Aerospace Industry Gas Detection Solutions: Nexisense Ensuring Fuel Safety and Reliable Operations

The aerospace sector involves large quantities of flammable fuels such as aviation kerosene (Jet A-1/JP-8), aviation gasoline, and diesel. During storage, transport, refueling, engine testing, and maintenance, even minor leaks can form explosive mixtures, causing fire or deflagration accidents. Historical incidents highlight the critical importance of early fuel leak detection for personnel safety, equipment integrity, and mission success.

Modern aerospace companies must strictly comply with explosion-proof standards (e.g., ATEX/IECEx, GB3836 series) and industry regulations (e.g., FAA, EASA fuel safety requirements). Deploying fixed gas detection systems has become standard practice. Nexisense provides high-precision online monitoring solutions for volatile combustible fuels, enabling real-time concentration monitoring, automatic alarms, and control integration in high-risk areas such as hangars, fuel storage, test stands, and assembly workshops.

Fuel Gas Risks and Monitoring Necessity

Major risks of aviation fuels arise from low flash points and high volatility:

• Aviation kerosene (density ~0.8g/cm³, flash point 38-60°C): heavier than air, can accumulate in low areas forming mixtures within LEL.

• Aviation gasoline: highly volatile, forming vapor clouds easily.

• Diesel: less volatile but still explosive under atomization or high temperature.

Typical scenarios include fuel warehouses, refueling stations, wing tank test areas, and engine test benches. Leaks may result from valve seal failure, pipeline corrosion, overflow, or static sparks. Effective monitoring triggers early warnings at 10-20% of LEL, linking ventilation, power cut-off, or emergency sprinklers to prevent accidents.

Selecting Aerospace Combustible Gas Detection Equipment

Selection should consider accuracy, response speed, explosion-proof rating, and integration:

• Detection principle: catalytic combustion (LEL 0-100%) or infrared (anti-poisoning, high stability).

• Explosion-proof certification: Ex d IIC T6 Gb or higher, suitable for Zone 1/Zone 2.

• Environmental adaptation: resistant to oil mist, temperature -40°C to +70°C, IP65+ protection.

• Output interface: 4-20mA, RS485 Modbus RTU for PLC/DCS/SCADA integration.

• Additional features: sensor life reminder, smart calibration, relay linkage.

Core Nexisense Products

Online Fixed Gas Detector — SGA-500 Series

Optimized for aviation fuel scenarios, using original imported sensor chips with patented algorithm (32-bit microprocessor + 24-bit ADC full-range temperature and humidity compensation) for high precision and low drift.

Single-unit 24V power, plug-and-play, supporting aviation kerosene, gasoline, diesel ranges (0-100% LEL). Real-time LCD display, automatic audible/visual alarms with relay output.

• Response time <10s, stable zero and span.

• High-brightness display for on-site reading.

• Explosion-proof housing suitable for fuel storage and hangars.

  
  

Alarm Controller and System Integration

Combined with SGA-800 series controller for multi-point centralized monitoring, unified power, and historical recording. Controller supports large-screen display for each channel, multiple built-in relays (220V/5A), linking fans, solenoid valves, and audible-visual alarms.

Seamless 4-20mA/RS485 interface with PLC/DCS, forming closed loop: over-limit → ventilation + pump cut-off. Successfully deployed in large aerospace companies like Hongdu Group for years.

Installation Positions and Guidelines

• Heavier-than-air gases (aviation kerosene, diesel vapor): install 30-60cm below leak source to capture settling layer.

• Lighter-than-air gases (hydrogen, some volatiles): install at top or 30-60cm below highest point.

• Horizontal distance: combustible gases ≤7.5m.

• Wiring: 3- or 4-core shielded cables, corresponding S+/V+/V- or S-/GND terminals to prevent interference.

• Avoid ventilation dead zones, direct sunlight, or oil splashes; clean sensors regularly.

Proper placement captures gas at initial diffusion, buying crucial emergency time.

Typical Applications

• Fuel warehouses and refueling stations: monitor kerosene/diesel leaks, link ventilation and cut-off.

• Aircraft maintenance hangars: fixed detection near wing tanks, engines; explosion-proof coverage.

• Engine test benches: real-time combustible gas monitoring ensures test safety.

• Aerospace launch fuel facilities: monitor kerosene-based propellants beyond LOX/LH2.

  
  

FAQ

1. Detection principle and range of SGA-500 for aviation kerosene?
Uses catalytic combustion sensors optimized for JP-8/Jet A-1, standard 0-100% LEL, customizable high-precision 0-50% LEL segment. Response <10s, strong oil mist resistance.

2. Explosion-proof rating and applicable zones?
Ex d IIC T6 Gb, suitable for Zone 1/Zone 2 explosive gas environments, compliant with aerospace fuel storage and hangar requirements. Robust and corrosion-resistant housing.

3. Integration with PLC/DCS and supported protocols?
Supports 4-20mA analog output (2/3-wire) and RS485 Modbus RTU. Direct integration with PLCs (Siemens S7, Rockwell) or DCS. Optional Modbus TCP for centralized monitoring and data upload.

4. Sensor lifespan, calibration cycle, maintenance difficulty?
Catalytic combustion sensor: 3-5 years depending on oil mist. Built-in life prediction and drift diagnostics; zero/span calibration every 6-12 months with standard gas. Easy maintenance, remote diagnostics supported.

5. Recommended placement and precautions in fuel warehouses?
For heavy vapors, install 30-60cm below leak source (valves, pumps, tank bottom), horizontal ≤7.5m. Avoid vents, drainage channels; use shielded cables; regularly check explosion-proof fittings and seals.

6. Multi-level alarm and linkage control?
Supports multi-thresholds: warning 10% LEL, alarm 20% LEL, high alarm 40% LEL; each linked to ventilation, power/pump cut-off, or sprinklers. Controller relays allow zone logic configuration.

7. High-temperature environments like engine test benches?
Operating -40°C to +70°C, optional high-temp sensors and protective covers. Remote monitoring avoids prolonged exposure in hot zones; proven stable operation near test benches.

8. How to obtain manuals, selection advice, project cases, and quote timeline?
Submit fuel type, environment, point count via website; team replies within 24h. Provides full manuals (range chart, explosion-proof certificate, installation diagrams), cases (e.g., Hongdu Group), and 3D models. Standard 1-3 working days quote; custom 5-10 days.

Conclusion: Nexisense Protects Every Inch of Aerospace Fuel Safety

Aerospace fuel safety impacts mission success and lives. Nexisense, with high-precision sensors, reliable explosion-proof design, and flexible integration, delivers end-to-end solutions for storage, hangars, testing, and more. Whether new explosion-proof systems or facility upgrades, it ensures efficient monitoring and minimal risk.

For projects involving aviation kerosene, gasoline, diesel, contact Nexisense for custom solutions, site surveys, and technical support. Safe flight begins with reliable early warning.