What Is The Pressure Decay Leak Testing Method?

Introduction to Pressure Decay Leak Testing

Pressure decay leak testing is one of the most widely used methods in manufacturing production lines. This method is simple, cost-effective compared to helium testing, and easy to automate, making it a preferred choice in various industries.

How Does Pressure Decay Leak Testing Work?

The pressure decay method involves filling a test component with pressurized air. Once the desired pressure is reached, the component is isolated from the air supply and allowed to stabilize. A sensor then measures any pressure drop over a set time.

Key principle: A decrease in pressure indicates the presence of a leak. The rate of pressure drop determines the severity of the leak. If no pressure change occurs, the component is considered leak-free.

Advantages of Pressure Decay Testing

Highly Accurate: Detects even the smallest leaks.

Cost-Effective: Uses air instead of expensive gases like helium.

Versatile: Applicable for both positive and negative pressure testing.

Broad Industry Applications: Used in automotive, medical, packaging, and industrial manufacturing.

Pressure Decay Testing Applications & Industries

Pressure decay leak testing is used across various industries, including:

Automotive – Fuel system components, radiators, and airbag systems.

Medical – Medical tubing, syringes, and sealed containers.

Packaging – Sealed food and beverage containers.

Industrial Manufacturing – Hydraulic and pneumatic components.

Pressure Decay Testing Procedure: Step-by-Step

1. Cartridge Installation & Wetting

Ensure all components are available.

Install the cartridge into the housing, securing all fittings.

If using a pre-wetted cartridge, proceed to testing.

To wet the cartridge, open valves to allow fluid flow and remove air bubbles.

2. Performing the Pressure Decay Test

Ensure all valves are initially closed.

Connect a regulated air or nitrogen source.

Slowly increase the pressure to the specified test value.

Close the valve and allow stabilization.

Measure pressure drop over a set time (typically 10 minutes).

If pressure drop is below the threshold, the component passes.

Pressure Decay Test Formula

The pressure decay rate can be calculated using the formula:

DP = D * T * Pa / V

Where:

DP = Maximum allowable pressure drop.

D = Diffusion rate limit.

T = Test duration in minutes.

Pa = Atmospheric pressure (14.7 psi).

V = Volume of test apparatus.

Common Issues and Troubleshooting

1. Air Leaks in Plumbing

Ensure all connections are airtight. Perform regular system leak checks.

2. Marginal Failures

Re-wet the cartridge and retest if necessary.

3. Incorrect Cartridge Installation

Ensure O-rings are undamaged and properly seated.

Conclusion

Pressure decay leak testing is a reliable, cost-effective, and widely adopted method for detecting leaks in manufacturing and industrial applications. By following the correct procedures and troubleshooting potential issues, manufacturers can ensure product integrity and safety.

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