Course Title

1. Introduction to Leak Detection Using NDT

• The role of leak detection in asset integrity management including (early leak identification before failure, regulatory compliance under API 570, and integration with Risk-Based Inspection (RBI) programs)

• Leak detection regulatory and standards framework including (ASME Section V Article 10, ASTM E432, API 570, and ISO 9712 personnel qualification requirements)

• Types of leaks encountered in industrial environments including (through-wall leaks, weeping leaks at joints and flanges, pinhole leaks from corrosion, and fugitive emissions from valve stems and pump seals)

• Overview of NDT leak detection methods covered including (ultrasonic testing — UT, acoustic emission — AE, bubble emission, thermal imaging — infrared thermography, tracer gas, and pressure decay)

• NDT method selection framework per ASTM E432 including (system type, fluid medium, leak rate sensitivity requirement, access constraints, and operational status — in-service versus out-of-service)

2. Ultrasonic Leak Detection

• Operating principles of ultrasonic leak detection per ASTM E1002: Standard Practice for Leaks Using Ultrasonics including (detection of high-frequency ultrasonic sound generated by turbulent fluid flow through a leak orifice)

• Ultrasonic leak detection equipment including (contact ultrasonic probes for solid-borne transmission, airborne ultrasonic detectors for gaseous leak detection, and directional parabolic dish attachments for locating remote leaks)

• Application scope for ultrasonic leak detection including (pressurized gas systems, compressed air lines, steam traps, valve seat leakage, and flange joint leaks in operating systems)

• Ultrasonic leak detection procedure including (baseline signal establishment, systematic scan technique, signal interpretation — distinguishing leak signal from background noise — and leak location marking)

• Limitations of ultrasonic leak detection including (background noise interference in high-vibration environments, minimum leak rate sensitivity, and inability to quantify leak rate from signal strength alone)

• Documentation requirements including (scan record, leak location sketch, signal strength reading, and recommended action classification)

3. Acoustic Emission Leak Detection

• Operating principles of acoustic emission leak detection per ASTM E1211: Standard Practice for Leak Detection and Location Using Surface-Mounted Acoustic Emission Sensors including (detection of stress wave energy emitted by turbulent flow at a leak site propagating through the pipe wall)

• Acoustic emission sensor installation including (surface-mounted sensor positioning, coupling medium application, sensor spacing for leak location triangulation, and signal acquisition system connection)

• Application scope for acoustic emission including (buried pipelines, insulated piping, aboveground storage tank floors, and in-service pressurized systems where access is restricted)

• Leak location by triangulation including (using time-of-arrival difference between sensor pairs to calculate leak position along the pipeline or vessel wall)

• Signal interpretation including (distinguishing genuine leak acoustic emission from mechanical noise, flow turbulence, and valve operation signals — and qualification of suspected indications)

• Advantages of acoustic emission for leak detection including (remote location capability, ability to monitor large structures from a small number of sensor positions, and suitability for continuous monitoring programs)

4. Bubble Emission, Thermal Imaging, and Tracer Gas Methods

• Bubble emission leak testing per ASTM E515: Standard Test Method for Leaks Using Bubble Emission Techniques including (application of soap solution or proprietary bubble fluid to pressurized joints and welds, and visual detection of bubble formation at leak sites)

• Bubble emission applications and limitations including (weld and flange joint leak verification after pressure testing, minimum detectable leak rate, temperature limitations of bubble fluid, and surface contamination effects on detection sensitivity)

• Thermal imaging — infrared thermography — for leak detection including (detection of temperature anomalies caused by fluid escape, evaporative cooling at leak sites, and insulation moisture ingress from leaking pipelines)

• Thermal imaging equipment and scan technique including (infrared camera selection, emissivity setting, scan distance and angle, and environmental condition requirements for reliable thermal contrast)

• Tracer gas leak detection methods including (helium mass spectrometry for high-sensitivity applications, SF6 tracer gas for large-volume systems, and halogen detector methods per ASTM E427 — and their respective sensitivity levels and application scope)

• Pressure decay leak testing including (monitoring system pressure over a defined period for drop indication, minimum detectable leak rate, and temperature compensation requirements for accurate pressure decay interpretation)

5. NDT Leak Detection Method Selection and Application

• Applying ASTM E432 method selection criteria to real scenarios including (matching method to fluid type — gas, liquid, or two-phase — system pressure, required sensitivity, access constraints, and in-service versus shutdown status)

• Complementary method use including (combining ultrasonic screening with bubble emission confirmation, and thermal imaging with acoustic emission for buried pipeline programs)

• Applying RBI principles to leak detection program design including (prioritizing inspection effort on high-consequence circuits, setting inspection frequency based on corrosion rate and consequence of failure, and integrating leak detection findings into the RBI database)

• Personnel qualification requirements under ISO 9712 including (Level I, II, and III qualification for applicable NDT methods, qualification scope limitations, and certification currency requirements)

• Equipment calibration and verification including (reference leak calibration for ultrasonic and tracer gas equipment, calibration record requirements, and out-of-calibration equipment withdrawal procedure)

6. HSE, Quality, and Findings Management

• Applying HIRARC to NDT leak detection operations including (hazards from detected gas leaks, confined space entry during sensor installation, chemical exposure from tracer gases, and working at height during pipe scan activities)

• HSE management during leak detection operations in accordance with ISO 45001 including (permit-to-work requirements, PPE selection for toxic or flammable fluid leak environments, and emergency response if a live leak is detected during inspection)

• Quality management in leak detection programs in accordance with ISO 9001 including (written inspection procedures, calibration records, inspection report format, and non-conformance management for identified leaks)

• Leak finding classification and reporting including (leak severity classification — immediate repair, monitor, or deferred action — notification to asset owner, and integration with the maintenance work order system)

• Leak detection records and traceability including (inspection record content, equipment history file update, regulatory authority notification obligations for significant leaks, and lessons learned integration)

7. Case Studies and Group Discussions

• Case studies from NDT leak detection programs in Middle East oil and gas, petrochemical, and utilities environments including (buried pipeline leaks located by acoustic emission before ground subsidence occurred, fugitive emissions programs using ultrasonic detection that identified significant product loss, and thermal imaging surveys that detected insulation failure and associated corrosion-under-insulation leak paths) and the importance of proper NDT leak detection training in protecting plant integrity and environmental compliance

• Group discussion on leak detection program challenges in regional industrial environments including (managing leak detection in extreme heat conditions — thermal imaging contrast reduction, selecting appropriate methods for dense multi-line piping corridors, and integrating leak detection findings into turnaround scope planning)

• Method selection exercise including (teams receive three presented leak detection scenarios and apply ASTM E432 criteria to select, justify, and compare methods — with findings presented for peer and facilitator review)