1) INTRODUCTION

Helium Leak Testing is a sensitive, reliable and most widely used method of leak
detection in manufacturing industries. The typical users are the manufacturers of
electronic tubes and other devices with critical operating conditions. Mostly the heavy
and light fabricated tubes, pressure vessels and assemblies are tested using Helium leak
test. The growth of Helium leak detection technique was accelerated in the late 1950’s by
the space exploration program. Nearly, everything in space vehicles from hermetically
sealed electronic components to fuel tanks, transfer lines and valves need to be leak free
or nearly so. The commercial market for appliance and other consumer goods spurred on
by the development of the space age began to expand in the 1960’s. These and other
requirements challenged leak detector manufacturers. Helium leak detectors appeared on
production floors testing, beverages can ends, pressure transducers, torque converters,
pressure vessels and heat exchangers. In some applications the unit were automated to the
point where the need of operators was virtually nil. Biotech companies use helium leak
detectors to helium leak test implant able medical devices such as pacemakers to insure
that the outer packages are protected from bodily fluids and to protect patients from
possible contamination from leaking batteries and other materials. Automobile
manufacturers use helium leak testing technology to test items such as air bag initiators,
radiators and air conditioning units. Semiconductor fobs are littered with helium leak
detectors used to leak test process equipment.

Although mass spectrometers can be traced as far back as the turn of the century the
helium leak detector mass spectrometer was developed during the Manhattan Project. The
gaseous diffusion method used to enrich uranium-235 required leak tightness far beyond
available means. Project scientists were able to improve upon current mass spectrometer
designs and eventually developed what is still the basic formula for most helium leak
detectors. Helium leak testing is used throughout industry to locate leaks in even the
most complex pressure, vacuum and hermetic systems and enclosures. The following are
just a few examples of the most common uses of helium leak testing:

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 1) Steam Turbine and Condenser Air in leakage Helium Leak Testing - Quickly
locate even the smallest vacuum leaks on the low-pressure side of any steam turbine or
condenser. Helium leak testing is widely recognized as the superior alternative to the
ultrasonic, smoke, and our favorite, the shaving cream method of vacuum leak testing
steam turbine condensers.

2) Chemical and Plastics Production - Oxygen and other contaminants entering through
leaks in flanges or broken welds can effect many manufacturing processes and result in
lower quality and efficiency or totally unusable product. Helium leak testing of multi
floor vacuum distillation towers, reactors and associated plumbing and pumps is easily
accomplished utilizing helium leak testing.

3) Heat Exchangers - Helium leak testing large tubular heat exchangers can be expensive
and time consuming. With the helium leak testing method thousands of tubes can be
scanned in a short period of time when compared to some of the other methods of
examination. Re-testing after plugging or other repairs are performed can be
accomplished immediately.

4) Underground Pipelines: - With helium leak testing we can locate leaks in underground
pipes to within a few feet keeping excavation to a minimum. Due to the versatility of the
helium leak testing method virtually any pressure or vacuum system can be tested with a
high

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2) FUNDAMENTALS OF LEAK DETECTION

1) Leak detection Defined:

A leak may be defined as an unintended crack, hole or porosity in a containing wall that
allows the admission or escape of fluid or gas. The basic function of leak detection is the
location and measurements of leaks in sealed products, which must contain or exclude
fluids.
2) The Need for Leak Detection:
Even with today’s complex technology, it is for all practical purposes, impossible to
manufacture a sealed enclosure or system that can be guaranteed to be completely leaking
proof without first being tested. The fundamental question in leak detection is; what is the
maximum acceptable leak rate consistent with reasonable performance life of the
product?
Anyone who manufactures or uses closed vessels needs leak detection. A partial list of
typical users includes:
a) Any industrial pressure vessel manufacturer
b) Manufacturers using tubular elements, such as refrigeration equipment
manufacturers, chemical plants etc.
c) Vacuum chamber manufacturers
In our case coolant carrying tube pipes of STIB Project were to be fabricated at the ends
with flanges and so required the Helium leak testing for its leak proof operation.
What type of leakage should these products avoid? For some, it is leakage, which will
damage the product or impair the process; for other, it is the loss of material vital to the
product or process.

There are four general classes of leak detection:

A) Hermetic Enclosures (Admission of material through leaks)
These are tested to prevent entrance of contaminants or loss of fluid that would affect
performance of the enclosed unit. Examples: electronic devices, integrated circuits, sealed
relays, motors, ring pull tab can ends, and multi-pin feed through.

