LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS

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TABLE OF CONTENTS
Abstract
Introduction
Leak Sizes and Measurements of Leak Rates
Leak Detection Methodes
Helium Mass Spectrometer (Ms-) Leak Detection
Conclusion
Literature
NDT.net - February 1999, Vol.4 No.2
LEAK DETECTION METHODS AND DEFINING THE SIZES OF
LEAKS
Andrej Pregelj, Marjan Drab, IEVT, Teslova 30, Ljubljana
Miran Mozetic, ITPO, Teslova 30, Ljubljana
The 4th International Conference of Slovenian Society for Nondestructive
Testing "Application of Contemporary Nondestructive Testing in
Engineering" 24 - 25 April 1997, Ljubljana, Slovenia. Table of Contents
ABSTRACT
There is a constantly growing need for products and
technologies that for their realisation require
hermetically closed elements, vessels and tubes. Envelopes with greater or smaller vacuum tightness
had to assure a satisfactory isolation between external atmosphere and inside over- or underpressure.
Crytical leak spots in closed systems are usually: connections, gaskets, welded and brazed joints,
defects in material etc. Regarding to quality demands in different production processes, technical
people very often encounter with standards for tightness testing. Wishing to state if an element or
system meets with corresponding standards we have to be familiar with the procedures enabling the
following appointments:
- question if there is leakage or not
- settlement of the leak size
- detection of leak locality
For solving the mentioned problems different treatments and techniques are known but among them
there is no an universal method, Each testing is suitable only for a selected leak rate or for fixed forms
and technologies. Our article presents the leak types, their sizes and various leak detection
techniques.
Keywords: tightness, leakage, trace gas, helium mass spectrometer leak detector, hermetic sealing
1. INTRODUCTION
The words "leak" and "leakage" appear in the field of vessels' hermetical closing and do not confront
only with vacuum technologists but also engineers working with high pressures. A leak means an
unintended crack, hole or porosity in an enveloping wall or joint which must contain or exclude
different fluids and gases allowing the escape of closed medium. The basic functions of leak detection
are the localization and size measurement of leaks in sealed products and systems For majority of
examples, a leak test procedure is a quality control step to assure a device integrity, and is one-time
nondestructive test.
Tipical products in which the leak detection has to be used are: vacuum chambers, TV- , and other
cathode tubes, hermetically sealed electronic components, pressure vessels, aerosol containers,
vacuum thermal isolation (e.g. dewars), pumps, refrigerating systems, chemical and nuclear plants,
beverage cans, products containing metal bellows, electron microscopes, peace makers, etc.
In spte of modem technologies it is practically impossible to manufacture a sealed enclosure or
system that can be guaranteed to be leakproof without first being tested. The main question is: what
is the maximum acceptable leak rate consistent with resonable performance life of the product.
We can distinguish different tipes of leak sources.
LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS
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Leaks caused by defects in the containing envelope. For example a too thin wall of a plastic bottle
becomes microscopic cracked at enough high pressure difference, or in canning industry if the score
mark is too deep in ring pull-tab can top, or porous cast in machine housing metallurgy, etc.
Leaks in newly manufactured products are most commonly imperfect joints or seals by which
various parts are assembled to form the final article. There are known demountable and fixed joints.
Between them the most often used are welds, brazed and soldered joints glass-to-metal and ceramic-
to-metal seals, O-rings and other gaskets, etc.
Materials permitting gas diffusion and permeation through the wall.
Virtual leak, a special type of leak in vacuum technique, which is not really a leak but is the internal
source of gas or vapor. These are cavities in a chamber wall with thin connections to the inner vessel
space such as improper welds, closed threads and holes etc.
2. LEAK SIZES AND MEASUREMENTS OF LEAK RATES
The shapes of leaks (cracks, fissures, porosity, damages, etc ... ) are very different, unknown and
non-uniform. Therefore it is impossible to measure their sizes with any geometrical dimension except
of course in the case of an ideal or artificial leak as used for calibration. How then to define the leak
size? A generally accepted method became the observation of gas or fluid flow through it in certain
conditions of temperature and pressure difference. Consequently leak rates can be defined in two
ways:
in terms of the application, e.g.: 3 g of refrigerant R-12 in 2 years at 5 bar, or 65 m of oil per
year at 60 C at atmosferic pressure, etc...
in terms of vacuum leak detection method, e.g.: 2 mbar pressure increase in I hour or 3x 10-7
mbarl/s helium (using He-detection method)
Each of the mentioned examples gives a legitimate description of leak rate but the generally accepted
unit is the last one because of very simple and understandable helium leak detection. Its efficiency is
the result of a fierce and highly competitive developments within the last 15-20 years.
