An Introduction To Helium Leak methods and Techniques

Mirza Safeer Ahmad

National Centre for NDT

INTRODUCTION
Helium Leak Testing is a sensitive, reliable and most widely used method of leak detection in manufacturing industries. Typical users are the manufacturers of electronic tubes and other devices with critical operating conditions.

INTRODUCTION
Mostly the heavy and light fabricated tubes, pressure vessels and assemblies are tested using Helium leak test. Helium leak testing is used throughout industry to locate leaks in even the most complex pressure, vacuum and hermetic systems and enclosures.

FUNDAMENTALS OF LEAK DETECTION

FUNDAMENTALS OF LEAK DETECTION

Leak:
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.

FUNDAMENTALS OF LEAK DETECTION

The Need for Leak Detection:
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.

Fundamentals of Leak Detection

The Need for Leak Detection:
The fundamental question in leak detection is; what is the maximum acceptable leak rate consistent with reasonable performance life of the product?

Why A Helium Leak Detector?

High Sensitivity
Wide Range Reliable

Quantitative
Dynamic Testing
SIMS 180TD+

Helium Leak Detection

Mass spectrometer is used for helium leak detection method. Good for leak detection as large as 1 std cc/Sec and up to 10 -11 std cc/Sec. Extremely sensitive and reliable quantitative measurement capability makes it very important for systems and components which require exact leak rate specification.

Mass Spectrometer Helium Leak Detector

1 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Backing pump Roughing pump Air cooled diffusion pump Test valve Roughing valve Test port Gross leak bypass valve Liquid nitrogen trap filter Quartz reference leak Mass spectrometer Backing volume Backing valve

Why Helium?

Low Background (5-20 PPM) Inert Safe Light

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Low Cost

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Operation of Mass Spectrometer Leak Detector

Mass spectrometer is a device for electromagnetic sorting of charged gaseous particles. Mass spectrometer leak detector (MSLD) is a complete system for locating and measuring the sizes of leaks.

Operation of Mass Spectrometer Leak Detector

MSLD operating principle consists of ionization of gases in vacuum. These ions are accelerated with high potential difference and magnetic field.

Operation of Mass Spectrometer Leak Detector

Factors to be Considered for the Selection of Helium Leak Testing Technique

Size, shape, and location of the equipment to be tested. Choice between use of pressure or vacuum or both for testing. Maximum leakage rate specified or that can be tolerated.

Factors to be Considered for the Selection of Helium Leak Testing Technique

Degree of automatic leak testing operation required. Number of parts or complexity of the system to be tested.

Operation of Mass Spectrometer Leak Detector

Tracer Probe Method

The mass spectrometer leak detector is connected to the internal volume of an evacuated test object (such as a vessel or piping system) while a helium spray tracer probe is moved over the external surface to detect the specific locations of leaks. The interior of the test piece is

Tracer Probe Method

The interior of the test piece is evacuated A probe is used to directly spray the test gas on the suspected leak sites Any leaks are evidenced when the tracer gas flows through the evacuated test piece and is detected by the leak detector.

Tracer Probe Method

Tracer Probe Method

Detector Probe Method

The test object or system is pressurized internally with helium or a gas mixture containing helium. The mass spectrometer leak detector is connected to the hose of a scanning probe that collects samples of gas leaking from the external surface into the surrounding atmosphere.

Detector Probe Method

To verify probe response before scanning the test object, the probe should be moved past the orifice of a known helium source at the same speed and distance as will be used for the test object.

Detector Probe Method

The detector probe technique can be used to determine leak locations but is inadequate for leakage measurement or for finding leaks smaller than I0-7 Pa-m3/s (I0-6 std cm3/s).

Detector Probe Method

Detector Probe Method

Hood Method (Outside In Mode)

When vacuum leak testing by the hood technique, the mass spectrometer leak detector is connected to the evacuated interior of the system under test. The test object or system is then placed under a hood or within a chamber containing helium gas or an air helium mixture usually at atmospheric pressure.

Hood Method (Outside In Mode)

This technique can be used to quantify the total leakage rate of the system. However, it cannot be used to determine the specific locations of leaks.

Hood Method (Outside In Mode)

Hood Method (Outside In Mode)

Bell Jar Method (Inside Out Mode)

Sealed components filled with helium or a gas mixture containing helium are placed in an evacuated testing chamber. The mass spectrometer connected to this vacuum chamber detects helium leaking from any part of the surfaces of the sealed test objects in the vacuum chamber.