B) Hermetic Systems

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These are tested to prevent loss of operating fluid or gas within the system. Examples:
Torque converters, hydraulic systems and refrigeration systems.
C) Evacuated Enclosures
These are tested to prevent too-rapid deterioration of vacuum with age. Examples:
electron tubes, TV picture tubes, bellows sensing elements, full-panel opening can ends,
etc.

D) Vacuum Systems
These are tested to minimize in leakage and allow attainment of better vacuum or higher
gas removal ability at any given vacuum (absolute pressure).

3) The sources of leak:

Imperfect joints or seals by which various parts are assembled to form the finished
products most commonly cause leaks in newly manufactured products. Still another class
of leaks consists not of holes or cracks in the usual sense. Instead the molecular structure
of the containing wall itself is arrayed in such a way as to permit gas diffusion through
the wall.

4) Leak Measurement terminology

Most leaks involve gas flow, and the most widely used methods of leak detection depend
upon observation of gas flow. Leaks are measured in units of gas flow per unit time. To
specify a quantity of gas, its pressure as well as its volume must be specified. Pressure is
customarily specified in “Torr” – a unit of measurement used in barometric
measurements. This gas volume per unit time is typically specified in “standard cubic
centimeters per second.” This practical limit of low-pressure measurement with a mercury
barometer is about 1 Torr.
1 Torr = pressure of 1 machine Hg.

Leak Rates can be defined in 2 ways: -

A) In terms of application, such as-
• 1 Oz. Of refrigerant R-12 in 2 years at 70 Psi or
• 65 cc of oil per year at 0 psig and 1400oF, or

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 B) In terms of the leak method detection method used, such as-
• 2 bubbles/sec (1/8” diameter) when pressurized to 40 psi (Bubble method)
• 1.8 X 10-7 std cc / sec of helium at 1 atm. (Helium method)
• 2 Psi pressure decay in 5 minutes at 60 psi (Pressure decay method)
The generally accepted unit of leak rate for leak detection is that cc/sec, because it
contains the units of flow rate, namely MASS/TIME. The term “std cc/sec ” is an
abbreviated form of “cubic centimeters of gas (at standard Temperature and Pressure) per
seconds.”
In vacuum work, where pumping speeds are measured in liters/sec and pressure in Torr,
the term “Torr-liters/sec” is widely used.
1 std cc/sec = 0.76 Torr-Liters/sec.
Conversions:
1 std cc sec 0.76 torr-liter/sec
1 torr-liter sec 1.3 std cc/sec
1 std cc/sec 9.7 x 10-4 micron cubic feet per hour
1 mcf/h Practically 10-5 std cc/sec

5) The size of leaks that Affect Product Life:

The maximum acceptable leak rate for a given product depends upon the nature of the
product. Since the cost of leak detection increases as the specified leak rate decreases.
Some examples of products leak specification:
Product or System Leak Rate Specification Comment
Chemical Process Equipment 10-1 to 1 atm cc/sec High Process flow
Rates
-3 -4
Torque converter 10 to 10 atm cc/sec Retention of liquid
Pacemaker 10-9 atm cc/sec Long life implanted in
body

Although industrial leak rate specification range from 10-9 atm cc/sec to 1 atm cc/sec, the
majority of products have leak rate specification laying in a narrow range, from 10-7 atm
cc/sec to 10-1 atm cc/sec. The upper part of this range is covered by bubble testing down
to 10-4 std cc/sec. Other methods overlap the bubble method and extend well below its
lower limit. The helium method can detect leaks smaller by a factor of 10,00,000. Leaks

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 larger than 10-1 atm cc/sec can usually be spotted visually. 5.0x10-8 Std cc/sec He, means
that .00000005 cubic centimeters of helium will leak every second given a constant
pressure differential across the leak of one atmosphere. Also used is atm cc/sec.

