Heat Exchanger Tube Leak Testing Services

A leaking exchanger tube contaminates one side of the process with the other, and the difficulty is rarely detecting that a leak exists — it is identifying which tube, out of hundreds, is responsible. ITMAD applies the method best suited to the exchanger, the fluids and the time available, and pinpoints individual tubes so repair or plugging is targeted rather than speculative.

Methods

• Helium mass spectrometryThe most sensitive option, detecting leak rates far below what pressure testing can resolve. Used where the consequence of a small leak is severe or where a leak has not been found by other means.
• Tracer gas detectionHydrogen or nitrogen mixtures introduced to one side and detected on the other. Fast across a full bundle, and effective for locating the leaking tube rather than only confirming that one exists.
• Acoustic and ultrasonic detectionDetects the signature of gas escaping through a defect. Applicable with the exchanger under pressure and without flooding, so no drying is required before return to service.
• Pressure and vacuum decayMeasures loss over a controlled hold period to confirm overall integrity. Used to establish whether a leak is present before committing to tube-by-tube location.

Why these rather than hydrotest

• Sensitivity well beyond hydrostatic testing, detecting leaks that only appear in service
• Dry techniques available, so water-sensitive processes need no drying before restart
• No chemical contamination of the process side
• Finds leaks that partially reseal when the exchanger cools and the metal contracts — a common reason a leak disappears during offline testing
• Minimal preparation, often no more than opening inspection hatches
• Faster turnaround, so the exchanger returns to line sooner

Method selection

Choice depends on the fluids, the sensitivity your process demands, whether the unit can be flooded, and how quickly it must return to service. Where the tube population needs condition assessment rather than leak detection alone, eddy current testing examines wall loss, pitting and cracking before failure occurs — leak testing finds tubes that have already failed. We will advise which answers your question.

Applications

• Shell and tube exchangers in process and refinery service
• Surface condensers and steam plant
• Air-to-air and air-to-water heating and cooling systems
• Coolers, chillers and HVAC plant
• Post-repair verification after tube plugging or replacement
• Investigation of process contamination of unknown origin

Accreditation and approvals

ITMAD is accredited to ISO/IEC 17020 as an inspection body, is an ADNOC approved inspection contractor, and is listed on the Abu Dhabi City Municipality register of Approved Third Party Inspection Bodies. Certificates are issued in the format required by the governing authority, including Dubai Municipality and the Dubai free zone authorities, and inspection is carried out across Dubai, Abu Dhabi, Sharjah and the northern Emirates. Testing is carried out on site during shutdowns and turnarounds.

What you receive

• A report identifying the exchanger, method applied and test parameters
• Leaking tubes identified by row and column position on the tubesheet
• Leak rate where the method provides a quantitative result
• Tubesheet map marking affected tubes for the repair team
• Pass or fail against your acceptance criteria