Innovations in Leak Detection
Presented by
Mike Ryan
Leak Detection Market Manager
INFICON
Two Technology Place
East Syracuse, NY 13057
315-434-1100
E-mail: mryan@[Link]
Innovations in Leak Detection
• Outline
– Production Leak Detection
• Current Practices
• Advances
• Future Trends
– Field Leak Detection (On-Site Service)
• Current Practices
• Advances
• Future Trends
Leak Detection
• If a System Leaks • Many Leak Detection Methods
– You Have a Problem – Some better than others
Production Leak Detection
• Current Situation
– System Integrity Test
• Pressure Decay for Gross Leak Test
• Pressure Burst Test
• Helium Mass Spectrometry Testing
– Final Test
• Charged System Tested under Operation Conditions
• Heated Diode, Quadrupole Mass Spectrometry or new
IR Sensor Detection
Production Leak Testing
• System Integrity - Pressure Decay Testing
– Pressurize system to high pressure and look for
ability to hold pressure
• Pressure decrease indicates large leak
• Inability to reach high pressure indicates gross leak
– Finds gross leaks
– Prevents helium contamination of work station
Production Leak Testing
• System Integrity - Helium
Leak Detection
– Helium is used as a tracer
gas to locate leaks
– Primary method is Sniffer
Leak Detection
• Unit is evacuated and
backfilled with Helium
• Operator scans product
with Sniffer Wand to find
and locate leaks
– Sensor Helium Mass Spec
Production Leak Testing
• System Integrity -
Helium Leak Detection
– Good Sensitivity
– Detects and Locates
Leaks
– Environmentally Friendly
– Results Dependent on
Operator and
Environment
Production Leak Testing
• Final Test – Refrigerant Leak Detection
– Refrigerant charge used as tracer gas
– Primary method is Sniffer Leak Detection
• Unit evacuated, charged with refrigerant and typically
goes through “Run Test”
• Operator scans product with Sniffer Wand to find and
locate leaks
– Good Sensitivity
– Detects and Locates Leaks
– Tests performed under operating conditions
– Results Dependent on Operator and Environment
Production Leak Testing
• Final Test – Refrigerant Leak Detection
– Sensors for Refrigerant Sniffer Leak Detection:
• Heated Diode Sensor
– Older technology still in use today
• Quadrupole Mass Spectrometer
– State of the art in gas detection
– Employed today and long into the future
– Extremely sensitive and extremely selective
• IR Sensor
– New sensor technology
– Technical advantages over the Heated Diode
Advances In Production Testing
IR Sensors
• Technology to displace Heated Diode Sensors
• Greater selectivity – less false alarms
• Equal Sensitivity to Large Range of Refrigerants
• Longer sensor life
• Adaptable to many refrigerants
– Halogenated Refrigerants, CO2, Ammonia, etc
– Better platform for new refrigerants and blends
• Consistent sensor sensitivity throughout life
• Better Cost of Ownership
The Infrared Cell – functionality, pt 1
The filtered infrared energy passes through the sampling cell, striking
the infrared detector. Only the specific wavelengths that are
absorbed by refrigerants are present in the cell. The IR Sensor
based leak detector is ready to sense any refrigerant that enters the
sampling cell.
The Infrared Cell – functionality, pt 2
The filtered infrared energy is absorbed by the refrigerant present in the
sampling cell and no longer strikes the infrared detector. This leads to a
drop in temperature on the surface of the infrared detector, causing the
IR Sensor based LD to alarm.
Advances in Production Testing
HLD5000 Dual Inlet Sampling
• Gas is drawn alternately from two inlets, alternating 3 times each second.
• Any Refrigerant in either of the two gas streams absorbs Infrared Light, as it fills
the cell.
• The signal from ambient is subtracted from the signal from the leak.
Future Trends In Production
• Removal of Operator Influence
– Advances in Probe Designs to Facilitate Testing
• Angled Probe Tip
• Lights in Probes to Illuminate area under test
• Displays in Probe Handle
– Leak rate
– Concentration bar graph indicator
– Pass/Fail Indicator
– Gas Display
• Vibrator and Alarm in Probe Handle
Future Trends In Production
• Removal of Operator Influence
– Advances in Probe Designs to Facilitate Testing
• Increased Sample Flow with Same Sensitivity
– Compensates for operator error
» Increase Probability of Finding Leaks at Greater Distance
» Increase Probability of Finding Leaks at Higher Scan Rates
» Faster Response
• Computer Aided Test Stations
• Motion Sensors in Probe
• Transponder Technology to Track Proper Probe Movement
• Vacuum Leak Testing
Field Service Leak Detection
• Current Situation
– A Number of Technologies are Employed
• Each has its Advantages and Disadvantages
– Current Leak Detection Technologies In Use
• Halide Torch
• Soap Bubbles
• Fluorescent Dye (UV Light)
• Ultrasonic
• Fluorescent Dye (UV Light)
• Electronic Leak Detectors
– Surface Reaction Sensor
– Corona Suppression (Corona Discharge)
– Heated Sensor (Heated Diode)
Advances In Field Leak Detection
• Heated Diode Sensors
– Numerous Models Available
– Improved Performance over other Methods
• Faster and More Reliable Detection
• Halogen Selective
– Reduces, but does not Eliminate False Alarms
• Sensitivity greater than 0.25 oz/yr for all refrigerants
(including blends)
• Humidity Immune
Advances In Field Leak Detection
• Heated Diode Sensors
– Disadvantages
• More Expensive Sensor and Support Electronics
• Sensor is a Consumable Item
– Effects Cost of Ownership
• Sensor Life Dependent on Refrigerant
• Exposure to Large Leaks Reduces Life
• Slower Recovery after Large Leak Exposure
• Platform not Fully Adaptable to New Refrigerants
The Future of Field Leak Detection
• IR Sensor Technology
– The Future is Here
• Miniaturization of Production IR Sensors
– Many Benefits
• Improved Sensitivity (approaching 0.04 oz/yr)
– Pick-Up Lower Refrigerant Concentrations
• Selective Sensor Technology
– Reduced Cross Sensitivity
• Fast and Accurate Leak Detection
– Greater Efficiency and Effectiveness when Leak Testing
» Time is Money
The Future of Field Leak Detection
• IR Sensor Technology
– Benefits (continued)
• Better Confidence in Results
• Long Sensor Life
– Better Cost of Ownership
• Detects New Refrigerants/Blends that Other
Technologies cannot.
• Adaptable Platform for Future Refrigerants and Blends
– Halogen and Hydrocarbon based gases
– CO2, Ammonia, and others.
– Need to Educate the Industry of the Benefits
Innovations in Leak Detection
Presented by
Mike Ryan
Leak Detection Market Manager
INFICON
Two Technology Place
East Syracuse, NY 13057
315-434-1100
E-mail: mryan@[Link]