Std cc /sec He Time to leak 1 cc of He Typical Products Remarks

1x10-2 100 seconds Oil from engine Protect engine

1x10-3 16 minutes Water tank Prevent water loss

Prevent loss of product. Protect

1x10-4 3 hours Storage tank
environment

1x10-5 26 hours
Beverage can top C02 Retention
-6
1x10 2 weeks

1x10-7 4 months
IC packages Package integrity
-8
1x10 3 years

1x10-9 30 years

1x10-10 320 years Implant able Prevent malfunction due to

1x10-11 3,200 years Medical Devices contamination. Long life

1x10-12 320,000 years

3) HELIUM AS A TRACER GAS

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Since a mass spectrometer may be tuned to virtually any mass, the choice of a tracer gas
is limitless. However, the particular application of leak testing and desired characteristic
for a tracer gas narrow this choice. A tracer gas for leak testing should have the following
characteristic:
• It should be non-toxic.
• It should diffuse readily through minute leaks
• It should be inert
• It should be present in not more than trace quantities in the atmosphere.
• It should be relatively inexpensive.
The lighter gases have the highest diffusion rates and will therefore give the best
sensitivity. Only hydrogen (mass H2=2) is lighter than helium (mass He=4). Of the inert
gases, helium is buy far the lightest and the concentration of helium is only 5 parts per
million in the atmosphere.
Helium Vs Air-
If helium is used as a tracer gas but air leaks into or out of the product, what is the
relationship between the two?
The mass spectrometer leak detector is capable of indicating leak rates only in the tracer
gas to which it is tuned and calibrated (nearly always helium). It cannot indicate leak rates
in air. There is however, an approximate relationship that is derived from the kinetic
theory of gases.
Kinetic theory of gases predicts that the relative flow rate of two gases through an ideal
leak under molecular flow conditions (roughly, below one millionth of atmospheric
pressure) will be inversely proportional to the square root of the average molecular
weight. Since the molecular weight of air about 29 and helium is 4, helium will flow 2.7
times as fast as air through this leak. The implication is that the minimum detectable leak
in terms of air is ½.7 of that for helium.

4) LEAK LOCATION AND MEASUREMENT

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Leak location:
Leak location is the testing approach used to find the precise location of individual leak.
Leak location is carried out by means of two techniques, termed the detector-probe mode
and tracer-probe mode.
In the detector-probe mode the test piece is filled with tracer gas and the exterior is
scanned with a probe that is attached to the inlet of the leak detector. The probe
continuously admits (or “sniff”) some of the air directly in front of the test piece. This air
is inducted to the analytical portion of the leak detector, where any of the tracer gas that
may be leaking from the test piece is detected.
In the tracer-probe mode, the leak detector is used to evacuate the interior of the test
piece, and a probe is used to discretely spray test gas on suspected leak sites. Any leaks
are evidenced when the tracer gas flows through the evacuated test piece and is detected
by the leak detector.

Leak measurement:
Leak measurement is the approach used to actually measure the total (ideally) or partial
(as compromise) leakage of a device or system.
The two standards leak measurement techniques are known as the inside-out mode and
the outside-in mode. With either of these approaches, the tracer gas may be allowed to
accumulate before detection, or may be detected continuously. Generally continuous
detection yields a faster test with adequate sensitivity; however, circumstances sometimes
require the accumulation of tracer gas prior to analysis.

5) METHODS OF LEAK DETECTION

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There is a wide range of methods available for finding and measuring leaks in products or
assemblies. The more commonly used methods are summarized below. Leaks are special
types of defects, which can have a major importance in systems where they have
influence on safety and performance. Many objects will have a reduced reliability if they
contain leaks.
Leak testing is a non-destructive examination method that is used for detection and
localization of leaks and for measurement of leakage in systems or objects that is under
vacuum or pressure.
Before a leak test examination is performed it is necessary to determine if the
examination is to ascertain whether leaks are present or not, overall leak detection, or if
the examination is to determine the location of a leak, localizing leak detection. In some
cases an examination for overall leak detection is performed first, and if leaks are
detected, the localizing method is applied for pinpointing of the leak. This is however not
always required nor possible.
Secondly it is necessary to determine the leak rate that can be tolerated, as no objects are
100% tight. That is the requirements to tightness of the object. If for example the object
have to be watertight, a leak rate below 10-4 mbar l/s will be sufficient. But if the object
for example is to be used in the chemical industry the requirements can be a leak rate
below 10-6 mbar l / s.
In leak testing a pressure difference between the outer and the inner side of the object to
be examined is produced. Subsequently the amount of gas or liquid that is passing
through a leak is measured.
In principle two methods are applied for leak testing and localization of leaks, the
"Vacuum method" and the "Overpressure method".
At the "Vacuum method" the object to be examined for leaks is evacuated and sprayed
from the outside with a search gas, in this case Helium. The gas enters through any leaks
present in the object and is detected by a sensor connected to the leak test instrument.
At the "Overpressure method" the object to be examined for leaks is filled with a search
gas, Helium, under slight overpressure. The search gas escapes through any leaks present
to the outside and is detected by a detector probe. This detector probe is in most cases
called a "sniffer" acting as a gas-sampling probe.
For both methods specially developed leak detectors are available.

