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    Shower Leak Test

    Uploaded by

    Suman Ghosh
    The document is a procedure for performing a shower leak test on welded ductwork at a power plant construction site in Indonesia. It details the equipment, materials, preparation, application process, acceptance criteria, repair process, cleaning, and reporting requirements for conducting the test. Pressurized air is blown on welded joints from outside the duct while a soapy water solution is applied inside. The welds pass if no bubbles are observed, and any leaks detected must be repaired and retested.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Shower Leak Test

    Uploaded by

    Suman Ghosh
    51 views12 pages
    The document is a procedure for performing a shower leak test on welded ductwork at a power plant construction site in Indonesia. It details the equipment, materials, preparation, application process, acceptance criteria, repair process, cleaning, and reporting requirements for conducting the test. Pressurized air is blown on welded joints from outside the duct while a soapy water solution is applied inside. The welds pass if no bubbles are observed, and any leaks detected must be repaired and retested.

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    Shower leak test

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    The document is a procedure for performing a shower leak test on welded ductwork at a power plant construction site in Indonesia. It details the equipment, materials, preparation, application process, acceptance criteria, repair process, cleaning, and reporting requirements for conducting the test. Pressurized air is blown on welded joints from outside the duct while a soapy water solution is applied inside. The welds pass if no bubbles are observed, and any leaks detected must be repaired and retested.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    51 views12 pages

    Shower Leak Test

    Uploaded by

    Suman Ghosh
    The document is a procedure for performing a shower leak test on welded ductwork at a power plant construction site in Indonesia. It details the equipment, materials, preparation, application process, acceptance criteria, repair process, cleaning, and reporting requirements for conducting the test. Pressurized air is blown on welded joints from outside the duct while a soapy water solution is applied inside. The welds pass if no bubbles are observed, and any leaks detected must be repaired and retested.

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    ( 2 / 3 )

    Doc.
    Revisions No. ES-(XTJB)5,6-09-00-0023

    Rev. Description Revised Checked Approved Date

    0 First issue - - - -

    Y.Ishii

    CONFIDENTIAL
    THIS DOCUMENT IS THE PROPERTY OF SUMITOMO CORPORATION BOILER DIVISION (SCBD) AND CONFIDENTIAL. IT MUST
    NEITHER BE COPIED NOR USED FOR ANY PURPOSE OR MANNER OTHER THAN EXPRESSLY PERMITTED BY SCBD OR WITH
    A PRIOR WRITTEN CONSENT OF SCBD NEITHER IS IT TO BE HANDED OVER NOR COMMUNICATED TO A THIRD PARTY IN
    ANY WAY. BREACH OR INFRINGEMENT OF ANY KIND WILL LEAD TO LEGAL ACTION.

    SUMITOMO CORPORATION BOILER DIVISION


    ( 3 / 3 )
    Doc.
    No. ES-(XTJB)5,6-09-00-0023

    (1) Scope
    This document covers the Shower Leak Test of boiler installation on Site.

    (2) Attached documents

    PTJEL-QCP-009_R3 SHOWER LEAK TEST PROCEDURE

    SUMITOMO CORPORATION BOILER DIVISION


    PT. Jurong Engineering Lestari
    PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
    COALFIRED POWER PLANT INDONESIA

    SHOWER LEAK TEST PROCEDURE


    (PTJEL-QCP-009)

    SHOWER LEAK TEST PROCEDURE


    Procedure No: PTJEL-QCP-009

    Page 1 of 7
    PT. Jurong Engineering Lestari
    PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
    COALFIRED POWER PLANT INDONESIA

    SHOWER LEAK TEST PROCEDURE


    (PTJEL-QCP-009)

    TABLE OF CONTENTS

    1.0 PURPOSE
    2.0 REFERENCE DOCUMENTS
    3.0 SCOPE
    4.0 RESPONSIBILITIES
    5.0 DEFINITION
    6.0 PROCEDURE
    7.0 ATTACHMENT

    Page 2 of 7
    PT. Jurong Engineering Lestari
    PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
    COALFIRED POWER PLANT INDONESIA

    SHOWER LEAK TEST PROCEDURE


    (PTJEL-QCP-009)

    1.0 PURPOSE

    This procedure is to describe all the activities to be performed in confirming the integrity of all Ducts
    welds at the erection for the construction of 2 x 1000 MW Tanjung Jati B 5&6 Coalfired power Plant
    project.

    2.0 REFERENCE DOCUMENTS

    2.1 Erection Drawings


    2.2 ASME Section I -2015
    2.3 ASME Section V -2015
    2.4 AWS D1.1 -2015
    2.5 Project ITP- TJB56-C2-OFF-C-00-Q-ITP-0020
    2.6 HSE Management plan TJB56-L2-ON-C-00-H-PLA-0001
    2.7 Weld Visual Report

    3.0. SCOPE

    This procedure defined the methods and procedure of testing the integrity of welds for Duct
    connections during the assembly and erection at site.

