AVIATION SOLUTIONS

Bearing and Gear Condition Indication

MetalSCAN

Aircraft engine bearing and gear component damage can progress to failure in-flight in 100’s or even 10’s of hours.

Through the use of MetalSCAN it is now possible to detect early damage, monitor the progression of this damage, and provide multi-level warning to maintenance and operations organizations before failure occurs, on-line and in-flight.

MetalSCAN
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Originally developed for the F-22 Advanced Tactical Fighter engine, MetalSCAN is available for a wide range of military and commercial aircraft applications. The sensor provides state-of-the-art engine, gearbox, and transmission protection and health monitoring for many of the world’s most advanced aircraft including the F-35 Lightning and Airbus A320neo.

The MetalSCAN sensor is installed in the full-flow of the lubrication system in a suitable location ahead of the system filter. The sensor’s signal conditioning electronics can be integrated directly into the engine control, monitoring unit or helicopter HUMS, or it can be implemented in a standalone configuration depending on the aircraft monitoring architecture.

MS1000 How it Works

Applications

Click on an engine model below to learn more

On-line Oil Debris Sensor that provides real-time detection of component damage.

ChipCHECK

When the lubricated components of aircraft engines are damaged, debris enters into the lubrication system and is captured on the lube system magnetic chip detectors.

ChipCHECK eliminates the visual guesswork required of the maintainer and provides a reliable quantitative indication of the number, size, and alloy composition of the chips, and using embedded predetermined condition indices empowers the maintainer to make the right Go/No-Go decision everytime.

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ChipCHECK Schematic

Applications

  • F-16 Fighting Falcon (F110)
  • MQ-9 Reaper (TPE331)
  • AH-64 Apache (T700)
  • UH-60 Black Hawk (T700)
  • Airbus A380 (GP7200)
  • Boeing B777 (GE90)

Deployable Chip Analysis system that provides

GO/NO-GO maintenance decision support.

FilterCHECK

When the lubricated components of aircraft engines are damaged, debris enters into the lubrication system and is captured by the system filter.

FilterCHECK is employed when chip detection inspection and analysis is insufficient. FilterCHECK unlocks the information buried in the filter to help maintainers validate conclusively if there is damage present and additionally, which specific component(s) are damaged within the gearbox.

FilterCHECK
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FilterCHECK is a key, proven component of numerous aircraft maintenance and test programs where traditional manual inspection methods have proven to be insufficient for safe and cost effective operations of the fleet. An example is J52 turbojet engine of the US Navy’s EA-6B aircraft which had experienced a serious in-flight shutdown problem, the root cause of which was traced to engine bearing failure. Since early damage could not be detected by traditional monitoring techniques, Gastops worked closely with the US Navy, the engine manufacturer and scientists from Joint Oil Analysis Program of the US Department of Defense to apply FilterCHECK to this serious problem.

In the first six months of the program, the new filter debris analysis procedure identified six bearing damage events, preventing a potential in-flight shutdown from occurring in all six cases. Today FilterCHECK is used by US Navy maintainers at all of the EA-6B operational units, including aircraft carriers, to prevent any future in-flight engine failures due to bearings.

FilterCHECK 400 Schematic

Applications

  • Eurofighter Typhoon (EJ200)
  • S-61/H3 Sea King (T56)
  • C-130 Hercules (T56)
  • EA-6B Prowler (J52)
  • UH-60 Black Hawk (T700)
  • C-17 Globemaster (F117)
  • P-3C Orion (T56)
  • Airbus A380 (GP7200)
  • Boeing B757 (RB211)
  • Pilatus PC-9 (PT6)

Deployable Filter Debris Analysis system that provides GO/NO-GO maintenance decision support.

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