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The object under test should, if possible, be tested according to its final mode of use, i.e.
if it is used under vacuum, the vacuum method should be applied, if it is finally
pressurized, the overpressure method should be adopted.
Examples of testing with the two methods are illustrated below. The Vacuum method is
illustrated with the Hood Test and the Tracer Probe Test and the Overpressure method
with the Hood test, the Bombing test and the Detector Probe or Sniffer test.

1) Vacuum method - Hood test

The Hood Test is an overall leak test. The evacuated test object is covered with a (plastic)
hood. The space between the test object and the hood is filled with Helium from the
search gas reservoir so the total outer surface of the test object is exposed to the Helium
search gas. The helium enters through all leaks present at the evacuated test object and
thus the detector connected to it. The detector now indicates the total leak rate.
The hood test can for example be used for examination of small vessels.

Fig 2: Helium Leak Test, Vacuum Method, Hood Test

2) Vacuum method - Tracer probe test

At the tracer probe test the same set-up as used for the hood test is applied, but without
the hood. A spray gun is used to spray a fine jet of helium search gas at areas suspected of
leaking. Again the helium enters through leaks present at the evacuated test object and the
detector connected to it. The detector indicates if a leak is present at the area the helium
search gas is exposed to.
The tracer probe test can for example be used on seals, flange connections, weld seams
etc.

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 Fig 3: Helium Leak Test, Vacuum Method, Tracer probe test

3) Overpressure method - Hood test

As in the vacuum hood test the overpressure hood test is an overall leak test. A test set-up
similar to the vacuum test is used. A vacuum chamber is used for the hood, which can be
evacuated by a auxiliary pump and to which the leak detector is connected. The leak
detector indicates the helium search gas that is escaping through leaks in the test object.
The use of a helium leak detector allows detection of extremely small leaks and is
suitable for automatic leak detection in industrial equipment.
The hood test can for example be used for examination of vessels, heat exchangers etc.

Fig 4: Helium Leak Test, Overpressure Method, Hood test.

4) Overpressure method - Bombing test

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The bombing test is a pressure/vacuum method of leak detection used for testing of
hermetically sealed components containing a cavity, which can be gas-filled or evacuated.
The object to be tested gets in a pressure chamber exposed to the helium search gas.
During an exposure time of up to several hours at a high helium pressure, the helium will
penetrate through any leaks present in the test object. This is the part referred to as the
"bombing". After the pressurization or bombing the objects are tested for helium emission
in a vacuum vessel, following the same procedure as in the hood test. This test permits
detection of the smallest leak rates and is especially used for objects, which cannot be
gas-filled by other means. The bombing test can for example be used for examination of
transistors, ampoules etc.

Fig 5: Helium Leak Test, Overpressure Method, Bombing test.

5) Overpressure method - Sniffer test

At this type of test the suspected areas of the test object are carefully explored by means
of a detector probe, a "sniffer", which is connected to the leak detector. The objects to be
tested are under helium search gas overpressure. The sensitivity of the method of the
method and the accuracy of localizing any leaky points depend on the nature of the search
gas, the design of the sniffer and the time constant of the actual leak-testing device.
The sniffer test can for example be used for examination of vessels, heat exchangers,
seals, flange connections, weld seams etc.

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 Fig 6: Helium Leak Test, Overpressure Method, Sniffer test.

