The State Committee of the USSR for Supervision over Safe

Conduct of Operations in Nuclear Pow er

Unified Testing Methods of Basic Materials (Semi-Finished Products),

Weld Joints and Weld Overlays of NPI. Leakage test. Gaseous and
Liquid Techniques

PNAEG-7-019-89

Effective since
01.07.1990

Moscow 1990
 TABLE OF CONTENTS

1. General provisions
2. Categories and selection procedures of leak detection systems
3. Hardware and materials

4. Gaseous leak detection techniques

4.1. Requirements to preparation of surfaces of structures subject to gaseous

leak testing
4.2. Leak detection by helium leak detectors
4.3. Leak detection by halide leak detectors Halide sniffer method
4.4. Leak detection by bubble tester
4.5. Leak detection by pressure gage leak detector (at pressure drop)

5. Liquid leak detection techniques

5.1. Requirements to preparation of surfaces of items subject to leak

detection by liquid techniques
5.2. Hydraulic method
5.3. Luminescent and hydraulic method
5.4. Hydraulic method with luminescent tracer coating
5.5. Gravity water method
5.6. Liquid luminescent penetrant method

6. Safety and industrial sanitation regulations

6.1. Safety requirements to leak testing

6.2. Safety requirements to operation of helium and halide leak detectors
and luminescence hardware
6.3. Safety requirements for handling of pressure cylinders
6.4. Safety requirements for handling of Dewar flasks and liquid nitrogen
while filling cooled traps
6.5. Safety requirements for operation of mechanical and steam-jet vacuum
injectors
6.6 Safety requirements for applying hydraulic methods
6.7. Requirements for work place and room for leak tests
6.8. Responsibility for compliance with requirements of this methodology,
applicable regulations and standards

7. Qualification of inspectors

8. Documenting requirements

Attachment [Link] of different gas flow rate units of measure

Attachment 2. List of major equipment, instruments and tooling used for leak
detection

Attachment 3. List of materials used in leak detection

Attachment 4. Methodology and procedure for determining threshold sensitivity

of helium leak detectors
Attachment 5. Methodology and procedure for determining threshold sensitivity
of helium leak detection methods

Attachment 6. Assessment of total helium flow

Attachment 7. Dependence of chladon-12 and chladon-22 saturated vapor

pressure from temperature

Attachment 8. Foam tracer composition and preparation method

Attachment 9. Preparation of 1 liter of aqueous solution of fluorescein ammonia

salt with 0.1% concentration

Attachment 10. Luminescent solution bleaching using liquid phase of bleaching

suspension and its preparation

Attachment 11. Tracer coating (mass and tape) composition and preparation

Attachment 12. Liquid penetrant and absorbing coating composition and

preparation

Attachment 13. Requirements to leak detection room

Attachment 14. Entry format of test results

Attachment 15. Test conclusion statement format

Table 1. Leak detection techniques

Table 2. Classification of leak detection systems

Table 3. Hold-up time of and leaktightness requirements to item

 1 GENERAL PROVISIONS

1.1. Structures and their units are tested for leaktigtness to detect
leaks resulted from through-cracks, losses of fusion, burns-through,
etc. in welded joints and metallic materials.

1.2. Leaktightness tests are based on the use of testing substances

and their penetration through leaks in structures that is registered by
various instruments – leak detectors and other testing substance
monitoring means.

1.3. Depending on properties of a testing substance and monitoring

principle the test is done using liquid or gaseous techniques. Each of
them includes a number of methods different in technology to
implement the registration principle of a given testing substance. In
doing so and depending on the method applied to detect leaks, a leak
location or cumulative leakage (non-integrity degree) is determined.
The list of techniques and methods applied is given in Table 1.

1.4. The leak rate or cumulative leakage is assessed by the air flow
rate through the leak or all leaks in an item to vacuum at normal
atmospheric conditions. The flow units of measure ratios are given in
the reference Attachment 1.

1.5. The testing system should mean a combination of specific

methods and monitoring modes, and a technique to prepare an item
for testing.

1.6. The threshold sensitivity of a monitoring system is characterized

by a magnitude of minimum detected leaks or cumulative leakage.

2. CLASSIFICATION AND SELECTION PROCEDURES OF LEAK

DETECTION SYSTEMS

2.1. In terms of sensitivity all systems are divided into five classes of
integrity, which are given in Table 2.

2.2. A Class of integrity is established by the design organization in

accordance with the requirements of the applicable Rules for
Inspection depending on the purpose, operating conditions of the item
and feasibility of testing methods as regards to a given class, and is
specified in the design documentation.

2.3. A specific leak detection system is selected basing on a

designated class of integrity, design and technological features of the
item as well as technical and economic indicators of testing.

2.4. According to the designated class of integrity, the testing is

carried out pursuant the testing flow-charts, which indicate specific
leak detection methods and methods for preparing an items for
testing. In case of a deviation from the requirements of this
methodology the documents should be agreed upon with the leading
industrial material study organization.
 3. HARDWARE AND MATERIALS

3.1. The equipment, instrumentation and materials for leak testing

should be selected in accordance with Attachments 2 and 3. It is
permitted to use domestic and foreign equipment, instrumentation and
materials not indicated in the attachments provided they satisfy the
requirements of this document.

3.2. Parameters and technical characteristics of equipment,

instrumentation and materials used for leak testing should comply
with the values given in their certificates, state standards and
technical conditions.

3.3. The instruments, which certificates indicate scope and nature of

metrological checks should be subjected to such checks. The checks
are done by Gosstandart units at relevant enterprises.

Frequency of checks is established in accordance with the

requirements indicated in an instrument certificate.

3.4. Irrespectively of the testing method selected the leak detectors

should be adjusted for the optimal sensitivity in accordance with their
technical description and operation manual.

4. GASEOUS LEAK DETECTION TECHNIQUES

4.1. Requirements to Preparation of Surfaces of Structures

Subject Gaseous Leak Testing

4.1.1. In case the item or assembly unit surface is covered with a

protective coating the leak testing should be done before the above
operation.

N o t e. If it is not technically possible the leak testing is permitted to

carry out after a protective coating has been applied provided it is
specified in the Production and Engineering Documentation (PED).

4.1.2. The surface of items, assembly units and welded joints of items
subject to leak testing should be free of traces of rust, oil, emulsion
and other soiling.

4.1.3. Organic soiling on the accessible sections of an item surface

should be washed off with organic solvents followed by tilting of the
item or bubbling of the present solvent. The amount of the poured
solvent should be not less than 100% of the free volume of the item.

4.1.4. Alcohol, acetone, white-spirit, gasoline, chladone or other

organic solvents ensuring quality removal of organic soiling should be
used as cleaning liquids.
4.1.5. After cleaning the solvent should be drained and the item cavity
should be blown-down with dry clean air until the solvent smell is
completely removed.

4.1.6. Cleaning quality should be controlled by sponging of the item

surface with a clean white and pileless tissue followed by the visual
inspection. Absence of soiling on the tissue witnesses the quality of
cleaning of the surface.

4.1.7. Upon a corresponding directive in the Process Regulations the

cleaning quality of a surface section of the item or welded joint should
be visually inspected in the ultraviolet light. If the surface is
inaccessible for such inspection, the cleaning quality should be
controlled by viewing a cloth of the unbleached calico in the
ultraviolet light after the cloth has been used for sponging the
surface.

Absence of luminous spots on the inspected surface or the cloth of

unbleached calico in the ultraviolet light proves the quality cleaning of
the surface.

4.1.8. The final preparatory operation – drying of the surfaces of

items and cavities of possible through defects to remove moisture and
other liquid media – should be done directly before the leak testing.
After the drying, the operations, which are to follow, should be carried
out by personnel in clean clothing (laboratory robes or service
overalls) and lining gloves to keep the items clean.

4.1.9. Electric furnaces, inductors, hot air systems, installations and

facilities for steaming, etc. should be used for heating. Direct or
alternating current electric resistance technique may be used for such
heating as well.

4.1.10. W hen the drying is not accompanied by depressurizing the

exposure time at the required temperature should not be less than 5
minutes. The temperature is determined by a given class of integrity.

4.1.11. If it is not possible to test integrity of items directly after

drying, it is permitted to store the items under conditions below not
more than 5 days:

• the controlled sections should be protected from soiling and

liquid media with protective materials;

• ambient air moisture should not condense on the controlled

item surface. To prevent moisture condensing (for example,
when items are brought in a room where air temperature is
higher than that of the item or when the temperature in the
room decreases or when the item is cooled down by a test
gas from the cylinder) it is necessary to take steps being
guided by the tables showing ratios of ambient air
temperature, relative and absolute humidity. For example, if
0
the relative air humidity is 80% and temperature is 20 С
0
the item surface temperature should not b less than 17 С;
 • air humidity in the room for storage of dried up items should
not exceed 80%.

4.1.12. W hen it is necessary to transport items a possibility for

soiling of and moisture condensing on the item surface should be
excluded.

4.2. Leak Detection by Helium Leak Detectors

4.2.1. Threshold sensitivity of helium leak detectors and testing

methods. Effective range of scale.

[Link]. Threshold sensitivity of leak detectors is characterized by a

minimum flow of a testing substance to be monitored by a leak
detector. Threshold sensitivity of helium leak detectors should not be
less than 1.3 * 10 - 1 0 m 3 * Pa/s (1 * 10 - 6 l * µkm mm Hg/s). Threshold
sensitivity of a testing method is characterized by a minimum flow or
amount of testing substance, which is monitored in the course of
testing where the method is applied.

[Link]. Threshold sensitivity of helium leak detectors is determined

according to the methodology given in Attachment 4 before each shift.

[Link]. Threshold sensitivity of a testing method is determined after

testing of an item, batch of similar items or dummy, which design is to
be agreed upon with the LIMSO in accordance with the methodology
given in Attachment 5.

[Link]. Threshold sensitivity of vacuum (helium) and thermal vacuum

methods should not be less than 6.7 * 10 - 1 0 m 3 * Pa/s (5 * 10 - 6 l µkm
mm Hg/s), and that of helium blow and helium sniffer methods – not
less than 6.7 * 10 - 9 m 3 * Pa/s (5 * 10 - 5 l * µkm mm Hg/s).

[Link]. If threshold sensitivity is below the values given in para.

[Link], the item or batch of items should be re-tested.

[Link]. Presence of a through-defect is indicated by an increase in

the instrument reading in excess of the background values by a value
equal to the difference between the maximum and minimum
background values as per the testing procedure. This value should
not exceed 50 mV for all testing methods (except for sniffer method)
and 100 mV for sniffer method.

N o t e s:

1. Before testing by any method the mean background values should

not exceed 2/3 of the effective range of scale.

2. If the background values exceed the above one the background

compensation arrangements should be in place.

