Leak Detection in half the time

Leak Detection in half the time Fuel leaks on aircraft Maintenance: Leaks may occur at anytime Leak repair time is long with traditional methods (soaping, helium, guesswork etc) Mean time to repair (MTTR) very hard to predict Repeat write-ups are common Production / overhaul: Don’t know if or where it may be leaking Leak Detection in half the time 2013-11-01

New leak locating method that… Cuts the time for leak locating in less than half Is more predictable in time Ensures a minimum of repeat write-ups Can be used by one (1) person Can be used after a minimum of training Can be used for leak detection BOTH outside AND inside tank Leak Detection in half the time 2013-11-01

Leak Detection in half the time In short… It saves a lot of time It requires less effort Leak Detection in half the time 2013-11-01

Basic method description (1) Basics of method: A - Standard mix of 5%H2/95%N2 as tracer gas B - Simple system for injecting the tracer gas at exit point C - Ex-classified leak detector ”Extrima” for pin pointing leaks Leak Detection in half the time 2013-11-01

Basic method description (2) Basics of method – maintenance: Leak indication leak indication on inside of skin = de-fuelling gas injection ”outside–in” leak locating inside tank repair verification of repair Leak Detection in half the time 2013-11-01

Basic method description (3) Basics of method – production/overhaul: usually a non-Ex situation Purpose: check for leaks on outside of skin gas injection ”inside–out” = filling the tank leak locating outside tank marking leaks venting tank gas injection ”outside-in” leak locating inside tank Leak Detection in half the time 2013-11-01

Leak Detection in half the time A – tracer gas General: Standard industrial grade gas mix (5%H2/95%N2) commonly used as shielding gas for welding stainless steel (forming gas) Name: Formier 5, Protec 5, RH, Leak Detection Gas Properties: non flammable, non corrosive, non toxic Cost: < 0,01 € / liter Consumption: Leak locating: 1-20 litres (cost 0,01 – 0,20 €) Repair verification: (size of tank x pressure) Leak Detection in half the time 2013-11-01

B – the injection system Injection Pads: for flat surfaces (joints, rivets, screws) Fix kit: adaptive parts for really tricky situations where the pads do not apply Injection Control: Panel for safe injection at the right pressure. Leak Detection in half the time 2013-11-01

C – the leak detector – Extrima Robust without moving parts Ex certified for Zone 0 (II 1 G Ex ia IIC T3) Low maintenance Intrinsically safe for use inside fuel tanks Clear and precise leak location Short introduction – easy to use Less problem with saturation. Leak Detection in half the time 2013-11-01

Leak Detection in half the time Certificates Holds the following certificates: ATEX (Europe) CSA (USA and Canada) IECEx (International) NEPSI (China) Leak Detection in half the time 2013-11-01

Leak Detection in half the time Fuel Leaks What makes pin pointing fuel leaks so difficult? Long leak paths Restricted visual access Multiple entry points for one leak Multiple leaks from one entry point Leak Detection in half the time 2013-11-01

Leak Detection in half the time Long leak path Leak Detection in half the time 2013-11-01

Leak Detection in half the time Test method = Fuel stain (outside wing) Gas signal = entry point (Inside tank) Defective seal Injection pad Gas injection hose External surface of wing Leak Detection in half the time 2013-11-01

Leak Detection in half the time Injecting the gas ”Flat” Injection Pad System handles both flat surfaces and tricky places Pressure up to 500 mBar / ≈ 7 PSI Pads come in Ø 60 mm (2.4 inch) and Ø 150 mm (5.9 inch) Fix Kit uses plastic tube and sealing compound ”Tricky” Fix Kit Leak Detection in half the time 2013-11-01

Leak Detection in half the time Locating the leak Get prepared – get inside – start locating Leak Detection in half the time 2013-11-01

Leak Detection in half the time Why half the time? Ex-rating removes need for venting to non Ex-level Tracer gas does not need drying Hydrogen disperses rapidly Detector reaction reduces time for pin pointing the leak Easy set-up for gas injection Easy to verify quality of repair Leak Detection in half the time 2013-11-01

Leak Detection in half the time Extrima successes Live situations Extrima found a leak in 20 minutes, that had evaded locating during 3 years Effects: saved a major tank replacement allowed the aircraft normal operating range Extrima located 3 out of 4 known leaks in 25% of the time it took with the standard method Effects: saved a repeat write-up proved its time saving capacity Leak Detection in half the time 2013-11-01

Some aircraft leak tested with the H2 Piper A400M CRJ Falcon VC10 Tornado Gripen A300 ATP Eurofighter Typhoon NH90 Lear KC135 Stratotanker Tiger You? Leak Detection in half the time 2013-11-01

Hydrogen, diluted as tracer gas Inexpensive standard gas mix 95%N2/5%H2 Safe, non-flammable, non-corrosive Easy to fill – easy to vent away Environmentally friendly – part of the ecological system Admitted in food stuffs E949 Low natural background (0,5ppm) Leak Detection in half the time 2013-11-01

Sensistor – The Hydrogen Sensor Technology Inexpensive standard gas mix 95%N2/5%H2 Safe, non-flammable, non-corrosive Easy to fill – easy to vent away Environmentally friendly – part of the ecological system Admitted in food stuffs E949 Low natural background (0,5ppm) Leak Detection in half the time 2013-11-01