The leak detection system discussed in this ITG is a mass spectrometer leak detector
tuned to detect small quantities of helium. It is utilized by pacemaker electronic
component manufacturers to test electronic components (integrated circuits, transistors,
capacitors, etc.) for hermetic loss. The system is typically portable (on casters) or bench
mounted and operates from a 115 volt, 60-Hertz power source. The system contains one
or more vacuum pumps, a magnetic mass spectrometer and auxiliary components
necessary for proper operation.
Industrial users employ mass spectrometer leak detection on all sizes of objects from
miniature components to large systems and there are various detection methods used. The
most popular leak detection method used by pacemaker manufacturers to leak test
electronic components is the bell jar or hood method using helium as the tracer gas. In
this method, the test object is placed in a pressure chamber and the chamber is filled with
commercially pure helium at a specified pressure. The test object is held in the
pressurized chamber (soaked) for a specified time (bomb time). Pressure and bomb time
vary according to the test specification used. Typically, bomb pressure is four
atmospheres minimum and bomb time is one to four hours. If there is an opening in the
test object, the pressurized helium will be forced through the opening into the test object.
The chamber pressure is then released and the test object is transferred to the leak
detector hood or bell jar. The bell jar interior is connected through a valve to the leak
detector mass spectrometer tube. Transfer time from chamber to bell jar should be kept at
a minimum to prevent loss of helium from the test object. Military and industrial
specifications typically specify a maximum time between removals from the pressure
chamber to detection of 30 minutes.

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When the detector test cycle is initiated, the test station automatically evacuates the free
volume under the test dome to a vacuum level compatible with the interior of the mass
spectrometer. The valve then opens allowing any tracer gas leaking from the test object to
enter the detector spectrometer tube.
Operation of the mass spectrometer is similar to standard mass spectrometer operation. In
the described system, the gases entering the spectrometer tube, such as nitrogen, oxygen,
carbon dioxide and helium (if a leak occurs) are ionized by an electron beam. The
spectrometer magnetic field separates the resulting ions according to mass. The helium
leak detector magnetic field is arranged such that only helium has the right mass to reach
the detector. As the helium ions strike the detector, a minute current flow is generated.
The current flow is amplified and the amplified flow (which is proportional to the amount
of helium in the tube) appears as a visual leak rate indication on the leak indicator meter.
6 The leak rate indicated on the detector meter is the equivalent air leak rate.
The measured leak rate is the quantity of gas in cubic centimeters that flows through an
aperture or porous wall in one second as determined under specified conditions. 5 It is
assumed that the gas is air at room temperature, and is at one atmosphere pressure on the
high-pressure side of the leak and the low-pressure side (vacuum) has a negligible effect
on the flow rate. Leak rate is commonly given in units of atm-cc/sec. The air leak rate can
be converted roughly to a helium leak rate by multiplying, Air leak rate x 2.8 = helium
leak rate.
The helium leak detector discussed here is used to detect leak rates in the 10 -4 to 10-10 atm
cc/sec range (fine leak) although units are now being developed to detect gross leaks, 10 -4
atm cc/sec or greater. There is presently no technical basis for maximum allowable leak
rate specifications. The reason for this is that there are no data presently available which
can be used to relate leak to component life. Acceptable leak rates may vary as the
internal free volume of the test object varies.
The sensitivity of the described system is such that gross leaks, or leaks with flow rates
10-4 atm cc/sec or greater cannot be accurately detected. Also, the tracer gas would be
removed from test objects with gross leaks when the system evacuated the bell jar and
little or no helium would reach the spectrometer tube. Some helium is removed from
objects with fine leaks during evacuation but the evacuation time is small (typically three
seconds) and detector manufacturers state that enough helium remains for detection
purposes. This is a questionable area. It is obvious that bomb time and pressure become

14
important. It is also apparent that test dome or bell jar volume should be kept small to
decrease evacuation time.
For leaks 10-4 atm cc/sec and larger (gross leaks) a bubble test is commonly utilized. The
test object is soaked in a pressurized chamber filled with helium or other gas (as done for
fine leak testing) and then the test object is immersed in a silicone or mineral oil, or
fluorocarbon liquid and observed for bubbles emanating from the object. Gross leak
testing should not be performed before the fine leak test, as there is a possibility that the
test liquid could temporarily plug a fine leak.
Calibration of the helium leak detector is presently accomplished using a calibrated
helium leak. The calibrated leak is typically in the form of a cylinder charged with helium
at atmosphere pressure. The cylinder contains a filter through which helium exits at a
fixed calibrated rate when the cylinder valve is opened. The temperature at which the
calibrated leak was calibrated is marked on the cylinder (typically 22-23 C) and the
calibrated helium leak cylinder should be at this temperature when calibrating the system
or a temperature compensation factor should be provided and used in calculating the test
object leak rate. The actual accuracy of calibrated leaks are questionable due to the lack
of standardization in calibration methods and the disagreement between different
calibration labs as to the accuracy of the calibrated leak rate. When using the calibrated
leak to set the sensitivity of the helium leak detector, the detector meter is set for direct
readout at the air leak rate figure marked on the calibrated leak cylinder.
Radioisotope and weighing are two other methods used for leak detection. Radioisotope
leak testing is generally felt to be a better leak testing method than helium leak detection.
In this method, the test object is soaked in a pressurized chamber of radioactive gas. The
object is then removed and the emissions of gamma rays penetrating the walls of the
object are counted, thereby measuring the amount of radioactive tracer gas trapped within
the leaking object. An Atomic Energy Commission license is necessary for possession
and use of radioisotope test equipment and manufacturers are reluctant to use this method.
Radioisotope leak testing will be covered in more detail in a future ITG.
A weight test method is also used in which the test object is weighed before and after
being pressurized in a test liquid, or before and after an extended time period.
The detection of loss of component package integrity is important because entrance of
damaging contaminants will reduce the components effective life. Water vapors both
sealed-in and that, which leaks into the package, is a contaminant of major concern.
Moisture inside the package may result from package leaks or the moisture may be sealed

