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FDA History

History

In the late 1990’s, the U.S. Navy was experiencing one in-flight shutdown per month on its Prowler aircraft. These aircraft are critical for aircraft carrier deployment in providing advanced electronic countermeasure capabilities. The Navy identified an urgent need for early detection of the failures in the J52-P-408 turbojet engines. The root cause of the failures was traced to #4½ roller bearing failure. These failures were not detected by traditional monitoring techniques. GasTOPS with its Filter Debris Analysis (FDA) instrument was tasked with finding a solution for early detection of these engine failures. GasTOPS is a company with 25 years of experiencing supplying innovative fluid sensing and analysis solutions with specialized engineering & technical services for advanced machinery monitoring and maintenance systems.

GasTOPS worked closely with the US Navy and scientists from the Military’s Joint Oil Analysis Program to develop and qualify their automated, field-deployable filter debris analysis (FDA) technique to identify early indication of the #4½ bearing failure. In the first six months, FDA using the GasTOPS FilterCHECK 300 instrument successfully diagnosed six #4½ bearing failures (verified by engine tear down). The US Navy’s J-52 program has achieved 95% success rate for hits (with no misses or escapes) on oil-wetted components since employing GasTOPS’ FDA. Automated FDA technology has been credited with keeping this invaluable aircraft operational and functional during the Afghanistan and Iraq conflicts. FDA meets the SAE standard for a condition monitoring technique.

The GasTOPS / Insight Services team is now transferring this technology, proven successful in a military application, to industry. In the same way FDA predicts engine failure in military jets, the technology can be utilized by maintenance managers to predict component wear in critical rotating equipment, thus avoiding operational downtime and reducing maintenance costs.

Filter Debris Analysis (FDA)
Service:

  • Benchmark metallic wear generation rates of machinery components
  • Quantify amount and size of abnormal metallic wear debris
  • Determine specific elemental makeup of wear debris being captured in your filters
  • Develop "go / no go" limits for yourfleet of critical machines
  • Diagnose the root cause of excessive filter replacements
  • Significantly enhance your existing oil analysis program

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Insight Services, Inc.  •  20338 Progress Drive  •  Cleveland, OH 44149  •  Phone: 216-251-2510  •  Fax: 216-251-2515
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