4.2.2. Helium (vacuum chamber) method.

[Link]. The helium or vacuum chamber method is to place the
subject item inside a leaktight metal chamber. A leak detector is
connected to the chamber through the auxiliary evacuation system.
After that pressurized helium is supplied into the chamber (helium
chamber method) or item (vacuum chamber method). If a leak is
present, helium, due to the pressure differential, gets into the
depressurized volume connected to the leak detector. The test flow
diagram is given in Fig. 1.

Fig. 1. Flow diagram of an installation for testing using the vacuum

chamber method.
1 – helium leak detector, 2 – inlet, 3 – argon cylinder, 4 - chamber, 5
- item, 6 – vacuum manometer, 7 – pressure reducer, 8 – helium
cylinder, 9 – vacuum pump, 10 – vacuum valve, 11 – reference leak

[Link]. The following requirements should be taken into account

while designing and manufacturing of the helium (vacuum) chamber):

• the chamber shape is recommended to be cylindrical to

expedite evacuation (it is permitted to manufacture the
chamber to match the shape of the structure);

• the flange connections should be leaktight, as well as the

structure outlet location or the engineered adapting pipe to the
helium cylinder;

• the subject structure should not contact the chamber inner

surface.

[Link]. Test procedure:

• the subject item is prepared as per the requirements of

Subsection 4.1;

• the item is place into the metal chamber, which inner surface
has been cleaned and dried;

• after the chamber lid has been sealed and manometer has
been installed, the chamber (item) cavity is depressurized up
-2
to the residual pressure of 7 - 8 Pa [(5-6) * 10 mm Hg;
 • before the subject item (chamber) is filled with helium its
cavity is depressurized up to the pressure value not higher
than 700-1400 Pa (5-10 mm Hg);

• after the required residual pressure has been achieved in the

chamber, the inlet valve of the leak detector is opened and the
auxiliary evacuation system is disconnected;

• in case where pressure in the mass-spectrometer chamber is

reduced gradually it is necessary to supply dry nitrogen into
the mass-spectrometer chamber using the controlling inlets;

• if pressure increases in the mass-spectrometer chamber it is

necessary to partly open the auxiliary evacuation system valve
or partly close the leak detector inlet valve;

• helium or air-helium mixture is supplied into the item

(chamber) cavity in proportions specified in the test flow-
charts;

• the item (chamber) is held-up under pressure.

[Link]. Duration of the item (chember) hold-up under pressure should

not be less than 5 minutes in case of depressurized volume of up to
3 3
0.1 m ; not less than 10 minutes – 0.1 up to 0.5 m ; not less than 15
3
minutes – over 0.5 up to 1.5 m ; not less than 20 minutes – over 1.5
up to 3.5 m 3 ; not more than 40 minutes – over 3.5 m 3 .

[Link]. Helium should be evacuated by blowing of the item (chamber)

cavity with pressurized air or by depressurization.

It is permitted to collect the evacuated helium for use during

subsequent testing.

[Link]. If it is necessary to test a section of the item or a separate

welded joint, it is permitted to arrange a local chamber for such
section or welded joint.

The test procedure is similar to that indicated in para. [Link].

Duration of the hold-up under pressure is established depending on

the depressurized volume pursuant para. [Link].

[Link]. W hen the closing weld of an item is tested, the item is

depressurized and helium is supplied into its cavity followed by
welding of the closing weld within the helium flow. After welding the
closing weld should be tested using a local vacuum chamber. The test
duration is regulated by para [Link].

[Link]. A quantitative assessment of the total testing substance flow

rate through leaks in the item should be done in accordance with the
methodology given in Attachment 6 (reference).

4.2.3. Helium pressure test of closed envelopes.

[Link]. Helium pressure test of closed envelopes is to place an item
or closing weld into a special chamber where the helium pressure is
gained. Should the weld be non-integral, helium gets into the closed
volume of the item. Then the item is controlled by accumulation of
helium in the vacuum chamber where the item is placed.

[Link]. It is recommended to carry out the leak testing of the closing

weld by helium pressure method with regard to items of smal volumes
(up to 10 l).

[Link]. The test procedure is as follows:

• the item is placed into the pressure chamber and held-up

under helium pressure during a certain period of time;

• after the pressure test the item is retrieved from the chamber
and blown over with compressed air or nitrogen on its outer
surface to clean it up from helium and held-up in the air for 1
to 2 hours;

• before the item is placed inside the inner cavity of the

chamber, connected to the leak detector, is depressurized by
the auxiliary pump. The background readings are recorded by
the outlet leak detector instrument when the chamber pressure
is 1 to 7 Pa [(1 - 5) * 10 - 2 mm Hg] and the auxiliary pump is
switched off;

• after the pressure test the item is placed into the vacuum
chamber, which is depressurized down to the pressure of not
more than 1 to 7 Pa; then the auxiliary pump is switched off and
helium is accumulated in the chamber during not less than 1
hour; then the leak detector inlet valve is set open and the leak
detector readings are recorded.

The presence of a leak in the item’ closing weld is indicated by an

increase in the magnitude of the leak detector outlet instrument signal
over the background values by 1 V and higher.

N o t e. To avoid an increase in helium background during the test it

is prohibited to use the same chamber where the item was subjected
to the helium pressure test.

[Link]. Duration of the helium pressure test should not be less than
120 hours at pressure 1 * 10 6 Pa (10 kgf/cm 2 ); not less than 50 hours
at 2 * 10 6 Pa (20 kgf/cm 2 ); not less than 13 hours at 5 * 10 5 Pa (50
kgf/cm 2 ).

4.2.4. Thermal vacuum test method.

[Link]. The method is to heat the subject item in the vacuum

chamber up to temperature of 380 - 400 0 С and pressure inside and
-3
outside the item not higher than 0.1 Pa (10 mm Hg), and then to
monitor it when helium is supplied into the heated item or chamber
where it is placed.

[Link]. Test procedure:

• the item is prepared for testing as per paras. 4.1.1 - 4.1.7;

• the item is placed into the metal chamber;
• the chamber and the inner cavity of the item are -3
depressurized down to pressure not more than 0.1 Pa (10
mm Hg);
• the 0item is heated in furnaces or by a heater up to 380 -
400 С and held-up at this temperature for 3 to 5 minutes.
The heating rate is determined by continuous
-3
retaining of
pressure not higher than 0.1 Pa (10 mm Hg) in the
chamber and item, and by the design of the item;
• the leak detector inlet valve is set open, the chamber (or
item) pumping set being simultaneously switched off. The
steady background values of the leak detector are recorded;
• helium is supplied to the subject item (or chamber) until the
required pressure is reached;
• the item (or chamber) is held-up under pressure with
simultaneous recording of the leak detector’s readings. The
hold-up duration is determined in accordance with para.
[Link];
• the chamber is opened after the item has been cooled down
to 50 0 С.

4.2.5. Helium sniffer method.

[Link]. The helium sniffer method is to fill the item with helium or air-
helium mixture up to the pressure to exceed the atmospheric one.
After that the outer surface of the item is monitored with a special
sniffer connected through a metal or vacuum rubber hose to the leak
detector. Due to a pressure differential helium passes through a
defect (if present) and gets into the mass-spectrometer chamber of
the leak detector via the sniffer and hose. A special sniffer capping
designed and manufactured to fit the shape of the subject surface
allows to locate a through-defect in the item. The shiffer capping
should cover the subject section not less than 5 mm both sides. If the
capping width is less, the testing should be done in several passes.

The helium sniffer test flow-diagram is given in Fig. 2.

 Fig. 2. Schematic diagram of installation for sniffer test
1 – helium leak detector, 2 – thermocouple bulb,
3 – vacuum hose, 4 – vacuum pump, 6 - item, 7 -sniffer,
8 – vacuum manometer, 9 – helium cylinder

[Link]. The sniffer test uses controlled sniffer-catchers with a cone

capping of not more than 1 mm 3 in volume and a distance between
the controlled locking needle and subject surface of not more than 5
mm. One of the possible design options is the sniffer-catcher as per
drawings 358-00-00 and 358-01-00.

[Link]. The installation for helium sniffer tests is subject to the

following requirements:

• all connections of the installation should be tested by blowing,

sniffer being closed;

• the part of installation intended for supply of helium to the

subject item should be tested by helium sniffer method at
helium pressure of not less than 1.5 P where P is the helium
pressure during the test;

• where the sniffer is connected to the leak detector via a

vacuum rubber hose, the hose should be washed by an alkali
solution (15%), fresh tub water, distilled water and dried with
rectified alcohol. The outer surface of the hose should be
sponged with castor oil;

• the hose length connecting the sniffer with leak detector should
as short as possible. Maximum hose length is determined as
per para. [Link] when the method sensitivity is assessed
pursuant Attachment 5.

[Link]. The test sequence should be as follows:

• sniffer 7 is closed (see Fig. 2) and the hose 3 is depressurized

by the vacuum pump 5 during 15 to 20 minutes;

• the sniffer is adjusted in such a way that during concurrent

operation of the vacuum pump and leak detector pumps the
residual pressure measured by the thermocouple bulb 2, which
 is installed at the leak detector flange, is equal to 25-30 Pa
-1
[(1.8-2.2) * 10 mm Hg]. The operating pressure in the hose
connecting the sniffer and leak detector should be gained by
the simultaneous adjustment of the sniffer and leak detector
inlet valve;

• a pump with evacuation capacity of 1 to 3 l/s should be used as

the auxiliary pump. If a higher capacity pump is used, the valve
4 should be opened partly to ensure the corresponding
evacuation rate;

• the item prepared for testing with plugged holes and flanges is
depressurized down to pressure not more than 700 - 1400 Pa
(5-10 mm Hg);

• helium or air-helium mixture (not less than 50% of helium) is

supplied into the item to create the excess pressure necessary
for the test.

N o t e s:

1. In case where it is impossible to depressurize piping or chamber-

type items beforehand, it is permitted to blow-down the cavity with
helium until it comes to the outlet of a pipeline or item. The
appearance of helium is registered by the sniffer as the instrument
readings increase above the background level by 100 mV and
higher.

2. To obtain helium concentration not less than 60% at pressure 0.1

MPa (1 kgf/cm 2 ) after the cavity has been blown with helium, the
item or pipeline is supplied with helium up to pressure of 0.1MPa (1
2
kgf/cm ). To obtain helium concentration not less than 75%,
pressure is decreased down to the atmospheric one and supply
helium again until pressure becomes 0.1MPa.

3. In case of dead-end cavities, which exclude a possibility for blow-in

and vacuumization the hold-up time to achieve the necessary
helium concentration is determined experimentally on the case-by-
case basis using a simulator.

