E2pro NA002

Leak Test
Basic Concepts

[Link]

E²pro Engineering

Prepared by: Paulo Schaefer

Revision 1.1

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Introduction easily. There are different methods of
detection that ranges from the fall of
Leak tests are simple pressure for the detection of atoms of
used to verify if a product does not helium. There is also the "helium sniffer".
it is leaking. The product may be a that allows detecting the presence of
plastic container, a valve, a helium atoms in the vicinity of the hole
faucet, the fuel tank of a where it is leaking. The systems more
car, the underground tank of the gas station sophisticated helium detection
gasoline etc. They work in a vacuum condition. The
the product under test is positioned inside
There are several methods to from a chamber where high vacuum is applied.
check the leak, each one more A small pressure of helium is applied.
suitable for the characteristics of the product inside the product being tested. In the chamber
in testing. We can cite the following a vacuum an electric field is applied
most common methods: capable of accelerating helium atoms that
spilled, loose within the vacuum. These
pressure drop detection atoms pass through special detectors,
simple; theoretically allowing detection up to the
differential pressure detection; passage 1 atom, conferring great
mass flow detection; sensitivity to system. They are
helium detection; high-cost equipment for
sound detection; to implement and to maintain, as the gas
detection by volume variation of helium is expensive and scarce.
liquid;
The leak detection method
In this work we will discuss the by sound, it uses ultrasound detection,
simple pressure drop detection and present in any gas leak
differential pressure. through small holes. When escaping through a
small hole, the atom generates waves of
The other methods are used sound in high frequencies, in the range of
usually when one desires discharge ultrasound. Using transducers for high
sensitivity and tend to be much more frequency, the presence of ultrasound can
dears. be detected and the leak confirmed.
The difficulty of this method is quantifying the
Mass flow detection uses leak. Limits can be established
large mass flow sensors for the presence of ultrasound but not a
sensitivity capable of detectar limit in cm3/min, for example.
small flows (usually of air) from the
order of 0.2 cm3/min. How do they measure When the container stores liquids
directly the airflow, caused by the inside it and the previous methods
leakage losses allow for a test are difficult to apply, one can detect
much faster compared to the the leak due to the variation of the level of
tests for pressure drop. liquid inside the container. This
the method is widely used in large
Detection using helium gas reservoirs such as gas station tanks
it applies to highly sensitive situations, fuel distributors, tanks
taking advantage of the size of the molecule industrial etc. Here various are employed
of helium, which being small, "leaks" more methods, the most common being in
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currently, pneumatic tests and the internal pressure of the product under test, in a
tests by magnetic restriction. fixed period of time. This
variation can be measured by a sensor
In the pneumatic test, a small simple or a differential sensor. No
the amount of air is injected into the tank by in the second case, the test pressure is
a device located at the bottom of the applied to the product and to a reservoir of
the same. The air pressure is increasing reference with volume equal to that of the product
up to the point where he starts to in test. The reference reservoir
bubbling inside the tank. From it must be watertight. One then measures the
from this point, the pressure inside the tube pressure difference between the product in
where the air is injected tends to stay test and the reference reservoir. How
constant e is proportional to the column of measures directly the difference of
liquid inside the tank. Just measure pressure it is possible arrive a a
this pressure and we will have a value much greater sensitivity and stability
corresponding to the liquid column. The compared to sensor detection
leakage can be detected by simple. But the calculations that we are going to
variation of this column over time. the following applies equally
to these two methods.
On magneto-based probes
restriction, a tube is inserted into the tank A watertight product is one that
with an external magnetic float attached to it. allows the maintenance of a certain
Inside the tube, a pair of wires is installed. fluid inside it without presenting a
with the property of magneto restriction. leakage to the external environment. The level of
These, in the presence of a field desired 'sealability' depends on
magnetic, they change slightly your application of the product. The required level for
dimension, at the point where the field is the fuel pipe of an airplane,
present. At the top of the tube, for example, it is much higher if
a frequency signal is applied that travels compared to that required for the
through the wires, inside the tube, to the bottom of bicycle tire valve.
tank. According to the position of the
magnetic float and therefore of Theoretically, one cannot speak of
surface of the liquid, the characteristics of tightness absolute then no
the resonance of the pair of wires changes, in we have methods to verify this
function of the mechanical alteration of the wires in condition. If the required tightness for
magnetic field point.. According to the bike tire was absolute, that is,
with this change, it is possible to detect with zero leakage, we would have to wait for a
precision the position of the float and therefore infinite time for the verification of this
from the liquid column inside the tank. condition. What is done in practice is to define
It is one of the most used methods in an acceptable maximum limit for the
level detection in fuel station tanks leak what no prejudice o
of fuel. product performance.