Bell Jar Method (Inside Out Mode)

This test does not permit location of leaks on the test object surfaces. The test part is filled with helium gas or gas mixture containing helium.

Bell Jar Method (Inside Out Mode)

Bell Jar Method (Inside Out Mode)

Accumulation Method
Leaking helium tracer gas is allowed to collect for a period of time before being sampled by the leak detector. The accumulation method does not usually permit leak location. However, by sealing off small surface areas and accumulating tracer gas within the sealed volume, areas of leakage can be localized.

Dynamic Testing
When Helium leak testing is performed with the high vacuum pump of a helium mass spectrometer continually pumping on the test object.

Static Testing
When the vacuum pump is disconnected from the test object.

This method accumulates helium leakage to make a more sensitive measurement and is relatively uncommon

Techniques for Locating Leaks

Spraying Method Sniffer Probe Technique

Spraying Method
This method is applied to objects and systems that can be evacuated. MSLD is connected directly to the interior volume of the system under test. After evacuation of the test object or system the exterior surface or suspected areas are sprayed with a fine jet of helium from a helium probe.

Spraying Method
A portion of any helium tracer gas entering the vacuum system through a leak is drawn into the mass spectrometer leak detector. The presence of helium in the mass spectrometer tube is indicated both audibly and visually by alarms.

Spraying Method
The concentration of the helium in the spectrometer tube is indicated by the deflection of the pointer on a panel meter. Careful scanning with the helium probe permits positive location of leaks.

Sniffer Probe Technique

Internal pressure instead of vacuum is used for conducting a leak test. This method of testing is referred to as pressure testing. Such tests require introducing a tracer gas within the test object or use a mixture of a trace gas and some other gas such as nitrogen, under a pressure greater than the atmospheric.

Sniffer Probe Technique

Sniffer Probe Technique

In the sniffing test, the probe used for the detection of leak location is called sniffer probe. This device attaches to the inlet of the leak detector with a long flexible tube and is used to pinpoint leaks from test parts pressurized with helium.

Sniffer Probe Technique

Vinyl tubing or flexible metal tubing may be used to connect the sniffer to the helium leak detector. The length of a vinyl probe hose should not exceed 2m (6 ft.) for optimum speed of response and clean up. The sensitivity of this technique varies with length of the probe hose.

Technique for Accumulation pressure testing

This technique detects the total amount of leakage by enclosing the component under test within the bag, box, shroud or container. Any gas leaking from the component accumulates in the space (volume) between the component and the enclosure.

Technique for Accumulation pressure testing

A measurement of the accumulation of tracer gas in a measured time period provides a measure of the leakage rate. The pressure method used to measure this type of leakage with a mass spectrometer leak detector is called accumulation testing.

Technique for Accumulation pressure testing

The vessel to be tested is pressurized with a tracer gas and placed in a sealed room with a leak detector and probe, or the instrument can be outside and the probe connected to the chamber through a port or opening.

Technique for Accumulation pressure testing

The accumulation technique may be applied to vessels of any size or configuration that are capable of being pressurized at greater than atmospheric pressure.

Parts per million testing

In this method, the vessel to be tested is pressurized with helium and placed in a sealed room with a leak detector, or the instrument can be out side and connected to the room by a test line. A sampling probe is attached with the leak detector and instrument pressure is set and maintained at 25m Pa (0.2 m of Hg).

Parts per million testing

The percentage of helium in air is 0.000 4%. To avoid confusion, it may be desirable to zero this reading out of the system, after calibration, and before leak testing the vessel. Then any leakage of helium from the pressurised vessel will be picked up by the leak detector.

Global Test
The best way to conduct this type of test is to enclose all or part of the evacuated system under test with an atmosphere containing helium. The helium will enter the system under test if any leaks are present. The internal volume of the test object is connected directly to a vacuum pump.

Global Test
The leak detector in turn is connected to the vacuum pump system. Helium leaking from the hood into the test object is detected by the leak detector. This test permit the determination of a total leakage rate for the entire system. The porosity of almost any material, including metals and ceramics, can be measured by this method.

Bomb and backfill (bell Jar)

This method is used for sealed objects which can not be attached directly to the detector. The object is first placed in a vessel containing helium under pressure. Helium penetrates into the object if it has a leak.

Bomb and backfill (bell Jar)

The object is then removed from the vessel and placed in another vessel which is connected to the detector. Helium escapes from the object through the leak, and produces a signal.