[Link]. The testing is done by moving the sniffer over the item
surface with a constant speed of 0.10 – 0.15 m/min:

• W hile moving the sniffer should touch the subject surface. A

recession of the sniffer from the subject surface at 5 mm
reduces detectability of defects by 10 to 15 times;

• The testing should start from the lower parts of the item moving
gradually upwards.

4.2.6. Helium blow-over method.

[Link]. The method is to connect the subject item to the leak

detector, depressurize it down to pressure, which makes possible to
open the leak detector inlet valve, and blow-over its surface with
helium.
Should a leak be present in the item, helium gets into its cavity and
registered by the leak detector. The schematic diagram of the helium
blow-over method is shown in Fig. 3.

Fig. 3. Schematic diagram of the installation for blow-over test

1 – helium leak detector, 2 - inlet, 3 – helium leak, 4 –
vacuum pump, 5 – argon cylinder, 6 – vacuum valve, 7 - item, 8 -
blower, 9 – chamber with helium

[Link]. The test sequence should be as follows:

• The item prepared in accordance with the requirements of para. 4.1

is depressurized up to pressure of 7 - 8 MPa [(5 - 6) * 10 - 2 mm Hg];

• when the leak detector inlet valve on the item is open the auxiliary
evacuation system is switched off and the outer surface of the item
is blown-over with helium. If it is not possible to maintain the
required pressure in the mass-spectrometer chamber when the
auxiliary evacuation system is switched off, it is permitted to carry
out the test while the auxiliary evacuation system valve is partly or
fully opened. In doing so, sensitivity should be determined in
accordance with Attachment 5 having the same valve position;

• the blow-over should start from the locations where the auxiliary
evacuation system is connected to the leak detector; then the item
itself is blow-over starting from the upper sections downward;

• at the first stage of test it is recommended to have a strong helium

flow to cover a larger area in one moment. Should a leak be
detected, the helium flow is to be reduced so that its pressure
would be slightly felt on the inspector’s lips at the blower jet
approach, then it is necessary to locate the through-defect spot.
Speed of the blower jet movement over the subject surface is 0.10-
0.15 m/min; when the large volume and length items are tested, the
blow-over speed should be reduced taking account of the signal
delay time;

• in case of large through-defects and impossibility to gain the

necessary vacuum in the item to have the leak detector inlet valve
fully open, when the auxiliary evacuation system is switched of, the
through-defects should be looked for while the auxiliary evacuation
 system is switched on. After large-size through-defects have been
detected and eliminated the re-testing is done to reveal the defects
with low leak rate.

[Link]. In some cases where it is necessary to test all surface of an

item or its part the subject surface is covered by a soft casing. Helium
is supplied under the casing in the amount roughly equal to the
volume under the casing. Hold-up time of the item under the casing is
5 to 6 minutes.

[Link]. The blow-over method is permitted for testing of unclosed

elements of structures. In such cases the vacuum suction chambers
should be used. They are applied to or fixed on the subject surface on
the side opposite to the one subjected to blowing. One of the suction
chamber designs is shown in Fog. 4. The test modes are given in
para. [Link].

Fig. 4. Vacuum suction chamber design

1 - cap, 2 - case, 3 - rubber seals, 4 - structure, 5 - pipeline, 6
– welded joint

4.3. Leak Detection by Halide Leak Detectors. Halide Sniffer

Method

4.3.1. Adjustment of leak detectors, determining and testing of the

threshold sensitivity of halide leak detectors should be done against
the reference halide leaks in accordance with the technical
description and instrument operators’ manual issued by the
manufacturing plant.

4.3.2. The halide sniffer method is to fill the pre-depressurized item

with chladone or air-chladone mixture to obtain the pressure higher
than the atmospheric one. As a result of pressure differential
chladone gets into a non-integrity and is registered by the leak
detector sniffer, which connected by an electric cable with the
measurement unit of the leak detector.
4.3.3. The schematic diagram of an installation for tests using the
halide sniffer method is shown in Fig. 5.

Fig. 5. Schematic diagram of installation for tests using halide sniffer

method:
1 – freon cylinder; 2 – reducing gage; 3 – vacuum pump; 4 – vacuum
manometer; 5 - valve; 6 - item; 7 – measurement unit of leak detector;
8 – remote sniffer of leak detector

The installation for supplying freon into the subject item should be
tested for leaktightness by a halide leak detector at the pressure of
saturated chladone vapor and temperature as for testing.

4.3.4. Test procedure:

• after all holes and flanged outlets have been plugged with through
and dead-end plugs the item is depressurized down to the residual
pressure of not higher than 700 - 1400 Pa (5 - 10 mm Hg);

• the vacuum pump is switched of by closing of the valve and

chladone is supplied into the item until the necessary excess test
pressure is gained;

• if it is impossible to depressurize the pipelines in advance, it is

permitted to press out air by chledone, provided the presence of
chladone is registered on the opposite end of the pipeline. Then
chladone is supplied into the pipeline until its concentration
becomes not less than 50%;

• in case chamber-type items it is permitted to pump in chladone

without depressurization of an item, provided its concentration in
the item is not less than 50%;

• the testing is done by movement of the remote sniffer over the item
surface with a constant speed;

• while being moved the sniffer should be at the minimum possible

distance from the surface. A recession of the sniffer from the
subject surface at 5 mm reduces detectability of defects by 10 to
15 times;

• the testing should start from the upper sections of the item
downwards.
4.3.5. Halide leak detector test modes:

• the speed of sniffer over the item surface should not exceed 0.10 –
0.15 m/min;

• chladone-12 or chladone-22 pressure should correspond to the

procedures of work drawings or testing flow-chart. Chladone
pressure in the item should be lower than that of its saturated
vapor.

N o t e. Pressure of saturated chladone-12 and chladone-22 vapor

depending on temperature is given in the reference Attachment 7.

4.3.6. After testing chladone should be evacuated off-working

premises by pumping out to obtain the residual pressure of 130 - 650
Pa (1 - 5 mm Hg). Then the subject item should be filled with air and
evacuated again to gain the above pressure.

N o t e. Double pumping out of the subject item to gain the residual

pressure of 130 - 650 Pa ensures that the residual chladone-12
content will not be more than 0.01 mg/l and chladone-22 – not more
than 0.006 mg/l.

4.4. Leak Detection by Bubble Tester

4.4.1. Pneumatic air invlation method.

[Link]. The method is to fill the subject item with a testing gas under
excess pressure. A foam-forming solution is applied to the item’s
outer surface. The testing gas causes formation of foam bubbles in
the leak locations (bubbles or ruptures of soap film if the soap
emulsion is used; foam bulges or film ruptures if a polymeric mixture
is used).

[Link]. Test procedure:

• the required excess pressure is gained in the subject item;

• a foam-forming solution is applied on the subject item
surface with a soft hair brush and then the visual inspection
is carried out.

N o t e. The foam-forming solution compositions are given in

Attachment 8 (reference).

[Link]. Observation of the surface conditions with the foam-forming

emulsion is 2 to 3 minutes.

[Link]. W hen a polymeric compound is applied to reveal large-size

defects (more than 1 * 10 - 4 m 3 Pa/s) the observation should be done
directly after the polymeric compound has been applied. To reveal
small-size defects the observation time should not be less than 20
minutes after the compound has been applied. The foam bulges
remain during one day.
4.4.2. Pneumatic-hydraulic submergence method.

[Link]. The method is to submerge an item filled with gas under the
excess pressure. The gas emerging in the locations of leaks produces
bubbles in the liquid.

[Link]. The test procedure is as follows:

• the subject item is placed in a tank;

• the excess pressure is gained within the item using the testing
gas;

• the tank is filled with the liquid to cover the subject item
surface not less than 100 - 150 mm above.

[Link]. A sign of the leak is the formation of bubbles or strings of

bubbles, which periodically form at a certain section of the item
surface and ascend to the surface of liquid.

4.4.3. Vacuum bubble method.

[Link]. The method is to apply the foam-forming compound on a

section of the subject structure, place this structure into the vacuum
chamber and vacuum it. Bubbles, bulges of film ruptures will form in
the leaking locations and be seen through a transparent window of
the chamber.

[Link]. To provide for 100% testing of the welded joint, the vacuum
chamber is positioned in such a way that it not less than 100 mm
overlaps the previously tested weld section.

The vacuum chamber may be of different shape depending on the

design of the subject item and type of welded joint. In case of butt
welded joints of sheet structures the flat chambers are manufactures;
for angle joints the angle-shaped chambers are used; and the annular
chambers may be manufactured to test annular welded joints. One of
the possible vacuum chamber design options is shown in Fig. 6.

Fig. 6. Schematic diagram of vacuum chamber for leak detection:

1 – rubber seals; 2 – chamber casing; 3 - window; 4 – vacuum gate;
5 – leak in the welded joint; 6 – rubber seals

[Link]. The test procedure is as follows:

• the foam-forming compound is applied to the subject section

of the unclosed structure;

• the vacuum chamber is installed on the subject section;

• pressure 2.5 - 3 * 10 4 Pa (180 - 200 mm Hg) is gained in the

vacuum chamber;

• time from the applying of the compound until the beginning of

visual examination should not exceed 10 minutes;

• the visual examination of the subject section is done through

the transparent window on the top of the chamber.

N o t e. W hen the polymeric compound is used the picture of defects

stays for one day.

4.5. Leak Detection by Pressure Gage Leak Detector (at Pressure

Drop)

4.5.1. To test by the pressure gage method the item is filled with the
testing gas under pressure, which higher than the atmospheric one,
and held-up for a certain period of time.

4.5.2. Pressure value and time are established by the technical

conditions for the item or by the design documentation.

4.5.3. An item is considered leaktight is the pressure drop of testing

gas during the hold-up under pressure does not exceed guidelines set
forth by the technical conditions or design documentation.

4.5.4. The gas pressure is measured by pressure gages of 1.5 to 2.5

precision class with the measurement limit of 1/3 higher than the
pressure test value. The gas-supplying pipe should be equipped with
a shutdown valve to control the gas sypply.

4.5.5. The quantitative assessment of the total non-integrity is done

using the formula:
∆P
Q = V
t

where V is the inner volume of the item and test system elements
measured in m 3 ;
∆P is a change in the testing gas pressure during the pressure test
measured in Pa;
t is the pressure test time measured in seconds.
 5. LIQUID LEAK DETECTION TECHNIQUES

5.1. Requirements to Preparation of Surfaces of Items Subject to

Leak Detection by Liquid Techniques.

5.1.1. Before testing the subject surface should be free of rust, dross,
slag, undercuts and falls in accordance with the requirements of
Rules for Inspection the visually inspected welded joints are subject
thereof.

5.1.2. The subject item (welded joint and metal) surface should be
cleaned from emulsion, oil and other organic compounds by
unbleached calico cloth wetted with acetone, gasoline, white-spirit or
aqueous cleaning agents.

