1. Leak Detection in half the time

2. Leak Detection in half the time
Fuel leaks on aircraft
Maintenance:
Leaks may occur at anytime
Leak repair time is long with traditional methods (soaping, helium, guesswork etc)
Mean time to repair (MTTR) very hard to predict
Repeat write-ups are common
Production / overhaul:
Don’t know if or where it may be leaking
Leak Detection in half the time

3. New leak locating method that…
Cuts the time for leak locating in less than half
Is more predictable in time
Ensures a minimum of repeat write-ups
Can be used by one (1) person
Can be used after a minimum of training
Can be used for leak detection BOTH outside AND inside tank
Leak Detection in half the time

4. Leak Detection in half the time
In short…
It saves a lot of time
It requires less effort
Leak Detection in half the time

5. Basic method description (1)
Basics of method:
A - Standard mix of 5%H2/95%N2 as tracer gas
B - Simple system for injecting the tracer gas at exit point
C - Ex-classified leak detector ”Extrima” for pin pointing leaks
Leak Detection in half the time

6. Basic method description (2)
Basics of method – maintenance:
Leak indication leak indication on inside of skin =
de-fuelling
gas injection ”outside–in”
leak locating inside tank
repair
verification of repair
Leak Detection in half the time

7. Basic method description (3)
Basics of method – production/overhaul: usually a non-Ex situation
Purpose: check for leaks on outside of skin gas injection ”inside–out” = filling the tank
leak locating outside tank
marking leaks
venting tank
gas injection ”outside-in”
leak locating inside tank
Leak Detection in half the time

8. Leak Detection in half the time
A – tracer gas
General: Standard industrial grade gas mix (5%H2/95%N2) commonly used as shielding gas for welding stainless steel (forming gas)
Name: Formier 5, Protec 5, RH, Leak Detection Gas
Properties: non flammable, non corrosive, non toxic
Cost: < 0,01 € / liter
Consumption: Leak locating: 1-20 litres (cost 0,01 – 0,20 €) Repair verification: (size of tank x pressure)
Leak Detection in half the time

9. B – the injection system
Injection Pads: for flat surfaces (joints, rivets, screws)
Fix kit: adaptive parts for really tricky situations where the pads do not apply
Injection Control: Panel for safe injection at the right pressure.
Leak Detection in half the time

10. C – the leak detector – Extrima
Robust without moving parts
Ex certified for Zone 0 (II 1 G Ex ia IIC T3)
Low maintenance
Intrinsically safe for use inside fuel tanks
Clear and precise leak location
Short introduction – easy to use
Less problem with saturation.
Leak Detection in half the time

11. Leak Detection in half the time
Certificates
Holds the following certificates:
ATEX (Europe)
CSA (USA and Canada)
IECEx (International)
NEPSI (China)
Leak Detection in half the time

12. Leak Detection in half the time
Fuel Leaks
What makes pin pointing fuel leaks so difficult?
Long leak paths
Restricted visual access
Multiple entry points for one leak
Multiple leaks from one entry point
Leak Detection in half the time

13. Leak Detection in half the time
Long leak path
Leak Detection in half the time

14. Leak Detection in half the time
Test method
= Fuel stain (outside wing)
Gas signal = entry point
(Inside tank)
Defective seal
Injection pad
Gas injection hose
External surface of wing
Leak Detection in half the time

15. Leak Detection in half the time
Injecting the gas
”Flat”
Injection Pad
System handles both flat surfaces and tricky places
Pressure up to 500 mBar / ≈ 7 PSI
Pads come in Ø 60 mm (2.4 inch) and Ø 150 mm (5.9 inch)
Fix Kit uses plastic tube and sealing compound
”Tricky”
Fix Kit
Leak Detection in half the time

16. Leak Detection in half the time
Locating the leak
Get prepared – get inside – start locating
Leak Detection in half the time

17. Leak Detection in half the time
Why half the time?
Ex-rating removes need for venting to non Ex-level
Tracer gas does not need drying
Hydrogen disperses rapidly
Detector reaction reduces time for pin pointing the leak
Easy set-up for gas injection
Easy to verify quality of repair
Leak Detection in half the time

18. Leak Detection in half the time
Extrima successes
Live situations
Extrima found a leak in 20 minutes, that had evaded locating during 3 years Effects:
saved a major tank replacement
allowed the aircraft normal operating range
Extrima located 3 out of 4 known leaks in 25% of the time it took with the standard method Effects:
saved a repeat write-up
proved its time saving capacity
Leak Detection in half the time

19. Some aircraft leak tested with the H2
Piper
A400M
CRJ
Falcon
VC10
Tornado
Gripen
A300
ATP
Eurofighter Typhoon
NH90
Lear
KC135 Stratotanker
Tiger
You?
Leak Detection in half the time

20. Hydrogen, diluted as tracer gas
Inexpensive standard gas mix 95%N2/5%H2
Safe, non-flammable, non-corrosive
Easy to fill – easy to vent away
Environmentally friendly – part of the ecological system
Admitted in food stuffs E949
Low natural background (0,5ppm)
Leak Detection in half the time

21. Sensistor – The Hydrogen Sensor Technology
Inexpensive standard gas mix 95%N2/5%H2
Safe, non-flammable, non-corrosive
Easy to fill – easy to vent away
Environmentally friendly – part of the ecological system
Admitted in food stuffs E949
Low natural background (0,5ppm)
Leak Detection in half the time