TUBE PLUGGING PROCEDURE Doc No: STS/QAC/SOP/08

Rev No: 00
Date Rev: 17 Dec 2008
Page No: 1 of 7

REVISION HISTORY

Rev Originator Description Of Amendments Date

00 Farid New Document 17.12.2008

Designation Name Signature

Originator Mechanical Eng Mohd Farid Abu Bakar

Reviewed

Approved

Controlled document: No part of this document may be printed or reproduced for external purposes
without the written permission of the management appointee of Science-Tech Solutions Sdn Bhd.

SCIENCE-TECH SOLUTIONS SDN BHD

1. SCOPE

This procedure provided necessary steps to rectify leak by using a tube plugging and seal welding
at both ends of tube for Air Fin Cooler / Heat Exchanger.

2. REFERENCE CODES & STANDARDS

2.1. ASME Section IX

2.2. ASME Section VIII Div. 1
2.2.1. UG-99 “Standard Hydrostatic Test”
2.2.2. UW-42 “Surface Weld Metal Build-Up”
2.2.3. Appendix 6, “Method for Magnetic Particle Test”
2.2.4. Appendix 8, “Method for Liquid Penetrant Test”
2.3. API 510 Pressure Vessel Inspection Code – Maintenance Inspection Rating, Repair and
Alteration

3. SPECIFICATION

3.1. Welding Procedure Specification (WPS) available as list below:

Welding Procedure Specification

WPS No. WQT No. P.No Range Welding Process

STS/WPS/(M)/001 P1 TO P1 GTAW

STS/WPS/(M) /002 P1 TO P1 GTAW+SMAW

STS/WPS/(M)/004 P8 TO P8 GTAW

4. PROCEDURES

4.1. Procedure for Tube Plugging is as follows:-

4.1.1. The extend of leaking of the tube to be utilized by tube plugging method shall be
determined through visual inspection or by leak test or any applicable inspection
methods.
4.1.2. The leaking tube shall be identify and clearly marked by client representative or
authorized third party Inspector.
4.1.3. Tube Plug shall be machined in a cone shape to an exact size to accommodate the
dimension of tube to be plug(s).
4.1.4. Tube surface shall be clean thoroughly using an appropriate tools. Proper methods of
cleaning (i.e.: wire brushing or grinding) shall be utilized to remove any irregularity
found especially at the internal surface of detected tube.
4.1.5. Push a plug carefully into the tube until it fits. Make sure the plug is force in parallel
motion inside the tube and fully touch the tube perimeter.
 4.1.6. If the opening is too small for hand plugging, a simple tools need to be fabricate to
enable the plug installation can be done properly.
4.1.7. Apply sufficient hammering techniques on the plug until it is stuck tight enough inside
the tube. Do not force too hard to avoid any damage to the tube.
4.1.8. Call client representative to inspect each of the plug installed. Assist them if they need to
perform any kind of inspection to confirm the plug tightness were satisfactory to their
requirement.
4.1.9. When client representative was satisfied with the repair done, housekeeping shall be
doing immediately.

4.2. Procedure for Plug Seal Wels is as follows:-

4.2.1. The leaking plug shall be identify and clearly marked by client representative or
authorized third party Inspector.
4.2.2. Surface area to be welding shall be clean to remove any rust, scale, grease, oil or dirt and
etc.
4.2.3. Used only similar to equipment base material grinding/brushing disc type.
4.2.4. Welding Process shall be strictly complying accordingly to the following document as
per Clause 3.0 which is relevant and approved by an authorized party before start any
work.
4.2.5. Only D.O.S.H approved or qualified welder shall be allowed to perform the welding
work.
4.2.6. Visual inspection shall be carried out and inspected by client after completion of seal
welding. Acceptance/rejection criteria as per Clause 5.0.
4.2.7. Once NDT result and client Representative were satisfied with the repaired work, the
equipment shall be re-testing for leak test.
4.2.8. If there is any defect detected during leak test or unsatisfactory result observed, the job
shall be repeated from Clause 4.2.3 to Clause 4.2.7 until the result is satisfactory.
4.2.9. Once repaired work completed, the equipment shall be housekeeping instantly to avoid
any foreign material which could be left which can cause dangerous hazard to the
equipment.

5. ACCEPTANCE CRITERIA
5.1. All plugged tube shall be inspected by visual inspection and final acceptance of leak
rectification can be concluded accordingly to leak test result. However the final decision
regarding acceptance tube plugging work can be solely made by owner justification.
5.2. Acceptance/rejection criteria for all testing shall be as per below:-
5.2.1. Visual inspection and evaluation shall be as per UW-42 of UW-38 ASME VIII Div. 1
5.2.2. Dye Penetration Testing or Magnetic Particle Testing as per ASME VIII Appendix 6 or
Appendix 8

6. WORK FLOW

6.1. Perform leak test to detect any leaking on tube and plug.
6.2. Any tube or plug found leak, mark the tube and plug.
 6.3. Plug new tube found leak and perform seal weld or plug found leak. Perform DPT/MPT after
completed welding.

6.4. Perform leak again to ensure that no tube or plug leaking.

7. APPENDIX

7.1. WPS/PQR
7.2. WQT