N o t e. An aqueous cleaning agent is made by dissolving of 10 grams

of a washing powder in 10 liters of tub water.

5.1.3. Before leak detection the cleanliness of the surface is checked

using the ultraviolet light whether spots or dots are present on it. If
the surface is inaccessible for such check, the surface is visually
inspected using a mirror.

5.1.4. If a welded joint surface or part of it is inaccessible for the

check with the ultraviolet light, the quality of cleaning is checked
through viewing a cloth of unbleached calico, used for cleaning of
inaccessible section of the welded joint, in the ultraviolet light. W hile
viewing in the ultraviolet light, the absence of luminous spots on the
cloth witness the quality cleaning.

5.2. Hydraulic method

5.2.1. The hydraulic method is to gain water pressure inside the

subject item. A leak location is determined visually by streams, drops
and flushes of water.

5.2.2. The subject item surface is prepared in accordance with the

requirements of Subsection 5.1.

5.2.3. The procedure and sequence of filling the items with water until
the necessary pressure is gained are similar to those applied for
hydraulic tests.

5.2.4. The test pressure and hold-up time are established by the
design documentation and specified in the drawings.

5.3. Luminescent and hydraulic method

5.3.1. The luminescent and hydraulic method is to gain an excess

pressure of an aqueous solution of luminophor with a certain
concentration in the subject item within a given period of time.

A leak location is detected by glowing of luminophorin the ultraviolet

light after the subject surface has been wetted.
5.3.2. The subject item surface is prepared in accordance with the
requirements of Subsection 5.1.

5.3.3. The procedure and sequence of filling the items with water until
the necessary pressure is gained are similar to those applied for
hydraulic tests.

N o t e s:

1. W hile the subject items are being filled with a luminescent solution
the measures should be taken to avoid the getting of the luminescent
solution on the outer surface of the item.

2. If the luminescent solution gets on the subject surface it should be

immediately removed with fresh water.

3. The dried luminescent solution should be removed with 1-3%

aqueous ammonia solution.

5.3.4. The pressure test of systems and pipelines using the

luminescent solution is done on the existing assemblies used for
hydraulic tests.

5.3.5. After sealing the subject item is pressurized using the aqueous
solutions of fluorescine disodium and ammonia salts with
concentration of 0.09-0.1% (1-0.9 g/l) up to the pressure required by
the drawing or corresponding design documentation. The pressure
should not exceed the value established by PNAE G-7-008-89.

Attachment 9 (reference) gives the method how to prepare the

fluorescine ammonia salt.

5.3.6. The hold-up time under the solution pressure should not less
than one hour.

5.3.7. To avoid removal of fluorescine salt, which penetrated through

a defect it is not permitted to sponge the subject sections after the
pressure in the subject item has been gained and until the test is
finished.

5.3.8. After hold-up as per para. 5.3.6 each subject section is viewed
in the ultraviolet light to reveal large-size defects; the fluorescine
solution water does not evaporate completely while coming through
them, thus in this case, the wetting is not required.

5.3.9. If large-size defects are absent, each weld or base metal

section should be wetted with a water spray and subjected to final
visual examination in the ultraviolet light.

Through-defects are revealed as glowing green dots and stripes

(cracks, pores, microporosity).
N o t e s:

1. The gap between the water spray and subject surface should be 0.3
– 0.5 m.
2. It is permitted to use service air supply for spraying of liquid
provided it is free of traces of oil and emulsions, which glow in the
ultraviolet light, as well as steam.

5.3.10. The examination of the subject surface section in the

ultraviolet light should be done in a completely dark room or when the
subject section is completely darkened (the illuminance is not more
than 10 lux). The pressure of solution in the subject item should be
partly or completely relieved immediately after wetting. In doing so,
the duration of examination should not exceed 1 minute.

5.3.11. If it is necessary to repeat the test or confirm the results the

following operations should be conducted:

• washing of the subject section with warm water to remove

fluorescine salt traces;

• examination of the subject surface in the ultraviolet light to

check whether the fluorescine salt traces have been
removed;

• hold-up of the item during 1 hour at the pressure applied for

the leaktightness testing;

• wetting and visual examination in the ultraviolet light.

N o t e. In case of repeated luminescent and hydraulic tests it should

be taken into consideration that the capability of the revealing of
defects sharply decreases due to decrease in the filtration rate
through a defect.

5.3.12. W hen the welds and other sections of subject items

inaccessible for wetting and examination in the ultraviolet light are
tested, the defect setting method is applied. The defects are set with
a marked tissue (medapolame, unbleached calico, gauze) or filtering
paper.

In doing so the following operations should be conducted:

• before the item is pressurized the subject sections are tightly

wrapped in one or two layers of tissue or filtering paper;

• the close contact of paper or tissue with the surface of subject

item is ensured by various fixing tooling (insulation tape, elastic
film, rubber, etc.);

• after pressure has gained and the subject section has been
held-up under pressure of luminescent solution, the tissue or
filtering paper is removed. The defect location is traced by
glowing of the luminescent solution penetrated through a defect
on the tissue or paper in the ultraviolet light.
N o t e s:

1. It is permitted to examine the marked tissue or filtering paper

removed from the weld in the ultraviolet light in the stationary
(laboratory) conditions.

2. It is permitted to use the fluorescine salt solution (0.1%) for many

times after it has been used for testing of clean (free of process
soiling) items and pipelines.

3. The luminescence solution should be stored in closed vessels. The

solution storage period in not limited.

5.3.13. The item should be washed of the luminescent solution by

multiple displacement of the solution from the item by water or
nitrogen (air) supplied from cylinders followed by filling with water.
Before draining into the service sewage the solution should be dyed
using the method outlined in Attachment 10.

5.4. Hydraulic Method w ith Luminescent Tracer Coating

5.4.1. W hen the hydraulic method with luminescent tracer coating is

applied the outer surface of subject item is covered with a tracer
coating, pressurized with water, held-up under test pressure during a
given time and examined in the ultraviolet light.

Should a leak be present, water penetrates on the outer item surface

and glowing appears on the tracer coating in the location of a defect.

5.4.2. The tracer coating (mass or tape) contains a water soluble

luminophor, which glows green in the ultraviolet light, and a sorbent,
which retains water for a long time.

The composition and preparation method of the tracer coating are

given in Attachment 11 (mandatory).

5.4.3. The tracer mass should be stored in a vessel excluding

evaporation of alcohol.

The tracer tape should be stored in drying bottles.

5.4.4. Before test the tracer mass and tape should be checked
whether the green spots, glowing in the ultraviolet light, are absent in
the coating applied to the reference sample.

5.4.5. The surface of subject item should be prepared in accordance

with the requirements of Subsection 5.1.

5.4.6. The procedure and sequence of filling the item with water are
similar to those of the hydraulic testing as applied at the enterprise,
which carries out such testing.
5.4.7. W hen it is not possible to evacuate air from the dead-air
spaces by pressing it out with water, it is necessary to depressurize
the system befor its filling.

5.4.8. After the item has been filled with water the following
operations should be carried out:

• the alcohol-containing tracer mass should be applied to the item

surface with a soft brush or tracer tape attached to it. W hen the
tracer tape is used the firm contact with all subject section surface
should be ensured;

• the quality of application of the tracer coating should be checked in

the ultraviolet light to ensure there is no a glowing background. The
outside moistening should be excluded for it may produce a wrong
picture of defects. To exclude the moisture ingress it is
recommended to protect the subject sections with a polyethylene
film;

• the item should be pressurized with water as it is required by the

corresponding documentation. During testing the pressure should
not exceed the value established in PNAE G-7-008-89. The water
temperature should not be lower than the air temperature in the
room where the subject item is located;

• after the item hold-up under the test pressure and after the
pressure has been relieved, the subject surfaces or tracer tape
removed from them should be examined in the ultraviolet light. The
examination should be done in the darkened room or the subject
section should be protected from direct light (the illumination is not
more than 10 lux).

After the test the tracer mass should be removed by hair brushes or
dry rags.

N o t e. In cases specified in the process regulations or process flow-

chart it is permitted to apply the tracer coating and carry out the
examination of subject welded joints, when the structure is under
pressure.

5.4.9. The item hold-up time under pressure should not be less than
one hour.

5.4.10. Through-defects appear as glowing green spots or stripes on

the tracer coating when viewed in the ultraviolet light.

5.4.11. The test conditions (subject item temperature, relative

humidity and air temperature) should exclude the condensing of
precipitation water on the item’s walls and appearance of the green
background at the tracer coating.

The subject item temperature should be equal (or higher) the ambient
air temperature.
5.4.12. In case of re-testing using the hydraulic method with the
tracer coating the detectability of defects decreases sharply.

The re-testing should be agreed upon with the leading material study
organization.

The following should be done in case of re-testing:

• to remove the tracer mass with a brush or dry rags;

• to wash the subject surface with ethyl alcohol, water added

with detergents or 1-3% aqueous ammonia solution;

• to check whether the luminophor traces have been removed

by viewing in the ultraviolet light;

• to apply the tracer mass on the subject item’s section and

carry out other operations listed in para. 5.4.8.

5.5. Gravity Water Method

5.5.1. The item is filled with water up to the level indicated in the
design documentation. The defect locations are traced by water flows,
leaks and drops on the subject surface.

5.5.2. The time period during which water should remain in the
subject item is established by design documentation considering the
period of time necessary for visual examination of all subject surface.

5.6. Liquid Luminescen Penetrant Method

5.6.1. The leak detection method using the liquid penetrants is to

apply a kerosene-based liquid penetrant of the item surface, the
opposite surface being covered with an absorbing coating. After hold-
up during a specified period of time, while the additional liquid
penetrant is periodically applied, the surface is viewed in the
ultraviolet light. In the ultraviolet light the luminescent liquid glows in
the leak locations.

The composition and method of preparation of the liquid penetrant

and absorbing coating are given in Attachment 12.

5.6.2. The test procedure of liquid penetrant method should be as

follows:

• the subject surface should be prepared in accordance with the

requirements of para. 6.1.2;

• the subject surface should be covered with a liquid penetrant

using a brush or wad;

• the coating is applied immediately after the applying of the

liquid penetrant;
 • after the absorbing coating has been applied the item should be
0
blown-over with hot air or nitrogen (temperature is 70 - 80 С)
until the coating is completely dry;

• the subject surface should be viewed in the ultraviolet light not

earlier than 10 minutes after the drying of the coating.

5.6.3. The item hold-up time, when it is in contact with the

luminescent solution, should be established depending on the
leaktightness requirements applicable to the item and the item wall
thickness in accordance with Table 3.

5.6.4. Defects reveal in the form of glowing dots or stripes on the

coating.

5.6.5. The sequence of operations when the kerosene-based tracer is

used, is similar to that described in para. 5.6.2. The subject surface is
visually examined in normal lighting.

