Helium boosting & decanting with hydro test. 150 bar.

Why integrated helium handling matters

Helium is the second lightest element, an inert noble gas with a boiling point of −269°C and unique penetration characteristics that make it the preferred medium for precision leak testing. Unlike compressed air or nitrogen, helium molecules are small enough to pass through micro-leaks that larger molecules cannot, making helium-based leak testing the most sensitive method available for critical pressure components.

At the same time, helium is expensive and scarce. An integrated boosting and decanting system is essential for helium conservation — recovering residual gas from test circuits, boosting cylinder pressure to maintain deliverable supply, and controlling decanting to prevent wastage.

Boosting system design

High-pressure storage

The system stores helium at 150 bar in high-alloy, non-corrosive steel tanks. This pressure rating ensures maximum gas content per cylinder volume and provides a high differential driving pressure for the boosting pump. Each storage cylinder connection is independently valved for safe isolation and replacement.

Motorised boosting pump

The boosting pump draws from the storage manifold and delivers helium to the required test or delivery pressure. A pressure-based auto-cutoff function prevents over-pressurisation — the pump shuts down when the downstream circuit reaches the setpoint. PLC interlocks prevent the pump from starting if downstream isolation valves are closed.

Decanting system design

The decanting unit receives high-pressure helium from the storage manifold or booster output and delivers it at controlled low pressure (up to 2 bar) to the end process. A solenoid-operated control valve, downstream pressure regulator, and pressure transmitter work together to maintain delivery pressure within the setpoint. The PLC monitors the transmitter output and commands the solenoid valve as required to maintain stable decanting pressure.

Hydrostatic test capability

The hydrostatic test function pressurises the test article (reciprocating cylinder, pressure vessel, or assembly) with helium to the specified test pressure. The system holds pressure for the required dwell time, then a calibrated pressure transmitter monitors for pressure decay. Any measurable decay indicates leakage, which is then localised using a helium sniffer probe or mass spectrometer detector.

Safety during hydrostatic testing

Safety relief valves on each circuit branch protect against over-pressurisation during the test cycle. The PLC provides interlocks that prevent pressure application if the circuit is not correctly configured, and automatically vents the circuit at the end of the test sequence before allowing operator access.

Automation and control

All valve sequencing, pressure ramp-up, dwell timing, and circuit venting are managed by the PLC control system. The operator interface displays real-time pressure readings from all transmitters, system status, and alarm states. Test sequences are parameterised — test pressure, ramp rate, dwell time, acceptance threshold — and can be saved and recalled by test article type. All test records are timestamped and logged for quality traceability.

Installation and commissioning

The system is delivered as a complete skid assembly with all inter-connections made. Neometrix provides site preparation drawings, P&IDs, mechanical installation support, leak testing of the complete assembled system, and operator training. Standard 12-month warranty covers all manufacturing defects. Annual maintenance contracts and on-site service are available post-warranty.