When designing a leak testing system for valves and fittings, there are several key factors to consider to ensure efficiency, accuracy, and safety. From deciding between manual and automated loading, selecting appropriate test methods, understanding test part materials, and more, each element plays a crucial role designing the ideal testing process. Here are 5 key questions to ask when developing a leak test solution, which will help you make a more informed decision that aligns with your production needs and quality standards.
1. Will the leak test solution be automatically or manually loaded?
Valves and fittings can be leak tested using either manual or automated loading methods (or a combination of both). The ideal choice depends on several factors, such as throughput goals, product variety, operator availability, budget, and other considerations. Our team can help you identify what is capable of being fully automated, and what may require manual operator support.
Whether your leak test machine is automatic or manual, operator safety is the first priority. All machines must ensure operator safety (including CE certification and TÜV regulations). Safety features may include ergonomic design, high pressure venting in case of bursting, closed-door systems for high-pressure, open-door setups for low-pressure and more.
2. What tests need to be performed?
The tests that will need to be performed will depend on the specific design elements of your part, and potential regulatory requirements of your industry and application. These tests could include one or more leak test procedures as well as several functional test processes. Common types of tests for valves and fittings manufacturers include external leak tests, internal leak tests, flow tests, membrane testing, back pressure testing, motion testing, latching test, and more.
3. How many part variants do you manufacture?
Valves and fittings manufacturers often have many different variants produced on the same line. The ability to combine different tests and test many part variants with one machine greatly optimizes the investments in tooling and training and can boost overall efficiency.
Since many tests must be performing on valves and fittings to ensure they meet product quality requirements, including leak tests and functional tests, it is common to design a leak test machine that can accommodate these different tests and product variations in one machine. This is made possible using flexible leak testers and strategic use of connectors and fittings. Ideally, the number of fixtures is kept to a minimum, with the goal of eliminating the need for changeovers as much as possible.
4. What materials are your parts made of?
Most commonly, valves and fittings are made from one of the following materials: steel, copper, or plastic. For steel and copper, test options are wider, though you do need to be sure to avoid any methods that could cause corrosion, deformation, cracks, etc.
If the part is plastic, you need to be particularly careful when designing the test. For example, some plastics are more malleable, and you will need to be careful to avoid ballooning or part expansion that could occur when testing with high test pressures, etc. Certain test materials like helium can also be a challenge as it can permeate certain plastics.
5. What test pressure is required?
The test pressures required for your valve and fitting tests could vary greatly; from vacuum to 1000bar. While most applications will not require pressures that high, special accommodations for safety and pressure control should need to be considered in your machine design. For optimal cost-effectiveness, ensure you are using a flexible, high-performance leak tester to be able to accommodate a wide variations of test pressures using the same machine.
Have questions about leak testing valves and fittings? Consult the leak test experts!
With more than 40 years’ experience supporting manufacturers, innomatec has engineered innovative solutions for safe, efficient, and precise valve and fitting testing. Our manual and automated systems streamline fixturing and sealing, even when testing multiple part variants on a single machine.
Contact us to develop a customized leak testing approach that ensures the quality and performance of your valves and fittings. Our team will ensure compliance with regulatory standards while delivering the most accurate, safe, and efficient testing process for your operations.