Technology Transfer

Space Shuttle Leak Detector Commercialized

AN ELMSFORD, NEW YORK, COMPANY specializing in leak detectors for pressurized cable is successfully commercializing an improved and more efficient ultrasonic leak detector. This new detector is based on technology developed in late 1990 to detect hazardous fluid leaks in the Space Shuttle fleet grounded at Kennedy Space Center.

A local and international supplier for local and international telephone companies, UE Systems Inc. offers an improved product that is a plug-in module for the firm's existing product line called the Ultraprobe™. The portable, handheld ultrasonic instrument detects compressed air leaks in cables and fittings, above ground and in vaults, transmitting very low-level ultrasound energy to the apex of a sensitive transducer in the device.

The unique parabolic-shaped collection horn gathers ultrasound from a distant leak source and helps screen out background noises. The parabolic design of the amplifying chamber reflects all signals directly to the transducer with minimal acoustic energy loss.

The signal from the transducer is preamplified and transferred to the Ultraprobe™ housing, where it is amplified again. The captured audio signal is then sent to headphones or a spectrum analyzer for further analysis or data storage. This "double amplification" effect works acoustically like a telescope and magnifies the leak for easier detection.

Instead of producing an entirely new instrument, UE Systems utilized NASA's innovative circuitry, improved transducers and unique collecting horn to create the highly reliable, versatile and sensitive plug-in module. The unit is small, lightweight and rugged compared to other systems and doubles the distance a leak is detectable. The user can remain safely on the ground while scanning overhead lines and other inaccessible areas for otherwise undetectable leaks.

The ultrasonic instrument provides testing capabilities that range from simple leak detection to more complex mechanical analysis. "Compressed air leak detection at a distance, electrical connections on overhead power transmission lines and pressurized overhead telephone cables are a few of the primary applications to use the [plug-in] module," stated Terrence O'Hanlon, UE Systems president.

NASA and the military are using the new detectors to find leaks on flight hardware and in fuel tank tests, as well as ground support equipment for future Shuttle missions. Using the improved leak detector could save U.S. manufacturers thousands of dollars in energy costs by minimizing the waste of energy associated with compressed air systems up to this point.

When STS-35 and STS-38 were grounded, Kennedy Space Center engineers developed new ultrasonic leak detectors to search for leaks in critical launch and ground support equipment and in the aft engine compartments. The leaks were found and fixed. Further enhancements were later made, and the detectors were used to find leaks in the solid rocket boosters.

For more information, contact Lewis Parrish at Kennedy Space Center.
Call: 407/867-6373, E-mail: ParriLM@kscgws00.ksc.nasa.gov
Please mention you read about it in Innovation.

A lead detector developed for the grounded Space Shuttle fleet in 1990 has been enhanced many times. The most current is an ultrasonic handheld plug-in model marketed widely, quickly and inexpensively.