Inefficient gas valve batch airtightness testing? Pressure drop method is your best choice

There are three prevailing methods for testing the airtightness of gas valves:Foam water test method(Intuitive but limited precision),pressure drop(the best option for balancing efficiency and cost),flow rate method(High Precision Professional Inspection). The choice depends on your specific requirements for accuracy, efficiency and budget.

Imagine a scenario where a tiny gas leak is silently building up in the early hours of the morning until it reaches the tipping point of explosion. This is not alarmist talk, but a real consequence of what can happen when a gas valve seal fails.

The annual accidents caused by gas leaks remind us:Gas tightness testing of gas valves is by no means optional, but is the last line of defense to protect life and property.

I. Technical analysis of the three detection methods

Foam water test method: simple but not sketchy

This is the oldest and most intuitive method of detection. When gas escapes from a leak, it forms a continuous bubble on the surface of the foamy water.

Testing process ::

1. Preparation of foam water or use of specialized leak detection fluids
2. Apply evenly with a brush to possible leakage areas
3. Observe for persistent air bubbles

Applicable Scenario Analysis ::

• ✅ Family self-examination:Almost zero cost and easy to operate
• ✅ Initial on-site screening:Rapid identification of obvious leaks
• ❌ Precision testing:No detectable small leaks (less than 1 x 10-³ Pa-m³/s)
• ❌ Batch production:Too inefficient to quantify results

The limitations of this approach areIt can only tell you"TheIs there a leak?"But I can't tell you."TheHow much is missing?"The

Pressure drop method: the mainstream choice for industrial inspection

The core idea of the pressure drop method is to trade time for accuracy. Fill a sealed valve with gas at a set pressure and watch the pressure change over time.

In-depth analysis of technical principles : When there is a leak in the valve, the internal gas escapes through the gap, causing a pressure drop.This rate of pressure drop data is a direct reflection of the severity of the leak.

Testing process::

1. Seal Preparation:Seal both ends of the valve with the special fixture
2. Inflated and stabilized:Fill the test gas to the set pressure and wait for the gas to saturate and stabilize.
3. Pressure retention testing:Shut off air supply and monitor pressure changes
4. Data analysis:Comparison of pressure drop values and leakage thresholds

Core Advantages::

• Quantifiable detection:Accurate measurement of leakage for quality control
• Non-destructive testing:Does not cause any damage to the product
• Automation friendly:Easy integration into production lines
• Cost-effective:Optimal balance between equipment investment and inspection accuracy

The technical challenge: Temperature fluctuations can affect gas pressure, but Precision Engineering'sairtight equipmentThis problem has been largely solved by temperature compensation algorithms.

Flow Methods: The Ultimate Means of Detecting Tiny Leaks

The flow method uses a more direct measurement idea: directly measuring the flow of the leaking gas.

Working mechanisms: The unit continuously supplies gas to the valve to maintain a constant pressure. If there are leaks, constant gas replenishment is required to maintain a stable pressure.This supplemental flow rate is the exact amount of leakage.

Technical Advantages::

• Extremely high precision:Detects extremely small leaks
• Rapid Response:Shorter detection time than pressure drop method
• Environmental adaptability:Unaffected by temperature changes
• Data visualization:Direct display of leakage flow values

Cost considerations: The price of the equipment is relatively high, but for application scenarios where high precision is required, the investment is worthwhile.

II. How to choose the most suitable testing method

Selection matrix based on application scenarios

application scenario	Recommended Methods	rationale
Daily home inspections	bubble water method	Low cost and easy to operate
Production line quality control	pressure drop	Optimal balance of efficiency and precision
High Precision Requirements	flow rate method	Detects the tiniest of leaks
Cost-sensitive batch testing	pressure drop	Moderate investment in equipment and reliable testing results

Quantitative analysis of accuracy requirements: Tolerance for leakage varies greatly from industry to industry:

• Residential gas valves:Typically, leakage rates of less than 1 x 10-² Pa-m³/s are required, which is well met by the pressure drop method.
• Industrial gas systems:It may be required that the leakage rate is less than 1×10-⁴ Pa-m³/s, which needs to be detected by the flow method.
• Special application scenarios:Leakage requirements may be more stringent, as in the case of medical gas valves.

III. Selection and application of specialized equipment

In the field of gas tightness testing of gas valves, the choice of equipment directly determines the reliability of the test results.

Shenzhen Jingchenggongke Technology Co., Ltd.has gained a wealth of experience in this field and is able to provide:

• Customization of technical solutions
  • Pressure drop test equipment::For different specifications of gas valves, to provide the corresponding detection accuracy and efficiency configuration. The equipment is equipped with a temperature compensation function to ensure the stability of the test results.
  • Flow method testing equipment::Suitable for application scenarios where high precision is required, it can detect extremely small leaks and provide the highest level of product quality assurance.
  • Specialized workholding fixtures:According to the specific structure and size of the valve, special sealing fixtures are designed to ensure the standardization and repeatability of the inspection process.
• Automation Integration Capabilities
  • Seamless integration of production lines:Perfect interface with existing production processes
  • Data is automatically recorded:Establishment of a complete quality traceability system
  • Intelligent Troubleshooting:Reduced equipment downtime
  • Remote monitoring capabilities:Realize real-time control of equipment status
• Integrity of the service system
  • Pre-consultation:Recommend the most appropriate testing program for your specific needs.
  • Equipment commissioning:Ensure that the equipment performs optimally in your production environment.
  • Operational training:Get your technical team up to speed on the essentials of equipment operation.
  • Ongoing support:Provide long-term technical support and equipment maintenance services.

IV. Long-term value of quality control

investment professionalAir tightness testing equipmentThe company has gained not only technological advancement, but also the accumulation of brand value.

• risk management: Eliminate safety hazards before they leave the factory and avoid subsequent huge losses.
• brand reputation: Every product that undergoes rigorous testing is a fulfillment of the brand's promise.
• Market Competitiveness: In a market environment with increasingly stringent safety requirements, quality testing capabilities have become an important competitive advantage.
• cost-effectiveness: Although an upfront investment in equipment is required, potentially huge losses such as product recalls and accident compensation are avoided.

Gas tightness testing of gas valves is not optional, but a necessity. Choosing the right testing method and equipment is responsible for the safety of the user and for the future of the company.

If you are looking for professional gas valve airtightness testing solutions, or have questions about existing testing methods, Precision Industrial Gas Tightness's professional team is ready to provide you with advice and technical support. Let the progress of technology to escort the safety, so that every test becomes a witness of quality.

Original Statement: this paper was written byShenzhen Jingchenggongke Technology Co., Ltd.Written by the technical team, reproduced with attribution.Data sources:Precision Engineering internal test data and customer cases.