Reducing Cost and Improving Safety with 3D Flame Detection Mapping in Aviation Hangars

Sector and Services: Aviation | Engineering Design & Technical Consultancy

Context and Challenge: Our client, operating a busy aviation maintenance hangar overseas, faced significant operational and financial challenges due to an aging fire detection system. The existing installation relied heavily on over 500 point-type heat detectors positioned approximately 40 meters above floor level. These detectors had become obsolete, were extremely costly to replace, and posed significant operational challenges during maintenance due to height access requirements. Furthermore, the effectiveness of these heat detectors in timely fire detection and response was questionable, as their positioning made rapid incipient-stage detection improbable. This outdated system, installed to comply with legacy NFPA standards, was becoming a significant burden both financially and from a fire safety perspective.

Our Approach: Adopting a back-to-basics, fundamental engineering approach, our team critically assessed both the client’s specific needs and the evolving regulatory landscape. Recognizing recent updates to NFPA 409, we identified an opportunity to transition from heat detectors to advanced IR3 flame detectors, specifically designed to provide early, reliable detection of hangar fires, including underwing and overhead incidents.

To effectively apply these detectors, we employed enhanced 3D flame mapping technology, which enabled us to accurately determine the precise placement and orientation of each detector. Unlike traditional 2D mapping approaches, our comprehensive 3D analysis accounted for obstructions like scaffolding and maintenance structures, ensuring robust and redundant coverage across the entire facility.

Our collaborative approach involved working closely with the client and securing approval from the Authority Having Jurisdiction (AHJ) through rigorous demonstration of technical reliability and compliance.

Technical Solution and Innovation: Our innovative use of 3D flame mapping represented a significant technological advancement over traditional detection systems. By quantifying coverage across multiple planes and axes, we assured comprehensive detection redundancy. The detailed 3D model facilitated precise detector orientation along x, y, and z axes, thereby ensuring optimal detector effectiveness and greatly simplifying the installation process.

This advanced mapping exercise successfully justified eliminating the costly heat detector system, replacing it with fewer but more strategically placed IR3 flame detectors. Additionally, the solution preserved the client’s preferred operational interface, a traditional push-button console, through custom electrical engineering tailored specifically for this unique project.

Outcomes and Benefits:

• Cost Efficiency: Achieved a remarkable 50% cost saving compared to the originally quoted systems, significantly reducing CAPEX requirements.
• Enhanced Reliability: Greatly improved fire detection effectiveness and response time through advanced IR3 flame detection technology.
• Simplified Maintenance: Dramatically reduced maintenance complexity and costs, eliminating the need for specialized height-access maintenance crews.

Why This Matters: This project exemplifies the significant value created by combining advanced engineering analysis, regulatory insight, and innovative technology applications. By moving beyond traditional approaches and leveraging enhanced 3D flame mapping, the solution not only achieved substantial cost savings but also significantly enhanced safety and operational efficiency, setting a new benchmark in aviation hangar fire detection and control systems.