5.6.6. The item hold-up time, when it is in contact with the kerosene,
should be established depending on thickness of the welded metal or
design height of the angle weld and spatial weld position.

Lower position:

Thickness of metal or weld leg... Up to 6 mm - 40 min

,, ,, ............ 6 - 24 mm - 60 min
,, ,, ............ Over 24 mm - 90 min

Vertical, horizontal and inverted positions:

Thickness of metal or weld leg ..... Up to 6 mm - 60 min

,, ,, ............. 6 - 24 mm - 90 min
,, ,, ......... ... Over 24 mm - 120 min

6. SAFETY AND INDUSTRIAL SANITATION REGULATIONS

6.1. Safety Requirements to Leak Testing

6.1.1. Individuals who did training in safety regulations and special

briefing on safety, electrical safety and fire safety rules and learned
correct and safe working methods should carry out the leak testing
operations. The knowledge in safety regulations is tested pursuant
the procedures applicable at the enterprise.

6.1.2. During the leak testing the parts, assembly units and items
should be anchored or placed on a sound foundation. The subject
items should be fenced as necessary.

6.1.3. During the testing the instrumentation should be earthed with a

2
copper wire with a cross-section not less than 2.5 mm .
6.1.4. The inspectors should wear hard caps while working inside the
structures.

6.1.5. W hen the testing is done in the assembling conditions the

hardware connection to and disconnection from the mains should be
done by an electrician-on-duty. Before switching on the hardware it is
necessary to get assurance that it is soundly earthed.

6.2. Safety Requirements to Operation of Helium, Halide Leak

Detectors and Luminescent Hardw are

6.2.1. During operation of helium, halide leak detectors and

luminescent hardware the requirements contained in the Operation
Rules for Consumers’ Electrical Installations and Safety Rules for
Operation of Consumers’ Electrical Installations should be met.

6.2.2. The following requirements should be met during operation of

helium leak detectors:

• leak detectors ПТИ-7, ПТИ-10 and others should be earthed,

and the connecting electric cables should be insulated;

• the test area should be restricted and marked with warning

signs;

• cleaning of the mass-spectrometer chamber of the helium leak

detector and replacement of the cathode are permitted only
after the voltage is off and power supply plugs are switched off
for the manometer is supplied with high voltage of 2,500 and
1,250 V;

• it is prohibited to replace radio valves without radio units’ power

supply plugs being switched off;

• adjustment and alignment of helium leak detectors should be

done having a dielectric rug under feet;

• repair and cleaning of power supply units should be done only

when the instrument is completely stopped and electric power
supply is disconnected;

• operation of helium leak detectors should take place only when

the doors of power supply cabinets are locked and the upper
cover is closed.

6.2.3. After the work is done:

• the leak detectors should be switched off;

• the subject structures should be relieved from pressure;
• the helium cylinders should be closed;
• the signs should be removed from the restricted area.

6.2.4. The following requirements should be met while operating the

halide leak detectors:
 • red-hot surfaces and open fire are prohibited in the area;

• the testing should be done at a distance of not less than 5 m

from the welding operations areas.

6.2.5. The combined extract an input ventilation should be on while

operating the ultraviolet radiation sources.

One should wear protective glasses while viewing an item in the

ultraviolet light.

6.3. Safety Requirements for Handling of Pressure Cylinders (One

should be guided by the Rules for Layout and Safe Operation of
Pressure Vessels).

6.4. Safety Requirements for Handling of Dew ar Flasks and Liquid

Nitrogen While Filling Cooled Traps.

6.4.1. The Dewar flasks should be painted in black and have an

inscription “Nitrogen” or in gray enamel and marked with black paint.
The use of liquefied gas from differently painted flasks is prohibited.

6.4.2. It is prohibited to throw, drop or shake the Dewar flasks.

6.4.3. The nitrogen flasks should be carried by two persons, each

holding one of the flask’s handles.

6.4.4. The flasks with liquefied nitrogen should be placed not less
than 1 meter apart from district heating heaters or other heat sources.

6.4.5. Nitrogen should be poured into the cooled traps through a

metal funnel with high walls and of not less than 120 mm of diameter.
It should be poured directly from the flask or sequentially from the
flask into a metal thin-walled cup with a long handle and then from the
cup into the trap through the funnel. The cup diameter should not be
less than 80 mm, the handle length being not less than 400 mm.

The tooling for pouring nitrogen (cup, funnel) should be degreased

before use.

6.4.6. W orkers who do not pour nitrogen into the traps should be kept
out from the pouring area.

6.4.7. It is strictly forbidden to smoke and light matches to the

workers who pour nitrogen.

6.5. Safety Requirements for Operation of Mechanical and Steam-

Jet Vacuum Injectors

6.5.1. All rotating parts of injectors (flywheels) should be protected

by casings. The injectors should be soundly anchored to the
foundation.
6.5.2. The mechanical vacuum pumps should be powered by three-
phase alternating current of 220/380 V; the pump should be earthed.

6.5.3. The following is necessary to operate mechanical pumps:

• to install a mechanical pump in locations remote from pathways

in accordance with the floor plan agreed upon with the
Industrial Safety Units;

• the rotating part of the pump should be installed so that it will

be accessible on the opposite side;

• the pump location should not be blocked by strange items;

• the large-size volumes should be depressurized below the

ambient pressure while the valve is partly opened to prevent oil
ejection from the pumps;

• after the pump stops it has to be supplied with the ambient air;

• it is prohibited to pour oil in the operating pump.

6.5.4. Steam-jet injectors should have heaters and conducting cables

in order. There should not be any flammable items near the heater.

6.5.5. After the complete stop of the steam-jet injector the cooling
system should be switched off.

6.6. Safety Requirements for Applying Hydraulic Methods

6.6.1. W hen the hydraulic, luminescent and hydraulic and hydraulic

with tracer coating methods are used the safety procedures for
hydraulic testing of equipment and piping should be followed as
developed by the enterprise carrying out the tests.

6.6.2. During the tests the controls should be in place over the
meeting of all safety requirements and over condition of the pressure
equipment, hardware and tooling.

6.6.3. The manometers should be calibrated and sealed.

6.6.4. It is forbidden to eliminate defects in the system under

pressure.

6.6.5. The entrance to the room where pressure tests are underway
should be provided with the signs allowing only relevant personnel
only.

6.6.6. During the pressure gaining in the system being tested the
inspectors should be at a safe distance.

6.6.7. The combined extract and input ventilation should be available

during application of tracer coatings, liquid penetrants and absorbing
coatings and during their removal from the surface.

6.6.8. Individuals wearing rubber or linen gloves should conduct all

operations where luminescent liquids are used.
6.6.9. W orkers wearing linen gloves, which have been examined in
the ultraviolet light to find out liquid tracer spots, should apply the
developing agents.

6.6.10. It is prohibited to prepare defectoscopic materials at the test

site.

6.7. Requirements to Work Place and Room for Leak Tests are given in
Attachment 13.

6.8. Responsibility for Compliance w ith Requirements of This

Methodology, Applicable Regulations and Standards

Such responsibility rests with the Administration of the enterprise,

Shop Supervisors and their units, Masters and Operation Supervisors.
Individuals who breached the requirements of safety regulations and
standards are subject to the applicable legislation.

7. QUALIFICATION OF INSPECTORS

The inspectors qualified pursuant the procedure described in PNAE

G-7-010-89 are permitted to carry out leak tests on welded joints,
equipment and pipelines of NPI; the inspectors qualified pursuant the
procedure similar to that described in PNAE G-7-010-89 are permitted
to carry out leak tests on the base metal.

8. DOCUMENTING REQUIREMENTS

8.1. Test results should be recorded in the “Leak Detection Log”. A

recommended format (with mandatory content) is given in Attachment
14.

8.2. The test information is entered in the Log during the test.

8.3. The Log’s pages should be numbered-through; they should be

tight together; and the Log should be signed by the Head of Non-
Destructive Analysis Unit. Corrections should be confirmed by the
signature of the Head of Non-Destructive Analysis Unit.

The Log should be kept not less than 5 years in the archive of the
Non-Destructive Analysis Unit of the enterprise.

8.4. A conclusion statement is drawn upon the leak test results.

The Conclusion Statement should include the name of system (unit),

drawing number, Class of Integrity, method and document relevant to
the test conducted, description of preparatory operations, monitoring
parameters and a conclusion regarding the fitness of the system
(unit). The Conclusion Statement is signed by the Head of Non-
Destructive Analysis Unit and the Performer of the test. A
recommended format is given in Attachment 15.

8.5. The Log and Conclusion Statement may be supplemented by

other information as per the system applied at the enterprise.
 ATTACHMENT 1
(reference)

RATIOS OF DIFFERENT GAS FLOW UNITS OF MEASURE

m3 * Pa l * µm cm3 * at cm3 * at mm3 *

Unit of ______ _______ ______ ______ MPa
measure s s s year ______
s
3
m * Pa
______ 1.0 7.6 * 103 1 3.1 * 108 1.0 * 103
s
l * µm
_______ 1.3 * 10-4 1 1.3 * 10-3 4.0 * 104 1.3 * 10-1
s
cm3 * at
______ 9.8 * 10-2 7.6 * 102 1 3.1 * 107 1.0 * 102
s
cm3 * at
______ 3.2 * 10-9 2.5 * 10-5 3.2 * 10-8 1 3.2 * 10-6
year
3
mm * MPa
______ 1.0 * 10-3 7.6 1.0 * 10-2 3.1 * 105 1
s

Note. The flow 1 m 3 * Pa/s means that in 1 m 3 pressure changes by 1

Pa within 1 second
 ATTACHMENT 2
(reference)

LIST OF MAJOR EQUIPMENT, INSTRUMENTS AND TOOLING

USED FOR LEAK DETECTION

1. Helium mass-spectrometer leak detectors ПТИ-7, ПТИ-7А, ПТИ-10

and others with component parts’ set, which threshold sensitivity
meets the requirements of this Methodology.

2. Halide leak detectors БГТИ-7, ГТИ-6 and others with component

parts’ set, which threshold sensitivity meets the requirements of this
Methodology.

3. Thermocouple ionizing vacuum meters ВИТ-2 or ВИТ-3 with sets of

gage heads ПМТ-2, ПМТ-4М, ЛТ-4М, ПМИ-10-2, ПМИ-2, allowing to
measure pressure within the range 10 2 up 10 - 5 Pa (1 -10 - 7 mm Hg).

4. Thermocouple vacuum meters ВТ-2, ВТ-3 with sets of gage heads

ПМТ-2, ПМТ-4, ПМТ-8 allowing to measure pressure within the range
10 3 up to 10 - 1 Pa (10 - 10 - 3 mm Hg).

