When cleaning components from aircraft, only very select and explicitly approved cleaning techniques and agents may be used. This of course also applies to helicopters. The highly structured surfaces should be cleaned of oil and grease deposits, including abrasion, as far as possible without applying too much pressure.
Up to now, only A III cleaners have been used for these applications. This required a considerable amount of time. Both the cleaning result and the time required were inacceptable in practice - as one of the employees put it rather bluntly: „The A III cleaners are without any effect".
The low-pressure hot cleaning devices are an ideal and cost-effective solution: With a low pressure of only 7.5 bar, the required rinsing performance is achieved without damaging sensitive components. At the same time, the high temperatures of 95°C ensure a maximum cleaning effect, so that work can be done quickly and efficiently.
- Fast and efficient work - considerable time savings and significantly better quality compared to manual cleaning with A III cleaner.
- Excellent cleaning results due to high temperature of up to 95°C and lances and nozzles that can access even hard-to-reach corners and angles.
- No damage to sensitive parts due to low pressure of 3 - 7.5 bar.
- Low investment, minimal operating costs.
It should be noted that our equipment has been explicitly approved by the German Armed Forces for cleaning helicopters.
- Efficiency/quality: Significant time saving due to fast and thorough cleaning:
- High temperature and sufficient pressure enable fast and thorough cleaning in a minimum of time.
- Our customer reduced cleaning times from 10 work days with 4 staff to below 5 work days with 4 staff, using 2 of our machines, and with significantly better results than with manual cleaning
- Minimal space requirement: Devices are self-contained and require very little space; no dedicated washrooms required.
- Minimal splash-back effects, no clouds of droplets, no aerosols, thus ideal in the workshop.
- Cleaning medium: In this particular case, hot water with minimal addition of an alkaline cleaner was used. This implies minimal costs for procurement and disposal, especially as the cleaning medium can be reused multiple times due to special recycling system.
- Considerably more pleasant, faster and more efficient work than by hand.
- Devices are universal and perfect for parts cleaning, especially greasy and oily parts.
- Occupational safety and environmental protection: No chemicals means incerased environmental compatibility, higher occupational safety and significantly lower costs.
In summary: Low investment, minimal space requirement, hardly any operating costs, no damages and no healt issues, but highly efficient and quality results in minimal time.
In the specific application, parts that are installed in turbines from GE needed to be cleaned. The parts were made of titanium and were perforated with holes with a diameter of 0.2 to 0.7 mm.
The parts cost between €1,000 and €40,000; therefore, the cleaning must not lead to any damage to the parts. Paraffin and test fluids that had settled in the holes had to be cleaned off, and the cleaning had to be absolutely perfect - no dirt residue was allowed to remain.
Until now, the parts were rinsed again and again in a washing machine with a rotating basket until a satisfactory result was achieved. Depending on the degree of contamination, several washing cycles had to be carried out. Despite all the care taken, the parts were repeatedly damaged, e.g. during transport to the washing machines.
In the low-pressure hot cleaning process, greasy and oily contaminants - in this case the paraffin and the test fluid - are cleaned with medium at up to 95°C and low pressure of up to 7.5 or 14 bar.
The gear parts could be ideally cleaned in the parts cleaning level of the 1000 series. The cleaning was done with hot water and 3% of our alkaline cleaner B1200.
The cleaning results were better than the previous method in every respect: although cleaning was now done by hand, less time was needed for cleaning by hand than for loading the washing machine several times, and travel and waiting times were saved. Staff members could immediately see where critical areas were and where additional cleaning was needed, and could thus achieve significantly better results much faster. In addition, the risk of damaging the parts during transport was eliminated because the hot cleaning device is mobile and could therefore be used directly on the turbine.
Low-pressure hot cleaning was the ideal solution here:
- Excellent cleaning quality, as even the particularly fine holes could be perfectly cleaned and rinsed at 95°C.
- No damage to sensitive parts due to the low pressure of 3 - 7.5 bar. In addition, the risk of damage during transport is eliminated.
- Significant savings in working time and much more efficient work; no travel times.
- Minimal splash-back effects, no clouds of droplets, no aerosols, thus ideal for indoor use.
- Adding 3% alkaline detergent (to approx. 90 litres of process water in a 1000 SR) saves a considerable amount of chemicals compared to the washing machine (which uses a multiple of the process water).
- Occupational safety and environmental protection: No or minimal chemistry means increased environmental compatibility, high occupational safety and significantly lower costs.
- Universal applicability: In this particular case, only gear parts were cleaned, but the unit can also be used for a variety of other applications in the workshop or directly on the aircraft, e.g. for engines, landing gear, brakes, aircraft fuel tank
- As the devices are mobile, they can be used directly "on site", often without having to dismantle parts.
- Economic efficiency: Low investment for the unit, no follow-up costs for washrooms, oil separators, etc., later minimal operating costs for electricity and water. Amortisation often after only a few months.
In summary: Low investment and minimal operating costs, but perfect quality, no damage to parts and significant time savings.
Over time, bacteria and germs develop in the jet fuel (paraffin) tanks of all aircraft types due to the formation of condensation in the jet fuel. In the worst case, these can damage the structure of the aircraft skin.
The paraffin tanks are located in the wings and are therefore very difficult to reach from the inside.
Previously, cleaning was done by hand. This involved an enormous amount of time and effort and was nevertheless not very effective.
Germs can be ideally cleaned off with the low-pressure hot cleaning process. For this purpose, the cleaning medium is heated up to 95°C - enough to loosen even stubborn germs. At the same time, the low pressure of up to 7.5 or 14 bar is sufficient to reach even the furthest corners and to rinse off contaminants without damaging sensitive parts.
In the tests we carried out, even the furthest corners could be easily reached and cleaned thanks to our long and narrow lances. If necessary, our telescopic lances or our push & pull lances can also be used. There were no splash-back effects and no damage.
All in all, a very good result could be achieved without aggressive chemicals, and thanks to the high efficiency, considerable working time for cleaning was saved at the same time.
Low-pressure hot cleaning was an ideal solution here:
- Excellent cleaning quality, as the germs could be cleaned and rinsed out very well at 95°C.
- No damage to sensitive parts or the tank due to the low pressure of 3 - 7.5 bar.
- Cleaning directly on the aircraft or wing.
- Significant savings in working time and much more efficient work.
- Minimal splash-back effects, no clouds of droplets, no aerosols, therefore ideal for use indoors or in the tank.
- Occupational safety and environmental protection: No or minimal chemicals means increased environmental compatibility, high occupational safety and significantly lower costs.
- Universal usage: In addition to cleaning the interior of the tanks, the devices can be used for a variety of other applications directly on the aircraft, e.g. for cleaning engines, turbine parts, landing gear, brakes, etc.
- Cleaning directly "on site" due to the mobility of the device - often even without having to remove parts – saves transport and dismantling times, on top of time savings for the cleaning itself.
- Excellent economics: Low investment, no follow-up costs for washrooms, oil separators, etc., later minimal operating costs for electricity and water. Amortisation often after only a few months.
In summary: Low investment and minimal operating costs, but excellent quality, no damage to the parts, improved occupational safety, and significant time savings.