vi ABSTRACT This thesis deals with the design and fabrication of leak test rig. This thesis will discuss about leakage problems in industrial pipelines. The objective of this thesis is to design and fabricate a leak test rig. The thesis describes the approaches of designing and fabricating a leak test rig. There are numerous steps taken to design and fabricate the test rig. The structural three-dimensional solid modelling design of test rig was developed by using the Solidwork engineering drawing software. The fabrication process also undergoes many steps such as material marking, cutting, drilling, welding and grinding. In addition, it also explains the procedure of testing by the simulation of three types of common leakages which includes pinhole, pipe crack/dent and gasket leak. The testing the rig is also explained in this thesis by maintaining a pressure of 4 bars in the test rig to prove whether the test rig is functioning efficiently. Finally, the conclusion about this project is that the project objectives were achieved which was design and fabrication of a leak test rig and the recommendations for the improvement of the rig are also included together with this thesis as for instance to design and fabricate a support the leak test rig to statically hold it in place.
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vi
ABSTRACT
This thesis deals with the design and fabrication of leak test rig. This thesis will
discuss about leakage problems in industrial pipelines. The objective of this thesis is
to design and fabricate a leak test rig. The thesis describes the approaches of
designing and fabricating a leak test rig. There are numerous steps taken to design
and fabricate the test rig. The structural three-dimensional solid modelling design of
test rig was developed by using the Solidwork engineering drawing software. The
fabrication process also undergoes many steps such as material marking, cutting,
drilling, welding and grinding. In addition, it also explains the procedure of testing
by the simulation of three types of common leakages which includes pinhole, pipe
crack/dent and gasket leak. The testing the rig is also explained in this thesis by
maintaining a pressure of 4 bars in the test rig to prove whether the test rig is
functioning efficiently. Finally, the conclusion about this project is that the project
objectives were achieved which was design and fabrication of a leak test rig and the
recommendations for the improvement of the rig are also included together with this
thesis as for instance to design and fabricate a support the leak test rig to statically
hold it in place.
vii
ABSTRAK
Tesis ini berkaitan dengan reka bentuk dan fabrikasi alat penguji kebocoran. Tesis ini
akan membincangkan tentang masalah kebocoran dalam paip perindustrian. Objektif
tesis ini ialah untuk merekabentuk dan menghasilkan alat penguji kebocoran. Tesis
menerangkan pendekatan reka bentuk dan fabrikasi pelantar ujian kebocoran.
Terdapat beberapa langkah yang diambil untuk mereka bentuk dan menghasilkan rig
ujian. Struktur tiga dimensi pemodelan pepejal rig ujian telah dibangunkan dengan
menggunakan perisian Solidwork lukisan kejuruteraan. Proses fabrikasi juga
menjalani langkah-langkah yang banyak seperti menandakan bahan, memotong,
penggerudian kimpalan, dan pengisaran. Di samping itu, ia juga menerangkan
prosedur ujian oleh simulasi tiga jenis kebocoran biasa yang termasuk lubang jarum,
paip retak / penyok dan kebocoran gasket. Ujian rig juga dijelaskan di dalam tesis ini
dengan mengekalkan tekanan 4 bar di pelantar ujian untuk membuktikan sama ada
pelantar ujian berfungsi dengan cekap. Akhirnya, kesimpulan tentang projek ini
adalah bahawa objektif projek telah dicapai yang reka bentuk dan fabrikasi alat
penguji kebocoran dan cadangan untuk penambahbaikan rig juga dimasukkan
bersama-sama dengan tesis ini sebagai contoh untuk mereka bentuk dan
menghasilkan sokongan bagi menempatkan alat penguji kebocoran secara statik.
