Kuwait International Industrial Laboratory
& Inspection Services. (KIL)
Quality Control Procedure
AIR LEAK TEST
QCP-KIL-11 Rev.0
1 04/02/08 For Review & Comments Prasanth.S
Rev Date Comments Prepared Checked Approved
By By By
KIL/QCP-11 Page: 1 of 5
Kuwait International Industrial Laboratory &
Inspection Services. (KIL)
METHOD STATEMENT (AIRLEAK TEST)
QCP-KIL-11 Rev.1
Index
1. Scope
2. Purpose
3. References
4. Procedure
5. Safety
6. Attachments
QCP-KIL-11
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Kuwait International Industrial Laboratory &
Inspection Services. (KIL)
METHOD STATEMENT (AIRLEAK TEST)
QCP-KIL-11 Rev.1
1. SCOPE
The scope of this procedure is to define how air leak test on the FCCU ESP in MAA refinery
KNPC have to be performed as per applicable project specification. This procedure can be
applied for the testing of ESP which can not be hydro tested or if the sensitiveness of the test
should be high. The air leak test shall only be used for the testing of new equipment.
2. PURPOSE
The purpose of issue of this procedure is to meet project specification requirements and
M/s ALSTOM procedure requirements.
3. REFERENCES
3.1 ALSTOM Procedure A.POEX0001-EP-D-070907 Rev 1 dtd. 23.11.07
4. DEFINITIONS
Design pressure : The gauge pressure used to be determined the thickness and stiffners of the
parts subjected to pressure
Test pressure : The pressure used to test the ESP
5. PROCEDURES
5.1 The air test shall be only be performed by means of air. Air is hazardous testing medium.
Special precautions shall be taken. During the entire test the safety of the employees shall
be ensured at all times. The applicable mandatory instructions which ensure safety are
described in this procedure.
5.2 The Limitations of material and temperature.
Air test shall never be performed on silos made of material with a high risk of fracture.
The air leak test is subjected to an important calculation criterion and has to be
considered from the very beginning. So that the correct material choice is made when
calculating as well as for the test. The environmental temperature has to be between 10
deg.C to 40 deg.C in any case, the metal temperature has to be sufficiently high in order
to minimize the risk of brittle fracture.
5.3 Leak test pressure
The exact air leak test pressure has to be specified on the drawing. The leak test pressure
shall be in accordance with M/s ALSTOM specification ie. 100mm,
150mm,200mm,250mm and 300mm water column. The duration of test shall be 10min
reach pressure range after achieving the steady state.
5.4 Preparations
QCP-KIL-11
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Kuwait International Industrial Laboratory &
Inspection Services. (KIL)
METHOD STATEMENT (AIRLEAK TEST)
QCP-KIL-11 Rev.1
Dust removal system shall not be connected to the hopper
Inlet and outlet duct connection shall be left open
No insulation to be done prior to conducting the test.
All the inlet and outlet funnel openings, Hopper outlets etc. shall be blind off
The ESP has to be set up in such a way that a complete exterior visual inspection is possible at
all the times. The ESP shall be completed welded and shall be released after final inspection.
Al surfaces have to be free from oil, grease and spatter.
5.5 Energy-content
During the Air leak test total energy content of the pressure has to be as little as possible.
Total energy has to be calculated prior to test.
5.6 Non-destructive examination
Before the leak test can take place 100% visual examination of all welds shall be performed.
Other non-destructive examination if any as per project specification
5.7 Equipment
A normal U-tube manometer shall be used. The U-tube manometer shall be placed in a
manner so that it can be seen when the ESP is being pressurised , during test and when the
pressure is being released.
As a source of air compressor 230V 3 phase shall be used.
5.8 Execution of the test
The pressure will be increased progressively. The test shall be stopped and the pressure shall
be released immediately when deformations should be found. The ESP will remain under
pressure during the time, mentioned in the specification and will be tested for leaks with soap
solution. During the inspection the ESP will not be submitted to shocks, such as eg,
hammering. After execution of the test the pressure shall be released slowly.
5.9 Test report
QCP-KIL-11
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Kuwait International Industrial Laboratory &
Inspection Services. (KIL)
METHOD STATEMENT (AIRLEAK TEST)
QCP-KIL-11 Rev.1
After the test, a test report will be issued. This report will be kept in the respective technical
file. When the leak test is finished and if the results were satisfactory, the quality plan will be
signed for release.
5.10 Non-conformity
If a leaks is detected or deformation is found a non-conformity report will be issued
6. SAFETY
The area around 5meters of ESP should be cordoned by warning tape. Only the persons
responsible for the test shall allowed to enter within cordoned area.
All personnel protective equipments like Hard helmet, Safety shoes, Goggles etc. should be
wear.
7 ATTACHMENTS
Air leak test report. KIL/PN/11 Rev.0
QCP-KIL-11
Page: 1 of 1
Kuwait International Industrial Laboratory &
Inspection Services. (KIL)
METHOD STATEMENT (AIRLEAK TEST)
QCP-KIL-11 Rev.1
This method statement is to define the minimum requirement of air leak test on the FCCU ESP
at MAA refinery.
This method statement is on the basis of ALSTOM procedure A.POEX0001-EP-D-070907
Rev.1 dtd 23.11.07
A PREPARATIONS
Dust removal system shall not be connected to the hopper
No insulation to be done prior to conducting the test.
All the inlet and outlet funnel openings, Hopper outlets etc. shall be blind off.
B TEST METHOD
Connect the compressor hose to the ESP through gate valve and non return valve.
Connect the U-Tube manometer to ESP through another out let.
Pressurise the ESP to 100mm water column and hold for 10min. If there is no drop in
pressure then increase the pressure to 150mm,200mm,250mm & 300mm.
Give 10min. Holding time at each intervals of pressure range.
Test report to be prepared after finish the test.
QCP-KIL-11
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