Procedure 

No.  : DCP/NDE/DV‐297/HLT‐01 
Revision  : 01 
HELIUM LEAK TEST Date  : 05/06/2015 
PROCEDURE  Job No.  : DV‐297 & DV‐298 
 
Page  : 1 OF 5 
 
NDE PROCEDURE

(HELIUM LEAK TEST PROCEDURE)

  CUSTOMER : CHAMBAL FERTILISERS AND CHEMICALS LIMITED (CFCL), GADEPAN, KOTA 
     
  PROJECT : CFCL GADEPAN UREA‐II 

  CODE OF : ASME Sec. VIII Div.1 & Div.2, Ed. 2013 & TEMA ‘R’ 
CONSTRUCTION
  P.O. NO. : CFCL:PUR:PAG:LOI DATED 30‐MAY‐2014 

  ITEM NO. : U‐EA 1102 & U‐EA 2102 

  IHZL JOB NO. : DV‐297 & DV‐298 

  INSPECTION : LLOYDS REGISTER ASIA (LRA) / CFCL 

                                                                                      REVISION DETAILS

REVISED TO INCORPORATE
R1 05/06/2015
COMMENTS
R0 05/01/2015 ORIGINAL
REV
DATE DESCRIPTION OF THE REVISION PREPARED BY CHECKED & APPROVED BY
NO.
 
 
LRA  CUSTOMER 
COMMENTS / REMARKS: COMMENTS / REMARKS:
   

SIGN & STAMP: SIGN & STAMP:

   
 
 
 
 
 
 
 
 
 Procedure No.  : DCP/NDE/DV‐297/HLT‐01 
Revision  : 01 
HELIUM LEAK TEST Date  : 05/06/2015 
PROCEDURE  Job No.  : DV‐297 & DV‐298 
 
Page  : 2 OF 5 
 
(HELIUM LEAK TEST PROCEDURE FOR LINER JOINT)

1.0 SCOPE
This procedure is applicable for Helium leak testing for Lining patrs of item No. U-EA 1102 & U-
EA 2102.

2.0 REFERENCE DOCUMENT:

1) Article 10 of ASME Section V, Edition 2013.
2) IHZL Drawing No: 2014-DV-297-S1
3) IHZL Drawing No: 2014-DV-297-S2
4) IHZL Drawing No: 2014-DV-297-S5
5) IHZL Drawing No: 2014-DV-297-S6 1 

3.0 EQUIPMENT & ACCESSORIES:

3.1 Helium Leak Detector Makes – Working on MSLD Principle, H. Fillunger/Alcatel or equivalent
reputed manufacture capable of demonstrating sensitivity of 1.0 X 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.
3.3 A constant voltage transformer may be used conjunction with the instrument when line voltage is
subjected to variation.
3.4 Pressure regulator & Calibrated pressure gauge to be capable to measure 1.5 to 4 times of test
pressure.
3.5 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.
3.6 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 before Hydro test (IHZL Internal Requirement) and 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 1X10-4 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
 Procedure No.  : DCP/NDE/DV‐297/HLT‐01 
Revision  : 01 
HELIUM LEAK TEST Date  : 05/06/2015 
PROCEDURE  Job No.  : DV‐297 & DV‐298 
 
Page  : 3 OF 5 
 
detector probe tip across the orifice of the leak standard Q. The probe tip shall be kept within 3
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 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 leak detection path utilized for filling the gas and
attaching the pressure gauge.
8.3 The Helium gas shall be filled from the Leak detection holes which are remained at bottom of the
equipment, and Pressure gauge shall be connected to Leak detection holes which are remained at 1
top of the equipment.
8.4 Prepare an envelope around the area/portion to be leak tested. All the openings/edges shall be
properly closed with suitable tape.
8.5 Fill up Helium gas within the space between Inner shell and Liner, and pressurize that to 0.3
kg/cm2(g). The concentration of helium gas shall be 100% by volume.
8.6 Allow soaking period for minimum 30 minutes.
8.7 Tune and warm up the Helium leak detector as per HLD manufacturer’s operating instruction.
8.8 Check and calibrate the instrument sensitivity with the standard leak for sensitivity required by
reference specification.
8.9 Insert the detector probe into envelope by puncturing plastic cover. Record the observation after
completing the response time of helium detector.

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 10-4 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.  : DCP/NDE/DV‐297/HLT‐01 
Revision  : 01 
HELIUM LEAK TEST Date  : 05/06/2015 
PROCEDURE  Job No.  : DV‐297 & DV‐298 
 
Page  : 4 OF 5 
 
(HELIUM LEAK TEST PROCEDURE FOR TUBE TO TUBE SHEET JOINT)

1.0 SCOPE
This procedure is applicable for Helium leak testing for Tube to tube sheet joint of item No. U-EA
1102 & U-EA 2102

2.0 REFERENCE DOCUMENT:

1) Article 10 of ASME Section V, Edition 2014.
2) IHZL Drawing No: 2014-DV-297-S1
3) IHZL Drawing No: 2014-DV-297-S2

3.0 EQUIPMENT & ACCESSORIES:

3.1 Helium Leak Detector Makes – Working on MSLD Principle, H. Fillunger/Alcatel or equivalent
reputed manufacture capable of demonstrating sensitivity of 1.0 X 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.
3.3 A constant voltage transformer may be used conjunction with the instrument when line voltage is
subjected to variation.
3.4 Calibrated pressure gauge to be capable to measure 1.5 to 4 times of test pressure.
3.5 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.
3.6. He gas (Welding Grade).

4.0 NDT PERSONNEL:

4.1 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

5.1 Helium leak testing shall be conducted before Hydro test (IHZL internal requirement) and after
Hydro test, for Tube to tube sheet joint. Testing shall be conducted at ambient temperature.

6.0 TEST MEDIUM

6.1 Helium Gas having purity at least 99%

7.0 CALIBRATION

7.1 Instrument Calibration

7.1.1 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 1X10-4 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 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.
 Procedure No.  : DCP/NDE/DV‐297/HLT‐01 
Revision  : 01 
HELIUM LEAK TEST Date  : 05/06/2015 
PROCEDURE  Job No.  : DV‐297 & DV‐298 
 
Page  : 5 OF 5 
 
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 openings shall be sealed using plugs, covers, sealing wax, cement or other suitable material
which can be readily and completely removed after completion of the test.
8.3 Prepare an envelope around the area/portion to be leak tested. All the openings/edges shall be
properly closed with suitable tape.
8.4 Pressurize the shell side of stripper with Nitrogen/Moisture free air at 0.9 kg/cm2(g).
8.5 Pressurize the stripper with Helium gas further up to 1.0 kg/cm2(g). The concentration of helium gas
shall be 10% by volume.
8.6 Allow soaking period for minimum 60 minutes.
8.7 Tune and warm up the Helium leak detector as per HLD manufacturer’s operating instruction.
8.8 Check and calibrate the instrument sensitivity with the standard leak for sensitivity required by
reference specification.
8.9 Insert the detector probe into envelope by puncturing plastic cover at bottom of tube sheet. Record
the observation after completing the response time of helium detector.

9.0 SYSTEM MEASURED LEAKAGE RATE:

After completion of the test leakage shall be determined as follows:
Actual leakage rate (QA) = (Observation - Background) 100/%TG
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 10-4 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.

 
 
 
 
 
 
 
  

 
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