15
in during component manufacture. Sealed-in moisture may result from improper or
inadequate handling or processing of materials. For example, the walls of ceramic
packages are a sink for moisture, which may later serve as a moisture source after sealing.
Glass, epoxies, shellacs and polyamides are also sinks. A proper bake-out period and
subsequent sealing in a moisture free environment can minimize moisture in these areas.
Hermetically sealed components are typically evacuated or are sealed in a dry nitrogen
atmosphere. Some component manufacturers are now including helium as part of the
component internal atmosphere to facilitate leak testing. The tubing through which the
sealing gas passes may emit moisture and contaminate the sealing gas. Also sufficient
moisture may penetrate the tubing to contaminate the package. Dynamic flow conditions
should exist to minimize moisture. Sealed-in moisture may be sufficient to block fine
leaks so that they are not detected.
To minimize leaks in the package hermetic seals, care should be taken in controlling
sealing materials. For example, sealing material additives designed to adjust the thermal
expansion coefficient between metal and glass may be contaminated or not be in proper
balance. Inadequate control over the mechanical handling of packages can also result in
degradation of the package seal.
There are presently a number of test specifications in use, both military and commercial,
for performing helium fine leak detection and gross leak detection. In the absence of a
standardized widely accepted test method, it is important that device manufacturers
a) Know the scientific capabilities of the methods being used
b) Conform to their own stated procedures and specifications and
c) Properly calibrate and maintain the device

6) THE HELIUM MASS SPECTROMETER

LEAK DETECTOR (MSLD)

The Helium mass spectrometer leak detector (MSLD) is a complete system for locating
and / or measuring the size of leak into or out of a device or a container. In use, this
method of leak detection is initiated when a tracer gas. Helium is introduced to a test art
that is connected to the MSLD system .The helium leaking from the test part diffuses
through the system, its partial pressure is measured and results are displayed on a meter.
The MSLD operating principle consists of ionization of gases in a vacuum and
accelerating of the various ions through a voltage drop and a magnetic field. The helium

16
ions are separated and collected, and the resulting ions current is amplified and indicated
on the meter.
An MSLD consists of a spectrometer tube, quantitively sensitive to the pressure of
helium; a vacuum system, to maintain adequate low operating pressure in the
spectrometer tube; mechanical pump(s), to evacuate the part to be tested; valves to
transfer the connection of the evacuated part from the mechanical roughing system to the
spectrometer vacuum system; amplifier and readout instrumentation, to monitor the
spectrometer tube output signal; electrical power supplies and control, for valve
sequencing, protective circuits etc., and fixing for attachment to the part be leak tested.

