Leak Testing of Hydraulic Applications

As manufacturers are keenly aware, the mechanical components of a hydraulic system must be very stable and able to withstand considerable pressure to avoid a leaking connection, resulting in a sudden loss of hydraulic fluid and rendering a machine inoperable from extensive contamination. Leak testing helps ensure the soundness of a hydraulic system.

Comprehensive leak testing of all components - tubes, hoses, pressure tanks, compressors, etc. - and any assembled hydraulic machine prior to being filled with hydraulic fluid is crucial. Once the hydraulic oil is in the system, any compromised component or leaky connection can result in the loss of a large amount of the fluid. Any subsequent leak testing (using a gas) becomes even more difficult, as small leaks can be temporarily plugged by residual oil, which can lead to leaks later on.

Helium leak testing is a simple and environmentally safe method to test for leaks. The pressure system (or specific parts) are evacuated and filled with helium or a helium-gas mixture at excess pressure. A helium sniffer then checks all critical points to detect any emerging test gas, which is fed to the leak detector. The detector unit calibrates the amount of measured gas, resulting in a precise estimate of the size of the leak. Taking the operation pressure into account, the leak size estimate is converted directly to the amount of hydraulic fluid that can potentially be lost. This leak test method is used when any loss of fluid could lead to environmental pollution or equipment downtime. The range of test applications includes all applications for hydraulic technology, including:

• Automotive - transmissions, brakes, power steering, injection pumps, valve control systems, etc.
• Construction equipment - chassis, rotating platforms, bucket hydraulics, and actuators for all accessory equipment
• Cranes - telescoping masts and support beams
• Airplanes - landing gear and steering mechanisms (flaps)
• Ships - bow doors and chain hoists
• Machine tools - presses, cutters, chuck tools, and trimmers

Further include elevators, forestry equipment, roller mills, mining equipment, and all jobs that need to move heavy loads.

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