Vacuum System of MSLD

Mechanical roughing pump. Mechanical rotary van backing or fore pump. Oil vapour diffusion pump or turbo molecular pump. Cryogenic pumping surface. Associated Valve & gauges.

Vacuum System of MSLD

Capabilities and Limitations of Helium Sniffer Leak testing

The sensitivity of the helium sniffer leak test method in a normal field environment will enable detection of leakage rates in the range of 10-3 to 10-4 pa. m3/sec (10-2 to 10-3 std. cm3/sec), at differential pressure of 100 kPa (1 atm.) using helium mixture of 2 to 5% by volume.

Capabilities and Limitations of Helium Sniffer Leak testing

Using the accumulation technique of bagging with polyethylene and rigidly controlling the factors affecting sensitivity, it is possible at a differential pressure of 100 Kpa ( 1 atm.) to detect much smaller leakage rates of 1 x 10-5 pa. m3/sec (10-4 std. cm3/sec) using helium mixture of 2 to 5% by volume.

Capabilities and Limitations of Helium Sniffer Leak testing

The increase of sensitivity obtained by bagging and accumulating is directly dependent on time of accumulation

Calibration of Helium Leak Detector

Calibration of the instrument merely correlates the output signal with a known flow of helium Calibration is usually accomplished by adjusting the gain, or amplifier feedback, until leak rate meter reading agrees with the value stamped on the standard leak.

Calibration of Helium Leak Detector

A standard calibrated helium leak with 100% pure helium at atmospheric pressure is generally used to calibrate the helium leak detector. The leaking membrane is a silica quartz bulb with diffusion type leakage. The calibration leaks are normally supplied in the 10-6 or 10-10 Std CC/Sec ranges.

Calibration of Helium Leak Detector

The calibration temperature is labelled on each standard leak, and a temperature correction factor is also given.

Concentration of tracer Gas

The concentration of helium tracer gas shall be approximately 10% by volume at the test pressure, unless otherwise specified by the referencing code section. The test pressure shall be held a minimum of 30 minute.

MASS SPECTROMETER
A mass spectrometer is a device that sorts and filters various types of charged particles. As gas enters an analyzer, a filament releases a stream of electrons that converts the gas particles into charged ions that are accelerated to a rapid speed.

MASS SPECTROMETER

Under a constant magnetic field, ions that share the same mass move along a specific trajectory toward a collector, which accumulates only the targeted molecules.

MASS SPECTROMETER

Specialized devices, such as helium mass spectrometers, can be configured to remain sensitive only to a particular range of atomic mass, allowing other molecules to pass through the detector without triggering the collector.

MASS SPECTROMETER

Mass spectrometers can only operate within a vacuum, making them effective for leak detection in vacuum systems, but can be adapted for pressurized tracer gas systems through the addition of a probe or an enclosure for collecting leakage.

MASS SPECTROMETER

However, a mass spectrometers sensitivity and minimum leak detection rate tend to decrease when the device is applied to a pressure system.

MASS SPECTROMETER
The mass spectrometer produces a beam of positive ions from a sample of tracer gas being investigated, sorts these ions into a spectrum of mass-to-charge ratios, and records or indicates the relative abundance of each species of ion present.

MASS SPECTROMETER
In mass spectrometers, the ion currents of specific ion species are detected electrically. The signal is usually amplified electronically before being displayed or recorded.

MASS SPECTROMETER
The primary functions of a mass spectrometer instrument are to be sufficiently sensitive to detect all desired ion currents and to be able to resolve or separate completely the ion currents due to different ion species.

MASS SPECTROMETER
Pumping tracer gas samples from leaks in test objects into the vacuum of the instrument. The ionization of gas sample molecules by electron impact. The sorting and identification of positive ions according to their mass-to-charge ratios.

MASS SPECTROMETER
Hot tungsten filaments High Potential Difference and vacuum Analyzing magnetic field Separating slits Target plate Electrometer (charge detector) Amplifier display meter Vacuum Pumps

SNIFFER
This simple tracer gas collection device is connected to a leak detector with a pumping system. The pump provides the suction necessary to draw tracer gas samples into the sniffer inlet, through the connecting hose, and into the sensing element of the leak detector.

SNIFFER
A screw adjustment on the sniffer gun provides for control of the gas intake and throughout to the leak detector instrumentation. A sleeve or rubber nozzle on the tip of the probe collects the leaking tracer gas which will travel to the detector.

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