Major components:
a) Spectrometer Tube: -
The heart of the MSLD is the spectrometer tube, which is essentially a partial pressure
ionization gauge that measures only the helium pressure in the system rather than the total
pressure. In spectrometer tube operation electrons produced by a hot filament enters the
ion chamber and collide with gas molecules, creating within the chamber ions
quantitatively proportional to the pressure in the ion chamber. These ions are repelled
out of the ion chamber through the exit slits by the repeller field. The combined
electrostatic effect of the repeller, exit slit, focus plates and ground slit collimates the ion
beam so that it enters the magnetic field as a straight “ribbon” of ions.
At the entrance to the magnetic field, ions of all gas species are present in the ion
chamber and if an ion collector were placed at this point, its voltage would be
proportional to the total pressure in the ion chamber. However, as the ions pass through
this magnet magnetic field, they are deflected in direction proportional to their mass to
-change ration. The spectrometer tube is typically designed and adjusted so that hydrogen
ions are deflected 1350, helium ions 900, and all heavier species less than 900.
Consequently, only helium ions pass through the field exit slits and arrive at the collector.
The collector current is therefore proportional to the partial pressure of helium in the
spectrometer tube and, within the normal operating pressure range of the MSLD, is not
affected by the pressure of the residual gases. The collector current is measured by an
electrometer amplifier and displayed on the meter.
A cold cathode ionization gauge is an integral part of the tube. It serves two functions
1) To monitor total pressure within the tube to initiate protection of the filament in
case of an excessive pressure rise.

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 2) Because of its location between the filament and the vacuum system, to minimize
the quantity of gaseous hydrocarbons reaching and damaging the filament.
The ion sources is a replaceable assembly consisting of two tungsten filament that
provides a source of electrons; an ionization chamber into which the electrons are beamed
to ionize gas molecules; a repeller plate that guides the positive ions through an exit slit;
and two focus plates that direct the ion beam towards a slit in the ground potential plate.
The magnetic fields are provided by an alnico V alloy block. The fields are adjusted by
fixed and movable pole pieces. The magnet provides fields for the cold cathode gauge
and ion source as well as the field, which separates the helium ions from the other gases.
The preamplifier assembly contains an ion collector assembly to translate helium ions
into an electrical signal from external interference and stabilize the meter reading.
During use, the ion source keeps the spectrometer tube assembly at normal high
temperature. When the ion source is turned off, however the 15-watt cartridge heater is
used to prevent condensation of contaminates in the tube and to keep it normal operating
temperature.

2) Vacuum system.
In all conventional helium leak detectors, the spectrometer tube is mounted on the inlet
side of the diffusion pump, which is connected to a mechanical pump (fore pump). The
diffusion pump keeps the spectrometer tube at the proper vacuum level. In addition,
conventional leak detectors utilize a liquid nitrogen trap to provide additional pumping
for condensable gases, such as water vapors. The trap also keeps the spectrometer tube
clean by collecting condensable contamination from the test pieces. A second mechanical
pump (roughing pump) may be used to provide faster pump down to the roughing
vacuum in the test port. A valving manifold used to affect transfer to high vacuum pump
(diffusion pump) and thereby bring the test piece to the same pressure as the spectrometer
tube.
The spectrometer tube pressure is maintained at less than 0.2 milliTorr during use. A
roughing pump is provided to evacuate the test port to a vacuum level that will not disturb
the diffusion pump’s operation (approximately < 100 milliTorr). This is typical of most
MSLD’s used in production today.

Supplementary aids to leak detector operation:

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3) Helium Spray Probe: -
In order to locate leaks when the leak detector is used to evacuate the test piece, it is
necessary to have a controllable source of helium so that the helium can be directed at the
point of leakage in small quantities. This procedure uses a spray probes and is an
examples of the outside-in test technique. The spray probe assembly consists of a flexible
hose connected to a regulated helium supply, a spring close valve, and a fine capillary
nozzle to direct the helium to a small area.

4) Sniffer Probe: -
The Sniffer probe is used in the leak location technique known as the detector probe
mode. This device attached to the inlet of the leak detector with a long flexible tube and is
used to pinpoint leaks from test parts pressurized with helium. The probe at the end of the
tube is a small orifice, which allows vacuum to be maintained in the tube at 100 milliTorr
in a Contra-Flow system or much lower in a conventional leak detector. This probe may
be a fixed orifice matched to the pump size or a variable orifice (needle valve) that can be
adjusted over the operating range of the pumping system. Any leakage in excess of 10 -5
std. cc/sec can be readily located.

5) Calibration leak: -
This device is an external reference standard that permits setting up the leak detector to
read the leak rate directly on the leak rate meter. It is a necessity if leak rated are to be
measured or if leak rates are to be measured or if the leak detector is to reject leaks in
excess of a predetermined value. The calibration leaks are normally supplied in the 10 -7 or
10-8 std. cc/sec ranges. The leak can be verified by actuating a switch.