A commonly used unit is the

Sealing by drop of cm³ / min (cubic centimeter per minute).
pressure If the limit set for the piping
of the plane for, for example, 0.001 cm³/min,
The leak test by it means that, if we gather all the
pressure drop, is based on the change in the fuel that leaks for 1,000,000
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in minutes (694 days) cannot pass
of 1 liter.

The fluid used in the test of We are considering the use

tightness, often for reasons of a gas as a test fluid. If this
of practicality or security, it is not that one gas presents a molecular mass
used by the product. In the test of small and we do not use large
airplane piping will normally be pressures, we could consider that if
used an inert gas instead of it will behave like a perfect gas. In this
fuel. Thus, the maximum limit case, by the gas law, in any
of the required leak, it must be the following equation holds:
suitable for the test fluid used. If
used helium gas, for example, which (P1 x V1)/T = K
there is a molecule much smaller than that of the
hydrocarbons what composes o Onde K = constante dependente da
fuel, one must wait for a level amount of gas inside the
greater than micro leak for helium. volume.

To normalize the unit of The K factor will remain constant

measuring the leak, in such a way that it since the amount of gas inside the
can be compared in experiments volume V1 should not change. For example
different we will use o scheme we inject double the molecules of
represented in figure 1. The square gas inside the volume V1, keeping the
represents the product in testing with a temperature T constant, the final pressure
internal volume V1 and a test pressure it will be 2xP1.
The balloon represents the volume that
leaked (V2), measured at pressure P2
(normally atmospheric pressure). We can conclude then that the
the variation of the pressure P1 will be directly
proportional to the variation in the quantity of
gas inside the volume V1 (considering
V1 and T constants), that is:

P1 P2 (∆P1xV1)/T =∆K
V1 V2
Now, to calculate what the
volume V2 that this parcel ∆K of gas
will occupy at pressure P2 (pressure
atmospheric) we have:
P1 = Pressão de Teste
V1 = Volume Interno do Produto
P2 = Atmospheric Pressure (P2xV2)/T =∆K
V2 = Volume de Fluido que vazou you, replacing,
Fig 1
P2 x V2 = ∆P1 x V1

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Vz = leak total in
If we consider the approximation: cm³/min;
∆Pt = change in pressure of
test during the time of
P2 = Patm = 1 bar we have: test in mBar;
Ts Testing time in
V2=∆P1xV1 seconds;
Vp Internal volume in cm³ of
product in testing
For this formula to hold, the volume And = Volume in cm³
V1 is the entire volume subjected to pressure
added by the
P1, during the test. In other words, we should
connections and hoses of
add the volume of the equipment equipment
(hoses, connections, etc. after the valve)
tank that applies the test pressure) to the We can then arrive at the following formula
volume V1 of the product under test (fig 2) final to define the leak in function
from pressure drop:

Valve for Vz = (∆Pt x (Vp + Ve)x 60) / (1000xTs)

application of
Pressure of The factor 60 is to convert the
test
result in cm³/min and the factor 1000 is for the
Sensor of definition of ∆Pt in mBar.
Pressure
If we want the value of the change
And of pressure as a function of the maximum limit of
S specified leak, we can use
the formula:
Ve: Volume
Added
hair ∆Pt = (Vz x Ts x 1000) / ((Ve + Vp) x 60)
Equipment