    4.0 RESPONSIBILITIES

    The Mechanical Group (LOT-2) doing the Duct assembly and erection works shall be responsible for
    the implementation of this procedure and ensure that the assembly/erection/installation is effectively and
    safely carried out.
    The Safety Engineer is responsible for ensuring that all activities are carried out in a safely manner and in
    compliance with the established safety procedure.
    The Mechanical QA/QC Inspector of LOT-2 shall be responsible to monitor, inspect and evaluate the leak
    testing works ensuring these are being done in compliance with this procedure, standard and Inspection test
    plan.

    5.0 DEFINITION

    This is process of checking the weld joints integrity using pressurized air blown on the joints outside Duct.
    Water with soap detergents will be sprayed on to the weld joints (Inside Duct).

    Page 3 of 7
    PT. Jurong Engineering Lestari
    PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
    COALFIRED POWER PLANT INDONESIA

    SHOWER LEAK TEST PROCEDURE


    (PTJEL-QCP-009)

    6.0 PROCEDURE

    6.1 Shower Leak test procedure for weld joints.

    6.1.1 Equipment and Materials

    • Air Compressor
    • Air Hoses, sufficient length
    • Air Hose Nozzle
    • Mixing Bucket
    • Leak Detector Solution (Water with soap)
    • Leak Detector Solution (Water with soap) Applicator (plastic squeeze bottle and hand operated spray
    applicator or brush)
    • Flashlight or other adequate light source
    • Clean dry rags / cloth or towel

    Important Notes:
    Prepare a solution of adequate liquid detergent or soap with water in advance to allow the
    bubble and foam to disperse

    6.1.2 Preparation/Sitting of Inspection

    1. Remove standing water, weld slag, mud, dirt and other debris which may prevent bubble formation
    from areas to be leak tested.
    2. Provide adequate lighting for examination (daylight, flash light or another sufficient source).
    3. Operate the Compressor until air pressure reaches between the ranges of 5 to 7 bar to be confirmed
    by reading on adequate Gauge.
    4. Positioning of Air Nozzle with control valve into position according to figure-1.

    6.1.3 Process Application (Inspection Procedure)

    1. Blow pressurized air from the outside duct of the weld joints. Air pressure should be between 5 to 7
    bar gauges.
    2. Apply the leak detector solution (Water with soap) by spray or brush on the inside on the weld
    where pressurized air is blown. Solution should be applied in a continuous film and relatively free
    from bubble. See Figure 1 for the typical configuration of the process.
    3. Observe the detector solution for leakage for at least ten (10) seconds at all locations.
    4. Continue the whole length of joint in each welding connection of Duct.

    6.1.4 Acceptance Criteria

    The area under test is acceptable when no bubbles formation is observed.

    Page 4 of 7
    PT. Jurong Engineering Lestari
    PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
    COALFIRED POWER PLANT INDONESIA

    SHOWER LEAK TEST PROCEDURE


    (PTJEL-QCP-009)

    6.1.5 Repair / Retest

    When bubble formation is observed, the location of the leak (s) shall mark and remedial repair
    works shall be made. The repair area shall be retest following process step "1” to "4" on the
    above process application to confirm the air tightness.

    6.1.6 Post Cleaning

    After testing, surface cleaning may be required for product serviceability. The post
    cleaning of the weld joint shall be done by waste clothes to keep it dry.

    6.1.7 Report

    The evaluation result shall be recorded in a report as shown in Attachment I.

    Figure -1
    Typical Application for Shower Leak Test

    Seal weld Inside

    Control Valve

    Page 5 of 7
    PT. Jurong Engineering Lestari
    PROJECT: 2 X 1000MW TANJUNG JATI B 5 & 6
    COALFIRED POWER PLANT INDONESIA

    SHOWER LEAK TEST PROCEDURE


    (PTJEL-QCP-009)

    ATTACHMENT 1

    SHOWER LEAK TEST RECORD

    Page 6 of 7
    2 X 1000MW TANJUNG JATI B 5 & 6 COAL FIRED POWER PLANT
    SCBD
    Sumitomo Corporation
    Boiler Division

    Report No TJ- SC(PTJEL) - QCP(009) -XXX -XXX


    SHOWER LEAK TEST RECORD
    RFI NO:

    SUB CONTRACTOR : PT JURONG ENGINEERING LESTARI DATE:

    STRUCTURE NO.:

    DESCRIPTION :

    DRAWING NO.:
    REF DOCUMENTS/ PROCEDURE : TJ-B5&6-M-PTJEL-QCP-009

    Stage of Examination As welded Blowing

    Surface Preparation Brushing Grinding

    Calibration Certificate
    Pressure Gauge No. Manufacturer Range Calibration Date Expiration Date
    No.

    ITEM NO DRAWING NO. JOINT NO. SIZE THICKNESS TEST PRESSURE OBSERVATION RESULT

    Result □ Acceptable □ Unacceptable


    PTJEL SCBD EPC-IHE BJP-PLN
    Name: Name: Name: Name:

    Signature/Date: Signature/Date: Signature/Date: Signature/Date:

    RESULT LEGENDS: A=ACCEPT, R=REJECT, NA=NOT APPLICABLE PTJEL-QCP-009

    Page 7 of 7

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