Leak Testing

Choosing the right pressure sensors and instruments is crucial for effective leak testing.

Key considerations for sensor selection include sensitivity (especially resolution for small leaks), stability (low drift over time and appropriate operating temperature), pressure type (gauge, absolute, or differential), test medium compatibility, and output signal. Digital indicators should have clear displays and configurable units. For automated testing, programmable alarms with appropriate outputs are important. Data loggers offer comprehensive analysis capabilities, so consider capacity, sampling rate, and data transfer methods.

• Sensitivity is paramount: Select sensors with high resolution to detect minute pressure changes indicative of small leaks. Consider the tested component’s volume and expected leak rates.
• Stability matters: Choose sensors with low drift over time and a suitable operating temperature range to ensure consistent, accurate readings.
• Match pressure type to application: Determine if you need gauge, absolute, or differential pressure measurement based on the specific leak test setup.
• Ensure media compatibility: Verify that sensor materials are compatible with the test gas or liquid to prevent corrosion or degradation.
• Consider integration needs: Select sensors and instruments with output signals and features (like alarms or data logging) that align with your existing data acquisition and control systems.

Whether you’re testing critical components or monitoring large systems, these sensors and instrumentation provide the accuracy and reliability you need for effective leak detection and prevention.

• Pressure Gauges with Integral Data Logger - Digital pressure gauges combined with a programmable data logger for recording pneumatic or hydraulic pressures at set time periods.
• High Accuracy, Precision & Resolution Pressure Gauges - Explore high accuracy pressure gauges with superior precision & digital resolution, ideal as secondary standards for calibration labs & ISO 9000 procedures.
• High Resolution Pressure Transducers - High resolution pressure transducers with an analog voltage output for detecting very small changes in pressure or measuring pressure to a high precision.
• Hydraulic Testing Intrinsic Safety Approved Pressure Data Loggers - Intrinsically safe pressure data loggers are essential tools for testing and validating the performance of hydraulic systems in hazardous environments where explosive atmospheres may be present.
• Air Pressure Data-Loggers - Air pressure data loggers are essential tools for monitoring and recording air pressure in various industrial and research settings.
• Low Pressure Data Loggers - Low pressure data loggers offer precise and reliable tracking of gauge or differential air pressures in critical environments such as ventilation systems and clean rooms.

• DM01 Multi-Range High Accuracy Pressure Gauge
• DPC Low Range Pressure Controller and Calibrator
• UPS-HSR USB Pressure Sensor with High Sample Rate Logging
• 33X High Accuracy Digital Output Pressure Sensor
• 41X Low Range Digital Output Pressure Sensor
• LEO3 Current or Digital Output Pressure Gauge
• LEX1 (Ei) High Accuracy Digital Pressure Gauge
• MultiCon Multichannel Controller and Datalogger
• XSYS-0011 Portable Multichannel Data Logger with Optional Printer and Integrated Transport Case

• 10Pa diff range 0-20mA output air pressure sensor for automotive component testing - A very low range pressure sensor for automotive component testing use to measure pressure of air over a range of 0 to 10 Pa diff from two barbed tube hose connections, and sending the corresponding 0-20mA signal through the DIN plug electrical connection.
• 15psig 0-10Vdc output pressure sensor for nitrogen filled antenna line leak testing use - A high resolution analog voltage output pressure sensor for nitrogen filled antenna line leak testing use to measure pressure of nitrogen over a range of 0 to 15 psi g from the 1/4 NPT male process connection, and sending the corresponding 0-10Vdc signal through the DIN plug electrical connection.
• 100 bar Pipeline Hydrostatic Leak Test Pressure Recorder - Record water pressure and temperature for hydrostatic leak testing a new section of pipeline.
• 10m range high resolution 4-20mA out submersible freshwater tank level sensor - A high resolution submersible water level sensor for submerging in a freshwater tank and measuring the depth over a range of 0 to 10m from the flush diaphragm, and sending the corresponding 4-20mA signal through the submersible cable electrical connection.
• Pass/Fail timed 500 kPa pressure leak test software and sensor - Pressure sensor that can be easily interfaced with a computer to log results for a PASS/FAIL pressure leak test to 500 kPa and monitored for a pressure drop over a 5-10 minute time period
• Leak testing at 0.5 bar to detect 200 Pascal pressure drop - The parts have to be checked at 0.5bar pressure. We are interested in measuring leakage which results in a drop of 200Pa pressure over a period of 10 sec.
• Aerospace component testing hi-temp air pressure sensor for up to 300C with 20 barg range - Conduct accurate aerospace component testing with the DMP 331P pressure sensor. With a 20 bar g range and 300°C temperature capability, it's ideal for testing pneumatic valves, heat exchangers, and sensors under simulated operating conditions.
• Automotive water testing pressure sensor with 10 barg range and 0-5v output - Economical corrosion resistant ceramic diaphragm pressure sensor for measuring water pressure over a 10 bar gauge pressure range on an automotive test rig and generating a 0 to 5 volts output signal.
• 150psig range wireless pressure sensing kit for leak testing use - Wireless pressure measurement kit for plumbing system leak testing use with a 150psig range plus a 1/4 NPT male fitting. Each pressure reading is transmitted wirelessly to a single channel base receiver, where it is converted to a 1-5Vdc or 4-20mA analogue output signal.
• 750psig range wireless pressure sensing kit for leak testing use - Wireless pressure measurement kit for leak testing use with a 750psig range plus a 1/4 NPT male fitting. Each pressure reading is transmitted wirelessly to a single channel base receiver, where it is converted to a 1-5Vdc or 4-20mA analogue output signal.
• Detecting leaks in industrial estate water supply network - We are looking for a solution to monitor water network pressure changes to detect leakage in a short time period.
• Pressure drop logging at 3 bar over a few seconds - I need to measure pressure drop in a leaking system. The initial pressure is 3 bar and I need to measure the pressure drop over a few seconds