7) TEST- CYCLE DESCRIPTION

Leak detector capable of detecting leaks from as large as 1 cc/sec to as small as 2x10-10
cc/sec (about 1 cc in 30 years). Major assemblies, which comprise the leak detector and
include – a mass spectrometer tube; a vacuum diffusion pump; thermocouple vacuum
gauge; a series of valves sequenced by an operating handle; a test port coupling for
connecting the objects to be tested; and two bar-graph displays, one for use with the
thermocouple gauge to indicate leak rate in the test object.
Initially, both the diffusion pump and the mechanical pump are running and the test port
is open (unplugged). With the operating handle in the VENT position, the vent valve is

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open and the rough valve is closed, so that air and other gases in the inlet manifolds are
vented to the atmosphere. At the same time, the test valve is open, so that the diffusion
pump evacuates the spectrometer tube and the mechanical pump evacuates the diffusion
pump through the fore line. When the diffusion pump is warned up, the spectrometer tube
is low enough (< 2 x 10-4 Torr) to permit the ion-source filament in the spectrometer tube
to be energized (there are actually two filaments, but only one is energized at a time.)
With the diffusion pump warms up and the ion-source filament energizes, the test object
is placed in (or connect to) the poet and secured, establishing a vacuum-tight seal. The
operating handle is then turned to START position, where upon the vent valve and the
test valve are closed, and the rough calve is opened. Under these conditions, the
mechanical pump is diverted from the primary function (as fore pump to the diffusion
pump) long enough to “rough” pump test object (Fig.) This “rough” pumping action may
take from several seconds to several minutes, depending on test object volume and
mechanical pump capacity. When the test port pressure is reduced from atmosphere down
to a safe level (approximately 100 milliTorr as indicated by the thermocouple gauge and
its associated horizontal bar graph display), the operating handle can be moved to the
TEST position. In this case, the test valve is opened and the mechanical pump is again
restored to its primary function as fore pump, while continuing to pump the test object.
Vacuum communication is now established between the test port and the spectrometer
tube. At this point, helium is applied sparingly to the test objects, such as from a spray
probe. If there is a leak in the test object, helium entering through the leak will spread to
all parts of the evacuated system. Some of this helium will be exhausted through the
mechanical pump to atmosphere; the rest of helium will be diffused through the diffusion
pump (against or “contra” the normal flow) and will reach the spectrometer tube is
indicated on the associated vertical bar-graph display and can be monitored on an internal
or optional external loudspeaker, as desired.
As long as helium from the spray probe enters a leak in the test object, the leak rate will
be displayed on the front panel of the leak detector. When the spray probe is removed, the
leak rate will drop rapidly as helium is quickly evacuated from the leak detector by action
of the diffusion and mechanical pumps. The end result is a rise and fall of the leak rate
indication on the display, which is a directly proportional to the leak rate in the test
object.

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 7) CONCLUSION: -

The helium leak testing is capable of detecting leaks as small as 10 -11 std cc/sec and it is
also capable of finding leaks as 1 std cc/sec. It’s extreme sensitivity in combination with
it’s capability for reliable quantitatively measurement have made it particularly popular in
many industrial application requiring exacting leak rate specification. During the last
decade this method has been simplified and automated, and it can be easily adapted to
difficult production application.
By 1970 a number of new developments has given the helium MSLD far more sensitivity
that was needed for most requirements & hence in subsequent design sensitivity was
traded for speed by simplifying & automating the cycle by integrating it into computer &
microprocessor controlled production line.
Improvements to simplify manual operations by automation reduced maintenance and
increased productivity of the helium leak detector have made it possible to expand it’s
usage and acceptance to areas not previously considered. Pharmaceutical, medical and
diagnostic equipments industries are beginning to utilize helium leak detection techniques
as appliance, automotive, chemical and similar industries have been doing in the past
decade. Meanwhile the electronics, R & D aerospace and nuclear industries that were,
once the sole domain of the helium leak testing, continues to enjoy the benefits of new
and more sophisticated leak detection equipments.
To summarize, some of the capabilities of the Helium Leak Test are listed below.
a) Leak rates down to 10-10 mbar l / s can be detected
b) Both objects with vacuum or overpressure can be examined
c) The objects can be examined during operation
d) The examination can be performed fast and effective
e) Non poisonous, non explosive and inexpensive gasses are applied
f) Leaks can be detected in due time to prevent safety or operational hazards
g) Leaks can be detected in due time to prevent unplanned and expensive shut downs

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