Hick - NEIWPCC

A New Standard inPreventive Leak TestingService Provided by CGRS, Inc.

Everything Leaks!It’s up to the user to determine what leakrate is acceptable.Service Provided by CGRS, Inc.

Current StandardsMonthly monitoring - 0.2 gph 1,752 asliquid (gallons in1year).Precision tank and line testing - 0.1 gph asliquid (876 gallons in 1 year).ELD standards - 0.005 gph as vapor (2 E-3 cc/sec) or (44 gallons of vapor per year).Pacemakers have an acceptable leak rateof 1 E-9 cc/sec (1 cc in 31 years) as vapor.Service Provided by CGRS, Inc.

Pressure DecaySoap Bubble / VisualVacuum DecayHydro TestingCurrent QC TestingMethodsService Provided by CGRS, Inc.

Commission TestingPrecision Tank andLine TestingMonitoring SystemTestingService Provided by CGRS, Inc.

New OpportunityDouble wall system designs.More complex in-field constructionpractices.Service Provided by CGRS, Inc.

Adopted in July of 2003California ELDRequirementsNewly installed USTs must pass an ELDtest in order to receive an operatingpermit.Service Provided by CGRS, Inc.

Enhanced LeakDetection (ELD)A leak testing method with a sensitivitycapable of detecting a 0.005 gallon perhour leak (as vapor) with a 95% probabilityof detection and 5% probability of a falsealarm.Leaks of this order of magnitude will notpass liquid.Service Provided by CGRS, Inc.

New Construction ELDNew UST systems arerequired to pass an ELDtest after construction iscomplete.Primary containmentsystems only.One time test.Only one technology metthis standard.Service Provided by CGRS, Inc.

Ouch!!!Initially failure ratesapproached 90%In some cases, new pipingsystems had to be removedand replacedAngry tank installers, ownersand equipment manufactures.Could new systems meet thisstandard?DISASTER!!Service Provided by CGRS, Inc.

Solution!Perform helium pre-test prior tobackfilling.Final test failure ratesimmediately dropped to lessthan 2%.Problem solved.Service Provided by CGRS, Inc.

Idea!Service Provided by CGRS, Inc.

ConceptDevelop a helium based ELD methodfor quality control testing newlyconstructed fueling systems.

Helium Leak Testing inIndustryOriginally used on Manhattan projectduring WWII for detecting small leaks inthe gas diffusion process in the early 40’s.Commercialized in the early 50’s spurredon by the space program.Rapid leak testing with helium is usedextensively in industry today.

Automotive o IndustryEngine Blocks• Automatic loading• 20 test/hour• 1e-3 atm cc/sec

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

Cylinder Heads• Automatic loading• 15 test/hour• 3e-2 atm cc/sec

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

Energy IndustryHeat exchangeand steam condensationlines

Semiconductor IndustryCitiCritical gasdistribution lines

Aviation IndustryAircraft Wing Tanks and OxygenPiping

We learned that…Quality control leak testing with helium isnot a new concept.Using a refined, scientific based processfor in-field quality control testing of fuelsystems would be a new application.0.005 gph as vapor sensitivity – could bedone in the field with a high degree ofconfidence.

R&DService Provided by CGRS, Inc.

Leak SimulationService Provided by CGRS, Inc.

Permeation CurveAMERON TEST 11.00E+001.00E-011.00E-021.00E-03Leak Rate ATM-CC C/S1.00E-041.00E-051.00E-061.00E-071.00E-081.00E-091.00E-101.00E-110 200 400 600 800 1000 1200 1400Time in MinutesLeak Rate ATM-CC/SPower (Leak Rate ATM-CC/S)Service Provided by CGRS, Inc.

VaporTite V005Enhanced Leak Detection(ELD) Method

CertificationsKen Wilcox and Associates –EPA Non-Volumetric(tracer)Protocol.National Work Group on LeakDetection Evaluation Listing(NWGLDE)California State WaterResource Control Board(SWRCB) listingService Provided by CGRS, Inc.

How it Works

Process1. Pre Testing2. Final Testing

Piping Primary

Tank Primary

Components inContainment

Test Setups

Connection at theturbineService Provided by CGRS, Inc.

Piping i Systems

Test Manifold Detail

Air Management System

No Leak

0.005 gph Leak

0.005 005 gph as vaporService Provided by CGRS, Inc.

Typical Leak

Real World ExampleService Provided by CGRS, Inc.

Real World ExampleService Provided by CGRS, Inc.

Real World ExampleService Provided by CGRS, Inc.

Typical Leak

Test Certification

Leak LocatesService Provided by CGRS, Inc.

Effect?Materials handlingInstallers strictly follow installationinstructionsPiping tools kept sharp and in goodconditionEliminated unnecessary fittingsModification of secondary access fittingsInstallers learned to build tighter systems.

TodayWe find 1-6 6l leaks on every site during pre-testing and rarely does a system ever fail afinal.Installers like knowing that their work hasbeen checked by a 3 rd party – beforebackfilling!Owners sleep better knowing that theirinstallation has been QC tested to a verytight standard.

Leak PreventionInsuring tighter installations today, willcertainly help prevent releases in thefuture.

Eric Hickehick@cgrs.comThank you for your time!Service Provided by CGRS, Inc.