Choosing the right pressure sensors and instruments is crucial for building an effective leak testing rig or integrating leak detection capabilities into your equipment. This guide outlines key considerations for selecting the appropriate components for your specific needs.

Sensitivity is paramount when selecting a pressure sensor for leak detection. The sensor must be capable of detecting the smallest pressure changes that indicate a leak. Consider the expected leak rate and the volume of the tested component. For very small leaks or large volumes, a high-resolution sensor with exceptional sensitivity is essential. Conversely, for larger leaks or smaller volumes, a sensor with moderate sensitivity might suffice. The sensor’s resolution, which refers to the smallest pressure change it can detect, is a critical specification to consider.

Stability is another important factor. The sensor should maintain its accuracy and reading stability over time, even in varying temperature and environmental conditions. Drift, which is a gradual change in the sensor’s output over time, can lead to inaccurate readings and missed leaks. Look for sensors with low drift specifications and consider recalibration schedules to maintain accuracy. The sensor’s operating temperature range should also be considered to ensure it functions reliably in the intended environment.

The type of pressure being measured is also crucial. Are you measuring gauge pressure, absolute pressure, or differential pressure? Gauge pressure is relative to atmospheric pressure, while absolute pressure is relative to a perfect vacuum. Differential pressure is the difference between two pressures. The choice of pressure type depends on the specific leak testing application. For example, testing for leaks in sealed enclosures often requires absolute pressure measurement, while testing for pressure drops in pipelines might use differential pressure.

Compatibility with the test medium is essential. The sensor’s materials of construction must be compatible with the gas or liquid being used in the leak test. Corrosion or degradation of the sensor due to incompatibility can lead to inaccurate readings and premature failure. Check the sensor’s specifications for compatibility with the intended test medium.

The output signal of the sensor is also important for integration with other instrumentation. Common output signals include analog signals such as voltage or current, and digital signals. Choose a sensor with an output signal that is compatible with your data acquisition system or control system.

When selecting a digital pressure indicator, consider the display resolution and accuracy. The display should provide clear and easy-to-read pressure readings. Features such as user-configurable units of measurement and graphical displays of pressure trends can be helpful.

For automated leak testing, programmable alarm modules are essential. These modules allow you to set specific pressure thresholds that trigger an alarm when breached. Consider the number of alarm points required and the types of alarm outputs available, such as audible alarms, visual alarms, or relay outputs for integration with other control systems.

Data logging capabilities are valuable for comprehensive leak analysis. Data loggers capture pressure readings over time, allowing you to identify trends and patterns. Consider the data logging capacity, sampling rate, and data transfer method when selecting a data logger. The ability to analyze the logged data can provide valuable insights into leak rates and system performance.

Related Online Tools

• Leak Rate Calculator
• Leak Rate Converter

Related Product and Application Guides

• Data Loggers

Related Application Questions and Answers

• USB pressure sensors for detecting water leaks & restrictions
• Leak testing set for checking 1mb/min drop at negative 10 mbar vacuum
• Pass/Fail timed 500 kPa pressure leak test software and sensor
• Leak testing at 0.5 bar to detect 200 Pascal pressure drop

Contact us about this Leak Testing page to request more information, or to discuss your application requirements.