P1
As an example of the application of this
V1
formula, let's consider the test
represented in figure 2.
Fig:2 The bottle has an internal volume of 2 liters.
e o volume added hair
The equipment is 0.1 liters. With a
test pressure of 10 bar was confirmed
For a small leak, where a pressure variation of 1mBar in 5
∆P1 is much smaller than P1, the volume V2 test minutes. The leak will be given
of the gas leaked, it will be proportional to by
test time, so we can arrive at
formula that defines the leak in Ts = 5 x 60 = 300 s
test time function, according to ∆Pt = 1 mBar
[Link] considerar as seguintes V1 = 2 Liters = 2000 cm³
definitions: And = 0.1 liter = 100 cm³

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applying the formula:
Leak Test using
Vz = (1 x (2000 + 100) x 60) / (1000 x 300)
the MOD485 system from E²pro
Vz = 0,42 cm³ / min
A complete Testing system
Sealing can be implemented
easily with a Kit made up of
Considerations on Testing following Modules of E²pro:
Sealing
PSM001 plate
As demonstrations previous Communication board and
highlighted 2 critical points in the tests feeding of the Modular System
of airtightness by pressure drop: the
Plate ASM001
temperature of the test fluid and the volume
Specific acquisition plate for
of the product under test. So that the result
Regarding the measurement being correct, these two leak test. Allows for
connection of up to 2 sensors of
parameters they must to remain
pressure, enabling the testing of
absolutely constant during the test.
up to 2 products simultaneously.
In practice, this doesn't happen, once
that, when we apply the test fluid, it Plate DSM001
it will normally not be the same Digital I/O board for actuation
product temperature, as well as suffer of solenoids and signal reading of
change of its initial temperature in buttons and sensors of the equipment
function of the compression process when being
injected into the product. The volume also is Power supply transformer
change, as the product may expand Power supply transformer of
with the internal pressure of the test fluid. plate PSM001
Other important factors that will cause the
the change in the product volume is Pressure Sensor
forces exerted by the fixing cylinders Sensor with 4 to 20 mA output,
or connection, usually used in provided together with the
testing equipment. In this last case, Modules of the KIT. This sensor must
the change in volume will only be critical if the be specified taking into account the
forces exerted by the cylinders if maximum pressure that the equipment
will change during the test, submitting the of the test will apply to the Product.
product to different deformations. For 1 sensor should be used for
minimizing this condition is always good each test cradle.
anticipate that the end of the courses of these
cylinders should be provided by a stop
mechanical instead of being defined by
shape of the product under test.

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The way to apply pressure of
the test is given by the graph in figure 3
The Leak Test is
Pressure totally controlled by computer.
In addition to the items that make up the kit,
The Device must be provided.
DPt Connection mechanic with the part in
test and pneumatic components for
A B automate the connection, if necessary. The Kit
E²pro is easily expandable and in
C supply condition already has 8
digital outputs open collector for
Ts Time activation of valve coils
pneumatic and 8 PNP 24V inputs for
A = Test Pressure Application verification of the status of contacts
B = Test Pressure Stabilization electronic switches or sensors.
C = Pressure Drop Verification
DPt = Queda de Pressão
Fig 3

The testing cycle is divided into 3 phases. In

phase A, the pressure application valve
the test is open and the test fluid is
injected into the interior of the product being tested.
Then this valve is closed and
the phase B begins. In this phase, we await
the pressure stabilization time
internal of the Product. This time is
dependent on testing conditions and
is usually defined in function of the
thermal stabilization of the test fluid. When
At the end of phase B, phase C begins, which is the
tightness test phase. The system
will wait for the test time Ts and will check
the drop in total pressure. If this drop
surpass the maximum limit set. The
the product will be rejected.

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