5. Vacuum pumps 3НВР-1Д, 3НВР-1ДМ, ВН-461М, АВ3-20Д (ЭВН-

1МГ), АВ3-40, АВЗ-63Д (ВН-7), АВ3-125Д (ВН-6ГМ).

6. Booster pumps НВБМ-0.5, НВБМ-2.5, НВБМ-5 and others.

7. High vacuum pumps Н 100/350 and others.

8. Vacuum manometers and manometers with the measuring limit 1/3

higher the test pressure.

9. Portable luminescence instruments КД-31Л, КД-32Л, КД-ЗЗЛ and

others.

10. Mobile ultraviolet light installation КД-21Л and others.

11. Aerosol cylinder charging device.

12. Liquid sprayers (atomizers) of any type (piston cyclic operation,

sprinkling-type, vacuum cleaner-type, etc.) with spraying of drops not
more than 0.3 mm.

13. Reference leaks "Gelit", "Galot" and others.

To determine sensitivity of the liquid methods, if necessary, it is

recommended to use specimens with artificial or natural leaks
emerging through defects like cracks, holes, losses of fusion, etc.
revealed by leak detector tests.

14. Through, dead-end and special plugs for leaktight sealing of holes
in the subject structures and their units.
15. Vacuum rubber hoses with diameter of 8 up to 50 mm.

16. Clamps for vacuum rubber hoses.

17. Vacuum valves.

18. Reducing pipes with flanges of different diameters.

19. Reducing pipes for connecting rubber hoses of different

diameters.

20. Blow-over jets with rubber chambers and replacement caps.

21. Vacuum chambers to leak tests of annular welded joints of

pipelines and other items using the helium (vacuum) chamber method.

22. Vacuum suction chambers.

23. Sniffer-catchers.

24. Liquefied nitrogen traps.

25. Dewar flasks.

26. Heaters: electric furnace, inductor.

27. x5-7 magnifying glasses.

28. Flat brushes.

 ATTACHMENT 3
(reference)

LIST OF MATERIALS USED FOR LEAK DETECTION

Name of material Regulation

Service purpose helium ТУ 51-689-75

High purity helium ТУ 51-940-80
Vacuum oil ГОСТ 23013-78
Vacuum lubricant ОСТ 380183-75
Service purpose acetone ГОСТ 2768-84
Rectified ethyl alcohol ГОСТ 18300-72
Service purpose gasoline Б-70 ТУ 38-101913-82
Lamp oil ГОСТ 4753-68
Chladone-12 ГОСТ 19212-73
Chladone-22 ГОСТ 8502-73
Fluorescine ТУ 6-09-2464-77
ТУ 6-14-39-79
Fluorescine disodium salt (uranin) ТУ 6-09-2281-77
ТУ 6-14-939-78
Filtering paper of "Ф" brand ГОСТ 12026-76
Noriol А ТУ 88ГССР01-78
Potato starch ГОСТ 17699-72
Starch gum ГОСТ 6034-74
Kaoline ГОСТ 21285-75
Cotton fabric ГОСТ 7138-73
ГОСТ 11680-76
Synthetic washing detergents ОСТ 615-933-75
Polyethylene film ГОСТ 10354-73
Drinking water ГОСТ 2874-82
Distilled water ГОСТ 6709-72
Laundry soap ГОСТ 5.1867-77
Vacuum rubber
flat ТУ 38-105116-81
cord ТУ 38-105108-76
tube ТУ 38-105881-75
 ATTACHMENT 4
(mandatory)

METHODOLOGY AND PROCEDURE OF DETERMINING THRESHOLD

SENSITIVITY OF HELIUM LEAK DETECTORS

Threshold sensitivity is determined either using the built-in leak

“Gelit”, located on the side of the leak detector inlet valve, or by the
“Gelit” leak located as it is shown on the schematic view given in Fig.
П 4.1.

Fig. A4.1. Schematic view of the installation for adjustment of helium

leak detectors

1 - helium leak detector; 2 - inlet; 3 – volume filled with argon;

4 – thermocouple bulb; 5 – vacuum valve; 6 – diffusion reference
leak;
7 – auxiliary vacuum pump

Threshold sensitivity is determined using the built-in leak in

accordance with the leak detector operator’s manual.

To determine threshold sensitivity using the leak arranged for

downstream the leak detector inlet valve, as per the drawing, the
following procedure is applied:

• when the leak is disconnected, the leak detector inlet valve is set
open until the operating pressure is gained in the mass-
spectrometer chamber and then the outlet instrument readings
are recorded for 5 minutes to determine a mean value of the
background signal, as well as the minimum and maximum
background values, after that the leak detector inlet valve is set
close;
-2
• the leak is blocked until pressure becomes 1.3 Pa (10 mm Hg);
it is achieved by the auxiliary pump 7, and then the pumping out
is stopped;
 • the leak detector inlet valve is set open and the reading
regarding the diffusion leak are recorded;

• threshold sensitivity is calculated using the formula:

QT
Qmin = (α Φ max − α Φ min ),
αT − αΦ

where Q min is the leak detector threshold sensitivity measured in m 3 *

Pa/s;
Q T is the helium flow rate through the reference leak measured in m 3 *
Pa/s;
α T is the signal from the leak measured in mV;
α Ô is the mean background signal value measured in mV;
α Φ max , α Φ min are the minimum and maximum values of background
signal measured in mV;

then the valve 5 connecting the leak with the main piping is set close.
 ATTACHMENT 5
(mandatory)

METHODOLOGY AND PROCEDURE FOR DETERMINING OF

THRESHOLD SENSITIVITY OF HELIUM LEAK DETECTION
METHODS

The reference helium leaks are used to determine threshold

sensitivity of the helium leak detection methods. The auxiliary vacuum
-2
pump allowing to gain pressure7-8 Pa [(5-6) * 10 mm Hg] is arranged
for to create vacuum in the leak nozzles.

The following operation sequence is applied for the methods using a

vacuum (helium) chamber and blow-over.

After the test of the item the background value readings and
fluctuations of them should be recorded during 5 minutes, the inlet
valve and auxiliary evacuation valve being in the same positions as
during the test.

To connect the leaking system to the remote section of the item

(when test is done applying the helium chamber or blow-over
methods) or the chamber (when the vacuum chamber method is
used).

To depressurize the leak nozzle by the auxiliary pump down to the

residual pressure equal to that of the chamber or item.

To switch off the auxiliary pump and open the valve connecting the
leak with the item (chamber) cavity.

To record the readings regarding the helium leak during the time
equal to the duration of helium test, the leak detector inlet valve and
the auxiliary evacuation pump valve being in the same position as
during the test.

To determine threshold sensitivity of the test using the formula:

QT
Qmin = (α Φ max − α Φ min ),
αT − αΦ

where Qmin is the test threshold sensitivity measured in m 3 * Pa/s;

QT is the helium flow rate through the reference leak measured in m 3 *
Pa/s;
α T is the signal from the leak mV;
α Φ is the mean background signal measured in mV;
α Φ max , α Φ min are the minimum and maximum background values
measured in mV.

To determine the sensitivity of helium sniffer test one should use

either the leak “Gelit” with a cap and sniffer, which are supplied with
the leak detector ПТИ-10 or any other reference leak producing a
constant helium flow.

N o t e. If it is impossible to arrange for the helium leak at the remote

section of the item, it is permitted not to determine the threshold
sensitivity of the method with regard to items of not more than 10 m
length and volume of not more than 5 m 3 provided the helium leak
detectors are adjusted to the threshold sensitivity of not less than
-11 3 -7
6.7 * 10 m * Pa/s (5 * 10 l * µm Hg).
 ATTACHMENT 6
(reference)

ASSESSMENT OF TOTAL HELIUM FLOW

1. The total flow Ц of testing substance through defects in the item is

assessed during the test by comparison of the leak detector readings
obtained through monitoring with the readings of the reference leak
“Gelit” located in the most remote section of the helium chamber
(item).
3
2. The flow Q measured in m * Pa/s is calculated using the formula:

α − αφ
Q= Q
αT − α φ T ,

where QT is the flow through the reference leak measured in m 3 *

Pa/s;
αT is the leak detector signal from the reference leak measured in
mV;
α is the signal of the leak detector during the test measured in mV;
α φ is the background signal measured in mV.

N o t e s:

1. The assessment of the total helium flow using leak detectors is

possible for through-defects producing signals not more than 30 mV.

2. The reference leak value should of order comparable to the flow

rate under estimation of the testing substance going through defects
in the item.
 ATTACHMENT 7
(reference)

DEPENDENCE OF CHLADONE-12 AND CHLADONE-22

SATURATED VAPOR PRESSURE FROM TEMPERATURE

0
Temperature, C 0 10 20 30 40

Pressure of Chladone- 3.1 4.3 5.8 7.6 9.8

saturated 12
2
vapor, kgf/cm
Chladone- 5.1 7.0 9.3 12.2 15.8
22
 ATTACHMENT 8
(reference)

FOAM TRACER COMPOSITION AND PREPARATION METHOD

1. Compound А:
3
W ater, cm ................................................. .....1000
Toilet or laundry soap 65%, g ...................... .....50

Compound B:
3
W ater, cm ................................................ ......1000
Licorice liquorice extract, g ........15

The soap (licorice liquorice extract) is thoroughly stirred in warm

water until it completely dissolves.

In winter time to prevent the solution from freezing the Compound B is

added with calcium chloride or sodium chloride in the amounts given
in Table П 8.1.

2. Polymeric foam-forming compound (mass %):

Dextrine ..................................................... 5 - 15
рН controlling agent .................................... 0.5 - 1
Surface active substance............................. 0,05 - 1
Glycerin with low-molecular alcohol with ratio 2:1 3 - 30
Other ......................................................... water

3. Polymeric foam-forming compounds (Svalan-1, Svalan-2,

Svalan-3)
(Table П8.2).

Table П8.1

Air temperature, Fr. 0 Fr. -5 Fr. - Fr. - Fr. -20 Fr. -25 Fr. -30
0
C to -5 to -10 10 15 to -25 to -30 to -35
to -15 to -20
Calcium Fr. -
chloride 100 170 220 15 303 329 366
Amount to -20
of,
g Sodium
chloride 83 170 222 290 -- -- --

Table П8.2
 State Composition, application
Standard, temperature range, mass of
Component Specification components, g
grade
Svalan-1, Svalan-2, Svalan-3,
+30...+5 +10..-17 -13...-28
0 0 0
C C C
Gelatin (edible or ГОСТ 11293-78 11 7 5,5
rd
photographic) 3 grade

Potato dextrine ГОСТ 6074-74 200 - -

Highest grade

Solvar – polyvinyl alcohol

with 10% content of ГОСТ 10779-80 - 200 200
acetate groups, 5%
aqueous solution

Glycerin
ГОСТ 6259-75 - 300 300
ЧДА
Ethylene glycol

"Progres" ГОСТ 10164-75 - - 100

Nekal (wetting agent NB) ТУ 38-10719-71 2 - -

Distilled water ГОСТ 6867-77 - 2.5 2.5

- 787 490,5 392

 ATTACHMENT 9
(reference)

PREPARATION OF 1 LITER OF AQUEOUS SOLUTION OF

FLUORESCINE AMMONIA SALT WITH 0.1% CONCENTRATION

The aquaeous solution of fluorescine ammonia salt is prepared in two

stages.

