This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd.

They are merely loaned and on the borrower’s express agre

reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the b

GENERAL SPECIFICATION FOR

HEATER SYSTEM LEAKAGE TEST
USING SMOKE GENERATION

SHT 1 OF 4

0 22.08.06 ISSUED AS STANDARD SPECIFICATION

NO. DATE REVISIONS BY CHD APPROVALS
ENEREFF ENGINEERS PVT. LTD. GENERAL SPECIFICATION FOR
SPECIFICATION NO. REV.
HEATER SYSTEM LEAKAGE TEST
NEW DELHI 3-12-041
USING SMOKE GENERATION
This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agre
reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the b

S.NO. DESCRIPTION PAGE NO.

1.0 INTRODUCTION 3

2.0 LEAKAGE TESTING 3

2.1 GENERAL 3

2.2 TESTING PROCEDURE 3

3.0 REPORTS/ RECORDS 4

SHT 2 OF 4
ENEREFF ENGINEERS PVT. LTD. GENERAL SPECIFICATION SPECIFICATION
FOR NO. REV.
HEATER SYSTEM LEAKAGE TEST
NEW DELHI
USING SMOKE GENERATION
3-12-041
 1.0 andINTRODUCTION
This drawing the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agre
reproduced, copied, loaned, exhibited, nor used
This specification except
covers theinrequirements
the limited way
ofand private use
checking thepermitted
adequacy byof
any written
the consent
Heater/ APHgiven by lender to the b
System
as regards sealing of all joints/ openings to avoid ingress or egress of air/ flue gases from or to the
atmosphere.
Heater system has numerous potential locations for leakages to occur. It is important to avoid
ingress of outside air and these points need to be sealed. This shall maintain the Heater system
efficiency close to its design value. This shall avoid higher operational costs as well as avoid un-
necessary maintenance to the system
2.0 LEAKAGE TESTING
2.1 General
Heater casing and ductwork are required to be leak tested at site/ fabrication yard by Heater
Contractor after completion of all mechanical works. The leakage test shall be carried out with the
intention of ascertaining the leaking locations and then taking corrective measures to seal such
points. The test shall be carried out by generating smoke (either white or coloured) through an
industrial smoke generator or by using smoke bombs. Generated smoke should be persistently
dense, non-toxic and non-inflammable. Smoke should not be harmful to the personnel deputed
around the test rig and should also not harm the Heater coil, refractory, other materials with
which this smoke comes in contact.
In order to make the smoke leakage test more meaningful, it is important to pressurise the smoke to
around 5mmWC. This makes smoke passing through the system more effective in testing and also
leads to a better detection of even minor leaks.
Contractor shall ensure adequate availability of all smoke generating consummables, equipment and
related equipment including but not limited to the smoke generator, air compressor/ air
blower.
Testing shall be undertaken in the presence of the Owner or his duly nominated representative/ third
party inspection agency.
2.2 Testing Procedure
Following activities shall be undertaken during Smoke Testing leakage testing:
- Isolate the firebox by closing off hot flue gas duct damper etc. (assuming the same is
attached to the ducting going into/ exiting the firebox
- Seal/ close all other openings such as sight doors, tube pulling doors, access doors, auxiliary
instrumentation/ other nozzles, header boxes etc.
- Leave open one horizontal opening through which smoke can be generated or introduced
either by smoke generator or by using some industrial smoke bombs. Smoke must be
generated in a large quantity so that during the duration of the test, smoke does not fall in-
adequate and the test has to be abandoned mid-way
- Wait for around 10 – 15 minutes for the smoke to spread throughout the firebox volume
- Provide a means of generating and measuring a slight amount of positive pressure of the
order of 5 mmWC in the firebox by use of a forced draft fan or an air blower
- Check all openings and joints and carry out a visual inspection to see if coloured smoke is
emanating from any of these joints/ openings

SHT 3 OF 4
ENEREFF ENGINEERS PVT. LTD. GENERAL SPECIFICATION SPECIFICATION
FOR NO. REV.
HEATER SYSTEM LEAKAGE TEST
NEW DELHI 3-12-041
USING SMOKE GENERATION
This drawing and the design it covers are the property of Enereff Engineers Pvt. Ltd. They are merely loaned and on the borrower’s express agre
- Identify the leaking spots and mark the places from where smoke is coming out
reproduced, copied, loaned, exhibited, nor used except in the limited way and private use permitted by any written consent given by lender to the b
- Start sealing these leaking areas by first tackling the major leaks and then progress to sealing
the less leaking joints

- After ensuring that all leaking points have been attended to, carry out the Smoke Leak Test
once again to confirm that complete sealing has been ensured
Adopt the same procedure for checking the soundness of ductwork also.
3.0 REPORTS/ RECORDS
Maintain proper records duly signed by the Client’s authorised representative. Records should
be such that each leak point gets identified by a unique tag/ number. This shall permit the user/
client to maintain the leak-tightness of the Heater system during actual operation and for
subsequent shutdowns/ preventive maintenance on the system.
These Records should be preserved by the Heater contractor and forwarded alongwith other
Inspection Reports to the client.

SHT 4 OF 4
ENEREFF ENGINEERS PVT. LTD. GENERAL SPECIFICATION SPECIFICATION
FOR NO. REV.
HEATER SYSTEM LEAKAGE TEST
NEW DELHI 3-12-041
USING SMOKE GENERATION