a new standard ina new standard in preventive leak testing

A New Standard inA New Standard inA New Standard in A New Standard in Preventive Leak TestingPreventive Leak Testing

Service Provided by CGRS, Inc.Service Provided by CGRS, Inc.

Everything Leaks!Everything Leaks!Everything Leaks!Everything Leaks!

It’s up to the user to determine what leak It’s up to the user to determine what leak rate is acceptablerate is acceptablerate is acceptable.rate is acceptable.


Current StandardsCurrent StandardsCurrent StandardsCurrent Standards

Monthly monitoring Monthly monitoring -- 0.2 0.2 gphgph 1,752 as 1,752 as liquidliquid (gallons(gallons in 1 yearin 1 year).).liquid liquid (gallons (gallons in 1 yearin 1 year). ). Precision tank and line testing Precision tank and line testing -- 0.1 0.1 gphgph as as liquidliquid ((876 gallons in 1 year876 gallons in 1 year))liquid liquid ((876 gallons in 1 year876 gallons in 1 year).).ELD standards ELD standards -- 0.005 0.005 gphgph as as vapor vapor (2 E(2 E--3 / ) (44 ll f )3 / ) (44 ll f )3 cc/sec) or (44 gallons of vapor per year).3 cc/sec) or (44 gallons of vapor per year).Pacemakers have an acceptable leak rate Pacemakers have an acceptable leak rate ppof 1 Eof 1 E--9 cc/sec (1 cc in 31 years) as vapor.9 cc/sec (1 cc in 31 years) as vapor.


Current QC Testing Current QC Testing Methods Methods

Pressure Decay Pressure Decay Soap Bubble / VisualSoap Bubble / VisualSoap Bubble / VisualSoap Bubble / VisualVacuum DecayVacuum DecayHydro TestingHydro Testing


Commission TestingCommission TestingCommission TestingCommission Testing

Precision Tank and Precision Tank and Line TestingLine TestingLine Testing Line Testing Monitoring System Monitoring System Testing Testing


New OpportunityNew OpportunityNew OpportunityNew Opportunity

Double wall system designs.More complex in-field constructionMore complex in-field construction practices.


California ELD California ELD Requirements Requirements

Adopted in July of 2003Adopted in July of 2003Newly installed USTs must pass an ELDNewly installed USTs must pass an ELDNewly installed USTs must pass an ELD Newly installed USTs must pass an ELD test in order to receive an operating test in order to receive an operating permit. permit.


Enhanced Leak Enhanced Leak Detection (ELD)Detection (ELD)

A leak testing method with a sensitivityA leak testing method with a sensitivityA leak testing method with a sensitivity A leak testing method with a sensitivity capable of detecting a 0.005 gallon per capable of detecting a 0.005 gallon per hour leak (as vapor) with a 95% probabilityhour leak (as vapor) with a 95% probabilityhour leak (as vapor) with a 95% probability hour leak (as vapor) with a 95% probability of detection and 5% probability of a false of detection and 5% probability of a false llalarm.alarm.

Leaks of this order of magnitude will not Leaks of this order of magnitude will not ggpass liquid.pass liquid.


New Construction ELDNew Construction ELDNew Construction ELDNew Construction ELD

New UST systems New UST systems are are required to pass required to pass an ELD an ELD test after construction is test after construction is complete.complete.Primary containment Primary containment systems only.systems only.y yy yOne time test.One time test.Only one technology metOnly one technology metOnly one technology met Only one technology met this standard.this standard.


Ouch!!!Ouch!!!Ouch!!!Ouch!!!

Initially failure rates Initially failure rates approached 90%approached 90%In some cases, new piping In some cases, new piping systems had to be removed systems had to be removed yyand replacedand replacedAngryAngry tank installers, ownerstank installers, ownersAngry Angry tank installers, owners tank installers, owners and equipment manufactures.and equipment manufactures.Could new systems meet thisCould new systems meet thisCould new systems meet this Could new systems meet this standard?standard?DISASTER!!DISASTER!!


DISASTER!!DISASTER!!

Solution!Solution!Solution!Solution!

Perform helium prePerform helium pre--test prior test prior to to backfilling.backfilling.Final test failure Final test failure rates rates immediately dropped to less immediately dropped to less yythan 2%.than 2%.Problem solved.Problem solved.Problem solved.Problem solved.


Idea!Idea!Idea!Idea!


ConceptConceptConceptConcept

Develop a helium basedDevelop a helium based ELD methodELD methodDevelop a helium based Develop a helium based ELD method ELD method for quality control testing newly for quality control testing newly constructed fueling systems.constructed fueling systems.

Helium Leak Testing in Helium Leak Testing in IndustryIndustry

Originally used Originally used on Manhattan on Manhattan project project during WWII for detecting small leaks induring WWII for detecting small leaks induring WWII for detecting small leaks in during WWII for detecting small leaks in the gas diffusion process in the early 40’s.the gas diffusion process in the early 40’s.Commercialized in the early 50’s spurred Commercialized in the early 50’s spurred on by the space program.on by the space program.on by the space program.on by the space program.Rapid leak testing with helium is used Rapid leak testing with helium is used

t i l i i d t t dt i l i i d t t dextensively in industry today. extensively in industry today.

