Glenn's Leak Sensors Promote Safety in Space and on Earth

By: Emily Groh

An entire launch may be aborted due to the possibility of oxygen or fuel leaks of any size on the spacecraft's surface because it poses a high risk for an explosion. At the very least, discovered leaks will result in schedule delays and timing issues for those supporting the launch.

In support of NASA's ongoing efforts to promote safety throughout the agency, Glenn Research Center has been developing leak sensors to detect potential fuel and oxygen leaks and help make the launch process go more smoothly. In spring 2005, the project achieved a major accomplishment by successfully integrating the wireless antenna into the postage stamp-sized board unit as well as further decreasing the size and power consumption of the system.

Glenn's leak sensor Technology Manager Dr. Gary Hunter has worked with Case Western Reserve University on the invention and fabrication of the leak sensor. Makel Engineering, Inc. has been involved in the integration and demonstration of the hardware while product testing has been conducted at NASA Kennedy.

According to Hunter, “We feel that this type of smart, integrated technology is leading the field and the general direction of future sensor technology.” He added, “I'm very pleased with the team's multidisciplinary nature and that we have a future potential customer, NASA Kennedy, as part of the development process.”

The leak sensor unit is composed of 3 different sensors: hydrogen, oxygen, and hydrocarbon. The recently integrated antenna, which used to be an attached component, enables wireless telemetry. This feature allows the unit to transmit leak rate data wirelessly to the remote central processing unit controlled by the user.

NASA leak sensor technology has been recognized with an R&D 100 Award, NASA's Turning Goals into Reality Award, and, most importantly, an increasing acceptance in multiple applications. Aside from preventing explosions, leak sensor technology can be used for safer, more efficient fuel management and chemical processing in space.

On Earth, leak sensors have been used to automatically check valves and fittings on automotive assembly lines and to improve the safety of hydrogen powered vehicles. Other potential ground applications include fuel cells, hydrogen storage tanks, emission sensors, and advanced fire detection.

The leak sensor project team at NASA Glenn will continue the miniaturization of the unit while minimizing the power consumption to extend its battery life. Long-term goals also include making the leak sensor a “lick and stick” device that may be easily transferred to any surface of the space vehicle or other.