging completed, fill in the shell side with air at required tightness test pressure.

9. Upon achieveing the required pressure, apply soap on tube-to-tubesheet and observe for
bubble sign.

10. Inspection to mark failed tube-to-tube sheet joints for both side and recommend
rectification method.
 PTG 12.21.11
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APPENDIX 3 : CHECKSHEET/ TEST RECORD FOR LEAK TESTING

Location: System / test number:

Equipment identification: Applicable code:

Test type:
 Hydrostatic
 Pneumatic
 Combination hydro-pneumatic
 Sensitive leak

Test media: Required Leak Test Pressure:

Dwg / Rev. No. Item ID / Equip Standard / Test Boundaries (Partial

No. / Line No. Specification Test Only)
From: To:

Pretest Inspection Checklist N/A Satisfactory Unsatisfactory

(To be completed by Inspection Representative) (Initial / (Initial / Date)
Date)
1) Approved test media source(s) identified / Located
2) Chloride content of water verified:
a) Max 50 ppm (Stainless and High Alloy Steels)
b) Max 250 ppm (carbon steel or low-alloy steel)
3) Item not to be subjected to test pressure have been
isolated from test (e.g., control valves, instruments,
etc.)
4) Equipment / bellow / piping is properly supported,
stops installed in spring supports.
5) Blinds are proper size /thickness for pressure and
correctly located /installed
6) All deviations to test procedures /codes /standards
have been approved and copies of approvals
attached
7) All rectification works completed and accepted.
8) Pressure gage /recorder ranges: Range from 0 to a
maximum of 1.5 times the leak test pressure
9) Required over pressurization protection devices
have been installed
10) All required welding NDE has been completed
11) Temperature of equipment and test media
stabilized and minimum test temperature verified
 PTG 12.21.11
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Date tested: Ambient Temp: Metal Temp:

Gage / recorder nos. and calibration due dates:
Actual test pressure: Test duration (hold time)
Test accepted:

Inspection / Maintenance Representative - Inspection / Maintenance Verifier - Owner

Owner

Test system drained /Flushed upon completion of testing:

 Not applicable

Testing Personnel - Sub-Contractor Representative – Sub-Contractor

Remarks:
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