Automotive Industry Automotive Industry u o o e dus yu o o e dus yEngine BlocksEngine Blocks

• Automatic loading• 20 test/hour• 1e-3 atm cc/sec1e 3 atm cc/sec

ValvesValvesValvesValves

• Automatic loadingg• 300 test/hour• 1e-6 atm cc/sec

Cylinder HeadsCylinder HeadsCylinder HeadsCylinder Heads

• Automatic loadingg• 15 test/hour• 3e-2 atm cc/sec

Power Steering UnitsPower Steering UnitsPower Steering UnitsPower Steering Units

• Manual loading• 90 test/hour• 2e-4 atm cc/sec

Energy IndustryEnergy IndustryEnergy IndustryEnergy Industry

Heat exchange d t d tiand steam condensation

lines

Semiconductor IndustrySemiconductor Industryyy

C iti lC iti lCritical gas Critical gas distribution linesdistribution lines

Aviation IndustryAviation Industryyy

Aircraft Wing Tanks and Oxygen Aircraft Wing Tanks and Oxygen PipingPipingPipingPiping

We learned thatWe learned thatWe learned that…We learned that…

Quality control leak testing with helium is Quality control leak testing with helium is not a new concept.not a new concept.ppUsing a refined, scientific based process Using a refined, scientific based process forfor inin field qualityfield quality control testing of fuelcontrol testing of fuelfor for inin--field quality field quality control testing of fuel control testing of fuel systems systems would be a would be a new application. new application. 0.005 0.005 gphgph as as vapor vapor sensitivity sensitivity –– could could be be done in the field with a high degree ofdone in the field with a high degree ofdone in the field with a high degree of done in the field with a high degree of confidence. confidence.

R & DR & DR & D R & D


Leak SimulationLeak SimulationLeak SimulationLeak Simulation


Permeation CurvePermeation CurvePermeation CurvePermeation Curve

AMERON TEST 1

1.00E-01

1.00E+00

1.00E-04

1.00E-03

1.00E-02

C/S

1.00E-07

1.00E-06

1.00E-05

Leak

Rat

e A

TM-C

C

1.00E-10

1.00E-09

1.00E-08

1.00E-11

0 200 400 600 800 1000 1200 1400Time in Minutes

Leak Rate ATM-CC/S Power (Leak Rate ATM-CC/S)


Leak Rate ATM CC/S Power (Leak Rate ATM CC/S)

VaporTite V005

Enhanced Leak Detection (ELD) Method

CertificationsCertificationsCertificationsCertifications

Ken Wilcox and Associates Ken Wilcox and Associates ––EPA NonEPA Non--Volumetric Volumetric (tracer) (tracer) ProtocolProtocol..National Work Group on Leak National Work Group on Leak Detection Evaluation Listing Detection Evaluation Listing (NWGLDE)(NWGLDE)( )( )California State Water California State Water Resource Control BoardResource Control BoardResource Control Board Resource Control Board (SWRCB) listing (SWRCB) listing


How it WorksHow it WorksHow it WorksHow it Works

ProcessProcessProcessProcess

1.1. Pre Testing Pre Testing 22 FinalFinal TestingTesting2.2. Final Final TestingTesting

Piping PrimaryPiping Primary

Tank PrimaryTank Primary

Components in pContainment

Test SetupsTest SetupsTest SetupsTest Setups

Connection at the Connection at the turbineturbine


Pi i S tPiping Systems

Test Manifold DetailTest Manifold DetailTest Manifold DetailTest Manifold Detail

Air Management SystemAir Management SystemAir Management SystemAir Management System

No LeakNo Leak

0.005 gph Leak

0 0050 005 gphgph as vaporas vapor0.005 0.005 gphgph as vaporas vapor


Typical Leak

Real World ExampleReal World ExampleReal World ExampleReal World Example


T i l L kTypical Leak

Test CertificationTest Certification

L k L tLeak Locates


Effect?Effect?Effect? Effect?

M t i l h dliM t i l h dliMaterials handlingMaterials handlingInstallers strictly Installers strictly follow installation follow installation yyinstructionsinstructionsPiping tools kept sharp and in goodPiping tools kept sharp and in goodPiping tools kept sharp and in good Piping tools kept sharp and in good conditionconditionEliminated unnecessary Eliminated unnecessary fittingsfittingsModification of secondary accessModification of secondary access fittingsfittingsModification of secondary access Modification of secondary access fittingsfittingsInstallers learned to build tighter systems.Installers learned to build tighter systems.

TodayTodayToday Today

W fi d 1W fi d 1 6 l k it d i6 l k it d iWe find 1We find 1--6 leaks on every site during pre6 leaks on every site during pre--testing and rarely does a system ever fail a testing and rarely does a system ever fail a final.final.Installers like knowing that their work hasInstallers like knowing that their work hasInstallers like knowing that their work has Installers like knowing that their work has been checked by a 3been checked by a 3rdrd party party –– before before b kfilli !b kfilli !backfilling!backfilling!Owners sleep better knowing that their Owners sleep better knowing that their p gp ginstallation has been QC tested to a very installation has been QC tested to a very tight standardtight standardtight standard. tight standard.

Leak PreventionLeak PreventionLeak Prevention Leak Prevention

Insuring tighter installations today, willInsuring tighter installations today, willInsuring tighter installations today, will Insuring tighter installations today, will certainly help prevent releases in the certainly help prevent releases in the futurefuturefuture.future.

Eric HickEric [email protected]

Thank you for your time!Thank you for your time!


a new standard ina new standard in preventive leak testing

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