Tube Leak Detection Services

Finding a leaking tube in condenser and heat exchanger tubes can be time-consuming and difficult. There is a risk of damage to the plant, and this can lead to expensive unplanned shutdowns.

Fairtex Group offers both on-line and off-line tube leak detection services that are relatively inexpensive and can quickly identify leaks, saving you money in downtime and costly repairs.

ON-LINE CONDENSER TUBE LEAK DETECTION:

A leaking tube in the condenser is a major concern, as it allows dirty river or seawater to contaminate the clean boiler water/steam. Left unchecked for too long, it can cause significant damage to the LP turbine and ultimately force a shutdown. Having the unit off-line and not generating is a serious, costly event, and the focus is now on finding that leaking tube as fast as possible.

We have developed a technique to locate these leaks quickly without the need to take the entire unit off-line. If there is more than one pass in the condenser, we can enter one pass to perform an on-line foam leak search.

USING FOAM TO SEARCH FOR ON-LINE LEAKS IS A RELATIVELY SIMPLE BUT EFFECTIVE METHOD TO QUICKLY FIND CONDENSER TUBE LEAKS.

By using a specially formulated foaming agent and foam-generating system, the tube plates are completely covered with foam, and the other ends of the tubes are plugged using rubber bungs. Any tubes where the foam is sucked in signify a leak. These leaking tubes are then verified using various instrumentation and can be plugged.

OFF-LINE LEAK DETECTION:

We have two main methods of finding leaking tubes that are off-line and not under vacuum. We can either positively pressurize the tube, or alternatively, we can create a vacuum in the tube with a vacuum detector gun using compressed air. For either method, two detector guns are used—one inserted into each end of the tube—and the rubber nozzles on the guns create the seal. Once pressurized, the gauge on the gun will indicate whether the tube is leak-free by showing a holding pressure/vacuum. If the needle falls on the gauge, this indicates a possible leaking tube.

Both of these methods require an operator at each tube to be tested.