ODS-FREE LEAK DETECTOR FOR FUEL CELLS

Revision Date: 9/00
Process Code: Navy/Marines: ID-14-99; Air Force: IN07; Army: ELM
Usage: Navy: Medium; Marines: Medium; Army: Medium; Air Force: Medium
Compliance Impact: Low
Alternative for: Product listed under Technical Order T.O. 1-1-3 NSN 6850-00-909-3123 (powder form), NSN 6850-01-130-2451 (aerosol form)
Applicable EPCRA Targeted Constituents: CFCs, 1,1,1-Trichloroethane (CAS: 71-55-6)
Overview:

The products approved for leak detection in fuel cells contain chlorofluorocarbons (CFCs) and are no longer manufactured. New products are undergoing performance testing, but no officially approved replacements have yet been selected. Nevertheless, interim approval for the products in testing may be requested from your command. Otherwise, fuel cell leak checks will have to be done visually until the new products are officially approved.

Non-destructive testing products are often dyes formulated with solvents, typically CFCs. The specific leak detecting products referenced above contain CFCs. As Class I ODSs, these solvents were the subject of a production ban on January 1, 1996. As a result, the manufacturers of these leak-detecting products have already eliminated CFC use in their process. They did this by stopping production of the leak test products altogether. In addition, the manufacturer is unfortunately not developing any replacements. The Office of Primary Responsibility (OPR) is performance-testing alternatives, but formulation changes may be needed before any products are officially approved. Any approved products will be added to the Qualified Products List.

Several products have had favorable test results; however, none are officially approved. Field units should request interim approval from their respective commands until a substitute is officially approved. If interim approval for one of the test products is not obtained, visual inspection will have to be relied upon to monitor fuel cell integrity.

Keystone Aniline Corporation makes the most promising replacements being tested:

Name Part Number
Keystone Oil Red OE Powder 60602650
Keystone Liquid Oil Red HF 60642950

Keystone Oil Red OE Powder is in fact a powder, and Keystone Liquid Oil Red HF is an oil formulation. These products should only be used if granted interim approval, and then only in accordance with the manufacturer’s product instructions.
Compliance Benefit:

Use of ODS-free leak detector products will help facilities meet the requirements under 40 CFR 82, Subpart D and Executive Order 12843 requiring federal agencies to maximize the use of safe alternatives to Class I and Class II ozone depleting substances, to the maximum extent practicable. In addition, the elimination of CFCs at the facility decreases the possibility that the facility would meet any of the reporting thresholds for CFCs under 40 CFR 355, 370 and EO 12856. Chemicals used as substitutions should be reviewed for SARA reporting issues.

The compliance benefits listed here are only meant to be used as a general guideline and are not meant to be strictly interpreted. Actual compliance benefits will vary depending on the factors involved, e.g. the amount of workload involved.
Materials Compatibility:

No materials compatibility issues were identified.
Safety and Health:

Consult your local Industrial Health specialist, your local health and safety personnel, and the appropriate MSDS prior to implementing any of these technologies.
Benefits:
  • Reduce the amount of ODSs going into the environment.
  • Reduces worker exposure to constituents that have adverse effects to human health.


Disadvantages: None identified.
Economic Analysis:

The economic analysis depends on the method chosen for leak detection. For both the Keystone Oil Red OE Powder and the Keystone Liquid Oil Red HF, the only cost associated with these alternatives is the initial cost. The Keystone Oil Red OE Powder comes in a 100 lb. drum at $11.66/lb. There is an additional repacking price for purchases under 100lb. The Keystone Liquid Oil Red HF comes in three sizes: 40 lbs. for $6.65/lb., 240 lbs. for $5.49/lb., and 400 lbs. for $5.46/lb. The cost for a 6-ounce methyl chloroform red dye cartridge is $11.34, and $14.03 for a 14oz. aerosol can.

Assumptions:

  • Equivalent labor rates.
  • Equivalent usage rate.
  • Cost of aerosol methyl chloroform: $16.03/lb.
  • Cost of Keystone Oil Red OE Powder: $11.66/lb.
  • The figures in the table are based on a 100lb. usage of leak detector dyes.

Cost Comparison for Keystone Oil Red OE Powder vs. Methyl Chloroform

 

Keystone Oil Red OE Powder

Methyl Chloroform

Operational Costs:

   

Labor Costs:

$0

$0

Materials:

$1,166

$1,603

Total Costs:

$1,166

$1,603

Total Income:

$0

$0

Annual Benefit:

-$1,166

-$1,603

Economic Analysis Summary

    Annual Savings for Keystone Oil Red OE Powder: $437
    Capital Cost for Diversion Equipment/Process: $1,166
    Payback Period for Investment in Equipment/Process: > 2.7 years

Click Here to view an Active Spreadsheet for this Economic Analysis and Enter Your Own Values.


Approving Authority:

Approval is controlled locally and should be implemented only after engineering approval has been granted. Major claimant approval is not required.
NSN/MSDS:
Product NSN Unit Size Cost MSDS*
Keystone Oil Red OE 9150-00-F04-0064 N/A $N/A Click me

*There are multiple MSDSs for most NSNs.
The MSDS (if shown above) is only meant to serve as an example.


Points of Contact:

Air Force:
Mr. Gary Foy
WR-ALC/LEM
225 Ocmulge Court
Robins Air Force Base, GA 31098-1647
Phone: (912) 926-2673
DSN: 468-6630
FAX: (912) 926-3348


Vendors:

Keystone Aniline Corp.
2501 W. Fulton St.
Chicago,  IL   60612
Phone: (800) 522-4393 
Service: CFC-free products
Sources:

Mr. Gary Foy, WR-ALC/LEM, Robins Air Force Base, GA, August, 1998.
Vendor Communication with Keystone Aniline Corp., August, 1998.

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