The basic experiment explaining the leakage of hermetic system (increasing pressure method) is
presented in Figure 1. The tested vessel or system with known volume (V
o
) is by a valve connected to
pump. After evacuation the connecting valve should be closed and then the pressure in volume
registered for a suitable long time periode. There are more possibilities: system is tight and clean (a),
fight and not clean (b), not tight and clean, i.e.: ideal leak (c), not tight and not clean, i.e.:
combination of leak and degassing.
As we can see in each case (except for a tight vessel) we have pressure increase and regarding to the
shape of diagram we can conclude the type of leak. Using the curve inclination data the leak size can
be determined by the following formula:
Q = ^p * V
o
/ ^ t (mbarl/ s)
This simple test helps us to describe the situation at the begining of leak tracing procedure. Very
similar test can be realized by pressurizing the the system (and detecting the pressure decay) but
gives only data on leak size and is not used so often.
The leak rate Q does not only depend on the geometric dimensions (diameter, lenght) of the leak but
also on the physical properties of the gas (or the liquid), such as viscosity, relative molecular mass
and on the pressure difference. For example: in the same environment conditions helium flows
through orifices 2.7 times faster than air. Because of different results if the same leak is measured by
various mediums it must be always noted with which gas a testing was performed.
The maximum acceptable leak rate for a given product depends on the nature of product. Since the
cost of leak detection (and manufacturing too hermetic envelopes) increases in inverse proportion to
a leak rate, it follows that testing for unnecessary small leaks causes unnecessary rise of production
LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS
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costs. Some examples of tolerated leaks in different elements and systems are shown in Table 1. We
can see very wide range of sizes: from great with some tenths mbarl/s in rough vacuum devices, to
milion- and more- times smaller in hermetically closed electronic elements. It is possible to state there
are no ideal products without leakage. We only can demand they have leaks smaller than the specified
leak.
Table 1. Leak rate specification for various elements and systems
Element or System Max. permissible Leakage Remark
chemical process equipment
10
-1
to 1 mbar l/s
great process flows
beverage can bottom
10
-5
to 10
-6
mbar l/s
retention of CO
2
dynamic pumped vacuum s.
10
-5
to 10
-7
mbar l/s
permanent pumping
IC-package
10
-7
to 10
-8
mbar l/s
pacemaker
cca 10
-9
mbar l/s
long time implanted in body
closed vacuum elements
10
-8
to 10
-10
mbar l/s
e.g. TV- and Xray- tubes
3. LEAK DETECTION METHODES
A few leak detection techniques are known. Their performances regarding to detecting sesitivity are
presented in Fig 2. Because of their advantages we shall concentrate attention on the helium mass
spectrometer tecniques but at first a short description of others is presented,
The spark coil technique uses a high voltage or Tesla cod and sparkling point to create the
electromagnetic radiation which causes the generation of glow discharge in neighbouring evacuated
ampoules. Normally it is possible only in non metal envelopes, that means first of all in glass and
plastic elements or tubing. Drawing the leak antenna along the tested element we can see plasma
inside and coming to the leak, a sharp arc passage between plasma and antenna appears. The defect
spot is very clearly marked and a skilled person can from the colour of plasma also estimate the inner
pressure. This simple metod however has a number drawbacks; since besides the restricted
application it is also to be avoided because of radiodisturbances.
Pressure change method uses pressure gauges which are ordinary used to monitor the system
performance. Suspected leak sites can be squirted with a solvent (i.e. acetone or similar) while
watching the gauge for a pressure rise that occurs when the solvent enters the leak. This method has
limited sensitivity (depending also on the type of pressure measurement cell) and some shortcomings
(possibility of solvent freezing causes temporary stuffing of leak, solvents may attack vacuum grease
and elastomer gaskets).