1. The obtaining of the fluorescine ammonia salt by mixing

fluorescine with ammonia solution as per the reaction:

С 2 0 Н 1 2 О 5 + 2NН 4 0Н 
→ С 2 0 Н 1 0 О 5 (NН 4 ) 2 + 2Н 2 О

To obtain 1 g of fluorescine ammonia salt it is required to have:

fluorescine (С 2 0 Н 1 2 О 5 ) – 0.9 ± 0.01 г;

25% ammonia solution (NН 4 0Н) – 0.9 ± 0.01 мл.

It is recommended to pound the fluorescine powder and mix it with

ammonia with a small addition of water to obtain a homogeneous
mass without lumps. The obtained solution should be filtered through
a mesh or gauze to remove the undissolved sediment.

2. The obtained fluorescine ammonia salt without the undissolved

sediment is dissolved in 1 liter of high purity water – distilled or tub –
being stirred under normal conditions.

3. To prepare a large quantity of fluorescine ammonia salt the amount

of fluorescine and 25% ammonia solution is proportionally increased.

4. The aqueous fluorescine ammonia solution is recommended to

store in glass or metal vessels.
 ATTACHMENT 10
(recommended)

LUMINESCENT SOLUTION BLEACHING USING LIQUID PHASE OF

BLEACHING SUSPENSION AND ITS PREPARATION

1. To bleach completely 100 g of fluorescine ammonia or disodium

salt with initial concentration of 0.09-0.1% it is necessary to use 6
liters of liquid phase of bleaching suspension with composition: 1 part
of bleaching powder and 4 parts of water.

In the settled suspension the liquid phase is 60% of the volume, the
rest of the volume is the sediment of undissolved bleaching powder.

To obtain 6 liters of the liquid phase necessary to completely bleach

100 grams of luminophor it is required to prepare 10 liters of
bleaching suspension.

2. To prepare the bleaching suspension the bleaching powder ГОСТ

1692-58 of A and B grades is used.

3. The amount of suspension to bleach the known volume of

fluorescine salt solution is determined in accordance with para. 1
herein giving the required amount of bleaching suspension and the
corresponding amount of components (bleaching powder and water).

4. Lump of bleaching powder are pound into powder. A necessary

amount of powder is measured and put into a vessel for preparing of
the suspension.

5. The vessel is filled with water in the amount corresponding to that

of the powder: 4:1.

6. The components are stirred and the suspension is settled not less
than 24 hours.

The water and suspension temperature during the preparation time

0
should be within the range of 15 - 20 С.

7. The following sequence should be observed to bleach the

luminescent solution:

• all solution from the item should be drained into the vessel for
bleaching;
• 6 liters of the settled bleaching suspension and 360 ± 10 g of
sodium sulfate should be added to each 100 liters of bleached
luminescent solution;
• to stir components and hold-up during 2 hours (during the hold-up
the component should be stirred each 25 – 30 minutes).

After the complete bleaching the obtained bleached solution should

be drained into sewage.

8. The completely bleached luminescent solution means a visually

colorless liquid of 200 mm column and absence of glowing in the
ultraviolet light.
 ATTACHMENT 11
(reference)

TRACER COATING (MASS AND TAPE) COMPOSITION AND

PREPARATION

1. COMPOSITION OF TRACER COATING BASED ON

FLUORESCINE DISODIUMС SALT AS PER ТУ 6-09-2281-72

1.1. The tracer mass contains:

Starch ............................................................ 290-300 g

Dextrine .......................................................... 45 - 50 g
Fluorescine disodium salt (uranin) 2.9 - 3 g
Ethyl alcohol ................................................... 1000 ± 10 cm 3

1.2. The tracer tape:

A white fabric like madapolame, unbleached calico, gauze or filtering

paper is soaked with 0.29 – 0.3 mass % of alcohol solution of
fluorescine disodium salt.

2. PREPARATION OF TRACER COMPOUND OF FLUORESCINE

DISODIUM SALT AS PER ТУ 6-09-2281-72

2.1. The tracer mass should be prepared by the dissolving of finely

pound the fluorescine disodium salt powder in ethyl alcohol in the
amount corresponding to numbers given in para. 1.1. Starch and
dextrine should be dried to dehydrate at temperature of 100-120 0 С
until the become loose (the layer thickness is 1 ± 0.1 cm; drying time
is 55-60 min), and in the corresponding amounts given in para. 1.1
add to the alcohol solution of the fluorescine disodium salt. The
prepared suspension should be thoroughly stirred.

2.2. The tracer tape should be prepared by soaking the preliminary

dried fabric or filtering paper with the alcohol solution of the
fluorescine disodium salt in the corresponding amount as given in
para. 1.2. The soaked fabric or paper should be dried by fan or in An
oven.

The quality of tracer tape is assessed by absence of glowing spots or

dots on the fabric or paper in the ultraviolet light.

3. COMPOSITION OF FLUORESCINE DISODIUM SALT-BASED

TRACER COATING AS PER ТУ 6-14-939-78

3.1. The tracer mass contains:

Starch ............................................................ 290-300 g

Dextrine .......................................................... 45 - 50 g
Fluorescine disodium salt ................................. 4.5 – 5.0 g
Ethyl alcohol ................................................... 1000 ± 10 cm
3
3.2. Tracer tape:

A white fabric like madapolame, unbleached calico, gauze or filtering

paper is soaked with the alcohol solution [0.45 - 0.5 mass %] of
fluorescine disodium salt.

4. PREPARATION OF FLUORESCINE DISODIUM SALT-BASED

TRACER COMPOUND AS PER ТУ 6-14-939-78

4.1. Fluorescine disodium salt should be preliminary dried at

temperature 120-130 0 С. W hen the layer thickness is 1 ± 0.1cm, the
drying time is 55-60 minutes.

4.2. The alcohol solution of fluorescine disodium salt, in the amount

indicated in paras. 3.1 and 3.2 should be filtered using the filtering
paper to remove the admixtures.

4.3. The tracer mixture and tracer tape preparation methodology are
similar to those described in paras. 2.1 and 2.2 of this Attachment.
 ATTACHMENT 12
(mandatory)

LIQUID PENETRANT AND ABSORBING COATING COMPOSITION

AND PREPARATION

1. The following compound is used as the liquid luminescent

penetrant:

Noriol А ................................................. 150-160 cm 3

3
Kerosene ............................................... 840 - 850 cm

Noriol is thoroughly stirred in kerosene until it completely dissolves.

2. The aqueous alcohol suspension of kaolin with kaolin concentration

of 350 – 500 g per 1 liter of the solution of the amounts of water and
ethyl alcohol being equal should be used as absorbing coating.

N o t e s:

1. At ambient air temperature of 0 up to +10 0 С the alcohol suspension

of kaolin with concentration of 350 – 360 g of kaolin per 1 liter of
ethyl alcohol should be used as the absorbing coating.

2. W hile preparing the absorbing coating the kaolin powder is

thoroughly mixed up with a small amount of an alchohol solution or
alcohol until the homogeneous mass is obtained, which does not
contain solid lumps, then the required amount of alcohol solution or
alcohol is added to obtain the necessary concentration.
 ATTACHMENT 13
(mandatory)

REQUIREMENT TO LEAK DETECTION ROOM

1. The working space should correspond to the standards ensuring

safe conduct of operations.

2. The working bay should be suitable for wet cleaning and

dessication from helium, chladone and other gases.

3. The bay should be equipped with the combined extract and input
veltilation, has tub water supply, supply of air or nitrogen cleaned
from oil and contaminants (by cylinders or fron air mains).

4. In the bay draughts should be eliminated during tests using blow-

over or sniffer techniques.

5. The exhaust piping of forepumps should be outside the working

bay.

6. The component parts of instruments, devices and tooling should be

stored in lockers or on racks.

7. All testing operations should be carried out by workers wearing

working overalls (laboratory coats or donkey jackets), and those using
liquid methods – with the rubber gloves on.

8. A fire tool board should be available at the test bay.

9. The bay illumination should correspond with the applicable

illumination standards for industrial shops.

10. It is permitted to conduct testing at the bays for manufacturing

and assembling provided the requirements of paras. 4, 6, 7 of this
Attachment and the conditions required for normal operation of
hardware and preparation and testing using the selected method are
met.
 ATTACHMENT 14
(recommended)

Test results entry format

MINISTRY FOR POWER ENGINEERING AND

ELECTRICITY SUPPLY OF THE USSR

Main Department

Unit

Plant, Power Plant, Assembling Organization

L O G
For recording of Leak Test Results on
W elded Joints

System

(name, legend, drawing number)

Subordinate to

Test regulations: ROI, OST, etc.

(title)

Test subject

W ork Supervisor

Started

Ended

Samples of signatures of individuals conducting the tests:

Name and Surname Grade Signature sample

 ATTACHMENT
15

TEST RESULTS CONCLUSION STATEMENT FORMAT

Conclusion on
Structures and their elements

Number of welded joints, pcs

the test results

Process code (flow diagram)

Statement and date of issue

Welded joint number as per

Instrument, serial number

conducted the inspection

Reg. No of Conclusion
Signature of inspector
Pressure in inspected
Welded joint category

After second refining

drawing (specification)

Inspection method
Inspection scope
Date of inspection

Drawing number

After fist refining

(running meter)

After first test

structure, Pa
(technique)

Sensitivity
Size, mm

Note
Date of test
Name of structures and their elements
Drawing number
Category of welded joint
Process flow-chart number
W elded joint number as per the drawing
Scope of test
Test method
Dimension-type, mm
Number of welded joints, (running meter)
Type of instrument (serial number)
Sensitivity
Pressure in subject structure, Pa
Conclusion statement upon test results:
at initial test
after initial correction
after secondary correction
Signature of inspector who did the test
Sequential number of Conclusion Statement and date of issue
Note
 Table 1
Leak Detection Techniques