viii
TABLE OF CONTENTS
BORANG PENGESAHAN STATUS THESIS i
SUPERVISOR’S DECLARATION ii
STUDENT’S DECLARATION iii
DEDICATION iv
ACKNOWLEDGEMENTS v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF SYMBOLS xiv
LIST OF ABBREVIATIONS xv
CHAPTER 1 INTRODUCTION
1.1 Introduction 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Scope of Work 3
ix
CHAPTER 2 LITERATURE REVIEW
2.1 Leak 4
2.2 Leakage Problem in Industry 4
2.3 Type of Leakage that Leads to Leakage 5
2.3.1 Pinhole-Type Pitting Corrosion 5
2.3.2 Gasket Failure 7
2.3.3 Cracking/Dent in Pipelines 8
2.4 Leak Test Rigs 11
2.4.1 Moisture-Sensitive Tape 11
2.4.2 Rod Seal Test Pod 13
CHAPTER 3 METHODOLOGY
3.1 Flow Chart 16
3.2 Design and Calculations 18
3.2.1 Hoop Stress Calculation 19
3.3 Three-Dimensional Drawings (3D) 21
3.3.1 Part Drawings 21
3.3.2 Assembly Drawings 24
3.4 Material Selection
x
3.5 Fabrication Process 27
3.5.1 Tools and Machines 28
3.5.2 Fabrication Process Steps 28
CHAPTER 4 RESULTS AND DISCUSSION
4.1 Results 33
4.2 Discussion 37
CHAPTER 5 CONCLUSION AND RECOMMENDATION
5.1 Conclusion 39
5.2 Challenges Faced During Project 40
5.3 Recommendations 41
REFERENCES 42
APPENDICES 44
A Figures of machines 44
B Figures of safety tools / wears 46
C Figures of Three Dimensional Drawings (Different Views) 47
D Gant Chart 49
xi
LIST OF TABLES
Table No. Title Page
3.1 Description of materials 27
3.2 Gantt chart 49
xii
LIST OF FIGURES
Figure No. Title Page
2.1 External and Internal Corrosion Defect 6
2.2 Characteristics of Different Types of Gasket 8
2.3 Dimensions of a Dent 9
2.4 Circumferential macro-crack in Connecting Weld 10
2.5 Moisture Sensitive Tape 11
2.6 Cross-section through Seal Test Pod 13
3.1 Mode Flow 16
3.2 Leak Test Rig 18
3.3 Part Drawing 1 21
3.4 Part Drawing 2 22
3.5 Part Drawing 3 22
3.6 Part Drawing 4 23
3.7 Part Drawing 5 23
3.8 Part Drawing 6 24
3.9 Assembly Drawing Front View 24
3.10 Assembly Drawing Side View 25
3.11 Assembly Drawing Top View 25
3.12 Assembly Drawing Isometric View 26
3.13 Measuring Tape 28
3.14 Disk Cutter Machine 29
xiii
3.15 Table-Drilling Machine 30
3.16 Grinding machine 30
3.17 Welding process 31
3.18 Bolts and Nuts 32
4.1 Pipe Reducer 34
4.2 Reducer with Ball-type Valve 34
4.3 Adapter with Pressure Gauge 35
4.4 Assemble of flange and pipes 36
4.5 Final Product 37
xiv
LIST OF SYMBOLS
Hoop Stress
max Maximum Allowable Stress
yield Yield Stress
P Pressure
R Radius
SF Safety Factor
mm Millimetre
Ø Diameter
xv
LIST OF ABBREVIATIONS
ASTM American Society for Testing and Materials
ASME American Society of Mechanical Engineers
MIG Metal inert gas
1
CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
Pipelines are the most economical and safest pipeline transport for mineral oil,
gases and other fluid products. Since pipelines are used for long-distance transportation,
high demands of safety, reliability and efficiency are needed to be fulfilled. The market
parameters for oil and gas pipeline construction experienced tremendous growth due to
the economy change in 2008. The industry grew from $23 billion in 2006 to $39 billion
in 2008 [3]. As pipelines for the transfer of liquids or gases usually are only
implemented at the beginning and the end, the intimation on a leak along the pipeline
during normal operation can only be based on these available measurements. Mostly just
the input and output flows are coherent. However, according to the inherent flow
dynamics and the superimposed noise, leaks can be detected with this simple method
which is about more than 2% for liquid and more than 10% for gas pipelines [1].
This significance now converses and proposes a leak detection method which is
able to detect considerably smaller leaks. The unintentional release of fluid from
pipelines is known as leak. Pipeline leak may result, for example, from bad
workmanship or from any destructive cause, due to sudden changes of pressure,
corrosive action, cracks, defects in pipes or lack of maintenance. In most cases, the
deleterious effects associated with the occurrence of leaks may present serious problems
and, therefore, leaks must be quickly detected, located and repaired [4].