Figure 1. Testing of tightness by increasing pressure method and various
LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS
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possible results
Bubble test (soap
painting)
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>
Bubble test (air,
water)
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-->
Bubble test (He,
alcohol
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--->
He sniffer
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--->
Halogen sniffer
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->
Pressure decay
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Acoustical
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->
Vacuum decay
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>
Spark tester
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Thermal conductivity
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Radioisotope
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>
Halogen detector
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Mass spectrometer
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>
Dye penetrant
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>
mbarl/s 100 10 1
10
-1
10
-2
10
-3
10
-4
10
-5
10
-6
10
-7
10
-8
10
-9
10
-10
10
-11
10
-
12
Figure 2. Sensitivity ranges of various leak detection methods
Overpressure methods can be performed by fluid or gas with which the tested element must be
filled. As a fluid usually the water from house installation is used. Observing the outside surface the
wetted areas show us great leaks and smaller ones up to approx. I mbarl/s. Testing with gas, the
vessel is subjected to overpressure of some bars (depending on material and wall thickness) and
immerged into the water. At leaks the gas bubbles begin to escape. In this manner the leaks up to 1.
10-3 mbarl/s can be detected. If the vessel is too great for immersion, the suspected points should be
painted by soap solution and again we can see the bubbles escaping if there is a leak. This method
enables detecting the leakage up to 10-5 mbarl/s and is usable also for very large systems.
Halogen leak detectors are used in the detector-probe mode (to 10-3 mbarl/s), requiring that the
system be pressurized with a gas containing an organic halide, such as one of the Freons. The
exterior of the system is then scanned with a sniffer probe sensitive to traces of the halogen -bearing
gas (Fig. 3). The principle is based on the increased positive ions (K or Na) emission because of
sudden halide composition presence. The ion current is the measure for a leak size. Halogen detectors
can be used also in turned mode: evacuated vessel is connected to detecting instrument and is
sprayed by freon. In this manner its performance is up to 5.10-7 mbarl/s and is used in rough,
medium and high vacuum.
LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS
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Figure 3. Halogen leak detector
Dye penetrant method is an adaptation of a technique used to find cracks in metals and defects
in welds. It uses a low viscosity fluid that exhibits a high rate of surface migration. This fluid is
painted on one side of a suspected leak site, and after a time, it is detected on the other side of the
wall. The test is simple, low cost, it leaves records, the sensitivity can be as high as 10-6 mbarl/s
Acoustical leak detection uses the sonic or ultrasonic energy generated by gas as it expands
through an orifice. Pressurized gas proceeds from tested system through leaks which are detected
outside by sensible microphone (tipically about 40 000 Hz). Acoustical leak detection is widely used in
testing high pressure lines, ductworks etc. It requires modest instrumentation; it is simple and fast but
is limited to about 10-3 mbarl/s.
Radioisotope method is useful only for testing hermetically sealed components. They are placed in
a chamber which is to be evacuated and filled with radioactive tracer gas (tipically krypton 85). It
difuses through present leaks in the components and after removing it from environs test gas expands
through leaks back and can be detected by radiation sensor. The instruments for this type leak tracing
are very expensive but they enables the measurement of flows up to 10- 11 mbarl/s.
Mass spectrometers as leak detectors are used as most sensitive instruments for stating leak
existance and presence in vacuum systems. They are adjusted on the atom respectively molecular
weight of tracer gas. It is usually helium because of.
- its small mass and atom volume assures good supply of gas through a leak -relative great mass
distance from neighbour mass enables greater sensitivity - its partial pressure in air is low, approx.
4.10-3 mbar
The first next suitable gas for leak detection purposes would be H
2
but it is dangerous and residual
atmosphere in vacuum systems always contains this gas. There are also spectrometers adjustable to
other gases e.g. argon.
4. HELIUM MASS SPECTROMETER (MS-) LEAK DETECTION
Helium leak detection systems work as follows: He is introduced to a test part that is connected to
the leak detector. The helium travels through leak into the leak detector, its partial pressure is senzed
respectively measured and results are displayed on istrument as flow rate.
The main part of the device is mass spectrometer, a sensor for different gas masses. In very low
pressure (or vacuum) the molecules of rest gasses are transformed in ions by electron impact.
Separating the ionized particles of different mass to charge ratios (q/m) it is possible to state the
partial pressures of present gases - in our case also the presence of the sought gas helium. For helium
MS- leak detectors, magnetic sector type mass spectrometers are preferably used as gas search
sensors. The low pressure (less than 2x10-4 mbar) required for operation of the mass spectrometers
is produced by an integrated high vacuum pump system. The auxiliary vacuum pump required for
rough pumping the tested equipment is either incorporated or can be attached via suitable
connection.
LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS
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Figure 4. Conventional type of the helium leak
detection apparatus
Figure 5. Main leak detection techniques
with MS-leak detector and He tracing gas. In
one mode (examples a and b) He flows from
outside into vacuum and in other it expands
from inner overpressure in atmosphere
As the necessary pressure for the mass spectrometer
cannot always be attained in the tested equipment within a
resonable pump-down time, various types of MS-leak
detectors with different performances have been
developed. The most used are constructions with "full flow
operation" (conventional) and with "contra-flow operation",
regarding to the way in which He is supplied towards MS-
sensor. For example the figure 4 shows schematically the
conventional type MSleak detector. In presented system,
vacuum is maintained in the spectrometer tube by use of a
diffusion pump in combination with mechanical pump. A
cold trap pumps condensable vapors such as oil and water.
A roughing pump is provided to evacuate the test port (and
the connected sample to be tested) to a pressure level that
will not disrupt diffusion pump operation. Reaching a
suitable vacuum the sample is valved off from the rough
pump and by opening test valve joint to the MS- vacuum
system. Helium sprayed near the leak on the sample surface has now an open way to the MS-tube
and there it is detected. After completing procedure the test port is valved off from the leak detector
and vented to air; than we can change the sample.
How to use a helium MS- leak detector? There are basically
four different techniques for finding leaks: two "OUTSIDE-IN"
and two "INSIDE-OUT" methods (Fig.5).
In the most commonly used "outside-in" technique, the sample
to be tested is connected to leak detector and evacuated
(Fig.5a). Than its surface is "probed" with a pointed jet of
helium. Coming over a leak detector gives an acoustic or visible
sign (exactly location) and the data about leak size.
The second technique (Fig.5b) consists of evacuating and
hooding the sample with something like a plastic sheet and
flooding the hood with helium. So it is possible quickly to
establish whether or not a sample leaks and to establishe the
total leak rate. This technique is most useful on production lines
where a test piece must be accepted or rejected.
In "inside-out" techniques the test configuration is reversed.
Instead of being evacuated, the sample is pressurized with He.
In this case the leak detector is equipped with so called
detector probe and it can be used in two modes presented in
figures 5c and 5d. In mode c) the test piece is probed with the
detector probe around suspected leak sites. This method
sensitivity (up to 1. 10-6 mbarl/s) is not as good as by others
because the helium in the air is constantly being admitted into
the detector.
Mode d) allows testing of a large number of samples
simultaneously. It is often called the bombing technique
because the parts are previously placed in a pressurized He
vessel where the helium leaks into the parts which leak. All parts are than exposed to detector probe
in closed container. The mentioned leak test techniques are the main methods for establishing
whether leaks exist and for locating where they are. Each has its own advantages and shortcomings,
each has also its own individual set of variations.
LEAK DETECTION METHODS AND DEFINING THE SIZES OF LEAKS
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5. CONCLUSION
Resarchers, technicians, scientists, producers etc who in their work need hermetically closed elements
and vessels, vacuum or only tight seals have to become familiar with measurements and localization
of leaks. In Slovenia there are already exist some groups (first of all on fakulties and institutes) which
have mentioned knowledge and there are also a few of technologies that use leak detection technique
in manufacturing and in production lines as a 100 % quality control. But in general engineering and
also in important projct organisations this technical field is nearly unknown. Wishing to progress on
our way towards more developed countries this situiation must be changed. Department for vacuum
elements and systems in Institute for electronics and vacuum technique (IEVT) is, beside others,
permanently occupied by tightness testing and leak detection for our own needs and as service for
customers. In cooperation with the Slovenian Vacuum Society we prepare every year educating
courses for vacuum techniques, where also this knowledge and skills are represented. Regarding to
mentioned circumstances this contribution with basics about leaks and detection methods was
prepared as information.
6. LITERATURE
1. J .L Ryan, D.L.Roper: Process vacuum system, design and operation; McGraw-Hill Book
Company, New York etc-, 1986
2. Nigel Harris: Modem vacuum practice, McGraw-Hill Book Company Europe, Berkshire, England,
1989
3. Varian: Introduction to Helium mass spectrometer leak detection; Varian Associates Inc., Palo
Alto, 1980
4. E. Kansky: Hermetologija sticnih ploskev in spojev, predavanja na III. st.- Vakuumistika.; FERI
Maribor, IEVT, Ljubljana; 1983
5. L.C.Beavis: Real leaks and real leak detection, Vacuum, Vol.20, No.6, p233, Pergamon Press,
London,1970
6. M.Wutz, H.Adam, W.Wachler Theorie und Praxis der Vakuumtechnik, F. Vieweg & Sohn Verlag
GmbH, Braunschwieg, 198"
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