Groups Name of Testing Record Defect Test

of method substance ing sign method Scope Name
method means
s
G a s e o u Ma s s - Helium Helium Arrow Helium or For items or welds where it is Determining
s spectrom leak instrument vacuum possible to gain vacuum (or excess whether an item
eter detecto readings, chamber pressure of helium) and which may or weld is
rs sound be placed in helium (or vacuum
signal chamber). For welds accessible for
installation of local chambers.
Prresurizat For closing weld of items, which Determining
ion of may be placed in helium pressure whether a weld
closed chamber is leaktight
shells
Thermal For items where it is possible to Determining
vacuum gain vacuum not higher than 0.1 whether an item
Pa (10-3 mm Hg) and which may be is
placed in vacuum chamber to be
0
heated up to 380-400 C
G a s e o u Ma s s - Helium Helium Arrow Helium F o r w e l d s o f p i p e s ys t e m s a n d Determining of
s spectrom leak instrument sniffer o t h e r t yp e s o f i t e m s w h e r e i t i s defect location
eter detecto readings, possible to gain helium excess
rs sound pressure
signal Helium For items where it is possible to The same
blow-over gain the required vacuum
Halide Chladone Halide The same Halide F o r w e l d s o f p i p e s ys t e m s a n d The same
leak sniffer o t h e r t yp e s o f i t e m s w h e r e i t i s
detecto possible to gain testing substance
rs excess pressure

Bubble Air, Soap Forming of For items where it is possible to Determining of

nitrogen, foam, bubbles gain excess pressure and cover defect location
argon, etc. p o l ym e r subject sections with foam-forming
ic compound
compou
nd
Gaseou Air, water, Forming of Pneumatic For items, which may be filled with Determining of
s nitrogen, alcohol bubbles and gas under excess pressure and defect location
argon, etc. h yd r a u l i c submerge in a water bath
aquarium-
t yp e
Air Soap Vacuum For open structures with one side
foam, access to subject surface
p o l ym e r
ic " "
compou
nd
Liquid Compres W ater W ater Drops, H yd r a u l i c F o r i t e m s o f a l l t yp e s w h e r e i t i s D e t e r m i n i n g o f
sion flows, possible to gain excess water defect location
streams pressure and subject sections are
accessible for examination Ma y b e
combined with
strength and
integrity tests
Liquid Compres Aqueous Source Glowing of F o r i t e m s w h e r e i t i s p o s s i b l e t o Ma y b e
sion and solution of of testing gain excess liquid pressure, and combined with
luminesc fluorescine ultra- substance non-washable areas and subject strength and
ence ammonia violet in the sections are accessible for visual integrity tests.
or light, ultraviolet examination in the ultraviolet light Determining of
disodium fabric light or application of fabric exact defect
salt location
 Table 1
(continued)

Groups Name of Testing Record Defect Test

of method substance ing sign method Scope Name
method means
s
Tracer Glowing of Hydraulic For items where it is possible to Ma y b e
Liquid The W ater mass tracer with gain excess liquid pressure, and combined with
same or tape, coating in l u mi n e s c e n t non-washable areas and subject strength and
ultravio the tracer sections are accessible for integrity tests.
let light ultraviolet coating a p p l yi n g o f t r a c e r c o a t i n g a n d Determining of
source light visual examination in the exact defect
ultraviolet light location
H yd r o s t a t Gravity Determining of
ic W ater ____ ____ water _____ defect location
filling

Capillary Luminopho Absorbi Glowing of W ith the F o r i t e m s , wh i c h s u r f a c e i s D e t e r m i n i n g o f

r organic ng tracer use of accessible on outer and inner exact defect
solutions substan coating in luminescen sides location
ce, the t liquid
source ultraviolet penetrants
of light
ultra-
violet
light
Liquid Chalk Kerosene W etting For items, which surface is
Kerosene coating spots on with accessible on outer and inner sides The same
chalk kerosene
coating
G a s e o u Ma n o m e t - - - At For closed structures where it is Determining of
s ric pressure possible to gain pressure higher total leak
drop than the atmospheric one

N o t e s: 1. Gases used for the bubble method should be cleaned of

oil and contaminants and should not provoke corrosion and change
mechanical properties of metal.
2. The halide method is not applicable for leaktightness
testing of oxygen systems.
 Table 2
Classification of Leak Detection Systems

T h r e s h o l d s e n s i t i vi t y o f
Class of leaktightness test Test method Requirements to item regarding the preparation and
integrity s ys t e m s leaktightness test

m
3
* Pa/s l*µm Hg/s I t e m d r yi n g b y h e a t i n g , 0 C Absolute pressure of
testing substance, P

2
In the air During Pa kgf/cm
vacuumization

I Fr. 6.7*10-11 Fr. 5 10

-7
Thermal vacuum -- 380-400 Р >2*10 4

to 6.7*10-10 to 5* 10 -6
5
Helium or vacuum 250-300 -- Р>1*10 Р>1
chamber
6
Helium sniffer Р>5*10 Р>50

II Over Over Helium or vacuum 1*105>Р>0.2*105 1>Р>0.2

6.7*10-10 5*10-6 chamber
-9 -5
to 6.7* 10 to 5* 10
5*106>Р>6*10
5
Helium sniffer 250-300 250-300 50>Р>6

Helium blow-over -- --

7
Luminescent and Not required Р>2*10 Р>200
h yd r a u l i c

III Over Over Helium or vacuum 100-120 (hold-

-9 -5 5
6.7*10 5*10 chamber up duration at Р>0,2*10 Р>0,2
to 6.7* 10 -7 to 5* 10 -3
vacuum
5
Helium sniffer 7-8 Pa is Р>2*10 Р>2
150-200 not less than
Helium blow-over 1 hour) -- --

6
Pneumatic air inlet Р>2*10 Р>20

Helium pressurizing
6
of closed shells Not required Р>1*10 Р>10

Luminescent and
h yd r a u l i c ,, 2*107 >Р>2,5*106 200>Р>25

H yd r a u l i c w i t h
,, 6
luminescent tracer Р>3*10 Р>30
coating

W ith use of
luminescent liquid ,,
penetrants
 Table 2 (continued)

Class of T h r e s h o l d s e n s i t i vi t y o f
integrity leaktightness test Test method Requirements to item regarding the preparation and
s ys t e m s leaktightness test

m3 * Pa/s l*µm Hg/s I t e m d r yi n g b y h e a t i n g , 0 C Absolute pressure of

testing substance, P

2
In the air During Pa kgf/cm
vacuumization
5
IV Over Over Helium or vacuum 10-30 (hold-up Р>0.2*10 Р>0.2
6.7*10-7 5*10-3 chamber time at vacuum
-6
to 6,7* 10 to 5* 10 -2
5
Helium sniffer 80-100 7-8 Pa is Р>1.5*10 Р>1.5
not less than
2 hours)
Helium blow-over -- --

5
Helium sniffer Р>5*10 Р>5

2*10 >Р ≥ 2*10

6 5
Pneumatic air inlet 20 >Р>2

5
Pneumatic Р>6*10 Р>6
aquarium

Bubble vacuum -- --

H yd r a u l i c Not required P>2 * 106 P>20

Luminescent and 2.5*106>Р>6*105 25>Р>6

h yd r a u l i c ,,

H yd r a u l i c w i t h
luminescent tracer ,, 3*106 >Р ≥ 6*105 30>Р>6
coating

W ith the use of

luminescence ,, -- --
liquid penetrants
5
Helium or vacuum Р>0.2*10 Р>0.2
chamber ,,
5
Helium sniffer ,, Р>1.2*10 Р>1.2

Helium blow-over ,, -- --

5
Helium sniffer ,, Р>2*10 Р>2

5
Pneumatic air inlet ,, Р>1.2*10 Р>1.2

5
Pneumatic ,, Р>1.5*10 Р>1.5
aquarium
6 5
H yd r a u l i c ,, 2*10 >P>2 *10 20>P2
 Table 2 (continued)

Class
of
integr T h r e s h o l d s e n s i t i vi t y o f Test method Requirements to item regarding the preparation
ity leaktightness test and leaktightness test
s ys t e m s

m3 * Pa/s l*µm Hg/s I t e m d r yi n g b y h e a t i n g , 0 C Absolute pressure of

testing substance, P

2
In the air During Pa kgf/cm
vacuumization

V Over Over H yd r a u l i c w i t h
6.7*10-6 5*10
-2
luminescent tracer Not required 6*105>Р≥2*105 6>Р≥2
-4
to 6.7*10 to 5 coating

Luminescent and
h yd r a u l i c ,, 6*105 >Р≥2*105 6>Р≥2

W ith the use of

luminescence ,, -- --
liquid penetrants

W etting with ,, -- --
kerosene

Gravity water ,, -- --
fillingа

Notes:

1. It is permitted to carry out the leak test of welds in accordance to

the given Class of Integrity without drying with heating if a contact
with water or organic liquids was excluded after welding (no hydraulic
tests or liquid penetrant, ultrasonic, magnetic particles testing done)
and the items were stored in accordance with para. 4.1.11.

2. It is permitted to prepare item by local heating of the subject item

sections up to the temperatures corresponding to the Class of
Integrity, and in doing so:
• if the item was subjected to hydraulic test, the local heating
is done concurrently with vacuumization of inner cavity of the
item down to pressure 7 - 8 Pa [(5 - 6) * 10 - 2 mm Hg];
• if the item was not subjected to hydraulic test but was in
contact with liquids due to liquid penetrant, ultrasonic or
magnetic particles testing, the local heating is done without
vacuumization.

3. It is permitted to test the integrity of items at higher temperature.

The test temperature is established by the design organization.

4. The time period when the item surface is in contact with a

luminescent liquid penetrant during the leaktightness test as per III,
IV and V Classes is given in Table 3.

5. W hen the hydraulic strength tests and leaktightness test by

hydraulic method are to be conducted, these test should be carried
out simultaneously.
6. Leak tightness test using luminescent and hydraulic and hydraulic
with luminescent tracer coating methods is carried out simultaneously
with hydraulic testing at pressure indicated in Table 2 and hold-up
time specified in paras. 5.3.7 and 5.4.9.

The testing medium pressure should not exceed the standards

established by the “Rules for Layout and Safe Operation of Equipment
and Piping of NPI”. The testing should be done at the item and testing
medium temperature, which exceeds the critical temperature of
material brittleness not less than 30 0 С (taking account of welded
joints) from which the subject item is made.

7. The threshold sensitivity of manometer test system method

depends on the volume of the subject item, testing gas pressurization
time, and calculated pursuant para. 4.5.4
 Table 3

Hold-up Time and Leaktightness Requirements to Item

Class of Leak flow rate Hold-up time in contact w ith luminescent solution
integrity at the subject item thickness of not less than, mm
3
M * Pa l * µm Hg
s s
0.5 1 5 10 20 40
-9 -5
III 6.7 * 10 5 * 10 11 21 min 1hr45 3.5 hr 7 14 hr
min min hr
-7 -3
IV 6.7 * 10 5 * 10 9 min 18 min 1 hr 3.0 hr 6 12 hr
hr
-6 -2
V 6.7 * 10 5 * 10 2 min 3 min 15 min 30 1 2 hr
min hr